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KTM 200 EXC - 2016 Manual

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TABLE OF CONTENTS 3
11.10 Adjusting the riding sag ............................... 45
11.11 Checking the basic setting of the fork ............... 45
11.12 Adjusting the compression damping of the
fork ............................................................... 46
11.13 Adjusting the rebound damping of the fork ........ 47
11.14 Adjusting the spring preload of the fork (EXC,
XC‑W) ............................................................ 48
11.15 Handlebar position.......................................... 49
11.16 Adjusting the handlebar position ................... 50
12 SERVICE WORK ON THE CHASSIS.............................. 52
12.1 Raising the motorcycle with the lift stand.......... 52
12.2 Removing the motorcycle from the lift stand...... 52
12.3 Bleeding the fork legs...................................... 52
12.4 Cleaning the dust boots of the fork legs............. 53
12.5 Removing the fork protector ............................. 53
12.6 Installing the fork protector.............................. 54
12.7 Removing the fork legs ................................. 54
12.8 Installing the fork legs ................................. 55
12.9 Removing the lower triple clamp
(200 XC‑W US, 250 XC‑W US, 300 EXC BR,
300 XC‑W US)................................................ 56
12.10 Removing the lower triple clamp (EXC EU,
EXC Six Days, EXC EU/AU, Six Days) ................ 57
12.11 Installing the lower triple clamp
(200 XC‑W US, 250 XC‑W US, 300 EXC BR,
300 XC‑W US)................................................ 57
12.12 Installing the lower triple clamp (EXC EU,
EXC Six Days, EXC EU/AU, Six Days) ................ 59
12.13 Checking the play of the steering head
bearing .......................................................... 62
12.14 Adjusting the play of the steering head
bearing ....................................................... 63
12.15 Greasing the steering head bearing ................ 64
12.16 Removing the front fender ............................... 64
12.17 Installing the front fender ................................ 65
12.18 Removing the shock absorber ....................... 65
12.19 Installing the shock absorber ........................ 65
12.20 Removing the seat .......................................... 66
12.21 Mounting the seat........................................... 66
12.22 Removing the air filter box lid .......................... 67
12.23 Installing the air filter box lid ........................... 67
12.24 Removing the air filter ................................. 67
12.25 Installing the air filter .................................. 68
12.26 Cleaning the air filter and air filter box .......... 68
12.27 Sealing the air filter box ............................... 69
12.28 Removing the main silencer ............................. 69
12.29 Installing the main silencer.............................. 69
12.30 Changing the glass fiber yarn filling of the
main silencer .............................................. 69
12.31 Removing the fuel tank ................................ 70
12.32 Installing the fuel tank ................................. 71
12.33 Checking the chain for dirt............................... 72
12.34 Cleaning the chain .......................................... 72
12.35 Checking the chain tension.............................. 72
12.36 Adjusting the chain tension.............................. 73
12.37 Checking the chain, rear sprocket, engine
sprocket and chain guide................................. 74
12.38 Checking the frame ..................................... 75
12.39 Checking the swingarm ................................ 76
12.40 Checking the routing of the throttle cable.......... 76
12.41 Checking the rubber grip ................................. 77
12.42 Additionally securing the rubber grip................. 77
12.43 Adjusting the basic position of the clutch
lever .............................................................. 77
12.44 Checking/correcting the fluid level of the
hydraulic clutch.............................................. 78
12.45 Changing the hydraulic clutch fluid ............... 78
12.46 Removing the engine guard.............................. 80
12.47 Installing the engine guard .............................. 80
13 BRAKE SYSTEM ........................................................ 81
13.1 Checking the free travel of the hand brake
lever .............................................................. 81
13.2 Adjusting free travel of hand brake lever (All
EXC models)................................................... 81
13.3 Adjusting the basic position of the hand brake
lever (All XC-W models) ................................... 81
13.4 Checking the brake discs ................................. 82
13.5 Checking the front brake fluid level .................. 82
13.6 Adding front brake fluid ............................... 82
13.7 Checking the front brake linings ....................... 83
13.8 Changing the front brake linings ................... 84
13.9 Checking the free travel of foot brake lever ........ 85
13.10 Adjusting the basic position of the foot brake
lever ........................................................... 85
13.11 Checking the rear brake fluid level.................... 86
13.12 Adding brake fluid for the rear brake ............. 87
13.13 Checking the rear brake linings ........................ 87
13.14 Changing the brake linings of the rear
brake ......................................................... 88
14 WHEELS, TIRES ........................................................ 90
14.1 Removing the front wheel ............................. 90
14.2 Installing the front wheel ............................. 90
14.3 Removing the rear wheel .............................. 91
14.4 Installing the rear wheel ............................... 92
14.5 Checking the tire condition .............................. 92
14.6 Checking the tire air pressure........................... 93
14.7 Checking the spoke tension.............................. 93
15 ELECTRICAL SYSTEM ................................................ 95
15.1 Removing the battery
(All 200/250/300 models)............................... 95
15.2 Installing the battery
(All 200/250/300 models)............................... 95
15.3 Recharging the battery
(All 200/250/300 models)............................... 96
15.4 Changing the main fuse
(All 200/250/300 models)............................... 97
15.5 Removing the headlight mask with the
headlight........................................................ 98
15.6 Refitting the headlight mask with the
headlight........................................................ 98
15.7 Changing the headlight bulb ............................ 99
15.8 Changing the turn signal bulb (All EXC
models).......................................................... 99
15.9 Checking the headlight setting ....................... 100
15.10 Adjusting the headlight range......................... 100
15.11 Changing the speedometer battery .................. 101
16 COOLING SYSTEM ................................................... 102
16.1 Cooling system ............................................. 102
16.2 Checking the antifreeze and coolant level........ 102
16.3 Checking the coolant level ............................. 103
16.4 Draining the coolant .................................. 103
16.5 Refilling with coolant ................................. 104
17 TUNING THE ENGINE.............................................. 106
17.1 Checking the play in the throttle cable ............ 106
17.2 Adjusting the play in the throttle cable ........ 106
… 5 …


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