Gebruiksaanwijzing /service van het product EXC 200 EXC van de fabrikant KTM
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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.
ENGLISH 1 IMPORTANT » Please insert the serial numbers of your motorcycle in the boxes below Frame number Engine number Key number Stamp of dealer All information contained is without obligation.
ENGLISH 2 INTRODUCTION » W e would like to congratulate you on your purchase of a KTM motorcycle. Y ou are now the owner of a state-of-the-art sports motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appropriately .
ENGLISH 3 IMPORTANT WARRANTY AND GUARANTEE INFORMATION » KTM sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions. The motorcycles comply with the regulations and categories currently in effect with the leading interna- tional motorcycle associations.
ENGLISH 4 TABLE OF CONTENTS » Page SERIAL NUMBER LOCA TIONS . . . . . . . . . . . . . . . . . . . .5 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Engine number , engine type . . . . . . . . . . . . . . . . . . . .5 OPERA TION INSTRUMENTS .
ENGLISH 5 SERIAL NUMBER LOCATIONS » Chassis number The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 1. Engine number, engine type The engine number and the engine type are stamped into the left side of the engine below the engine sprocket.
ENGLISH 6 OPERATION INSTRUMENTS » TEST All of the display segments briefly light up for the display function test. WS (wheel size) The display changes and the circumference of the front wheel is briefly dis- played in millimeters (2205 mm corresponds to a front wheel circumference of 21" with production tires).
ENGLISH 7 OPERATION INSTRUMENTS » SPEED / LAP (lap time) display mode Y ou can use the manual stop watch to stop and store up to 10 lap times, which you can view in the LAP/LAP display mode (see below). LAP displays the lap times in hours, minutes and seconds.
ENGLISH 8 LAP / LAP display mode (to view lap times) The LAP/LAP display mode will only be shown if lap times have been stored and the front wheel has stopped. It will display the lap number and the stopped lap time in hours, minutes and seconds. Press the + button to access the next lap time.
ENGLISH 9 Kilometers or miles The unit (kilometers or miles) can also be changed. The ODO figure will be retained and converted accordingly . The TR1, A1, S1, TR2 and A2 figures will be cleared. T o select the unit, select the SPEED/H mode and hold the | button for 3 sec- onds to access the SETUP menu.
ENGLISH 10 OPERATION INSTRUMENTS » Setting the clock T o set the clock, switch the ignition off and select the SPEED/CLK mode. Press and hold the | button for 3 seconds. The blinking digits can be changed using the + and – buttons. Press the | button to move to the next digit.
ENGLISH 11 OPERATION INSTRUMENTS » Short circuit button (SX) The short circuit button [1] turns off the engine. When pressing this button, the ignition circuit is short-circuited. Combination switch (EXC) The light switch has 2, respectively 3 switch positions.
ENGLISH 12 Filler cap T o open it: turn filler cap counter-clockwise. T o close it: put filler cap back on and tighten it by turning it clockwise. Install tank breather hose [1] without kinks. Filler cap (XC, XC-W) To open the filler cap: T urn the filler cap 45 ° counter -clockwise.
ENGLISH 13 OPERATION INSTRUMENTS » Kickstarter The kickstarter is mounted on the left side of the engine. Its upper part can be swivelled. Foot brake pedal The foot brake pedal is disposed in front of the right foot rest. Its basic posi- tion can be adjusted to your seat position (see maintenance work).
ENGLISH 14 Compression damping of fork Hydraulic compression damping determines the reaction when the fork is com- pressed. The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs.
ENGLISH 15 OPERATION INSTRUMENTS » Compression damping of shock absorber (XC-W, EXC) The compression damping (during compression) can be adjusted for the XC- W and EXC shock absorbers (Mono Compression Control). The degree of damping can be adjusted by turning adjusting screw [1] with a screwdriver .
ENGLISH 16 GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE » Instructions for your first ride – Make sure the work for the "pre-delivery inspection" was per- formed by your authorized KTM workshop. The DELIVERY CER- TIFICA TE and SERVICE MANUAL will be handed over when you pick up your vehicle.
ENGLISH 17 DRIVING INSTRUCTIONS » What you should check before each start When you start off, the motorcycle must be in a perfect technical condition. For safety reasons, you should make it a habit to perform an overall check of your motorcycle before each start.
ENGLISH 18 DRIVING INSTRUCTIONS » Starting when the engine is cold 1 Open fuel tap 2 T urn on ignition or emergency OFF switch 3 Swing up the side stand 4 Put the gear in neutral 5 Activate cold-starting aid (choke) 6 Leave throttle closed or open it no more than 1/3 and kick down kick- starter vigorously all the way .
ENGLISH 19 DRIVING INSTRUCTIONS » – AFTER F ALLING WITH THE MOTORCYCLE, CHECK ALL ITS FUNC- TIONS THOROUGHL Y BEFORE USING IT AGAIN. – A TWISTED HANDLEBAR MUST AL WA YS BE REPLACED. DO NOT ADJUST THE HANDLEBAR, IT WILL LOSE ST ABILITY . – HIGH RPM RA TES WHEN THE ENGINE IS COLD HAVE AN ADVERSE EFFECT ON THE LIFE OF YOUR ENGINE.
ENGLISH 20 PERIODIC MAINTENANCE SCHEDULE » 125/200 SX/XC/EXC/XC-W 2006 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY after every race 1st service after 10 hours every 20 hours ever.
ENGLISH 21 PERIODIC MAINTENANCE SCHEDULE » 125/200 SX/XC/EXC/XC-W 2006 IMPORTANT RECOMMENDED MAINTENANCE WORK THAT CAN BE CARRIED OUT BY EXTRA ORDER Every 20 hours Every 40 hours Every 80 hours At le.
ENGLISH 22 PERIODIC MAINTENANCE SCHEDULE » 250/300 SX/XC/EXC/XC-W 2006 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY after every race 1st service after 10 hours every 20 hours ever.
ENGLISH 23 250/300 SX/XC/EXC/XC-W 2006 IMPORTANT RECOMMENDED MAINTENANCE WORK THAT CAN BE CARRIED OUT BY EXTRA ORDER Every 20 hours Every 40 hours Every 80 hours Every 120 hours At least once a year E.
ENGLISH 24 MAINTENANCE WORK ON CHASSIS AND ENGINE » MAINTENANCE AND ADJUSTING WORK MARKED WITH AN ASTERISK * REQUIRES EXPERT SKILLS AND TECHNICAL KNOW -HOW . FOR YOUR OWN SAFETY , AL W AYS HA VE SUCH WORK PERFORMED BY A SPECIALIZED KTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALL Y SERV- ICED BY APPROPRIA TEL Y QUALIFIED, SKILLED ST AFF .
ENGLISH 25 MAINTENANCE WORK ON CHASSIS AND ENGINE » 50 SPRING RA TE 55 60 65 70 75 80 RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM 76-250 69-250 for example 125 SX Shock absorber Basic suspension setup .
ENGLISH 26 MAINTENANCE WORK ON CHASSIS AND ENGINE » According to our experience, the damping rate of the compression stage can remain unchanged. The damping rate of the rebound stage can be reduced by a few clicks for a softer spring or increased by a few clicks for a harder spring.
ENGLISH 27 Breather plug front fork After every 5 hours of use for competitive racing, slacken the breather plugs [1] a few turns in order to relieve excess pressure from the inside of the fork. T o do this, place the motorcycle on a stand with the front wheel lifted off the ground.
ENGLISH 28 MAINTENANCE WORK ON CHASSIS AND ENGINE » Changing the fork offset (caster) (SX / XC) * The fork offset [A] in the SX models (center fork legs - center steering head angle) can be set to either 18 or 20 mm. This allows you to optimize the han- dling to match the race course.
ENGLISH 29 MAINTENANCE WORK ON CHASSIS AND ENGINE » Mount the lower triple clamp, upper steering head bearing, protection ring, O-ring, upper triple clamp and the blind screw . T ighten the collar screw on the lower triple clamp to 60 Nm. Mount the fork legs and tighten the clamp screws on the lower triple clamp to 12 Nm in 3 stages.
ENGLISH 30 MAINTENANCE WORK ON CHASSIS AND ENGINE » How to change the handlebar position The handlebar position can be readjusted by 22 mm. Thus, you can put the handlebar in the position that is the most convenient for you. The upper triple clamp [1] includes 2 bores arranged at a distance of 15 mm (0.
ENGLISH 31 Chain maintenance For long chain life, good maintenance is very important. X-ring chains require only modest maintenance. The best way is to use lots of water , but never use brushes or solvents. After letting the chain dry , you can use a special X-ring chain spray (Motorex Chainlube 622).
ENGLISH 32 MAINTENANCE WORK ON CHASSIS AND ENGINE » General information about KTM disc brakes BRAKE CALIPERS: The brake calipers of this series use a „floating“ mount. This means that the brake calipers are not solidly attached to the caliper support, which enables them to ”float” for maximum braking contact.
ENGLISH 33 Adjusting the free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustment screw [1] . In this way , the position of the point of pressure (i.e. the resis-tance you feel on the hand brake lever when the brake pads are pressed against the brake disc) can be adjusted for any hand size.
ENGLISH 34 MAINTENANCE WORK ON CHASSIS AND ENGINE » Changing the basic position of the foot brake pedal * The basic position of the foot brake pedal can be altered by turning the stop screw [5] . The free play at the foot brake pedal must then be adjusted by means of the piston rod [6] .
ENGLISH 35 Checking the rear brake pads The brake pads can be inspected from the rear . The thickness of the linings may not be less than 1 mm (0.04 in). A T THEIR MOST WORN POINT BRAKE P AD LININGS SHOULD NOT BE THINNER THAN 1 MM, OTHERWISE THEY COULD LEAD TO BRAKE F AILURE.
ENGLISH 36 MAINTENANCE WORK ON CHASSIS AND ENGINE » Before remounting the front wheel, clean and grease the shaft seal rings [A] and the bearing surface [B] of the distance bushings and mount the distance bushing T o install the front wheel, lift it into the fork, position and mount the axle shaft.
ENGLISH 37 Tires, air pressure T ire type, tire condition, and air pressure level affect the way your motorcy- cle rides and must therefore be checked whenever you are getting ready to go anywhere on your motorcycle.
ENGLISH 38 MAINTENANCE WORK ON CHASSIS AND ENGINE » Check/set distance of the magnetic sensor The distance between the magnet [2] and the sensor [1] must be 2-4 mm, otherwise malfunctions on the speedometer might occur . This distance can be corrected by screwing the sensor [1] in or off.
ENGLISH 39 Cooling system The water pump in the engine circulates the cooling liquid. However , the cool- ing liquid can only circulate properly if the cooling circuit contains no air bubbles. Bleeding of the cooling system is therefore required a) after adding more than 0.
ENGLISH 40 MAINTENANCE WORK ON CHASSIS AND ENGINE » Refilling/Bleeding the cooling system The cooling system must be bled as described below after draining the cooling liquid or after adding more than 0.25 l (0.06 US gallons) cooling liq- uid. Make sure that the drain screw [1] is fastened.
ENGLISH 41 Exhaust system * If the end cap [1] can be removed, the silencer is filled with glass-fiber yarn. Have the filling checked regularly by an authorized KTM workshop (see Lubrication and Service Chart). The insulating material fibers escape through the holes in the perforated pipe with time, causing the silencer to “burn out”.
ENGLISH 42 Bleeding the hydraulic clutch * The clutch control needs to be bled as soon as the resistance in the clutch lever starts to feel unresponsive. Y ou will need a bleeder syringe (special tool) and biodegradable hydraulic oil. Both are available from your KTM dealer .
ENGLISH 43 MAINTENANCE WORK ON CHASSIS AND ENGINE » Carburetor adjustment * Basic information on the original carburetor setting The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient temperature of approx.
ENGLISH 44 Part-throttle range C Operation with partly open throttle valve. This range is only influenced by the jet needle (shape and position). The optimum part-throttle setting is controlled by the idling setting in the lower range and by the main jet in the upper range.
ENGLISH 45 MAINTENANCE WORK ON CHASSIS AND ENGINE » Engine characteristic 250/300 SX/XC/EXC* The engine characteristic can be modified through various thicknesses of the auxiliary spring [1] . An auxiliary spring designed for „good driveability“ (smooth power application) is mounted in the condition at delivery .
ENGLISH 46 Check transmission oil level (125/200) In order to check the transmission oil level the control screw [1] on the clutch cover is to be removed. Oil should just barely escape from the inspection open- ing when the motorcycle is in an upright position.
ENGLISH 47 CLEANING » CONSERVATION FOR WINTER OPERATION » STORAGE » Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces. The best manner would be to use warm water that has been mixed with a normal brand-name washing detergent and a sponge.
ENGLISH 48 CHASSIS 125 SX 125 EXC 200 EXC Frame Central chrome-moly-steel frame Fork WP Suspension – Upside down 48 MA Wheel travel front/rear 300/335 mm (11.8/13.2 in) Rear suspension WP PDS 5018 (Progressive Damping System) shock absorber , aluminium swingarm Front brake Disc brake with carbon-steel brake disc Ø 260 mm (10.
ENGLISH 49 TECHNICAL SPECIFICATIONS – CHASSIS 125 SX, EXC, 200 EXC » TIGHTENING TORQUES – CHASSIS Collar screw , front wheel spindle M24x1,5 40 Nm Brake caliper , front M8 Loctite 243 + 25 Nm Bra.
ENGLISH 50 TECHNICAL SPECIFICATIONS – ENGINE 125 SX, EXC, 200 EXC » ENGINE 125 SX 125 EXC 200 EXC Design Liquid-cooled, single-cylinder , two-stroke engine with intake and exhaust control Piston displacement 124.8 ccm 124.8 ccm 193 ccm Bore / stroke 54 / 54.
ENGLISH 51 TECHNICAL SPECIFICATIONS – ENGINE 125 SX, EXC, 200 EXC » TIGHTENING TORQUES - ENGINE Flange bolts - cylinder -head M7 18 Nm Nuts-cylinder base M8 30 Nm Flywheel collar nut M12x1 60 Nm Nu.
ENGLISH 52 CHASSIS 250 SX 300 XC 250/300 EXC Frame Central chrome-moly-steel frame Fork WP Suspension – Upside down 48 MA Wheel travel front/rear 300/335 mm (11.8/13.2 in) Rear suspension WP PDS 5018 (Progressive Damping System) shock absorber , aluminium swingarm Front brake Disc brake with carbon-steel brake disc Ø 260 mm (10.
ENGLISH 53 TECHNICAL SPECIFICATIONS – CHASSIS 250 SX, EXC, 300 XC, EXC » TIGHTENING TORQUES – CHASSIS Collar screw , front wheel spindle M24x1,5 40 Nm Brake caliper , front M8 Loctite 243 + 25 Nm.
ENGLISH 54 ENGINE 250 SX 250 EXC 300 XC/EXC Design Liquid-cooled single-cylinder two-stroke engine with KTM T win V alve Control exhaust system and KTM T orque Chamber Piston displacement 249 ccm 249 ccm 293.15 ccm Bore / stroke 66.4 / 72 mm (2.62 / 2.
ENGLISH 55 TECHNICAL SPECIFICATIONS – ENGINE 250 SX, EXC, 300 XC, EXC » TIGHTENING TORQUES - ENGINE Flange bolts - cylinder -head M8 27 Nm Nuts-cylinder base M10 35 Nm Flywheel collar nut M12x1 60 .
ENGLISH 56 INDEX » Page Activating and deactivating display modes . . . . . . . . .7 Adjusting the free travel at the hand brake lever . . . . .33 Basic suspension setup for the weight of the driver . . .25 Bleeding the hydraulic clutch . . . . . . .
ANHANG – APPENDICE APPENDIX – APÉNDICE 1 SCHALTPLAN » WIRING DIAGRAMM 6 0 0 2 0 0 3 - 5 2 1 C X E m m a r g a i d g n i r i w 0 5 3 . 5 7 0 . 1 1 .
ANHANG – APPENDICE APPENDIX – APÉNDICE 2 SCHALTPLAN » WIRING DIAGRAMM 2006 0 5 2 - 0 0 2 W - C X m m a r g a i d g n i r i w s s e n r a h n i a m 0 0 0 .
ANHANG – APPENDICE APPENDIX – APÉNDICE 3 SCHALTPLAN » WIRING DIAGRAMM 2006 0 0 3 -W C X m m a r g a i d g n i r i w s s e n r a h n i a m 0 0 1 .
ANHANG – APPENDICE APPENDIX – APÉNDICE 4 SCHALTPLAN » WIRING 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 .
ANHANG – APPENDICE APPENDIX – APÉNDICE 5 SCHALTPLAN » WIRING DIAGRAMM ENGLISH DEUTSCH IT ALIANO Capacitor Kondensator Condensatore CDI CDI CDI Driving light lamp Fernlichtkontrolle Spia abbaglia.
ANHANG – APPENDICE APPENDIX – APÉNDICE 6 SCHALTPLAN » WIRING DIAGRAMM ENGLISH FRANCAIS ESP ANOL Capacitor Condensateur Condensador CDI CDI CDI Driving light lamp T emion feu route Lampara aviso .
ANHANG – APPENDICE APPENDIX – APÉNDICE 7 VERGASERTABELLE » CARBURETOR TABLE VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK 36S AG 125 EXC 2006 MEERESHÖHE ALTIDUDE TEMPERATUR TEMPERATURE - 20.
ANHANG – APPENDICE APPENDIX – APÉNDICE 8 VERGASERTABELLE » CARBURETOR TABLE VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK 38 AG 200 EXC 2006 MEERESHÖHE ALTIDUDE TEMPERATUR TEMPERATURE - 20.
ANHANG – APPENDICE APPENDIX – APÉNDICE 9 VERGASERTABELLE » CARBURETOR TABLE VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK 36S AG 250 SX 2006 MEERESHÖHE ALTIDUDE TEMPERATUR TEMPERATURE - 20.
ANHANG – APPENDICE APPENDIX – APÉNDICE 10 VERGASERTABELLE » CARBURETOR TABLE VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK 36S AG 250 EXC 2006 MEERESHÖHE ALTIDUDE TEMPERATUR TEMPERATURE - 2.
ANHANG – APPENDICE APPENDIX – APÉNDICE 11 VERGASERTABELLE » CARBURETOR TABLE VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK 36S AG 300 EXC 2006 MEERESHÖHE ALTIDUDE TEMPERATUR TEMPERATURE - 2.
ANHANG – APPENDICE APPENDIX – APÉNDICE 12.
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.
Een belangrijk punt na aankoop van elk apparaat KTM EXC 200 EXC (of zelfs voordat je het koopt) is om de handleiding te lezen. Dit moeten wij doen vanwege een paar simpele redenen:
Als u nog geen KTM EXC 200 EXC heb gekocht dan nu is een goed moment om kennis te maken met de basisgegevens van het product. Eerst kijk dan naar de eerste pagina\'s van de handleiding, die je hierboven vindt. Je moet daar de belangrijkste technische gegevens KTM EXC 200 EXC vinden. Op dit manier kan je controleren of het apparaat aan jouw behoeften voldoet. Op de volgende pagina's van de handleiding KTM EXC 200 EXC leer je over alle kenmerken van het product en krijg je informatie over de werking. De informatie die je over KTM EXC 200 EXC krijgt, zal je zeker helpen om een besluit over de aankoop te nemen.
In een situatie waarin je al een beziter van KTM EXC 200 EXC bent, maar toch heb je de instructies niet gelezen, moet je het doen voor de hierboven beschreven redenen. Je zult dan weten of je goed de alle beschikbare functies heb gebruikt, en of je fouten heb gemaakt die het leven van de KTM EXC 200 EXC kunnen verkorten.
Maar de belangrijkste taak van de handleiding is om de gebruiker bij het oplossen van problemen te helpen met KTM EXC 200 EXC . Bijna altijd, zal je daar het vinden Troubleshooting met de meest voorkomende storingen en defecten #MANUAl# samen met de instructies over hun opplosinge. Zelfs als je zelf niet kan om het probleem op te lossen, zal de instructie je de weg wijzen naar verdere andere procedure, bijv. door contact met de klantenservice of het dichtstbijzijnde servicecentrum.
