200 XC-W USA 2010

SPARE PARTS MANUAL: CHASSIS

ART.NO.: 3CF7275J3EN

ENGLISH
FRONT FORK DISASSEMBLED HANDLEBAR, CONTROLS FRAME

FRONT FORK, TRIPLE CLAMP

SIDE / CENTER STAND SWING ARM

SHOCK ABSORBER

SHOCK ABSORBER DISASSEMBLED
EXHAUST SYSTEM AIR FILTER

TANK, SEAT, COVER

MASK, FENDERS
FRONT WHEEL REAR WHEEL WIRING HARNESS
REAR BRAKE CONTROL BRAKE CALIPER REAR

HAND BRAKE CYLINDER

BRAKE CALIPER FRONT
INSTRUMENTS / LOCK SYSTEM ACCESSORIES KIT
All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above items, all without previous announcement and without giving reasons. KTM may stop manufacturing certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models. by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in extracts, with written allowance of KTMSPORTMOTORCYCLE AG, Mattighofen only.
FIG 1* 32* 34* 85* 92* PART NUMBER 14187J0025080356 0025080256S 7800109410030
DESCRIPTION FORK KTM 125/200 EXC/XC-W2010 HH COLLAR SCREW M8X25 TX40 HH COLLAR SCREW M8X35 TX40 HH COLLAR SCREW M8X25 TX40 AH SCREW DIN6912-M10X35 10.9 O-RING 25X3,55 NBREJOT PT SCREW K60X20 ALU WS=6 BOT.FORK PLATE CPL. 22MM TOP FORK PLATE 22MM STEER.HEAD SCREW M20X1,5 WS=27 HANDLEBAR CLAMP 28MM 05 HANDLEB.SUPP. D=28MM H=37MM 05 TAPERED ROLLER BEARING CPL. 06 %O-RING SUPPORT W. SEALING LIP STEARING HEAD GASKET TOP CLAMP F.SPEED.CABLE D=6MM 08 STEERING HEAD COVER SPECIAL SCREW M6X12,5 WS=8 FORK PROTECTION LE+RI BLACK QTY 1

095230110 / C105230110

* NEW PART

X AS REQUIRED

FRONT FORK DISASSEMBLED
FIG 5 6* 40 42* PART NUMBER 48600812S 48600428 48600557S 91410012S 91410013S 91410014S 91410015S 91410016S 91410017S 48600830S 40540486 48600764
DESCRIPTION ADJUSTING KNOB + SCREW VENT SCREW M4X8 O-RING NBR 3X1,5 O-RING NBR 45X2 OUTER TUBE L577 D54/60MM 2L FORK PROTECTION RING 08 DU-BUSH D48XD52X12DDL02 SUPPORT RING 50 X 57,6 X 1,5 OIL SEAL RING 48X57,8X9,LOCK WASHER SB58 DUST CAP D=48 58,4X11,8 DU-BUSH D47XD49X20DDL02 HYDR.STOP L=200 D=31,9 CPL. 07 ADJUSTING TUBE L=PISTON ROD D=12 L=554 ALU ADJUSTER NEEDLE 07 O-RING 2X1,5 NBR REBOUND SPRING C=4N/MM WASHER 32X42X2,5 SPRING 3,8N/MM SET D=4,9MM SPRING 4,0N/MM SET D=5,0MM SPRING 4,2N/MM SET D=5,0MM SPRING 4,4N/MM SET D=5,1MM SPRING 4,6N/MM SET SPRING 4,8N/MM SET INTERM. RING 26,2 X 43 X 3 GUIDING BUSH REBOUND SPRING SCREW SLEEVE M27X0,8 O-RING 6X1,2 NBR REBOUND SPRING L=32 C=17 PISTON ROD REBOUND SHUTTLE VALVE SPRING C=0,4 PISTON RING 5X1X68 PISTON REBOUND SX 2007 NUT M6X0,5 REBOUND ADAPTER SLEEVE D23/D28 QTY 2 x x x x x x 2

105230130 / C105230130

FIG 60* 61* 99 PART NUMBER 48600860SA 48600861S48600586S 48600141 48600765S1 48600431S48600053 T511 R14016
DESCRIPTION PIPE D23/LO-RING NBR 46 X 2 AXLE CLAMP L/S + TUBE CPL. AXLE CLAMP R/S + TUBE CPL. 09 HH COLLAR SCREW M8X25 TX40 CHECK VALVE NUT M6X0,5 D=2 SPRING CHECK VALVE D=0,7 TAP COMPRESSION CPL. 07 PISTON COMPRESSION D=27,9 O-RING NBR 21X2 O-RING NBR 24X2 COPPER WASHER 29,5X33,5X1 RUBBER CAP D=35MM FORK OIL SAE5 5L 2008 PRE-LOAD ADJ. M51X1,SPACER 42X26,5X2,5 SPACER 42X26,5X5 SPACER 42X26,5X10 SPACER 42X26,5X1,5 SILICONE GREASE F. DUST STRI REPAIR-KIT EXC FRONT FORK 2009 QTY 2 x x x x 1 1

HANDLEBAR, CONTROLS

FIG 1* 10* 11* 15 17* 63 PART NUMBER 0025060166 50332063200
DESCRIPTION HANDLEBAR D=28MM BAR PAD CPL. WIRING HOLDER 12MM CLAMP 5/7 MM 06 HAND GUARDS CPL.L/S+R/S OR. 09 THROTTLE GRIP CPL. 09 TWIST GRIP COVER GRAY/ORA.09 PROTECTION COVER '97 THROTTLE C. 125-380 DOM./KEIH. SHORT CIRCUIT BUTTON 02 FIXED GRIP GRAY/ORANGE 09 CABLE TIE 200/3,6MM BLACK MASTER CYLINDER CPL. 9,5MM 09 CLUTCH LEVER CPL. 2009 REP.KIT PISTON 9,5MM 09 COVER HYDR. CLUTCH CPL. 09 RUBBER FOR RESERVOIR 09 OIL FOR HYD. CLUTCH 75ML MUD CAP 09 LEVER SCREW SHORT CPL. 09 CLAMP, CYL. PIN, O-RING PUSH ROD CPL. 09 HH COLLAR SCREW M6X16 TX30 CLUTCH PIPE L=970MM 04 QTY 1 1

095230210 / C105230210

FIG 15 16* 17* 18* 19* 63* 64 PART NUMBER 54603013000 0019080206S 77303053010
DESCRIPTION FRAME BLACK M"BB10" SUB FRAME SX "Q7" 07 SUB FRAME APPLICATION LEFT 08 SUB FRAME APPLICATION RIGHT 08 REINFORCING B. 200 EXC 08 ADH. FOIL TRANSP. 80X80 MM 04 SPECIAL SCREW M8X26 WS=10 HEXAGON NUT DIN0934-M 8 ENGINE BRAC.SCR. M10X105 WS=13 FLAT HEAD SCREW M. ISA45 M8X20 COLLAR SCREW M8X42 WS=13 10.9 BLIND PLUG-IN NUT M5 WN 22A 03 CABLE TIE 300/4,8MM BLACK COU.SUNK SCR. AH ISO7380 M5X25 BUSH F. FRAME PROTECTION 03 PLASTIC CAP SFL10 SELF LOCKING NUT M8 10.9 SELF LOCKING NUT M10 CU WS=14 HH COLLAR SCREW M8X30 TX40 HH COLLAR SCREW M6X40 TX30 WASHER DIN0125-A 6,4 FOOTREST L/S 08 FOOTREST R/S 08 BOLT FOR FOOT PED 03 FOOTREST SPRING L/S & R/S WASHER DIN0125-A10,5 PIN DIN0094-3,2X25 STEEL FOOTREST L/S + R/S CPL. 09 ANGEL PIECE '97 PVC-HOSE 7X10 PER METER SPROCKET COVER 250 SX 07 CHAIN SLIDING PIECE BELOW 07 BLIND RIVET NUT EM6-60LF/HX PLASTIC FRAME PROTECTION SET CHAIN SLIDING P. BELOW CPL. 07 QTY 2 x 1

105230310 / C105230310

SIDE / CENTER STAND
FIG 29 PART NUMBER 0019080266S 78003023055 50303018000
DESCRIPTION SIDE STAND CPL. 08 SCREW M5X14 TORX SPRING BRACKET F. SIDE ST. 08 SIDE STAND BUSHING EXC USA 08 O-RING 18,00X2,00 NBR 70 SPACER BUSH. SPRING BRACKET SIDE STAND SPRING EYE MOVEABLE ONLY FOR EXC SIDE STAND STOP SCREW M10X12 COUNTER-SUNK SCREW ISA45 M8X26 HH COLLAR SCREW M8X30 TX40 ONLY FOR EU O-RING 12,00X2,00 NBR 70 WASHER F. SIDE STAND 12,2X29,5 O-RING 12,5X1,5 NBR SIDE STAND BUSHING EXC-EU 08 ONLY FOR EU SIDE STAND SPRING 08 ONLY FOR XC STAND BASE RUBBER L=145MM QTY 1

085230360 / C105230360

SWING ARM
FIG 99 PART NUMBER 54804230210
DESCRIPTION SWINGARM CPL. 07 CHAIN SLIDING PROTECTION BUSHING F. CHAIN SLIDING PR.07 SPECIAL SCREW M 5,0X10 BRAKE HOSE GUIDE LOWER 07 SPECIAL SCREW M6X13 WS=8 10.9 BUCKET F. SHAFT SEAL RING 03 SHAFT SEAL RING 25X32X7 BUSHING SLEEVE F. SWING ARM 03 NEEDLE BEARING HK 2216 STOP DISK 22,2X31,7X1 CHAIN GUIDE CPL. SPECIAL SCREW M6X19 WS=8 10.9 HH COLLAR SCREW M6X45 TX30 INSERTION NUT F. CHAIN GUIDE PIVOT BEARING+BUSHES PDS '99 TOOL BEARING MOUNTING PDS PLUG SFL13 SWINGARM BOLT M16X1,SELF LOCK.NUT M16X1,5 WS=CLOSING COVER ROUND 03 CHAIN GUARD CPL. 06 PRESS IN NUT M6 STEEL ZINC CHAIN GUIDE KIT REAR 08 SWINGARM REPAIR KIT 05-07 QTY x

095230490 / C095230490

FIG 8 10* PART NUMBER 0025120506S 12187J0201
DESCRIPTION HH COLLAR SCREW M12X50 TX45 MONOSH. PDS B07MA125/200EXC 10 QTY 2 1

085030410 / C105230410

FIG 1* 12* PART NUMBER 50180733SA 50180213SR50180520S 50180114 91210053S 91210054S 91210055S 91210068S 91210069S 91210070S 50180273 50180463S 50180603S 50180604 50180605S 50180103 46180119
DESCRIPTION TOP PART CPL. M57,5X1 H30,DCC-COMPR.DAMP.CONTROL CPL. 07 ADAPTOR BUSH KGW 12X24 REP. KIT BEAR./SEAL UP. 07 BLEED PLUG R 1/8 WP CAUTION (PDS KTM) O-RING NBR 5,28X1,78 SCREW PLUG M5X6 RUBBER CAP "DO NOT OPEN" SPRING RETAINER M57,5X1 +SCREW AH SCREW M5X30 DIN912 INTERM.RING SCREW SPRING RET. INTERM.RING SCREW SPRING RET. SPRING 250 63N/MM ORANGE SPRING 250 66N/MM ORANGE SPRING 250 60N/MM ORANGE SPRING 250 69N/MM ORANGE SPRING 250 72N/MM ORANGE SPRING 250 76N/MM CIRCLIP 58,2X2 SPRING RET. D=80 W. O-RING 05 O-RING VITON 66,27X3,53 PISTON ROD NUT M20X1 O-RING VITON 44,17X1,78 PISTON RING 50-8 PISTON D=20 TAP D20 M20X1 L45,REBOUND DISC D43 H0 T4 PISTON 6+6X7/4,5 ADAPTOR CPL. D=50 H=STEEL DISC 18X,5X43,7X6 REBOUND RUBBER SHIM D29,75 X D19 X T0,SEAL D18X30XO-RING 41X5 DU-BUSH 18X20X12 QTY 1 x x x x x x 1

105230430 / C105230430

FIG 90* 99 PART NUMBER 50180512SA50180222 50180434S 50180342S1 R12015
DESCRIPTION DUST SEAL CIRCLIP 53X1,75 RESERVOIR CAP D=50 H=BUMP RUBBER D58 D17 HSHOCK ABS. LOWER PART CPL. 10 THREADED BUSH M12 PDS STEEL BALL D=3MM SPRING D=2,9 L=7,9 O-RING NBR 4X1,5 ADJUSTING SCREW REBOUND TRAVEL SHOCK ABSORBER FLUID 5 LT '03 REPAIR KIT 5018 PDS 08 QTY 1 1

EXHAUST SYSTEM

FIG 7* PART NUMBER 54805078450
DESCRIPTION EXHAUST MANIFOLD O-RING 44,00X3,00 VITON TEN.SPRING L=62MM EY.MOVEABLE WASHER 6 X 12 X 3 SILICON SLEEVE D=25/27MM SWINGELEMENT FOR EXHAUST PIPE HH COLLAR SCREW M6X15 TX30 HH COLLAR SCREW M6X10 TX30 RANGE CHANGE METAL NUT M6 EXH. SILENCER CPL. EXC 06 BUSHING 7.5x12x28x7.EXHAUST BRACKET RUBBER BLACK BUSHING SIL.-SMR REAR 2004 SILENCER ENDCAP 2-STROKE 2004 SILCENCER RUBBER 2-STROKE 2005 SILENCER DISC 2004 SILENCER SCREW 2-STROKE 2004 0-RING 55,00X2,00 NBR70 SILENCER CONNECTING-CAP 2004 HH COLLAR SCREW M6X35 TX30 SPRING WASHER DIN0137-B 6 HH COLLAR SCREW M6X30 TX30 STUFFING YARN-SET 450 GRAM 04 QTY 1

095230511 / C105230510

AIR FILTER
FIG 1* 15* 79 PART NUMBER 77304066050
DESCRIPTION AIR BOX PART BLACK AIR BOX COVER SX BLACK 07 REAR PART FILTER BOX 07 QUICK RELEASE-NIPPLE 03 BLIND RIVET 3,3X9,7 GROOVED 04 QUICK RELEASE-SPRING HANGER FENDER FOR FILTER BOX AIR FILTER FILTER CARRIER 2S SX 07 FILTER SUPPORT CPL. 07 FILTER SUPPORT BUSH 07 FASTEN. DEVICE FILTER S. SX 07 CABURETOR CONNECTING 2S 07 HOSE CLAMP 50-70MM EJOT PT SCREW K60X20 ALU WS=6 EJOT PT SCREW K60X20 WS=6 BUSHING F. CHAIN SLIDING PR.07 QTY x 1 2

105230610 / C105030610

FIG 50* PART NUMBER 7730805410004B 0025060126 0024060273
DESCRIPTION FUEL TANK CPL. BL. 11L 2T XC08 GAS COCK ON/OFF/RES 03 O-RING 11X2 VITON PVC-HOSE 5,6X10X270MM TANK PLUG ORANGE/BLACK TANK BUSHING 07 TANK ROLLER 12X26X12 '98 FUEL PREFORMED HOSE SX 2001 CLAMP YDNAC 10128 12MM EJOT PT SCREW K60X20 WS=6 EJOT PT SCREW K60X20 ALU WS=6 ANGLE PIECE 90 DEGREE M10X1 SEAT SX 07 SEAT COVER 07 SPOILER KIT ORANGE EXC/XC-W 10 WITH DECAL BUSH FOR SPOILER 6X11X16X5 MM HH COLLAR SCREW M6X20 TX30 HH COLLAR SCREW M6X12 TX30 COLLAR SCREW M6X27 TX QTY 1

095230710 / C105230710

FIG 33 PART NUMBER 0017060204
DESCRIPTION START NUMBER PLATE ORANGE 07 BRAKE HOSE GUIDE ORANGE 07 HH COLLAR SCREW M5X16 TX30 FRONT FENDER 07 SPACER BUSHING 03 WASHER DIN9021-A 6,4 HH COLLAR SCREW M6X40 TX30 HH COLLAR SCREW M6X20 TX30 COLLAR BUSH. F.REAR FENDER 07 COLLAR BUSHING 4,5/12,6/23 REAR PART EXC ORANGE 08 COLLAR NUT M12X1/WS17 H=5MM BUSHING FOR SEAT FASTENING 03 HH COLLAR SCREW M6X25 TX30 BUSH FOR SPOILER 6X11X16X5 MM HH COLLAR SCREW M6X20 TX30 EJOT PT SCREW K60X20 ALU WS=6 QTY 1

095230810 / C095230810

FIG 1* 2* PART NUMBER 52308399000 52308391100
DESCRIPTION DECAL KIT SX/XC/XC-W 2010 DISPLACEM. STICKER 200 XC-W 10 QTY 1 1

105230830 / C105230830

FRONT WHEEL
FIG 1* 2* 12* 40 PART NUMBER 55003135000 54809081070
DESCRIPTION FRONT WHEEL CPL.1,6X21"EXC.10 FRONT WHEEL HUB CPL. BEA.SPACERTUBE 35X2 L=79,GR.BALL BEAR.6906 DDU2CG23S6NM SHAFT SEAL RING 35X47X7 TC SPACER BUSHING F. FR. WHEEL 08 SPOKE M4,5x226-21" 08 SPOKE NIPPLE M4,5X0,75 8X21 RIM FRONT 1,6X21" EXCEL AL7 RIM BAND 21" FRONT WHEEL REP. KIT RIM LOCK VM1 (1,60") NUT FOR WHEEL HOLDER '96 BRAKE DISC FRONT 260 SPECIAL SCREW M6X13 WS=8 10.9 WHEEL SPIN.FR. D=26 M24x1,SPINDLE SCREW M24X1,5 WS=PLUG BUSHING WS=PLUG FOR RIM AUXILIARY SCREW FRONT 06 QTY x 1 x 1

105230910 / C105230911

REAR WHEEL
FIG 1* 2* 9 10* 22 23* 24* 44 PART NUMBER 58310151052 0019080266S 58414030000 50310099000
DESCRIPTION REAR WHEEL CPL. 2,15X18"EXC.09 REAR WHEEL HUB CPL. BUSHING SPACER TUBE 121,5MM 01 GR.BALL BEAR.6005 DDU2CG23S6NM CIRCLIP DIN0472-47X1,75 SHAFT SEAL RING 32X47X7 BSL BUSHING FOR HUB 08 SPOKE M5X193- 18" SPOKE NIPPLE M5-TA 8X21MM RIM 2,15X18" EXCEL AL7 BLACK BRAKE DISC REAR 220 SPECIAL SCREW M6X13 WS=8 10.9 RIM BAND 18" AND 19" REAR WHEEL REP. KIT REAR SPROCKET 38-T REAR SPROCKET 42-T REAR SPROCKET 40-T REAR SPROCKET 45-T REAR SPROCKET 48-T REAR SPROCKET 49-T REAR SPROCKET 50-T REAR SPROCKET 51-T REAR SPROCKET 52-T COUNTER-SUNK SCREW ISA45 M8X26 SELF LOCKING NUT M8 10.9 CHAIN DID 118 ROLLS CONNECTING LINK F. 78010167118 RIM LOCK VM3 (2.15") NUT FOR WHEEL HOLDER '96 PLUG FOR RIM COVERING CAP SFL16 WHEEL SPINDLE RE. CPL.265MM 07 CHAIN TENSIONER R/S 2000 SCREW M10X1,25X50 WS=10 HH COLLAR NUT M10X1,25 WS=13 HEXAGON NUT M20X1,5 '98 QTY x x x x x x x x x x 2 1

085481010 / C105231011

WIRING HARNESS
FIG 20 PART NUMBER 54814060100
DESCRIPTION WIRING HARNESS EXC-USA 2KWIRING HOLDER 16MM VOLTAGE REGULATOR 04 HH COLLAR SCREW M6X12 TX30 PULL SWITCH LOOSE SPEC. NUT F. PULL SWITCH WS=17 CABLE TIE 200/3,6MM BLACK CABLE TIE 300/4,8MM BLACK SPEEDOMETER BRACKET XC-W 08 QTY 1 x x x 1

085231110 / C095231110

REAR BRAKE CONTROL
FIG 80 PART NUMBER 54603062000 0025060206S 00062030000
DESCRIPTION REAR BRAKE CYLINDER CPL. 2004 REPAIR KIT PISTON 13MM 06 REAR BRAKE CYL. COVER CPL. 04 FOOT-BRAKE CYL. GASKET SX 03 BANJO SCREW 08 BRAKE HOSE REAR 655MM 03 COPPER GASKET DIN7603-10X14X1 FOOT BRAKE LEVER CPL. 07 STEP PLATE FOR BRAKE LEVER HH COLLAR SCREW M5X12 TX30 RETURN SPRING FOR BRAKE LEVER HH COLLAR SCREW M6X20 TX30 PUSH ROD L=28MM 03 SELF LOCK. NUT DIN0985-M 6 SWIVEL HEAD KAAH SCREW DIN6912 M10X40 10.9 SPECIAL SCREW M8X26 WS=10 COLLAR NUT M8 WS=10 BALL BEARING SKF 6000-2RS1 COLLAR NUT M10 WS=13 HH COLLAR SCREW M6X12 TX30 BELLOWS FOR REPAIR KIT 06 BRAKE FLUID DOT5.1 0,25L QTY 1

085031330 / C095231330

BRAKE CALIPER REAR
FIG 12 PART NUMBER 0603100141
DESCRIPTION BRAKE CAL. RE. - WITHOUT PADS REPAIR KIT SEALING RINGS 26MM BOLT SET FOR BRAKE CALIPER 03 BRAKE PAD SET REAR TOYO BRAKE PISTON 26MM 2003 RETAINING SPRING SET 2003 BRAKE CALIPER SUPPORT REAR CUP SET SHORT BRAKE HOSE REAR 655MM 03 BLEEDER SCREW CPL. 05 COPPER GASKET DIN7603-10X14X1 QTY 2

095031390 / C105031390

FIG 1* 9 10* 15 20* 21* 31* 32 34* 80 PART NUMBER 54802051000 00062030000
DESCRIPTION HAND BRAKE CYLINDER CPL. SX 09 HANDBRAKE CYL.COVER CPL.NATURE REP.SET PISTON D=12MM 2009 CLAMP CPL. NATURE HH COLLAR SCREW M6X25 TX30 LEVER SCREW CPL. 2001 HAND BRAKE LEVER + SPRING 2009 ADJUSTING SCREW CPL. SX 2009 PROTECTION CAP HAND BRAKE CYL. BRAKEHO. FRONT 1300MM 2000 BANJO SCREW 08 COPPER GASKET DIN7603-10X14X1 VALVE BRAKE FLUID DOT5.1 0,25L QTY 1 1

097701310 / C105231310

FIG 1* 2* 5* 6* 7* 8* 9 10* 35 PART NUMBER 54613218000 0025080356S 50213025000
DESCRIPTION CALIPER NAT. WITHOUT PADS BRAKE CALIPER SUPPORT FRONT 09 REP. KIT SEALS 24MM REP. KIT PISTON 24MM BOLT CPL. 09 RETAINING PLATE SET BREMBO BRAKE PADS TOYO B153 BLEEDER SCREW WITH CAP CUP SET SHORT HH COLLAR SCREW M8X35 TX40 BRAKEHO. FRONT 1300MM 2000 COPPER GASKET DIN7603-10X14X1 HOLLOW SCREW M10X1X19 QTY 1

097701361 / C105231360

INSTRUMENTS / LOCK SYSTEM
FIG PART NUMBER 54814060051 54813026000
DESCRIPTION SPEEDOMETER MPH F. 21" 2005 REPROGRAMMABLE: MPH - KM/H BATTERY COVER F. SPEEDOM. 2005 BATTERY F. SPEEDOM. M.A.E. 02 SPEEDOMETER TOP PART 05 CABLE FOR DIGITAL SPEEDOM. 06 CLAMP D=6/8MM, BLACK MAGNET FOR DIGITAL SPEEDOM. 03 CIRCLIP DIN0471- 9X1 INOX WASHER DIN9021-A 5,3 SCREW FOR PLASTIC K50X12 T20 RUBBER GROMMET 16X10,8XHH COLLAR SCREW M6X20 TX30 BUSHING F. SPROCKET COVER RAC. SPEEDOMETER BRACKET XC-W 08 SPACER TUBE SPEEDOM. XC-W 08 CABLE SUPPORT 10/6MM 06 QTY 1 2

095231430 / C095231430

ACCESSORIES KIT
FIG 1* 1* 1* 33 PART NUMBER 3211466EN 3CF7275J3EN 3CM082030JEN 60029070200
DESCRIPTION DOCUMENTS BAG 2006 KTM BALLPOINT ORANGE CUSTOMER WELCOME LETTER HAND GUARDS CPL.L/S+R/S OR. 09 PLASTIC FRAME PROTECTION SET FRONT FENDER 07 MOUNTING KIT FRONT FENDER FOOTREST L/S + R/S CPL. 09 OWN.MAN. 125-300 XC-W/EXC 2010 SPC CHASSIS 200 XC-W USA 2010 SPC ENGINE 200 EXC 2010 ORIGINAL EQUIPMENT TOOL KIT GRIP ORANGE B&F WRENCH SW=17/21/27/32 B&F WRENCH WS=13 B&F + OPENER T-WRENCH WS=6/8/10 TX=45 B&F QTY 1 1

085032001 / C105232001

200 EXC 2010
SPARE PARTS MANUAL: ENGINE

ART.NO.: 3CM082030JEN

SPECIAL TOOLS
CYLINDER, CYLINDER HEAD CRANKSHAFT, PISTON REED VALVE CASE

ENGINE CASE CLUTCH COVER

CARBURETOR

CLUTCH

TRANSMISSION I - MAIN SHAFT TRANSMISSION II - COUNTERSHAFT

KICK STARTER

SHIFTING MECHANISM

COOLING SYSTEM

EXHAUST CONTROL IGNITION SYSTEM
FIG 38 PART NUMBER 50329038000 DESCRIPTION ASSY SUPPORT WITH ENGINEHOLDER HOLD. PLATE CLUTCH 125/200 '98 HOLDER FOR PRIMARY GEAR '98 MAGNETIC PULLER M 27X1 KOKUSAN SPECIAL CIRCLIP PLIER HOLD. SPANNER ROTOR 2K-1/2/3/4 DIAL GAUGE 0-10MM DIAL GAUGE SUPPORT LOCTITE 243 BLUE 6CCM MOUNTING TOOL INNER RING NJ206 BRACKET FOR LOCATING DRUM '98

05503290 / C085232911

CYLINDER, CYLINDER HEAD
FIG PART NUMBER DESCRIPTION INTERMEDIATE FLANGE CYLINDER CYLINDER HEAD STUD DIN0835-M 8X35 10.9 O-RING 72,00X2,00 VITON CU-SEAL RING 7,3 X 12 X 0,5 CYLINDER BASE GASKET 0,20MM CYLINDER BASE GASKET 0,25MM CYLINDER BASE GASKET 0,40MM CYLINDER BASE GASKET 0,50MM CYLINDER BASE GASKET 0,75MM CYL.HEAD SEAL RING HH COLLAR SCREW M 5X20 WS=6 HH COLLAR NUT M 8 WS=12 INTERMED.GASKET 1,1MM RETAINING PLATE HH COLLAR SCREW M6X10 TX30 CU-SEAL RING DIN7603-6X10X1 CYL. HEAD BOLT M 7X40 WS=10 GASKET SET CYL. 125/200 98-06

QTY x x x x x 1

085233050 / C095033051

CRANKSHAFT, PISTON

FIG 82 PART NUMBER 52330007300 I 52330007300 II 50330082000 DESCRIPTION PISTON I CPL. 64MM PISTON II CPL. 64MM SPACER BUSHING 12MM CON.ROD REPAIR KIT 200'07 CRANKSHAFT CPL. 200 EXC 2007 LOCKING RING VSK 12 COLLAR NUT M12X1 R/S WOODRUFF KEY DIN6888-3X5X13 WOODRUFF KEY 5X6,5 HARDED PRIMARY PINION 23-T 125/LOCKING RING VSK 16 HEXAGON NUT M 16 X 1,5 - L/S SQUARE RING 64X2002 PISTON PIN 11X16X02 NEEDLE BEARING KV16X20X20 FN SHAFT SEAL RING 25X35X7 BTSL SHAFT SEAL RING 32X45X6,5 BT WIRE LOCK RING 16X1,2 O-RING 25,00X2,00 NBR 70 BALL BEARING 6305 JR2 CS36 CYL.ROLLER BEAR.NJ206 ET2XCS46

QTY x 1 1

085233060 / C095233062

REED VALVE CASE

FIG PART NUMBER DESCRIPTION RUBBER BOOT CPL. BOYESEN 2002 REED VALVE CPL. BOYESEN 02 CLAMP 54/09 MIXED HH COLLAR SCREW M6X25 TX30 SPRING WASHER DIN0137-B 6 REED VALVE ASSY CPL. 2000 REED VALVE PLATE 6MM GASKET REED V.PLATE V-FORCE 04

QTY 1 2

085233070 / C095233070

ENGINE CASE

FIG PART NUMBER DESCRIPTION ENGINE CASE CPL W.TRAN.BEAR.07 IGNITION COVER DOWEL BUSHING 13,8X11X12 OILDRAIN PLUG W.MAG. M 12X1,5 CU-SEAL RING DIN7603-12X18X1,5 ENGINE CASE GASKET 0,5MM '98 HH COLLAR SCREW M6X50 TX30 HH COLLAR SCREW M6X55 TX30 HH COLLAR SCREW M 5X16 WS=6 HH COLLAR SCREW M6X60 TX30 OIL GUARD GROMMET 25X31 '98 GASKET KIT 125 07

QTY 1 1

095033010 / C105033010

CLUTCH COVER

FIG 90 PART NUMBER 49030090000 DESCRIPTION CLUTCH COVER CPL. 125/PLUG DIN0910-M 10X1 COPPER GASKET DIN7603-10X14X1 HH COLLAR SCREW M6X50 TX30 HH COLLAR SCREW M6X12 TX30 CU-SEAL RING DIN7603-6X10X1 O-RING 19,00X3,00 NBR OIL FILLER CAP M24x3 WITH O-R O-RING 16,00X3,00 NBR 70 CLUTCH COVER GASKET 0,5MM CLUTCH OUTSIDE COVER CLUTCH OUTS.COVER GASKET 1MM HH COLLAR SCREW M6X40 TX30 HH COLLAR SCREW M6X35 TX30 HH COLLAR SCREW M6X30 TX30 WATER PUMP COVER 125/200 '98 DOWEL 9,8 X 7 X 10

095033020 / C105033020

FIG 23 PART NUMBER 54531623165 DESCRIPTION CARBURETOR KEIHIN PWK36S AG 07 ONLY FOR EXC AUS CARBURETOR KEIHIN PWK36S AG 08 ONLY FOR EXC EU CARB. KEIH. PWK 36S AG FKONLY FOR XC-W USA+ZA IDLE JET 35 KEIHIN IDLE JET 38 KEIHIN IDLE JET 40 KEIHIN IDLE JET 42 KEIHIN IDLE JET 45 KEIHIN IDLE JET 48 KEIHIN IDLE JET 50 KEIHIN IDLE JET SIZE 35X35 KEIHIN ARM PIN FLOAT FLOAT CPL. GASKET FLOAT CHAMBER FLOAT CHAMBER PWK38-S AG RETAINING PLATE FOR BLEEDER STARTER JET 50 KEIHIN STARTER JET 85 KEIHIN HH COLLAR SCREW M 4X16 WS=6 SPRING FOR ADJUSTMENT SCREW ADJUSTMENT SCREW SPRING ADJUSTMENT SCREW M 5 FLOAT NEEDLE CLAMP MAIN JET GR 100 MAIN JET 150 KEIHIN MAIN JET 152 KEIHIN MAIN JET 155 KEIHIN MAIN JET 158 KEIHIN MAIN JET 160 KEIHIN MAIN JET 162 KEIHIN MAIN JET 165 KEIHIN
QTY x x x x x x x x x x x 2 x x 1 x x x x x x x x

085033111 / C095233111

FIG PART NUMBER DESCRIPTION MAIN JET 168 KEIHIN MAIN JET 170 KEIHIN MAIN JET 172 KEIHIN MAIN JET 175 KEIHIN SPECIAL-AH-SCREW M 4X12 THROTTLE CALBE HOLDER M6X0,75 CARBURETOR COVER PWK36-S AG GASKET FOR CARBURETOR COVER CLIP FOR JET NEEDLE SLIDING SPRING SPRING CAP NIPPLE JET NEEDLE R 1475 J KEIHIN JET NEEDLE NOZ D KEIHIN JET NEEDLE NOZ E KEIHIN JET NEEDLE NOZ F KEIHIN JET NEEDLE NOZ G KEIHIN JET NEEDLE NOZ H KEIHIN JET NEEDLE NOZ I KEIHIN JET NEEDLE KEIHIN N84I THROTTLE VALVE 7 FOR 38 PJ '00 CABLE F. COLD START ACT. 08 ONLY FOR EU CONNECT. COLD START CABLE CPL. ONLY FOR EU STARTER PISTON CPL. CLAMP 6 MM PVC-HOSE 4X6MM PVC-HOSE 3X5MM PLUG M 18X1 O-RING 18,00X2,30 NBR 70 SLIDE STOP L=38MM SLIDE STOP L=O-RING 6,00X1,78 WASHER ADJUSTING SCREW O-RING ADJUSTING SCREW

QTY x x x x x x x x x x x x 1 x x x x x 1 1
FIG 10* PART NUMBER 0993012000 DESCRIPTION OUTER CLUTCH H.73-T 125/200 WITHOUT PRIMARY PINION INNER CLUTCH HUB 125/200'98 PRESSURE PLATE INTERMEDI. DISC STEEL 1,5MM'98 INTERMEDIATE DISC 1,5MM LINING DISC 3,0MM 05 INNER RING 20X26X25,9 '98 SHEET METAL LOCK 1,5MM '98 HEXAGON NUT DIN0936-M18X1,5 R. STOP DISK 20X39,6X3 '98 PRIM. PINION 23-T 125/200'98 CLUTCH KIT 200 EXC 09 WASHER 6,2X18X2 PUSH ROD L=178 125/PRESSURE PIECE 125-380 '98 CYLINDER CPL. 125/200'98 HOLLOW SCREW CPL. M 10X1 '98 CLUTCH RELEASE GASKET 0,3MM CLUTCH RELEASE GASKET 0,5MM CLUTCH RELEASE GASKET 0,75MM BALL DIN5401-7 CU-SEAL RING DIN7603-10X16X1 PISTON W. O-RING 125/HH COLLAR SCREW M6X40 TX30 HH COLLAR SCREW M6X20 TX30 HH COLLAR SCREW M6X25 TX30 VENT INJEKTION HYDR. CLUTCH CLUTCH SPRING 2,4X40 200'98 NEEDLE BEARING K26X30X22ZW.KSE AXIAL NEEDLE BEARING AXK 1226 AXIAL WASHER AS1226 12X26X1 AXIAL WASHER 12,5X25,8X1,5 CIRCLIP DIN7993-RW12

QTY 1 x x x 1 x 1

085033211 / C105233210
TRANSMISSION I - MAIN SHAFT
FIG PART NUMBER DESCRIPTION MAIN SHAFT CPL. 12-T '98 IDLER G. 5TH G.17-T "5G17H" 04 SLIDING GEAR 3/4.G. 17/19-T 04 "3S17H"-"4S19H" IDLER G.6TH G. 22-T "6G22H" 04 SOLID GEAR 2ND G.15-T"2S15" 03 GROOVED BALL B. 16003 C4 J1 BALL BEARING 6004 TN9 C4 IDLER GEAR BUSH. 22X25X11,1 A STOP DISC 22,2X27,8X1 A STOP DISC 17,2X26X1 B STOP DISK 22,2X27,8X1 LOCK RING 22X1,2

085233330 / C085233331

TRANSMISSION II - COUNTERSHAFT
FIG PART NUMBER DESCRIPTION COUNTER SHAFT 125/200 '98 IDLE G.3RD G.28-T "3S28H" 04 IDLE G.4TH G.26-T "4S26" '98 SLIDING GEAR 6TH G. "6E20H" 04 IDLER G. 2ND G. 31-T "2G31"'98 IDLER G. 1ST G. 33-T "1G33"'98 SLIDING G.5TH G.19-T"5G19H" 04 IDLER GEAR BUSHING 17X20X9,7 B IDLER GEAR BUSHING 22X25X8,1 C IDLER GEAR BUSHING 25X28X9,7 D LOCK RING DIN0471-25X1,64SD FRONT SPROCKET 13-T FRONT SPROCKET 14-T BALL BEARING 6003 TN9 C4 BALL BEARING 6205 TN9 C3 STOP RING SHAFT SEAL RING 32X45X7 BSLNBR SPACER BUSHING 12MM O-RING 23,00X2,00 NBR70 STOP DISC 22,2X27,8X1 A STOP DISC 17,2X26X1 B STOP DISK 22,2X28X1 C STOP DISC 25,2X32X1 STOP DISC 22,2X30X2,5 LOCK RING 22X1,2 LOCK RING 25X1,2

QTY 1 x x 1

085233360 / C085233361
FIG PART NUMBER DESCRIPTION STOP DISK 17,2X24X1 CIRCLIP DIN0471-17X1 THRUST WASHER DIN0988-16X22X1 SPACER BUSHING 16X23X26X6,1 HH COLLAR SCREW M8X20 TX40 HH COLLAR SCREW M6X16 TX30 STOP DISC 17,2X26X1 B KICKSTARTER SHAFT 125/200'98 KICKSTART.GEAR 26-T 125/200'98 KICKSTARTER RATCHET INTERMEDIATE GEAR 27-T 04 KICKSTARTER SPRING 2,6MM '98 DRIVING HUB 125/200'98 SPRING 1,4MM '98 STOP MET.SHEET 4MM 125/200'98 KICK STARTER CPL. SHAFT SEAL RING 17X28X7 B WASHER 8,2X22X4,5 '98

085033390 / C105033390

FIG PART NUMBER DESCRIPTION SHIFTING FORK 5TH/6TH GEAR SHIFTING FORK 2ND/4TH GEAR SHIFTING FORK 1ST/3RD GEAR SHIFTING SHAFT 125/200'98 SPRING FOR RATCHET 0,5X11,5 RATCHET SUPPORT 125/200'98 STOP DISK 8,2X26X0,7 BUSHING 6X8X12X4,5 SHIFTING RATCHET 125/200'98 PRESSURE END PAD 4,1X5,6X8,4 SHIFTING DRUM 06 LOCATING DRUM 125/200'98 RETURN SPRING 3MM SPECIAL SCREW M8X21,5 WS=12 SHIFTING GATE 3MM 125/200'98 NEEDLE ROLLER ZRB 6X10 SHIFTING ROD DRIVE 11,8X67,5 SHIFT. ROD DRIVE END 11,8X94,5 LOCATING LEVER SPRING 2,5MM'98 LOCATING LEVER CPL. 08 BALL BEARING 6000 RS1 C3 BALL BEARING 61805 C3 FLAT H.SCEW DIN7991-M5X10 10.9 LOCK RING DIN0472-26X1,2 SPRING WASHER 12,2X25X0,9 NEEDLE ROL.DIN5402 NRB 4X9,8 NEEDLE BEAR.HK 1412 14X20X12 STOP DISK 14,3X20X1 LOCK WASHER DIN0471-14X1 STOP DISK 14,2X22X1,5 SHAFT SEAL RING 14X24X6 B SPECIAL SCREW M6X16 WS=8 10.9 PAIR OF WASHERS M 6 NORDLOCK HH COLLAR SCREW M6X16 TX30 WASHER DIN0125-A 8,4 WASHER DIN7349-5X15X2

085233410 / C095033410

FIG 58 PART NUMBER 54634131000 DESCRIPTION HH COLLAR SCREW M5X20 TX30 STEEL WASHER 6,4X17X3 SLEEVE FOR LOCKING LEVER SHIFT LEVER CPL. 2-STROKE 2001 SHIFTING LEVER SPRING 250 BOLT 6X25 FOR SHIFT LEVER STEP PLATE FOR SHIFT LEVER 250
FIG 7 8* 9* 21* PART NUMBER DESCRIPTION RADIATOR LEFT "VW1595" 08 RADIATOR RIGHT 45620U RADIATOR CAP SMALL 1,8 BAR T-CONNECTOR CPL. 07 HOSE CLAMP GEMI 16-27 HOSE CLAMP NORMA 12/24 ANGEL PIECE '97 PVC-HOSE 6X9 MM PER METER RADIATOR H. 200 W. THERM.THERMOSTAT 55C 2004 RADIATOR HOSE 18X25 125/200'98 O-RING 32,00X2,00 SCREW FOR PLASTIC D=4X18 RADIATOR PROTECTION BLACK 07 HOSE CONNECTOR 2 STROKE 07 RUBBER SLEEVE D=12MM WASHER FOR RADIATOR 08 COLLAR SCREW M6X12 TX

QTY 1 x 4 4

085033532 / C105233530

EXHAUST CONTROL

FIG PART NUMBER DESCRIPTION STOP DISK 14,2X22X1,5 SIDE COVER R/S '98 GASKET SIDE COVER R/S SIDE COVER LEFT MGASKET SIDE COVER L/S ANGLE PIEC 90 DEGREE M10XO-RING 8,00X2,00 NBR HH COLLAR SCREW M 5X12 WS=6 NEEDLE ROL. DIN5402 NRB 5X15,8 HH COLLAR SCREW M5X12 TX30 TUBE RUBBER 6X9 DVOH 200MM CU-SEAL RING DIN7603-26X32X2 WASHER 5,2 X 12 X 3 HH COLLAR SCREW M6X10 TX30 ECCENTRIC FOR CRANKBOLT 200'98 CRANK BOLT F.CONTROL FL.200'98 CONTROL FLAP 200 '98 AXLE FOR CONTRIL FLAP 01 CU-SEAL RING DIN7603-6X10X1 GROOVED BALL BEAR. 608 2RS C3 CIRCLIP DIN0472-22X1 WASHER DIN2093-8,2X16X0,6 SPACER BUSHING 8X12X2,3 O-RINGSTRING 4MM NBR 70 PER/M O-RING 16,00X3,00 NBR 70 SHEET METAL GUIDE 3MM 200'98 CLOSING COVER '98 CLOSING COVER GASKET 1MM CENTRIFUGAL TIMER CPL. 200'98 BUSHING HOLDER M 26X1 '98 CLOSING NUT M 26X1 WS=30 CONTROL LEVER 125/200'98 CONTROL SHAFT M 6 WS=10 '98 CONTROL SHAFT CPL.L/S CONTROL SHAFT CPL.R/S HH COLLAR SCREW M6X12 TX30

QTY 1 x 1 4

085233710 / C095233710
FIG 79 PART NUMBER 50337079000 DESCRIPTION LEVER F. CONTROL SEGMENT '98 CONTROL SHAFT SEGMENT 200'98 DRIVE WHEEL 26-T 125/200'98 BUSHING SUPPORT WATER PUMP '98 ROLLER GUIDE 5X6,1X8X4 '98 SHAFT SEAL RING 8X24X7 A DUO BALL BEARING 6000/C3 O-RING 49,00X2,50 NBR WATER PUMP SHAFT 125/200'98 WATER PUMP WHEEL 07 LOCK METAL SHEET 2MM '98

IGNITION SYSTEM

FIG 44 PART NUMBER 0025060206 DESCRIPTION FLYWHEEL KOKUSAN 2K-3 '98 STATOR KOKUSAN 2K-SPARK PLUG CAP NGK REINFORC.04 SEALING CUP FOR SPARK PLUG SPARK PLUG NGK BR8EG IGNITIONCOIL "IG5128" CDI UNIT 200 XC/EXC 08 WIRING HARNESS F.CDI 2-ST.SX07 VOLTAGE REGULATOR 04 CONDENSATOR 2200MF ADP-COLLAR SCREW M6X12 TX HH COLLAR SCREW M5X16 TX30 HH COLLAR SCREW M6X12 TX30 HH COLLAR SCREW M6X16 TX30 HH COLLAR SCREW M6X20 TX30

085233911 / C105233910

3 Removing the headlight mask with the headlight (All EXC models).. 85 Refitting the headlight mask with the headlight (All EXC models).. 86 Changing the headlight bulb (All EXC models). 86 Checking the headlight setting (All EXC models).. 87 Adjusting the headlight range (All EXC models). 87 Changing the speedometer battery.. 87 COOLING SYSTEM.. 89 Cooling system.. 89 Checking the antifreeze and coolant level. 89 Checking the coolant level... 90 Draining the coolant.. 90 Refilling with coolant.. 91 TUNING THE ENGINE.. 93 Checking the play in the throttle cable.. 93 Adjusting the play in the throttle cable.. 93 Carburetor... 93 Carburetor - adjusting the idle speed. 94 Emptying the carburetor float chamber.. 95 Checking the basic position of the shift lever.. 96 Adjusting the basic position of the shift lever. 96 Engine characteristic - auxiliary spring (All 250/300 models).. 96 Engine characteristic - adjusting the auxiliary spring (All 250/300 models).. 96 SERVICE WORK ON THE ENGINE.. 98 Checking the gear oil level... 98 Changing the gear oil.. 98 Draining the gear oil.. 99 Refilling with gear oil.. 99 Adding gear oil.. 100 CLEANING, CARE... 101 Cleaning the motorcycle.. 101 Checks and maintenance steps for winter operation. 102 STORAGE... 103 Storage... 103 Preparing for use after storage.. 103 TROUBLESHOOTING.. 104 TECHNICAL DATA - ENGINE.. EXC EU, 125 EXC SIX DAYS EU.. 106 All 200 models... 106 All 250 models... 107 All 300 models... 107 Capacity - transmission oil.. 108 Capacity - coolant... 108 TECHNICAL DATA - ENGINE TIGHTENING TORQUES. 109 All 125/200 models.. 109 All 250/300 models.. 110 TECHNICAL DATA - CARBURETOR.. EXC EU, 125 EXC SIX DAYS EU.. EXC EU... EXC AUS... XCW USA... EXC EU, 250 EXC SIX DAYS EU.. EXC AUS... XCW USA... EXC EU, 300 EXC SIX DAYS EU.. EXC AUS... XCW USA... 113 Carburetor configuration (125 EXC EU, 125 EXC SIX DAYS EU).. 113
Carburetor configuration (All 200 models).. Carburetor configuration (All 250 models).. Carburetor configuration (All 300 models).. General carburetor configuration.. TECHNICAL DATA - CHASSIS.. Lighting equipment... Tires... Capacity - fuel... TECHNICAL DATA - FORK.. All 125/200 models.. All 250/300 models.. TECHNICAL DATA - SHOCK ABSORBER.. All 125/200 models.. All 250/300 models.. TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS.. SUBSTANCES... AUXILIARY SUBSTANCES.. STANDARDS.. INDEX...

MEANS OF REPRESENTATION

Symbols used
The symbols used are explained below. Indicates an expected reaction (e.g., to a work step or a function).
Indicates an unexpected reaction (e.g., to a work step or a function).

Fuel, oils, etc.

You should use the fuels, oils and greases according to specifications as listed in the owner's manual.

Spare parts, accessories

For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss. Certain spare parts and accessories are specified in parentheses in the descriptions. Your KTM dealer will be glad to advise you. You will find the current KTM PowerParts for your vehicle on the KTM website. International KTM Website: http://www.ktm.com

Work rules

Special tools are needed for certain tasks. They are not included with the vehicle but can be ordered under the number in parentheses. E.g.: bearing puller (15112017000) When the vehicle is assembled, non-reusable parts (e.g., self-locking screws and nuts, gaskets, seal rings, O-rings, splints, lock washers) must be replaced with new parts. Where thread lockers are used on screw connections (e.g., Loctite), follow the instructions for use from the manufacturer. After disassembly, clean the parts that are to be reused and check them for damage and wear. Replace damaged or worn parts. After you complete the repair or maintenance work, check the roadworthiness of the vehicle.

Transport

Danger of damageThe parked vehicle may roll away or fall over. Always place the vehicle on a firm and even surface.
Fire hazardSome vehicle components become very hot when the vehicle is operated. Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run. Always let the vehicle cool first. Switch off the engine. Turn handle of the fuel tap to the OFF position. Use straps or other suitable devices to secure the motorcycle against accidents or falling over.

Environment

Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it is a potential problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such problems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.

Notes/warnings

Pay close attention to the notes/warnings.
Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing, you or others may not recognize potential hazards and may therefore be injured.

Grades of risks

Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.

Warning

Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Caution

Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.

Owner's manual

It is important that you read this owner's manual carefully and completely before making your first trip. It contains information and tips that will assist you in operating and handling your motorcycle properly. Only then will you learn how to adjust the motorcycle to your own requirements and how to protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle. The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.

VIEW OF VEHICLE

View of vehicle, front left (example)

B00784-10

Hand brake lever ( Kill switch ( Clutch lever ( Air filter box lid Fuel tap ( Chain guide Side stand ( Shift lever ( p. 23) p. 22) p. 21) p. 12)

p. 12)

Fork rebound adjustment Fork compression adjustment
View of vehicle, rear right (example)

B00783-10

Filler cap Bleeder screw, fork leg Throttle grip ( Kickstarter ( p. 12) p. 10) p. 23) p. 22) Chassis number ( Foot brake lever (

Shock absorber, compression adjustment Level viewer, rear brake fluid Shock absorber, rebound adjustment

SERIAL NUMBERS

Chassis number
(XC-W) The chassis number is stamped on the right side of the steering head.

B00015-10

(All EXC models) The chassis number is stamped on the right side of the steering head.

303438-10

Type label
(XC-W) The type label is fixed to the front of the steering head.

400284-10

(All EXC models) The type label is fixed to the front of the steering head.

303439-10

Key number (All EXC models)
The key number for the steering lock is stamped onto the key connector.

500125-10

Engine number
The engine number is stamped on the left side of the engine under the engine sprocket.

B00016-10

Fork part number
The fork part number is stamped on the inner side of the fork stub.

B00265-01

Shock absorber part number
The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side.

B00786-10

CONTROLS

Clutch lever

(All 125/200 models) The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting.

B00001-10

(All 250/300 models) The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting.

B00009-10

Hand brake lever
Hand brake lever is located on the right side of the handlebar. The hand brake lever is used to activate the front brake.

400196-10

Throttle grip
Throttle grip is fitted on the right side of the handlebar.

B00060-10

Kill switch (All EXC models)
The kill switch is fitted on the left side of the handlebar. Possible states Kill switch in basic position In this position, the ignition circuit is closed and the engine can be started. Kill switch pressed In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.

B00078-10

Short circuit button (XC-W)
Short circuit button is fitted on the left side of the handlebar. Possible states Short circuit button in basic position In this position, the ignition circuit is closed, and the engine can be started. Short circuit button pressed In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.

B00002-10

Light switch (All EXC models)

B00292-10

63 N/mm (360 lb/in) 66 N/mm (377 lb/in) 69 N/mm (394 lb/in)
Weight of rider: kg (lb.) (All 250/300 models) Spring rate Weight of rider: kg (lb.) Weight of rider: kg (lb.) Weight of rider: kg (lb.)
66 N/mm (377 lb/in) 69 N/mm (394 lb/in) 72 N/mm (411 lb/in)
The spring rate is shown on the outside of the spring. Install the shock absorber.
p. 54) p. 38) p. 39) p. 37)
Check the static sag of the shock absorber. ( Check the riding sag of the shock absorber. (
Adjust the rebound damping of the shock absorber. (
Checking the basic setting of the fork
For various reasons, no exact riding sag can be determined for the forks. As with the shock absorber, smaller differences in the rider's weight can be compensated 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.

401000-01

Adjusting the compression damping of the fork
The hydraulic compression damping determines the fork suspension behavior. Remove protection covers. Turn adjusting screws clockwise all the way.
Adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs.

100020-10

Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline (All 125/200 models) Compression damping Comfort Standard Sport Full payload (All 250/300 models) Compression damping Comfort Standard Sport Full payload 24 clicks 22 clicks 20 clicks 20 clicks 24 clicks 22 clicks 20 clicks 20 clicks
Turn clockwise to increase damping; turn counterclockwise to reduce damping. Mount protection covers.
Adjusting the rebound damping of the fork
The hydraulic rebound damping determines the fork suspension behavior. Turn adjusting screws clockwise all the way.
Adjusting screws are located at the top end of the fork legs. Make the same adjustment on both fork legs. Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline (All 125/200 models)

800017-10

Rebound damping Comfort Standard Sport Full payload (All 250/300 models) Rebound damping Comfort Standard Sport Full payload 22 clicks 20 clicks 18 clicks 18 clicks 22 clicks 20 clicks 18 clicks 18 clicks
Adjusting the spring preload of the fork
Turn the adjusting screws counterclockwise all the way.
Make the same adjustment on both fork legs. Turn back clockwise by the number of turns corresponding to the fork type. Guideline (All 125/200 models) Spring preload - Preload Adjuster

B00028-10

mm (0.12 0.2 in)
If the free travel does not meet specifications: Adjust the basic position of the foot brake lever.

p. 73)

Reconnect spring.
Adjusting the basic position of the foot brake lever
Danger of accidentsBrake system failure. If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to overheating. Adjust free travel on foot brake lever according to specifications.
Disconnect spring. 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 individually, loosen nut and turn screw accordingly.
The range of adjustment is limited.

B00828-10

Turn push rod accordingly until you have free travel. If necessary, adjust the basic position of the foot brake lever. Guideline Free travel at foot brake lever mm (0.12 0.2 in)
Hold screw and tighten nut. Guideline Nut, foot brake lever stop MNm (22.1 lbf ft)
Hold push rod and tighten nut. Guideline Remaining nuts, chassis MNm (7.4 lbf ft)
Checking the rear brake fluid level
Danger of accidentsReduced braking effect caused by 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.) Stand the vehicle upright. Check the brake fluid level in the viewer. If an air bubble is visible in viewer : Add brake fluid for the rear brake.

p. 74)

B00829-10
Adding brake fluid for the rear brake
Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container! Stand the vehicle upright. Remove screw cap with membrane and the O-ring. Add brake fluid to level. Brake fluid DOT 4 / DOT 5.1 ( p. 126)
Mount the screw cap with the membrane and the O-ring.

400233-10

Checking the rear brake linings

400238-10

If the minimum thickness is less than specified: Change the rear brake linings.

p. 76)

Check the brake linings for damage and cracking. If damage or cracking is visible: Change the rear brake linings. p. 76)
Removing the rear brake linings
Danger of accidentBrake system failure. Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.) Press the brake caliper onto the brake disc by hand in order to push back the brake piston.
Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.

400236-10

Remove locking split pins , withdraw bolt , and take out the brake linings. Clean the brake caliper and brake caliper support.
Installing the rear brake linings
Danger of accidentsReduced braking efficiency due to use of non-approved brake linings. Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid. Check the brake discs. ( p. 70)
Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly.
The arrow on the leaf spring points in the rotation direction of the brake disc.

500122-10

Insert the brake linings, insert bolt , and mount locking split pins.
Make sure that the decoupling plate is mounted on the piston side of the brake lining. Operate the foot brake lever several times until the brake linings are lying correctly against the brake disc and there is a pressure point.

400237-10

Changing the rear brake linings
Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container!

Do not operate the foot brake when the rear wheel is removed. Always lay the wheel down in such a way that the brake disc is not damaged.

B00830-10

400260-11
Installing the rear wheel
Check the wheel bearing for damage and wear. If the wheel bearing is damaged or worn: Change the wheel bearing. p. 128)

400260-10

Lift the rear wheel into the swing arm, position it, and insert wheel spindle. Apply the chain.

B00831-10

Position chain adjuster. Mount nut , but do not tighten it yet. Make sure that chain adjusters are fitted correctly on adjusting screws. Check the chain tension. ( Tighten nut. Guideline Nut, rear wheel spindle M20x1.Nm (59 lbf ft) p. 61)
The wide adjustment range of the chain adjusters (32 mm (1.18 in)) enables different secondary ratios with the same chain length. Chain adjusters can be turned by 180. Operate the foot brake lever several times until the brake linings are lying correctly against the brake disc and there is a pressure point. Remove the motorcycle from the lift stand. ( p. 44)

B00825-11

Checking the tire condition
Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on handling characteristics. The type, condition and air pressure of the tires all have an important impact on the handling characteristics of the motorcycle. The front and rear wheels must be mounted with tires with similar profiles. Worn tires have a negative effect on handling characteristics, especially on wet surfaces. 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.
Note local national regulations concerning the minimum tread depth.

400602-10

Minimum tread depth

2 mm ( 0.08 in)

If the tread depth is less than the minimum permissible depth:
Change the tire. Check the tire age.
The tire's date of manufacture is usually part of the tire markings and is indicated by the last four digits of the DOT marking. The first two digits indicate the week of manufacture and the last two digits the year of manufacture. KTM recommends that the tires are changed at the latest after 5 years, regardless of the actual state of wear. If the tire is older than five years: Change the tire.
Checking the tire air pressure
Low tire air pressure leads to abnormal wear and overheating of the tire. Correct tire air pressure ensures optimal riding comfort and maximum tire service life. Remove the dust cap. Check the tire air pressure when the tires are cold. Tire air pressure off road Front Rear Tire air pressure, road (All EXC models) Front

400695-01

1.0 bar (15 psi) 1.0 bar (15 psi)
1.5 bar (22 psi) 1.5 bar (22 psi)

B00834-10

B00835-10
Checking the antifreeze and coolant level
Danger of scaldingDuring 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. Allow the engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
Danger of poisoningCoolant is poisonous and a health hazard. Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children. Condition The engine is cold. Stand the motorcycle upright on a horizontal surface. Remove the radiator cap. Check the coolant antifreeze. C (F)

400243-10

If the coolant antifreeze does not meet specifications: Correct the coolant antifreeze. 10 mm (0.39 in)
Check the coolant level in the radiator. Coolant level above the radiator fins. Correct the coolant level. Alternative 1 Coolant ( Alternative 2 Coolant (mixed ready to use) ( p. 126) p. 126)
If the level of the coolant does not meet specifications:

Mount the radiator cap.

Checking the coolant level
Danger of poisoningCoolant is poisonous and a health hazard. Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children. Condition The engine is cold. Stand the motorcycle upright on a horizontal surface. Remove the radiator cap. Check the coolant level in the radiator. Coolant level above the radiator fins.

10 mm (0.39 in)

If the level of the coolant does not meet specifications: Correct the coolant level. Alternative 1 Coolant ( Alternative 2 Coolant (mixed ready to use) ( p. 126) p. 126)

Draining the coolant

Danger of poisoningCoolant is poisonous and a health hazard. Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children. Condition The engine is cold. Position the motorcycle upright. Place a suitable container under the water pump cover.
(All 125/200 models) Remove screw. Remove radiator cap. Completely drain the coolant. Mount screw with a new seal ring and tighten it. Guideline Drain plug, water pump cover M10xNm (11.1 lbf ft)

401060-01

Treat the engine, swingarm and all other bright and zinc-plated parts (except for the brake discs) with a wax-based corrosion inhibitor.
Corrosion inhibitor is not permitted to come in contact with the brake discs as this would greatly reduce the braking force. Clean the chain. ( p. 60)

STORAGE

Storage
If you want to put the motorcycle into storage for a longer period, take the following actions. Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the new season. Clean the motorcycle. ( Change the gear oil. p. 101) p. 98) p. 89) p. 95)
Check the antifreeze and coolant level. ( Empty the carburetor float chamber. Check the tire air pressure. (
Drain the fuel from the tank into a suitable container.
p. 81) p. 83) p. 83) C (F)

401058-01

(All 250/300 models) Remove the battery. Guideline
x( Recharge the battery. x (
Storage temperature of battery without direct sunlight
Store the vehicle in a dry location that is not subject to large fluctuations in temperature.
KTM recommends raising the motorcycle. Raise the motorcycle with the lift stand. ( p. 44)
Cover the vehicle with a tarp or cover that is permeable to air.
Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Because the engine will not warm up sufficiently, the water vapor produced during combustion will condense, causing engine parts and the exhaust system to rust.
Preparing for use after storage
(All 250/300 models) Recharge the battery. (All 250/300 models) Install the battery.

401059-01

p. 83) p. 83)

Refuel. (

p. 32)
Perform checks and maintenance work when preparing the vehicle for use. ( p. 30) Make a test ride.

TROUBLESHOOTING

Faults The engine cannot be cranked (electric starter) (All 250/300 models) Possible cause Operating error Battery discharged Action Main fuse is blown Starter relay faulty Starter motor faulty Engine turns but does not start Operating error Motorcycle was out of use for a long time and there is old fuel in the float chamber Fuel feed interrupted Go through the steps of starting the engine. ( p. 30) Recharge the battery.

Lighting equipment

Headlight (All EXC models) Parking light (All EXC models) Indicator lamps (All EXC models) Turn signal (All EXC models) Brake/tail light (All EXC models) License plate lamp (All EXC models)
S2 / socket BA20d W5W / socket W2.1x9.5d W2.3W / socket W2x4.6d R10W / socket BA15s LED W2.3W / socket W2.1x4.6d
12 V 35/35 W 12 V 5W 12 V 2.3 W 12 V 10 W 12 V 2.3 W
Validity (All 125/200 EXC models) (All 250/300 EXC models) (200 XCW USA) (250/300 XCW)
Front tire 90/90 - 21 M/C 54M M+S TT Metzeler MCE 6 DAYS EXTREME 90/90 - 21 M/C 54M M+S TT Metzeler MCE 6 DAYS EXTREME 80/100 - 21 51M TT Dunlop GEOMAX MX 51 80/100 - 21 51M TT Dunlop GEOMAX MX 51
Rear tire 120/90 - 18 M/C 65M M+S TT Metzeler MCE 6 DAYS EXTREME 140/80 - 18 M/C 70M M+S TT Metzeler MCE 6 DAYS EXTREME 100/100 - 18 59M TT Dunlop GEOMAX MX 51 110/100 - 18 64M TT Dunlop GEOMAX MX 51
Additional information is available in the Service section under: http://www.ktm.com

Capacity - fuel

Total fuel tank capacity, approx. (EXC EU, EXC SIX DAYS) Total fuel tank capacity, approx. (EXC AUS, XCW)

9.5 l (2.51 US gal)

Super unleaded gasoline, mixed with 2-stroke engine oil (1:60) ( p. 127) Super unleaded gasoline, mixed with 2-stroke engine oil (1:60) ( p. 127) 2 l (2 qt.) 2.5 l (2.6 qt.)
Fuel reserve, approx. (EXC EU, EXC SIX DAYS) Fuel reserve, approx. (EXC AUS, XCW)

TECHNICAL DATA - FORK

Fork part number Fork Compression damping Comfort Standard Sport Full payload Rebound damping Comfort Standard Sport Full payload Spring preload - Preload Adjuster Comfort Standard Sport Full payload Spring length with preload spacer(s) Weight of rider: kg (lb.) Weight of rider: kg (lb.) Weight of rider: kg (lb.) Spring rate Weight of rider: kg (lb.) Weight of rider: kg (lb.) Weight of rider: kg (lb.) Fork length Air chamber length Fork oil per fork leg 620 ml (20.96 fl. oz.)
14.18.7L.61 WP Suspension Up Side Down 4860 MXMA PA 24 clicks 22 clicks 20 clicks 20 clicks 22 clicks 20 clicks 18 clicks 18 clicks 1 turn 2 turns 2 turns 4 turns 513 mm (20.2 in) 513 mm (20.2 in) 513 mm (20.2 in) 3.8 N/mm (21.7 lb/in) 4.0 N/mm (22.8 lb/in) 4.2 N/mm (24 lb/in) 940 mm (37.01 in) 110+10 mm (4.33+0.39 in) 20 0.79 Fork oil (SAE 5) ( p. 126)

Super unleaded (ROZ 95/RON 95/PON 91)
According to DIN EN 228 (ROZ 95/RON 95/PON 91) Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade. Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use.
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).
Super unleaded gasoline, mixed with 2-stroke engine oil (1:60)
According to DIN EN 228 JASO FC ( 1:60 Supplier Motorex Cross Power 2T p. 130) (1:60) 2-stroke engine oil ( p. 126) Super unleaded (ROZ 95/RON 95/PON 91) ( Mixture ratio p. 127)

AUXILIARY SUBSTANCES

Air filter cleaner
Guideline KTM recommends Motorex products. Supplier Motorex Twin Air Dirt Bio Remover

Chain cleaner

Guideline KTM recommends Motorex products. Supplier Motorex Chain Clean
Cleaning and preserving materials for metal, rubber and plastic
Guideline KTM recommends Motorex products. Supplier Motorex Protect & Shine

High viscosity grease

Guideline KTM recommends SKF products. Supplier SKF LGHB 2

Long-life grease

Guideline KTM recommends Motorex products. Supplier Motorex Bike Grease 2000

Motorcycle cleaner

Guideline KTM recommends Motorex products. Supplier Motorex Moto Clean 900

Off-road chain spray

Guideline KTM recommends Motorex products. Supplier Motorex Chainlube Offroad

Oil for foam air filter

Guideline KTM recommends Motorex products. Supplier Motorex Twin Air Liquid Bio Power
Rubber grip adhesive (00062030051)
Supplier KTM-Sportmotorcycle AG GRIP GLUE

Universal oil spray

Guideline KTM recommends Motorex products. Supplier Motorex Joker 440 Synthetic

STANDARDS

JASO FC
JASO FC is a classification 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.

JASO T903 MA

Different technical development directions required a new specification for 4-stroke motorcycles the JASO T903 MA Standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines. With most motorcycles, the gearbox and the clutch are lubricated with the same oil as the engine. The JASO MA Standard meets these special requirements.

The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscosity. The viscosity describes only one property of oil and says nothing about quality.
131 Compression damping fork, adjusting. 41 Compression damping, high-speed shock absorber, adjusting. 36 Compression damping, low-speed shock absorber, adjusting. 37 Coolant draining. 90 refilling. 91 Coolant level checking. 89-90 Cooling system. 89 D Difficult operating conditions. dry sand. high temperatures. low temperatures. muddy surfaces. riding at low speeds. snow. wet sand. wet surfaces. E Electric starter button. 14 Emergency OFF switch. 13-14 Engine running in. 26 Engine characteristic auxiliary spring. 96 auxiliary spring, setting. 96 Engine number. 11 Engine sprocket checking. 61 Environment. 7 F Filler cap closing. 22 opening. 21 Filling up fuel. 32 Foot brake lever. 23 basic position, adjusting. 73 free travel, checking. 73 Fork basic setting, checking. 40 Fork legs bleeding. dust boots, cleaning. installing. removing. spring preload, setting Fork part number. 27 28
A Accessories. 6 Air filter cleaning. 57 installing. 56 removing. 56 Air filter box cleaning. 57 Air filter box lid installing. 56 removing. 56 Antifreeze checking. 89 B Basic chassis setting checking with rider's weight. 36 Battery installing. 83 recharging. 83 removing. 83 Brake discs checking. 70 Brake fluid front brake, adding. 70 rear brake, adding. 74 Brake fluid level front brake, checking. 70 rear brake, checking. 74 Brake linings front brake, changing front brake, checking rear brake, changing rear brake, checking rear brake, installing rear brake, removing C Carburetor. 93 float chamber, emptying. 95 idle speed, adjusting. 94 Chain checking. 61 cleaning. 60 Chain guide adjusting. 64 checking. 61 Chain tension adjusting. 63 checking. 61 Chassis number. 10 Cleaning, care. 101-102 Clutch fluid level, checking. 67 fluid, changing. 67 Clutch lever. 12 basic position, adjusting. 66. 76 75
Fork protector installing. 48 removing. 47
Frame checking. 65 Front fender installing. 54 removing. 54 Front wheel installing. 78 removing. 78 Fuel tank installing. 59 removing. 58 Fuel tap. 21 Fuel, oils, etc. 6 Fuse main fuse, changing. 84 G Gear oil adding. changing draining refilling. 100. 98. 99. 99
132 installing. 58 removing. 57 Motorcycle cleaning. 101 raising with lift stand. 44 removing from lift stand. 44 O Overview of indicator lamps. 14 Owner's manual. 7 P Preparing for use advice on first use. 25 after storage. 103 checks and maintenance work when preparing for use. 30 R Rear sprocket checking. 61 Rear wheel installing. 79 removing. 79 Rebound damping fork, adjusting. 41 shock absorber, adjusting. 37 Riding sag adjusting. 40 Rubber grip checking. 66 securing. 66 S Seat mounting. 55 removing. 55 Service. 6 Service schedule. 34-35 Shift lever. 22 basic position, adjusting. 96 basic position, checking. 96 Shock absorber compression damping, general information installing. removing. riding sag, checking. spring preload, setting. static sag, checking. Shock absorber part number Short circuit button. Side stand. Spare parts. 23. 15 15