KTM EXC 200 EXC Owner'S Manual Download Page 1

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KTM-Sportmotorcycle AG

A–5230 Mattighofen

www.ktm.at

KTM Group Partner

125 SX, EXC

200 EXC, XC, XC-W

250 SX, EXC, XC, XC-W

300 EXC, XC, XC-W

OWNER’S MANUAL

2006

ART. NR. 3.211.72EN

ENGLISH

Summary of Contents for EXC 200 EXC

Page 1: ...KTM Sportmotorcycle AG A 5230 Mattighofen www ktm at KTM Group Partner 125 SX EXC 200 EXC XC XC W 250 SX EXC XC XC W 300 EXC XC XC W OWNER S MANUAL 2006 ART NR 3 211 72EN ENGLISH...

Page 2: ...reserved Reprint also in extracts with written allowance of KTM SPORTMOTORCYCLE AG Mattighofen only Please read this manual carefully and completely before going on your first ride It contains a great...

Page 3: ...se you decide to sell it We expressly point out that work marked with an asterisk in the chapter Maintenance work on the chas sis and engine must be performed by a KTM workshop If maintenance work sho...

Page 4: ...nipulations or conversions to the motorcycle The use of the motorcycle under extreme conditions e g on extremely muddy and wet terrain can lead to higher than average wear on components such as the dr...

Page 5: ...rk offset caster SX XC 28 Page Checking and adjusting the steering head bearing 29 How to change the handlebar position 30 Check chain tension 30 Correct chain tension 31 Chain maintenance 31 Chain we...

Page 6: ...r The clutch lever 1 is located on the left side of the handlebars The adjust ing screw A is used to change the original position of the clutch lever see maintenance work on chassis and engine The clu...

Page 7: ...SPEED ODO display modes are activated in the condition at delivery SPEED H is displayed whenever the display is activated and the front wheel is not turning It automatically changes to the SPEED ODO...

Page 8: ...hold button 3 secs set the clock menu To set the clock see Setting the clock Activating and deactivating display modes In the display mode SPEED H press and hold the button for 3 seconds to access th...

Page 9: ...ted by the first impulse received from the wheel sensor when the front wheel starts to turn and stops 3 seconds after the last impulse is received when the front wheel has stopped The TR1 A1 and S1 fi...

Page 10: ...figure can deviate from the actual average speed if the TR2 figure was changed manually or if S2 was not stopped after the trip button no function button no function briefly press button changes to th...

Page 11: ...F THE ELECTRONIC SPEEDOMETER FUNCTIONS display briefly press button briefly press button briefly press button hold button 3 secs X SPEED H no function no function next display mode displays the SETUP...

Page 12: ...tch 4 Flasher switch The flasher switch is a separate unit and is mounted on the left portion of the handlebar The wire harness is designed in a way that whenever you want to use your bike off road yo...

Page 13: ...ped until the rotating handle is turned to the RES position Fill the tank as soon as possible and remember to turn the rotating handle back to the ON position so that you will have backup fuel next ti...

Page 14: ...d it with the motor cycle Make sure that you put your bike on solid ground and in a secure posi tion For off road riding you can use the rubber band 1 to additionally secure the center stand in its fo...

Page 15: ...n of shock absorber SX The shock absorber on the SX models can synchronize the compression damping in the low and high speed range separately Dual Compression Control Low and high speed refers to the...

Page 16: ...SHOCK ABSORBER APART OR TO DO ANY MAINTENANCE WORK YOURSELF SEVERE INJURIES COULD BE THE RESULT NEVER UNSCREW THE BLACK SCREW 2 CONNECTION 24MM Rebound damping of shock absorber SX XC W EXC By using t...

Page 17: ...ngine needs to be broken in For this reason during its first 500 kilometers 300 miles or 5 hours the engine must not be revved up to its perform ance limits Apply low but changing loads for running in...

Page 18: ...aking system Verify that there is suf ficient brake fluid in the reservoir The reservoirs have been designed in such a way that brake fluid does not need to be refilled even when the brake pads are wo...

Page 19: ...ly if the float chamber is filled with fresh ignitable fuel Starting when the engine is warm 1 Open fuel tap 2 Turn on ignition or emergency OFF switch 3 Swing up the side stand 4 Put the gear in neut...

Page 20: ...u apply the brakes on sandy wet or slick surfaces Always apply the brakes intuitively locked wheels can cause the bike to skid or crash Shift down to a lower gear to match your speed Always apply the...

Page 21: ...eck headlamp setting z z Check function of electric systems low beam high beam break light indicator z z z indicator lamps speedometer illumination horn emergency OFF switch or button BRAKES Check bra...

Page 22: ...luid C C H C H C H 125 200 SX XC EXC XC W 2006 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER before each start after every cleaning for cross country use once a year Check gear box o...

Page 23: ...eck headlamp setting z z Check function of electric systems low beam high beam break light indicator z z z indicator lamps speedometer illumination horn emergency OFF switch or button BRAKES Check bra...

Page 24: ...C C H C H C H C H 250 300 SX XC EXC XC W 2006 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER before each start after every cleaning for cross country use once a year Check gear box oi...

Page 25: ...S ARE NOT ADEQUATELY TIGHTENED THEY CAN BECOME LOOSE AND CAUSE THE MOTORCYCLE TO GO OUT OF CONTROL WHILE YOU DRIVE TIGHTENING THE SCREWS AND NUTS TOO TIGHTLY CAN DAMAGE THE THREAD AND COMPONENTS LET Y...

Page 26: ...ground again Ask a helper to hold the motorcycle in vertical position Measure the distance between the rear axle and the fixed point again to establish dimension B The static sag is the difference bet...

Page 27: ...ring preload will not affect the rebound damping adjustment Generally if the spring preload is higher the rebound damping should also be set higher STANDARD SETTING Unscrew the adjusting screw to the...

Page 28: ...oker 440 or engine oil Then push the dust protection bellows into the outer tubes by hand NO OIL MAY REACH THE FRONT TIRE OR THE BRAKE DISKS SINCE THIS WOULD CONSIDERABLY REDUCE THE TIRE S ROAD GRIP A...

Page 29: ...tie to keep the brake line from kinking see illustration Loosen the clamp screws and take the fork legs out of the triple clamps Loosen the collar screw 2 on the lower triple clamp 2 turns Remove the...

Page 30: ...ally To check put the motorcy cle on a stand so that the front wheel is off the ground Now try to move the fork forward and backward To adjust the 5 clamping screws 1 and 3 loosen the upper triple cla...

Page 31: ...ld be the same size in the front and in the rear THE SCREWS 4 MUST BE SECURED WITH LOCTITE 243 Check chain tension Jack the motorcycle up on its frame so that the rear wheel no longer touches the grou...

Page 32: ...e sprockets should also be replaced New chains wear faster if used on old used sprockets WHEN YOU ASSEMBLE A REAR SPROCKET WITH 14T THE COLLAR MUST BE ON THE INSIDE SECURE THE SCREWS OF THE CHAIN WHEE...

Page 33: ...innest point A Check the thickness of the brake disk at several points A BRAKE DISK WORN DOWN TO LESS THAN 2 50 MM FRONT 3 50 MM REAR IS A SAFETY RISK HAVE THE BRAKE DISK REPLACED AS SOON AS IT REACHE...

Page 34: ...IMMEDIATELY Refilling the front brake fluid reservoir Loosen screws 2 and remove lid 3 and membrane 4 Place hand brake cylinder in a horizontal position and fill the brake fluid reser voir to 5 mm 0...

Page 35: ...rew Spilled brake fluid must be rinsed off with water NEVER USE DOT5 BRAKE FLUID IT IS BASED ON SILICONE OIL AND OF A PURPLE COLOR SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT STORE BRAKE FL...

Page 36: ...ix it with the pin Slide in the right brake pad and knock the bolt 3 in as far as it will go Mount the safety device 2 IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS OTHER...

Page 37: ...r wheel Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground Remove the collar nut 1 remove the chain tensioner 2 and pull out the wheel spindle 3 until you can push...

Page 38: ...LY WORN TIRES CAN HAVE A NEGATIVE EFFECT ON HOW YOUR MOTORCYCLE PER FORMS ESPECIALLY ON WET SURFACES IF AIR PRESSURE IS TOO LOW ABNORMAL WEAR AND OVERHEATING OF THE TIRE CAN RESULT Checking spoke tens...

Page 39: ...rking light lamp Loosen both rubber bands and tilt the headlight mask to the front Pull the parking light lamp with holder 3 carefully out of the reflector Pull connector 4 off the headlamp and remove...

Page 40: ...T GETS INTO YOUR EYES RINSE THEM OUT WITH WATER IMMEDI ATELY AND GO SEE A DOCTOR Use a mixture of 50 antifreeze and 50 distilled water for the cooling liq uid The antifreeze should be designed for tem...

Page 41: ...s the front Detach the bottom of the filter retaining bracket 4 tilt aside and remove the throttle cap 5 and the air filter 6 and filter support 7 from the filter box The SX models do not have a throt...

Page 42: ...e distance between the clutch lever and the handlebar Turning the adjusting screw counterclockwise increases the distance between the clutch lever and the handlebar ADJUSTMENT OF THE CLUTCH LEVER POSI...

Page 43: ...d the rubber boot 8 Fill the bleeder syringe 9 with a suitable fluid see Technical Specifications Engine Remove the bleeder screw from the slave cylinder 10 and mount the bleeder syringe Press oil int...

Page 44: ...R ADJUSTMENT OF THE CARBURETOR PROCEED CAUTIOUSLY ALWAYS REDUCE THE JET SIZE IN STEPS OF ONE NUMBER TO AVOID OVERHEATING AND PISTON SEIZURE NOTE If the engine does not run properly despite a changed a...

Page 45: ...leaning procedure the float chamber of the carburetor should be drained in order to remove any water that may have penetrated into it Water in the float chamber leads to engine malfunction Make sure y...

Page 46: ...spring for aggressive engine characteristic included in scope of sup ply Spare part number 548 37 072 000 RED color mark To mount tilt the motorcycle approx 45 to the left remove both screws 2 lift o...

Page 47: ...USE TOO LITTLE OR LOW GRADE OIL USE ONLY HIGH GRADE OIL E G MOTOREX TOP SPEED 4T 15W50 Check transmission oil level 250 300 In order to check the transmission oil level the control screw 5 on the clu...

Page 48: ...or brake discs with a wax based anti corro sion agent KEEP THE ANTI CORROSION AGENT FROM GETTING INTO CONTACT WITH THE BRAKE DISCS OTHERWISE THIS WILL SIGNIFICANTLY REDUCE THE BRAKING POWER AFTER RIDE...

Page 49: ...uel tank capacity 7 5 liters 2 US gallons 8 5 liters 2 2 US gallons 8 5 10 liters 2 2 2 8 US gallons Final drive ratio 13 50 t 14 42 t 13 50 t 14 42 t 14 48 t Final drive ratio XC W 14 48 t Chain 5 8...

Page 50: ...Clamping screws fork stubs M8 15 Nm Collar nut rear wheel spindle M20x1 5 80 Nm Hexagon nut swing arm bolt M16x1 5 100 Nm Hexagon collar screw handlebar clamp M8 20 Nm Allan head screw handlebar suppo...

Page 51: ...gap 0 60 mm Dimension Z 43 5 mm 1 68 in 43 5 mm 1 68 in 47 mm 1 85 in Primary drive straight cut spur gears primary ratio 23 73 Clutch multiple disc clutch in oil bath hydraulically operated Motorex...

Page 52: ...125 SX 125 EXC EU 4 2 KW 125 EXC SIX DAYS 200 XC 200 XC W 200 EXC AUS 200 EXC EU 7 KW Carburetor Keihin PWK 39 Keihin PWK 36S AG Keihin PWK 36S AG Keihin PWK 38 AG Keihin PWK 38 AG Carburetor setting...

Page 53: ...uel tank capacity 7 5 liters 2 US gallons 11 2 liters 2 9 US gallons 8 5 10 liters 2 2 2 6 US gallons Final drive ratio 13 48 t 13 40 t Final drive ratio XC W 13 48 t 13 50 t 13 50 t Chain 5 8 x 1 4 A...

Page 54: ...Clamping screws fork stubs M8 15 Nm Collar nut rear wheel spindle M20x1 5 80 Nm Hexagon nut swing arm bolt M16x1 5 100 Nm Hexagon collar screw handlebar clamp M8 20 Nm Allan head screw handlebar supp...

Page 55: ...BR7 ES NGK BR 7 ES Electrode gap 0 60 mm Dimension Z 47 5 mm 1 87 in TVC start open 5200 min TVC fully open 7000 min red spring 7500 min yellow spring 7900 min green spring Primary drive straight cut...

Page 56: ...0 Nm Spark plug M14X1 25 25 Nm Other screws M 6 10 Nm M 8 25 Nm M 10 45 Nm BASIC CARBURETOR SETTING 250 SX 250 XC W 300 XC XC W 250 EXC SIX DAYS 300 EXC SIX DAYS 250 300 EXC EU 250 300 EXC AUS 250 6 6...

Page 57: ...SX 14 Determining the riding sag of the shock absorber 25 Determining the static sag of the shock absorber 25 Dismounting and mounting the front wheel 35 Dismounting and mounting the rear wheel 36 Dra...

Page 58: ...m a e b w o l h g i h n o t t u b p o t s h c t i w s n r o h G y a l e r r e h s a l f rear light brakelight r o t i c a p a c v r o s n e s d e e p s h c t i w s r a b e l d n a h l a n o i t p o U...

Page 59: ...r light brakelight v r o s n e s d e e p s h c t i w s r a b e l d n a h l a n o i t p o h c t i w s p o t s h c t i w s t h g i l C D I headlight G 3 r o t a r e n e g p u k c i p U r e i f i t c e r...

Page 60: ...rakelight v r o s n e s d e e p s h c t i w s r a b e l d n a h l a n o i t p o h c t i w s p o t s h c t i w s t h g i l C D I G 3 r o t a r e n e g p u k c i p U r e i f i t c e r r o t a l u g e r...

Page 61: ...RING DIAGRAMM 6 0 0 2 0 5 2 5 2 1 X S 5 0 0 2 3 0 6 2 l i o c n o i t i n g i n o t t u b p o t s G 3 r o t a r e n e g p u k c i p C D I 0 0 0 2 3 0 9 3 8 4 5 red white red black e t i h w e u l b n...

Page 62: ...flasher linker vorderer Blinker Indicatore ant sx Left rear flasher linker hinterer Blinker Indicatore post sx Multi func digital speedometer Multifunktionsdigitaltacho Tachimetro digitale multifunzio...

Page 63: ...ignotant avant gauche Luz intermitente izquierda delantera Left rear flasher Clignotant arri re gauche Luz intermitente izquierda trasera Multi func digital speedometer Ordinateur de bord Veloc metro...

Page 64: ...models The carburetor adjustments described above only apply to dethrottled motorcycles Other measures will be required in addition to the car buretor adjustment for full engine performance Your KTM...

Page 65: ...EXC models The carburetor adjustments described above only apply to dethrottled motorcycles Other measures will be required in addition to the car buretor adjustment for full engine performance Your K...

Page 66: ...buretor adjustments described above only apply to dethrottled motorcycles Other measures will be required in addition to the car buretor adjustment for full engine performance Your KTM dealer will be...

Page 67: ...rburetor adjustments described above only apply to dethrottled motorcycles Other measures will be required in addition to the car buretor adjustment for full engine performance Your KTM dealer will be...

Page 68: ...rburetor adjustments described above only apply to dethrottled motorcycles Other measures will be required in addition to the car buretor adjustment for full engine performance Your KTM dealer will be...

Page 69: ...ANHANG APPENDICE APPENDIX AP NDICE 12...

Page 70: ...KTM Sportmotorcycle AG A 5230 Mattighofen www ktm at KTM Group Partner 125 SX EXC 200 EXC XC XC W 250 SX EXC XC XC W 300 EXC XC XC W OWNER S MANUAL 2006 ART NR 3 211 72EN ENGLISH...

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