2011r 125-200 Repair manual.pdf

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REPAIR MANUAL
2011
125 EXC EU
125 EXC SIX DAYS EU
125 EXC Factory Edition EU
200 EXC EU
200 EXC AUS
200 XC‑W USA
Art. no. 3206105en
INTRODUCTION
Read this repair manual carefully and thoroughly before beginning work.
INTRODUCTION
1
Only use
ORIGINAL KTM SPARE PARTS.
The vehicle will only be able to meet the demands placed on it if the specified service work is performed regularly and properly.
This repair manual was written to correspond to the latest state of this series. We reserve the right to make changes in the interest of
technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that the repair work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-
tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-
cial equipment that does not belong to the regular scope of delivery.
© 2011 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright
owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
TABLE OF CONTENTS
TABLE OF CONTENTS
2
Servicing the shock absorber ..........................................
Removing the spring ......................................................
Disassembling the damper .............................................
Disassembling the piston rod ..........................................
Disassembling the seal ring retainer ................................
Replacing the pilot bushing ............................................
Checking the damper .....................................................
Disassembling the rebound adjuster ................................
Removing the heim joint ................................................
Installing the heim joint .................................................
Assembling the rebound adjuster ....................................
Assembling the seal ring retainer ....................................
Assembling the piston rod ..............................................
Assembling the damper..................................................
Bleeding and filling the damper ......................................
Filling the damper with nitrogen .....................................
Installing the spring.......................................................
Changing the heim joint .................................................
05/EXHAUST ....................................................................
Removing the main silencer............................................
Installing the main silencer ............................................
Changing the glass fiber yarn filling of the main silencer ...
06/AIR FILTER..................................................................
Removing the air filter box lid.........................................
Installing the air filter box lid..........................................
Removing the air filter ...................................................
Installing the air filter ....................................................
Cleaning the air filter and air filter box ............................
07/FUEL TANK, SEAT, TRIM..............................................
Opening the filler cap ....................................................
Closing the filler cap......................................................
Removing the seat .........................................................
Mounting the seat .........................................................
Removing the fuel tank ..................................................
Installing the fuel tank ...................................................
Fuel tap........................................................................
08/MASK, FENDER ...........................................................
Removing the front fender ..............................................
Installing the front fender...............................................
Removing the start number plate (200 XC‑W USA) ...........
Installing the start number plate (200 XC‑W USA) ............
Removing the headlight mask with the headlight (All
125/200 EXC models) ...................................................
Refitting the headlight mask with the headlight (All
125/200 EXC models) ...................................................
09/FRONT WHEEL ............................................................
Removing the front wheel ...............................................
Installing the front wheel................................................
Checking the brake discs................................................
Removing the brake disc of the front brake ......................
Installing the brake disc of the front brake .......................
Checking the tire condition.............................................
Checking the tire air pressure .........................................
Checking the spoke tension ............................................
10/REAR WHEEL ..............................................................
Removing the rear wheel ................................................
Installing the rear wheel .................................................
Removing the brake disc of the rear brake........................
Installing the brake disc of the rear brake ........................
Checking the chain tension ............................................
Adjusting the chain tension ............................................
Adjusting the chain guide...............................................
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MEANS OF REPRESENTATION ............................................ 5
IMPORTANT NOTES ............................................................ 6
SERIAL NUMBERS.............................................................. 7
Chassis number............................................................... 7
Type label....................................................................... 7
Engine number................................................................ 7
Fork part number............................................................. 8
Shock absorber part number............................................. 8
MOTORCYCLE..................................................................... 9
Raising the motorcycle with the lift stand .......................... 9
Removing the motorcycle from the lift stand ...................... 9
Starting .......................................................................... 9
Starting the motorcycle for checking ............................... 10
01/FORK, TRIPLE CLAMP.................................................. 11
Adjusting the compression damping of the fork ................ 11
Adjusting the rebound damping of the fork....................... 11
Adjusting the spring preload of the fork ........................... 11
Bleeding the fork legs .................................................... 12
Cleaning the dust boots of the fork legs ........................... 12
Loosening the fork protection.......................................... 13
Positioning the fork protection ........................................ 13
Removing the fork legs................................................... 13
Installing the fork legs ................................................... 14
Removing the fork protector............................................ 15
Installing the fork protector ............................................ 15
Performing a fork service................................................ 15
Disassembling the fork legs ............................................ 16
Cartridge disassembly .................................................... 18
Disassembling the compression damping fitting ............... 20
Checking the fork legs.................................................... 21
Assembling the compression damping fitting.................... 22
Assembling the cartridge ................................................ 23
Assembling the fork legs ................................................ 24
Greasing the steering head bearing.................................. 28
Removing the lower triple clamp (EXC EU/AUS) ............... 28
Removing the lower triple clamp (EXC SIX DAYS,
EXC Factory Edition, XC‑W) ............................................ 29
Installing the lower triple clamp (EXC EU/AUS) ................ 29
Installing the lower triple clamp (EXC SIX DAYS,
EXC Factory Edition, XC‑W) ............................................ 31
Checking the play of the steering head bearing................. 33
Adjusting the play of the steering head bearing ................ 33
02/HANDLEBAR, INSTRUMENTS....................................... 35
Handlebar position ........................................................ 35
Adjusting the handlebar position..................................... 35
Adjusting the basic position of the clutch lever................. 35
Checking the throttle cable routing.................................. 36
Checking the play in the throttle cable............................. 36
Adjusting the play in the throttle cable ............................ 36
04/SHOCK ABSORBER, SWINGARM................................... 37
Adjusting the high-speed compression damping of the
shock absorber .............................................................. 37
Adjusting the low-speed compression damping of the
shock absorber .............................................................. 37
Adjusting the rebound damping of the shock absorber....... 38
Measuring the sag of the unloaded rear wheel .................. 38
Checking the static sag of the shock absorber .................. 38
Checking the riding sag of the shock absorber .................. 39
Adjusting the spring preload of the shock absorber ........... 39
Adjusting the riding sag ................................................. 40
Removing the shock absorber ......................................... 40
Installing the shock absorber .......................................... 40
TABLE OF CONTENTS
Checking the chain, rear sprocket, engine sprocket and
chain guide................................................................... 75
Checking the chain for dirt ............................................. 77
Cleaning the chain......................................................... 77
11/WIRING HARNESS, BATTERY ....................................... 78
Ignition curve plug connection ........................................ 78
Checking the capacitor................................................... 78
13/BRAKE SYSTEM........................................................... 79
Checking the front brake linings...................................... 79
Changing the front brake linings ..................................... 79
Checking free travel of hand brake lever........................... 81
Adjusting the basic position of the hand brake lever
(200 XC‑W USA) ........................................................... 81
Adjusting free travel of hand brake lever (All
125/200 EXC models) ................................................... 81
Checking the front brake fluid level ................................. 82
Adding front brake fluid ................................................. 82
Changing the front brake fluid ........................................ 83
Checking the rear brake linings ....................................... 84
Removing the rear brake linings ...................................... 84
Installing the rear brake linings....................................... 84
Changing the rear brake linings....................................... 85
Checking the free travel of foot brake lever....................... 86
Adjusting basic position of foot brake lever ...................... 86
Checking the rear brake fluid level .................................. 86
Adding brake fluid for the rear brake ............................... 87
Changing the rear brake fluid.......................................... 87
14/LIGHTING SYSTEM, INSTRUMENTS ............................. 89
Adjusting the speedometer functions............................... 89
Setting kilometers or miles ............................................. 89
Activating the additional functions .................................. 90
Setting the wheel circumference ..................................... 90
Setting the clock ........................................................... 91
Changing the speedometer battery .................................. 91
Checking the headlight setting (All 125/200 EXC
models) ........................................................................ 92
Adjusting the headlight range (All 125/200 EXC
models) ........................................................................ 92
30/ENGINE....................................................................... 93
Removing the engine ..................................................... 93
Installing the engine ...................................................... 96
30/DISASSEMBLING THE ENGINE................................... 101
Clamping the engine into the engine work stand ............. 101
Draining the gear oil .................................................... 101
Removing the shift lever............................................... 101
Removing the engine sprocket ...................................... 102
Removing the clutch push rod ...................................... 102
Removing the spacer ................................................... 103
Removing the alternator cover....................................... 103
Removing the kick starter ............................................. 104
Removing the cylinder head.......................................... 105
Removing the cylinder ................................................. 106
Removing the piston .................................................... 107
Removing the water pump cover ................................... 107
Removing the clutch cover ........................................... 107
Removing the clutch discs............................................ 108
Removing the outer clutch hub ..................................... 108
Removing the primary gear ........................................... 109
Removing the kick starter shaft..................................... 110
Removing the shift shaft .............................................. 110
Removing the shift drum locating unit ........................... 110
Removing the rotor ...................................................... 111
Removing the stator.....................................................
Removing the reed valve housing ..................................
Removing the left engine case section ...........................
Removing the shift rails ...............................................
Removing the shift drum ..............................................
Removing the shift forks ..............................................
Removing the transmission shafts .................................
Removing the crankshaft ..............................................
30/ENGINE - WORK ON INDIVIDUAL PARTS.....................
Work on the right section of the engine case ..................
Work on the left section of the engine case ....................
Removing the crankshaft bearing inner race ...................
Installing the crankshaft bearing inner race....................
Changing the connecting rod, conrod bearing, and
crank pin ....................................................................
Checking the crankshaft run-out at the bearing pin .........
Checking/measuring the cylinder...................................
Removing the exhaust control .......................................
Checking the exhaust control in the cylinder ..................
Installing the exhaust control........................................
Cylinder - Nikasil
®
coating ............................................
Checking/measuring the piston .....................................
Checking the piston ring end gap ..................................
Piston/cylinder - measuring the mounting clearance........
Checking the reed valve housing, reed valve and intake
flange.........................................................................
Changing the water pump bearing .................................
Removing the exhaust control in the clutch cover ...........
Checking the exhaust control in the clutch cover ............
Installing the exhaust control in the clutch cover ............
Checking the clutch.....................................................
Changing the absorbing element of the clutch ................
Preassembling the shift shaft........................................
Checking the shift mechanism ......................................
Disassembling the main shaft .......................................
Disassembling the countershaft ....................................
Checking the transmission............................................
Assembling the main shaft ...........................................
Assembling the countershaft.........................................
Checking the kick starter..............................................
Preassembling the kick starter shaft ..............................
30/ASSEMBLING THE ENGINE ........................................
Installing the crankshaft...............................................
Installing the transmission shafts ..................................
Installing the shift forks ...............................................
Installing the shift drum...............................................
Installing the shift rails ................................................
Installing the left engine case section............................
Installing the reed valve housing ...................................
Installing the stator .....................................................
Adjusting the ignition...................................................
Installing the rotor .......................................................
Installing the shift drum locating unit............................
Installing the shift shaft ...............................................
Installing the kick starter shaft .....................................
Installing the primary gear............................................
Installing the outer clutch hub......................................
Installing the clutch discs ............................................
Installing the clutch cover ............................................
Installing the water pump cover ....................................
Installing the piston.....................................................
Installing the cylinder ..................................................
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