KTM 200 EXC 2016, Setup Instructions

Page 1: ...SETUP INSTRUCTIONS 2016 125 EXC 200 EXC 200 XC W 250 EXC 250 XC W 300 EXC 300 XC W Art no 3213437en ...

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Page 3: ...s well as to stop production of a particular model without prior notice KTM accepts no liability for delivery options devi ations from illustrations and descriptions misprints and other errors The models portrayed partly contain special equipment that does not belong to the regular scope of supply 2015 KTM Sportmotorcycle GmbH Mattighofen Austria All rights reserved Reproduction even in part as we...

Page 4: ...page Indicates information with more details or tips Indicates the result of a testing step Denotes a voltage measurement Denotes a current measurement Denotes a resistance measurement 1 2 Formats used The typographical formats used in this document are explained below Proprietary name Identifies a proprietary name Name Identifies a protected name Brand Identifies a trademark Underlined terms Refe...

Page 5: ...otorcycle from falling over 402050 01 Together with an assistant take the vehicle off the palette Position the vehicle on a lift stand Check the vehicle for transport damage B02008 10 Package 12 Remove the box and the plastic packaging Info An assistant prevents the motorcycle from falling over To avoid damaging the motorcycle during the setup leave the protective film on the vehicle until you hav...

Page 6: ...he screws of the triple clamp Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Screw bottom triple clamp M8 15 Nm 11 1 lbf ft Info The rebound damping is located in right fork leg REB red adjusting screw The compression damping is located in left fork leg COMP white adjusting screw Grooves are milled into the side of the upper end of the fork legs The topmost milled groove must be flush with ...

Page 7: ...andlebar clamps Mount and tighten the screws evenly Guideline Screw handlebar clamp M8 20 Nm 14 8 lbf ft Info The markings on the handlebar should be at the center of the handlebar clamps Keep the gap widths equal when tightening Position the speedometer and connector board Mount and tighten the screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft B02185 01 XC W Six Days EXC EU 300 EXC BR...

Page 8: ...l wiring harness against the main wiring harness and secure with cable ties Install the fuel tank p 11 Position the turn signal indicator lamp in the speedometer holder B02188 10 Insert the black and violet cables of bulb included in the separate enclosure into the socket and position it in the turn signal indicator lamp Secure turn signal relay with a cable tie and plug in the connector Position ...

Page 9: ...ct the connector of the right turn signal with the connector that is marked green Connect the connector of the left turn signal with the connector that is marked red 800035 10 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 Avoid contact with battery a...

Page 10: ... All EXC models Mount the mirror clamps on both sides B00909 01 Mount and tighten the rear mirror on both sides Mount the reflector Set kilometers or miles p 17 Set the speedometer functions p 18 Set the clock p 18 Position all controls in their exact positions on the handlebar Tighten all screws Refuel p 17 Prepare the vehicle according to the specifications in the KTM Dealer net for han dover to...

Page 11: ...l away or fall over Always place the vehicle on a firm and even surface 401943 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle press side stand to the ground with your foot and lean the motorcycle on it Info When you are riding the side stand must be folded up and secured with the rubber band 3 3 Removing the seat B00817 10 Remove screw Lift up the seat at...

Page 12: ...thing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that has been contaminated with fuel Store fuel properly in a suitable canister and keep away from children Preparatory work Remove the s...

Page 13: ...sician immediately Change clothing that is contaminated with fuel 602721 01 Main work Check the routing of the throttle cable Position the fuel tank and fit the two spoilers to the sides of the radiator bracket Make sure that no cables are trapped or damaged 602720 10 Mount the fuel tank vent hose Mount and tighten screw with the rubber bushing Guideline Remaining screws chassis M6 10 Nm 7 4 lbf f...

Page 14: ...Remove the motorcycle from the lift stand p 9 3 8 Installing the front 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 102293 11 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change the front wheel bearing Cle...

Page 15: ...ower steadily The charge state and the type of charge are very important for the service life of the battery Rapid recharging with a high charging current shortens the battery s service life If the charging current charging voltage and charging time are exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted from starting the vehicle repe...

Page 16: ...be mounted under screws and cable sockets with the claws toward the battery terminal Slide positive terminal cover over the positive terminal Position negative cable and mount and tighten the screw Guideline Screw battery terminal M5 2 5 Nm 1 84 lbf ft Finishing work Mount the seat p 9 3 11 Installing the front fender B02156 10 Main work Position the front fender Mount and tighten screws Guideline...

Page 17: ...g the headlight setting 400726 10 Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight Make another mark a distance under the first mark Guideline Distance 5 cm 2 in Position the vehicle vertically a distance away from the wall Guideline Distance 5 m 16 ft The rider now sits down on the motorcycle Switch...

Page 18: ...m and may emerge if overfilled Follow the instructions on refueling 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 Immediately clean contaminated areas on the skin with soap and water If fuel is swal...

Page 19: ...ngine Open the filler cap p 16 400382 10 Fill the fuel tank with fuel up to measurement Guideline Measurement of 35 mm 1 38 in Total fuel tank capacity approx EXC EU EXC Six Days EU 300 EXC BR 9 5 l 2 51 US gal Super unleaded 95 octane mixed with 2 stroke engine oil 1 60 p 20 EXC EU EXC Six Days EU Super unleaded type C ROZ 95 RON 95 PON 91 mixed with 2 stroke engine oil 1 60 p 20 300 EXC BR Total...

Page 20: ...losed Repeatedly press the button briefly until the desired function flashes The selected function flashes Activating the function Press the button The symbol continues to appear in the display and the next function appears Deactivating a function Press the button The symbol disappears in the display and the next function appears 3 20 Setting the clock Condition The motorcycle is stationary 400330...

Page 21: ...Screw bottom triple clamp Six Days EXC EU AU M8 15 Nm 11 1 lbf ft Screw chain sliding piece M8 15 Nm 11 1 lbf ft Screw engine brace M8 33 Nm 24 3 lbf ft Loctite 2701 Screw fork stub M8 15 Nm 11 1 lbf ft Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Screw handlebar clamp M8 20 Nm 14 8 lbf ft Screw side stand attachment M8 35 Nm 25 8 lbf ft Loctite 2701 Screw subframe M8 35 Nm 25 8 lbf ...

Page 22: ...0 Super unleaded ROZ 95 RON 95 PON 91 p 20 Recommended supplier Motorex Cross Power 2T Super unleaded type C ROZ 95 RON 95 PON 91 mixed with 2 stroke engine oil 1 60 Standard classification Resolução n 6 da ANP Agência Nacional do Petróleo ROZ 95 RON 95 PON 91 mixed with 2 stroke engine oil JASO FD p 22 1 60 Mixture ratio 1 60 Engine oil 2 stroke p 20 Super unleaded type C ROZ 95 RON 95 PON 91 p 2...

Page 23: ...6 AUXILIARY SUBSTANCES 21 Long life grease Recommended supplier Motorex Bike Grease 2000 ...

Page 24: ...ification for a 2 stroke engine oil that was specifically developed for the extreme demands of racing Thanks to first rate synthetic esters and specially designed additives superb combustion is achieved even under extreme operating conditions ...

Page 25: ... 3213437en 3213437en 11 2015 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...