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KTM 200 XC-W User Manual

KTM 200 XC-W
154 pages
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OWNER'S MANUAL 2016
125 EXC EU
125 EXC Six Days EU
200 EXC EU
200 EXC AU
200 XC‑W US
250 EXC EU
250 EXC AU
250 EXC Six Days EU
250 XC‑W US
300 EXC EU
300 EXC AU
300 EXC Six Days EU
300 EXC BR
300 XC‑W US
300 XC‑W Six Days US
Art. no. 3213334en

Table of Contents

Questions and Answers:

KTM 200 XC-W Specifications

General IconGeneral
StarterElectric Starter
Transmission6-speed
Fuel SystemKeihin PWK 36S AG
IgnitionKokusan
Rear SuspensionWP Xplor PDS shock absorber
Front BrakeDisc brake
Rear BrakeDisc brake
Ground Clearance370 mm
Seat Height960 mm
Engine Type2-stroke
Bore x Stroke64.0 mm x 60.0 mm

Summary

Means of Representation

Symbols and Formats Used

Explains symbols and typographical formats used in the manual for clarity.

Safety Advice

General Safety Guidelines

Covers intended use, risk degrees, tampering warnings, and general safe operation practices.

Protective Clothing and Work Rules

Emphasizes protective gear and outlines basic work rules for maintenance.

Environmental Responsibility and Owner's Manual

Discusses environmental considerations and the importance of reading the owner's manual.

Important Notes

Guarantee, Warranty, and Service

Details warranty conditions, service requirements, and customer support information.

Operating Substances and Spare Parts

Specifies approved fluids, lubricants, and the use of genuine spare parts for safety.

View of Vehicle

Motorcycle Component Identification

Illustrates and identifies key components of the motorcycle from front and rear views.

Serial Numbers

Locating Vehicle Identification Numbers

Details the location of chassis, type, key, engine, fork, and shock absorber part numbers.

Controls

Handlebar Controls Overview

Identifies and describes clutch, brake levers, throttle, kill switch, horn, and light switches.

Additional Controls and Indicators

Covers starter buttons, emergency off switch, and indicator lamps for various models.

Fuel and Starting Controls

Explains the operation of the fuel filler cap, fuel tap, and choke lever.

Chassis and Starting Controls

Details the kick starter, foot brake lever, side stand, and steering lock mechanisms.

Speedometer

Speedometer Operation and Display Modes

Explains how to activate, test, and navigate through various speedometer display modes.

Setting Speedometer Functions

Covers setting units, clock, and other configurable functions for the speedometer.

Preparing for Use

First Use and Initial Setup

Provides advice for the initial use of the motorcycle, including control familiarization and adjustments.

Engine Break-in Procedure

Outlines the recommended procedure for running in the engine to ensure longevity.

Adapting for Difficult Riding Conditions

Details preparations for riding in sand, wet conditions, and varying temperatures.

Riding Instructions

Pre-Ride Checks and Starting Procedure

Lists essential checks before riding and the correct starting procedure for the engine.

Shifting, Braking, and Parking

Guides on proper gear shifting, braking techniques, and safe stopping/parking procedures.

Transportation and Refueling

Covers safe transport methods and essential steps for refueling the motorcycle.

Service Schedule

Regular Maintenance Schedule

Outlines routine checks and maintenance tasks based on operating hours or races.

Additional Service Work

Lists service tasks that are recommended as additional orders or at specific intervals.

Tuning the Chassis

Basic Chassis and Suspension Setup

Explains how to adjust basic chassis settings and suspension components based on rider weight.

Shock Absorber Adjustment

Details how to adjust compression and rebound damping for the rear shock absorber.

Fork Adjustment

Guides on adjusting compression and rebound damping for the front forks.

Handlebar Position Adjustment

Explains how to adjust the handlebar position for optimal rider comfort and control.

Service Work on the Chassis

Motorcycle Lifting and Wheel Removal

Covers procedures for raising the motorcycle and removing front/rear wheels for maintenance.

Fork Leg Service

Details cleaning dust boots, removing/installing fork protectors, and removing/installing fork legs.

Triple Clamp and Steering Head Service

Explains removal and installation of triple clamps and checking/adjusting steering head bearing play.

Fender, Shock Absorber, and Seat Service

Covers removing/installing front fender, shock absorber, seat, and related components.

Air Filter Box and Chain Maintenance

Details procedures for removing/installing air filter box lid, cleaning air filter, and chain maintenance.

Exhaust System and Fuel Tank Service

Covers main silencer maintenance, fuel tank removal/installation, and related checks.

Brake System

Hand Brake Lever Checks and Adjustments

Explains how to check and adjust free travel and basic position of the hand brake lever.

Brake Disc and Fluid Checks

Covers checking brake disc wear limits and front/rear brake fluid levels.

Brake Lining Service

Details checking and changing front and rear brake linings for optimal braking performance.

Foot Brake Lever Adjustments

Explains checking and adjusting the free travel and basic position of the foot brake lever.

Wheels and Tires

Front and Rear Wheel Service

Covers procedures for removing and installing front and rear wheels.

Tire Condition and Air Pressure Checks

Details how to check tire condition, tread depth, age, and air pressure.

Spoke Tension Check

Explains how to check and adjust the spoke tension for wheel balance and integrity.

Electrical System

Battery Service

Covers procedures for removing, installing, and recharging the motorcycle battery.

Fuse and Headlight Service

Details changing the main fuse and replacing headlight bulbs.

Headlight and Turn Signal Checks

Explains checking headlight settings and changing turn signal bulbs.

Speedometer Battery Replacement

Guides on how to replace the battery in the speedometer unit.

Cooling System

Coolant Level and Antifreeze Checks

Explains how to check coolant level, antifreeze protection, and radiator cap.

Coolant Draining and Refilling

Provides instructions for draining and refilling the cooling system with fresh coolant.

Tuning the Engine

Throttle Cable Adjustment

Details how to check and adjust the play in the throttle cable for smooth operation.

Carburetor Idle Speed Adjustment

Guides on adjusting the idle speed and mixture for optimal engine performance.

Carburetor Float Chamber Emptying

Explains how to empty the carburetor float chamber for maintenance or storage.

Shift Lever Position Adjustment

Covers checking and adjusting the basic position of the shift lever for rider comfort.

Auxiliary Spring Engine Characteristic

Explains how engine characteristics are influenced by auxiliary springs and how to set them.

Service Work on the Engine

Gear Oil Level Check and Change

Details procedures for checking, draining, and refilling the engine's gear oil.

Cleaning and Care

Motorcycle Cleaning Procedures

Provides instructions for cleaning the motorcycle, including precautions for pressure washers.

Winter Operation Maintenance

Outlines checks and maintenance steps necessary for winter storage and operation.

Storage

Motorcycle Storage Procedures

Details recommended actions for storing the motorcycle for extended periods.

Preparing for Use After Storage

Outlines necessary checks and maintenance before putting the motorcycle back into service.

Troubleshooting

Common Engine Starting and Running Issues

Provides solutions for common problems like engine not cranking, not starting, or having no idle.

Performance and Overheating Issues

Addresses troubleshooting for engine over-revving, power loss, and overheating problems.

Technical Data

Engine Specifications

Lists detailed technical specifications for the engine across different models.

Chassis and Suspension Specifications

Provides data on frame, fork, shock absorber, brakes, wheels, and tires.

Electrical System Components

Details specifications for battery, fuses, lights, and other electrical parts.

Carburetor Settings

Lists detailed settings for carburetors across various models and conditions.

Carburetor Tuning

Carburetor Tuning Charts

Provides tuning charts for different models based on altitude, temperature, and conditions.

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