Instruction/ maintenance manual of the product 200 XC-W (2015) KTM
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OWNER'S MANUAL 2015 125 EXC EU 125 EXC Six Days EU 125 EXC Factory Edition EU 200 EXC EU 200 EXC AU 200 XC ‑ W US 250 EXC EU 250 EXC AU 250 EXC Six Days EU 250 EXC Factory Edition EU 250 XC ‑ W US 300 EXC EU 300 EXC AU 300 EXC Six Days EU 300 EXC Factory Edition EU 300 XC ‑ W Six Days US 300 XC ‑ W US 300 EXC BR Art.
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DEAR KTM CUSTOMER 1 DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-ar t sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly. We wish you a lot of enjoyment in riding this vehicle.
TABLE OF CONTENTS 2 TABLE OF CONTENTS 1 MEANS OF REPRESENTAT ION ............................ ......... 5 1.1 Symbols used ....................................... ............ 5 1.2 Formats used ................................ .................... 5 2 SAFETY ADVICE .
TABLE OF CONTENTS 3 11.4 Adjusting the high-speed compression damping of the shock absorber ......................... 42 11.5 Adjusting the rebound damping of the shock absorber ................. ............................ ............ 42 11.6 Measuring the sag of the unloaded rear wheel .
TABLE OF CONTENTS 4 16 COOLING SYSTEM .......................................... ........... 98 16.1 Cooling system ..................................... .......... 98 16.2 Checking the antifreeze and coolant level .......... 98 16.3 Checking the coolant level .
1 MEANS OF REPRESENTATIO N 5 1.1 Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). All work marked with this symbol requires specialist knowledge and technical understanding.
2 SAFETY ADVICE 6 2.1 Use definition - intended use (All EXC models) KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations.
2 SAFETY ADVICE 7 2.5 Safe operation Danger Danger of accidents Danger arising from the rider's judgement being impaired. – Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired.
3 IMPORTA NT NOTES 8 3.1 Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's Service & Warranty Booklet and in the KTM Dealer.net ; otherwise, all warranty claims will be void.
4 VIEW OF VEHICLE 9 4.1 View of vehicle, front left (example) B02140-10 1 Hand brake lever ( p. 13) 2 Kill switch ( p. 13) 2 Kill switch ( p. 14) 3 Clutch lever ( p. 13) 4 Chain guide 5 Air filter box lid 6 Side stand ( p. 19) 7 Shift lever ( p. 18) 8 Fuel tap ( p.
4 VIEW OF VEHICLE 10 4.2 View of vehicle, rear right (example) B02141-10 1 Filler cap 2 Throttle grip ( p. 13) 3 Chassis number ( p. 11) 4 Kick starter ( p.
5 SERIAL NUMBERS 11 5.1 Chassis number 401946-10 The chassis number is stamped on the right side of the steering head. 5.2 Type label 401946-10 The type label is fixed to the front of the steering head. 5.3 Key number (All EXC models) 402247-10 The key number for the steering lock is stamped onto the key connector.
5 SERIAL NUMBERS 12 5.6 Shock absorber part number 0 0 1 1 401948-10 The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side.
6 CONTROL S 13 6.1 Clutch lever 602726-10 (All 125/200 models) The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. B01496-10 (All 250/300 models) The clutch lever is fitted on the left side of the handlebar.
6 CONTROL S 14 6.5 Kill switch (Six Days EU) 102044-10 The kill switch is fitted on the left side of the handlebar. Possible states • Kill switch in the basic position – In this position, the ignition circuit is closed and the engine can be started.
6 CONTROL S 15 6.10 Light switch (Six Days EU) 102045-10 The light switch is fitted on the left side of the handlebar. Possible states Low beam on – Light switch is in the central position. In this position, the low beam and tail light are switched on.
6 CONTROL S 16 6.15 Electric starter button (All 200/250/30 0 EU/US models, 300 EXC BR) 602699-10 The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button in basic position • Electric starter button pressed – In this position, the electric starter is actuated.
6 CONTROL S 17 Warning Danger of poisoning Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician.
6 CONTROL S 18 6.22 Choke B00004-10 The choke lever is fitted on the left side of the carburetor. Activating the choke function frees an opening in the carburetor through which the engine can draw extra fuel. This creates a richer fuel-air mixture, as is required for a cold start.
6 CONTROL S 19 6.26 Side stand 401943-10 The side stand is on the left side of the vehicle. 401944-10 The side stand is used to park the motorcycle.
6 CONTROL S 20 6.29 Unlocking the steering (All EXC models) 400731-01 – Insert the key in the steering lock, turn it to the left, pull it out and turn it to the right. Remove the key. You can now steer the bike again. Info Never leave the key in the steering lock.
7 SPEEDOM ETER 21 7.1 Speedometer overview 401761-01 – Press the button to control different functions. – Press the button to control different functions. Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated.
7 SPEEDOM ETER 22 7.4 Setting the speedometer functions Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. Condition The motorcycle is stationary. 400318-01 – Repeatedly press the button briefly until H appears at the bottom right of the display.
7 SPEEDOM ETER 23 400321-01 – Repeatedly press the button briefly until LAP appears at the bottom right of the display. – Briefly press the button . LAP 1 appears on the left side of the display. – The laps 1 – 10 can be viewed with the button .
7 SPEEDOM ETER 24 Briefly press the button . Activates the flashing display and changes to the next display Press the button for 2 – 3 seconds. No function Briefly press the button . Deactivates the flashing display and changes to the next dis- play Press the button for 2 – 3 seconds.
7 SPEEDOM ETER 25 7.12 Setting the clock 400319-01 Condition • The motorcycle is stationary. – Repeatedly press the button briefly until CLK appears at the bottom right of the display. – Press the button for 2 – 3 seconds. Press the button for 2 – 3 seconds.
7 SPEEDOM ETER 26 7.15 Display mode SPEED/ODO (odometer) 400317-01 – Repeatedly press the button briefly until ODO appears at the bottom right of the display. The total traveled distance is shown in display mode ODO . Press the button for 2 – 3 seconds.
7 SPEEDOM ETER 27 Info The TR2 value can also be corrected manually during the journey with the but- ton and the button . If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0. Press the button for 2 – 3 seconds. Increases value of TR2 .
7 SPEEDOM ETER 28 7.21 Display mode SPEED/S1 (stop watch 1) 400327-01 – Repeatedly press the button briefly until S1 appears at the top right of the dis- play. S1 (Stop watch 1) shows the riding time based on TR1 and continues running as soon as an impulse arrives from the wheel speed sensor.
7 SPEEDOM ETER 29 Display Press the but- ton for 2 – 3 seconds. Briefly press the button . Press the but- ton for 2 – 3 seconds. Briefly press the button . Wait 3 – 5 sec- onds Wait 10 – 12 sec- onds Display mode SPEED/LAP (lap time) The stop watch and the lap time are reset.
8 PREPARIN G FOR USE 30 8.1 Advice on first use Danger Danger of accidents Danger arising from the rider's judgement being impaired. – Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired.
8 PREPARIN G FOR USE 31 – Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. – If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dis- tribution between the front and rear wheels.
8 PREPARIN G FOR USE 32 8.4 Preparations for riding on dry sand 600872-10 – Check the radiator cap. Value on the radiator cap 1.8 bar (26 psi) » If the displayed value does not equal the setpoint value: Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
8 PREPARIN G FOR USE 33 – Change the radiator cap. 600870-01 – Mount the rain cover for the air filter. Rain cover for air filter (59006021000) Info Read the KTM PowerParts installation instructions. – Adjust the carburetor jetting and setting. Info Your authorized KTM workshop can recommend the right carburetor tuning.
8 PREPARIN G FOR USE 34 – Change the radiator cap. 600868-01 – Adjust the secondary ratio to the terrain. Info The engine oil heats up quickly when the clutch is operated frequently due to an excessively high secondary drive. – Clean the chain. Chain cleaner ( p.
9 RIDING INSTRUCTIO NS 35 9.1 Checks and maintenance work when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the gear oil level.
9 RIDING INSTRUCTIO NS 36 – Pull out the choke lever all the way. (All 200/250/300 models) – Press the electric starter button or press the kick starter robustly through its full range. Info Do not turn the throttle. (All 125 models) – Press the kick starter robustly through its full range.
9 RIDING INSTRUCTIO NS 37 – On sandy, wet or slippery surfaces, use the rear brake. – Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed. 9.6 Stopping, parking Warning Risk of misappropriation Usage by unauthorize d persons.
9 RIDING INSTRUCTIO NS 38 9.8 Refueling Danger Fire hazard Fue l is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components.
10 SERVICE SCHEDUL E 39 10.1 Service schedule Every 40 operating hours/after every race Every 20 operating hours Check that the electrical equipment is functioning properly. ● ● Check and charge the battery. (All 200/250/300 models) ● ● Check the front brake linings.
10 SERVICE SCHEDUL E 40 10.2 Service work (as addition al order) Annually Every 80 operating hours/every 40 operating hours when used for motorsports Every 40 operating hours Once after 10 operating hours Change the front brake fluid. ● Change the rear brake fluid.
11 TUNING THE CHASSIS 41 11.1 Checking the basic chassis setting with the rider's weight Info When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.
11 TUNING THE CHASSIS 42 (All 250/300 models) Compression damping, low-speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing.
11 TUNING THE CHASSIS 43 B00792-10 – Turn adjusting screw clockwise up to the last perceptible click. Info Do not loosen nut ! – Turn counterclockw ise by the number of clicks corresponding to the shock absorber type.
11 TUNING THE CHASSIS 44 11.8 Checking the riding sag of the shock absorber 400990-10 – Measure distance of the unloaded rear wheel. ( p. 43) – With another person holding the motorcycle, the rider, wearing full protective cloth- ing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down a few times.
11 TUNING THE CHASSIS 45 Info Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring preload. – Tighten screw . Guideline Screw, shock absorber adjusting ring M5 5 Nm (3.7 lbf ft) Finishing work – Install the shock absorber.
11 TUNING THE CHASSIS 46 401000-01 – As with the shock absorber, smaller differences in the rider's weight can be com- pensated by the spring preload. – However, if the fork is often overloaded (hard end stop on compression), harder springs must be fit to avoid damage to the fork and frame.
11 TUNING THE CHASSIS 47 (250/300 Six Days) Compression damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 11.13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior.
11 TUNING THE CHASSIS 48 (250/300 Six Days) Rebound damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 11.14 Adjusting the spring preload of the fork (EXC, XC ‑ W, EXC Factory Edition) M00092-01 – Turn the adjusting screws counterclockwise all the way.
11 TUNING THE CHASSIS 49 11.16 Adjusting the handlebar position Warning Danger of accidents Handlebar breakage. – If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handle- bar. 101488-10 – Remove screws .
12 SERVICE WORK ON THE CHASSIS 50 12.1 Raising the motorcycle with the lift stand 401942-01 Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine.
12 SERVICE WORK ON THE CHASSIS 51 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 50) – Loosen the fork protection. ( p. 51) M00131-10 Main work – Push dust boots of both fork legs downwards.
12 SERVICE WORK ON THE CHASSIS 52 12.7 Removing the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 50) – Remove the front wheel. ( p. 86) – Remove the headlight mask with the headlight. ( p. 94) B00798-10 Main work – Remove screws and take off the clamp.
12 SERVICE WORK ON THE CHASSIS 53 M00592-10 (EXC Factory Edition) – Position the fork legs. Info Grooves are milled into the side of the upper end of the fork legs. The second milled groove (from the top) must be flush with the top edge of the upper triple clamp.
12 SERVICE WORK ON THE CHASSIS 54 12.10 Installing the fork protector 101327-10 Main work – Position the fork protection on the left fork leg. Mount and tighten screws . Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) – Position the fork protection on the right fork leg.
12 SERVICE WORK ON THE CHASSIS 55 602734-10 Main work – Remove screw . Remove screw . Pull off the upper triple clamp with the han- dlebar and hang it to one side. Info Protect the components against damage by covering them. Do not bend the cables and lines.
12 SERVICE WORK ON THE CHASSIS 56 B02153-10 – Tighten screws . Guideline Screw, bottom triple clamp M8 15 Nm (11.1 lbf ft) B02153-11 – Tighten screw . Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) B02153-12 – Tighten screw .
12 SERVICE WORK ON THE CHASSIS 57 12.14 Installing the lower triple clamp (Six Days, EXC Factory Edition) B01218-10 Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 137) – Insert the lower triple clamp with the steering stem.
12 SERVICE WORK ON THE CHASSIS 58 602739-10 – Tighten screw . Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) 602740-10 – Mount and tighten screw . Guideline Screw, top steering stem M8 17 Nm (12.5 lbf ft) Loctite ® 243™ 602741-10 – Tighten screws .
12 SERVICE WORK ON THE CHASSIS 59 400738-11 Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. » If there is noticeable play present: – Adjust the play of the steering head bearing.
12 SERVICE WORK ON THE CHASSIS 60 M00593-10 (EXC Factory Edition) – Loosen screws . Remove screw . – Loosen and retighten screw . Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) – Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
12 SERVICE WORK ON THE CHASSIS 61 12.19 Installing the front fender B02156-10 Main work – Position the front fender. Mount and tighten screws . Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) B02155-11 – Mount and tighten screws .
12 SERVICE WORK ON THE CHASSIS 62 Guideline Screw, bottom shock absorber M12 80 Nm (59 lbf ft) Loctite ® 2701™ Info The heim joint for the shock absorber at the swing arm is Teflon coated. It must not be lubricated with grease or with other lubricants.
12 SERVICE WORK ON THE CHASSIS 63 B00817-10 – Mount and tighten screw of the seat fixation. Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) 12.24 Removing the air filter box lid B02159-10 – Pull off the air filter box lid in area sideways and remove it toward the front.
12 SERVICE WORK ON THE CHASSIS 64 12.27 Installing the air filter 301262-10 Main work – Mount the clean air filter on the air filter support. – Grease the air filter in area . Long-life grease ( p. 137) B02160-11 – Insert both parts together, position them and fasten them using air filter holder .
12 SERVICE WORK ON THE CHASSIS 65 12.29 Sealing the air filter box Preparatory work – Remove the air filter box lid. ( p. 63) 401527-10 Main work – Seal the air filter box in the marked area . Finishing work – Install the air filter box lid.
12 SERVICE WORK ON THE CHASSIS 66 401045-10 Main work – Remove screws . – Pull out inner tube . – Remove glass fiber yarn filling from the inner tube. – Clean the parts that need to be reinstalled and check for damage. – Mount the new glass fiber yarn filling on the inner tube.
12 SERVICE WORK ON THE CHASSIS 67 602721-10 – Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank. 12.34 Installing the fuel tank Danger Fire hazard Fue l is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first.
12 SERVICE WORK ON THE CHASSIS 68 12.35 Checking the chain for dirt 400678-01 – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 68) 12.36 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip.
12 SERVICE WORK ON THE CHASSIS 69 M00102-10 Main work – Pull the chain at the end of the chain sliding piece upward to measure chain ten- sion . Info The bottom chain section must be taut. When the chain guard is mounted, it must be possible to pull up the chain at least to the point where it makes contact with chain guard .
12 SERVICE WORK ON THE CHASSIS 70 12.39 Checking the chain, rear sprocket , engine sprocket and chain guide Preparatory work – Raise the motorcycle with the lift stand. ( p. 50) 400227-01 Main work – Shift gear to neutral. – Check the rear sprocket and engine sprocket for wear.
12 SERVICE WORK ON THE CHASSIS 71 B00824-01 – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check the chain sliding piece for tightness.
12 SERVICE WORK ON THE CHASSIS 72 12.41 Checking the swingarm 401341-01 – Check the swingarm for damage, cracking, and deformation. » If the swingarm shows signs of damage, cracking, or deformation: – Change the swingarm. Info A damaged swingarm must always be changed.
12 SERVICE WORK ON THE CHASSIS 73 12.43 Checking the rubber grip 401197-01 – Check the rubber grips on the handlebar for damage and wear and to ensure they are firmly seated. » If a rubber grip is damaged, worn, or loose: – Change and secure the rubber grip.
12 SERVICE WORK ON THE CHASSIS 74 12.46 Checking/co rrecting the fluid level of the hydrau lic clutch Info The fluid level rises with increasing wear of the clutch lining discs. 400245-10 (All 125/200 models) – Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi- tion.
12 SERVICE WORK ON THE CHASSIS 75 B02164-10 – Fill bleeding syringe with the appropriate hydraulic fluid. Bleed syringe (503290500 00) Hydraulic fluid (15) ( p. 136) – On the slave cylinder of the clutch, remove bleeder screw and mount bleed- ing syringe .
12 SERVICE WORK ON THE CHASSIS 76 12.48 Removing the engine guard (Six Days, EXC Factory Edition) B01204-10 – Turn quick release counterclockwise until it disengages.
13 BRAKE SYSTEM 7 7 13.1 Checking the free travel of the hand brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due to overheating.
13 BRAKE SYSTEM 7 8 13.4 Checking the brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay.
13 BRAKE SYSTEM 7 9 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
13 BRAKE SYSTEM 8 0 13.8 Changing the front brake linings Warning Danger of accident Brake system failure. – Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Br ake fluid can cause skin irritation on contact.
13 BRAKE SYSTEM 8 1 100397-01 – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. M00112-01 – Insert the new brake linings, insert the pin, and mount the cotter pins. Info Always change the full set of brake linings.
13 BRAKE SYSTEM 8 2 402026-10 – Disconnect spring . M00595-10 – Loosen nut and, with push rod , turn it back until you have maximum free travel. – To adjust the basic position of the foot brake lever to individual requiremen ts, loosen nut and turn screw accordingly.
13 BRAKE SYSTEM 8 3 13.12 Adding brake fluid for the rear brake Warning Danger of accidents Brake system failure. – If the brake fluid level drops below the specified marking or the specified value, this is an indication that the brake system is leaking or that the brake linings are completely worn down.
13 BRAKE SYSTEM 8 4 13.14 Changing the brake linings of the rear brake Warning Danger of accident Brake system failure. – Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Br ake fluid can cause skin irritation on contact.
13 BRAKE SYSTEM 8 5 100407-10 – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. M00115-01 – Insert the new brake linings, insert the pin, and mount the cotter pins. Info Always change the brake linings in pairs.
14 WHEELS, TIRES 86 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 50) M00116-10 Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes.
14 WHEELS, TIRES 87 M00117-11 – Lift the front wheel into the fork, position it, and insert the wheel spindle. The brake linings are correctly positioned.
14 WHEELS, TIRES 88 14.4 Installing the rear wheel Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
14 WHEELS, TIRES 89 400602-10 – Check the front and rear tires for cuts, run-in objects and other damage. » If the tire exhibits cuts, run-in objects or other damage: – Change the tire. – Check the depth of the tread. Info Note local national regulations concerning the minimum tread depth.
14 WHEELS, TIRES 90 400694-01 – Briefly strike each spoke with the tip of a screwdriver. Info The tone frequency depends on the length of the spoke and the spoke diam- eter. If you hear different tone frequencies from different spokes of equal length and diameter, this is an indication of different spoke tensions.
15 ELECTRIC AL SYSTEM 91 15.1 Removing the battery (All 200/250/300 models) Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles.
15 ELECTRIC AL SYSTEM 92 15.3 Recharging the battery (All 200/250/30 0 models) Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles.
15 ELECTRIC AL SYSTEM 93 15.4 Changing the main fuse (All 200/250/300 models) Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never bypass or repair fuses. Info The main fuse protects all power consumers of the vehicle.
15 ELECTRIC AL SYSTEM 94 15.5 Removing the headlight mask with the headlight 602762-10 – Switch off all power consumers and switch off the engine. – Remove screw and take off the clamp. – Release rubber straps . Slide the headlight mask up and swing it forward.
15 ELECTRIC AL SYSTEM 95 602762-11 – Position the headlight mask and fix it with rubber straps . The holding lugs engage. – Position the brake line and wiring harness. Put the clamp on and mount and tighten screw . Finishing work – Check the headlight setting.
15 ELECTRIC AL SYSTEM 96 101722-10 Main work – Remove the screw on the rear of the turn signal housing. – Carefully remove turn signal glass . – Lightly squeeze orange cap in the area of the holding lugs and take it off.
15 ELECTRIC AL SYSTEM 97 15.11 Changing the speedometer battery Preparatory work – Remove the headlight mask with the headlight. ( p. 94) 602746-10 Main work – Remove screws . – Pull the speedometer upward out of the holder. 602748-10 – Using a coin, turn protection cap all the way counterclockwise and remove it.
16 COOLING SYSTEM 98 16.1 Cooling system B02167-10 (All 125/200 models) Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap .
16 COOLING SYSTEM 99 16.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot.
16 COOLING SYSTEM 100 B02168-11 (All 250/300 models) – Remove screw . Take off radiator cap . – Completely drain the coolant. – Mount and tighten screw with a new seal ring. Guideline Drain plug, water pump cover M10x1 15 Nm (11.1 lbf ft) 16.
16 COOLING SYSTEM 101 – Place the vehicle back on a level surface. M00597-10 – Fill the radiator completely with coolant. – Mount radiator cap .
17 TUNING THE ENGINE 102 17.1 Checking the play in the throttle cable 400192-10 – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back- wards and forwards to ascertain the play in the throttle cable.
17 TUNING THE ENGINE 103 The idle speed is adjusted with adjusting screw . The idle mixture is adjusted with the idle air adjusting screw . 500282-01 Idle air range A Operation with the throttle slide closed. This range is influenced by adjusting screw and the idle air adjusting screw .
17 TUNING THE ENGINE 104 – Adjust the idle speed with adjusting screw . Guideline Choke function deactivated – The choke lever is pushed in all the way. ( p. 18) Idle speed 1,400… 1,500 rpm – Turn idle air adjusting screw slowly in a clockwise direction until the idle speed begins to fall.
17 TUNING THE ENGINE 105 17.6 Checking the basic position of the shift lever 400692-10 – Sit on the vehicle in the riding position and determine the distance between the upper edge of your boot and the shift lever. Distance between shift lever and upper edge of boot 10… 20 mm (0.
17 TUNING THE ENGINE 106 B02129-10 Main work – Remove screws . B00056-11 – Take cap , adjusting spring , auxiliary spring , and spring insert out of the clutch cover.
18 SERVICE WORK ON THE ENGINE 107 18.1 Checking the gear oil level Info The gear oil level must be checked while the engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. B02173-10 Main work (All 125/200 models) – Remove screw from the opening used to check the gear oil level.
18 SERVICE WORK ON THE ENGINE 108 18.3 Draining the gear oil Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.
18 SERVICE WORK ON THE ENGINE 109 – Mount and tighten the oil filler plug. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
18 SERVICE WORK ON THE ENGINE 110 – Start the engine and check that it is oil-tight. Finishing work – Check the gear oil level. ( p. 107).
19 CLEANING , CARE 111 19.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors , cables, bearings, etc.
19 CLEANING , CARE 112 19.2 Checks and maintenance steps for winter operation Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro- sion. If the vehicle was operated in road salt, clean it with cold water after riding.
20 STORAGE 113 20.1 Storage Warning Danger of poisoning Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician.
21 TROUBLE SHOOTING 114 Faults Possible cause Action The engine cannot be cranked (elec- tric starter) (All 200/250/300 models) Operating error – Carry out the start procedure. ( p. 35) Battery discharged – Recharge the battery. ( p. 92) – Check the charging voltage.
21 TROUBLE SHOOTING 115 Faults Possible cause Action Engine stalls or is popping into the carburetor Engine takes in bad air – Check the intake flange and carburetor for tightness. The connector or ignition coil is loose or oxidized – Clean the connector and treat it with contact spray.
22 TECHNICA L DATA 116 22.1 Engine 22.1.1 All 125 models Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 124.
22 TECHNICA L DATA 117 5th gear 17:19 6th gear 22:20 Ignition Contactless controlled fully electronic ignition with digital igni- tion adjustment, type Kokusan Ignition point (BTDC) 1.6 mm (0.063 in) Spark plug NGK BR 8 EG Spark plug electrode gap 0.60 mm (0.
22 TECHNICA L DATA 118 Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing Needle bearing Piston pin bearing Needle bearing Pistons Aluminum cast Piston rings 2 half keystone rings X (upper edge of piston to upper edge of cylinder) 0… 0.
22 TECHNICA L DATA 119 Screw, gear oil level check M6 10 Nm (7.4 lbf ft) – Screw, ignition system/sta tor (All 200 models) M6 8 Nm (5.9 lbf ft) Loctite ® 243™ Screw, intake flange/reed valve housing M6 10 Nm (7.4 lbf ft) – Screw, kick starter stop plate M6 10 Nm (7.
22 TECHNICA L DATA 120 Screw, shift lever M6 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, slave cylinder of the clutch M6 10 Nm (7.4 lbf ft) – Screw, starter motor M6 8 Nm (5.9 lbf ft) – Screw, stator M6 8 Nm (5.9 lbf ft) Loctite ® 243™ Screw, water pump cover M6 10 Nm (7.
22 TECHNICA L DATA 121 Front 2.5 mm (0.098 in) Rear 3.5 mm (0.138 in) Tire air pressure, road (All EXC models) Front 1.5 bar (22 psi) Rear 1.5 bar (22 psi) Tire air pressure off road Front 1.
22 TECHNICA L DATA 122 22.6 Tires Validity Front tires Rear tires (125 EXC EU) 80/100 - 21 M/C 51M TT MAXXIS MAXX CROSS SI PRO 120/90 - 18 M/C 65R TT MAXXIS MAXX ENDURO (125 EXC Six Days EU, 125 EXC F.
22 TECHNICA L DATA 123 Comfort 20 clicks Standard 18 clicks Sport 16 clicks Spring preload - Preload Adjuster Comfort 1 turn Standard 2 turns Sport 2 turns Spring length with preload spacer(s) Weight of rider: 65… 75 kg (143… 165 lb.) 513 mm (20.2 in) Weight of rider: 75… 85 kg (165… 187 lb.
22 TECHNICA L DATA 124 Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 3.8 N/mm (21.7 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 4.0 N/mm (22.8 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 4.2 N/mm (24 lb/in) Fork length 932 mm (36.
22 TECHNICA L DATA 125 Comfort 28 clicks Standard 24 clicks Sport 22 clicks Spring preload Comfort 7 mm (0.28 in) Standard 7 mm (0.28 in) Sport 7 mm (0.28 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 66 N/mm (377 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.
22 TECHNICA L DATA 126 Screw, top steering stem (EXC, XC ‑ W) M8 20 Nm (14.8 lbf ft) – Screw, top steering stem (Six Days, EXC Factory Edition) M8 17 Nm (12.5 lbf ft) Loctite ® 243™ Screw, top triple clamp (EXC, XC ‑ W) M8 20 Nm (14.8 lbf ft) – Screw, top triple clamp (Six Days, EXC Factory Edition) M8 17 Nm (12.
22 TECHNICA L DATA 127 22.10 Carburetor 22.10.1 All 125 models Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK125 Needle position 4th position from top Jet needle N84I (N1EF / N1EG) Main jet 100 (172/175) Idling jet 38x38 (42/45) Starting jet 50 (85) Idle air adjusting screw Open 2.
22 TECHNICA L DATA 128 402138-01 M/FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Does not apply to sand surfac.
22 TECHNICA L DATA 129 22.10.3 200 EXC EU Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK027 Needle position 3rd position from top Jet needle NPRH (N1EH / N1EI / N1EJ) Main jet 100 (162/165) Idling jet 35x35 (40) Starting jet 50 (85) Idle air adjusting screw Open 1.
22 TECHNICA L DATA 130 402139-01 M/FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Does not apply to sand surfac.
22 TECHNICA L DATA 131 22.10.7 250 EXC EU, 250 EXC Six Days EU, 250 EXC Factory Edition EU Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK028 Needle position 2nd position from top Jet needle N84K (N2ZW / N2ZH / N2ZJ) Main jet 110 (172/175) Idling jet 38x38 (38/40) Starting jet 50 (85) Idle air adjusting screw Open 1.
22 TECHNICA L DATA 132 402140-01 M/FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Does not apply to sand surfac.
22 TECHNICA L DATA 133 22.10.11 300 EXC EU, 300 EXC Six Days EU, 300 EXC Factory Edition EU Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK029 Needle position 2nd position from top Jet needle N84K (N8RG / N8RH) Main jet 115 (170/172/175) Idling jet 38X38 (35) Starting jet 50 (85) Idle air adjusting screw Open 1.
22 TECHNICA L DATA 134 402141-01 M/FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Does not apply to sand surfaces! 22.10.15 General carburetor tuning 0 0 4 4 0 0 3 3 0 0 5 5 0 0 2 2 0 0 1 1 B00075-10 1.
23 SUBSTAN CES 135 Brake fluid DOT 4 / DOT 5.1 Standard/classific ation – DOT Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corre- sponding properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ® – Brake Fluid DOT 5.
23 SUBSTAN CES 136 Hydraulic fluid (15) Standard/classific ation – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. Recommended supplier Motorex ® – Hydraulic Fluid 75 Shock absorber fluid (SAE 2.
24 AUXILIAR Y SUBSTANCES 137 Air filter cleaner Recommended supplier Motorex ® – Racing Bio Dirt Remover Chain cleaner Recommended supplier Motorex ® – Chain Clean Fuel additive Recommended supp.
24 AUXILIAR Y SUBSTANCES 138 Universal oil spray Recommended supplier Motorex ® – Joker 440 Synthetic.
25 STANDAR DS 139 JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation.
INDEX 140 INDEX A Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Air filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 installing . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX 141 Fork basic setting, checking . . . . . . . . . . . . . . . . . . . . . . . 45 Fork legs bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 dust boots, cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 51 installing .
INDEX 142 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 riding sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . 44 spring preload, adjusting .
An important point after buying a device KTM 200 XC-W (2015) (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought KTM 200 XC-W (2015) yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data KTM 200 XC-W (2015) - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, KTM 200 XC-W (2015) you will learn all the available features of the product, as well as information on its operation. The information that you get KTM 200 XC-W (2015) will certainly help you make a decision on the purchase.
If you already are a holder of KTM 200 XC-W (2015), but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime KTM 200 XC-W (2015).
However, one of the most important roles played by the user manual is to help in solving problems with KTM 200 XC-W (2015). Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device KTM 200 XC-W (2015) along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
