2012r 125-200 Repair manual.pdf

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REPAIR MANUAL
2012
125 EXC EU
125 EXC SIX DAYS EU
200 EXC EU
200 EXC AUS
200 XC‑W USA
Art. no. 3206132en
INTRODUCTION
Read this repair manual carefully and thoroughly before beginning work.
INTRODUCTION
1
This vehicle can only fulfill the demands placed on it in the long run if the specified service work is performed regularly by qualified
experts.
The repair manual was written to correspond to the most current state of this model series. We reserve the right to make changes in
the interest of technical advancement without, at the same time, updating this repair 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 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 supply.
© 2013 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
7.4
Checking the throttle cable routing ...................
7.5
Checking the play in the throttle cable ..............
7.6
Adjusting the play in the throttle cable..............
8
SHOCK ABSORBER, SWINGARM ................................
8.1
Adjusting the high-speed compression
damping of the shock absorber.........................
8.2
Adjusting the low-speed compression damping
of the shock absorber ......................................
8.3
Adjusting the rebound damping of the shock
absorber.........................................................
8.4
Measuring the sag of the unloaded rear wheel....
8.5
Checking the static sag of the shock absorber ....
8.6
Checking the riding sag of the shock absorber....
8.7
Adjusting the spring preload of the shock
absorber.........................................................
8.8
Adjusting the riding sag ...................................
8.9
Removing the shock absorber ...........................
8.10 Installing the shock absorber............................
8.11 Servicing the shock absorber............................
8.12 Removing the spring........................................
8.13 Disassembling the damper ...............................
8.14 Disassembling the piston rod ...........................
8.15 Disassembling the seal ring retainer..................
8.16 Replacing the pilot bushing .............................
8.17 Checking the damper ......................................
8.18 Disassembling the rebound adjuster..................
8.19 Removing the heim joint..................................
8.20 Installing the heim joint...................................
8.21 Assembling the rebound adjuster......................
8.22 Assembling the seal ring retainer ......................
8.23 Assembling the piston rod................................
8.24 Assembling the damper ...................................
8.25 Bleeding and filling the damper .......................
8.26 Filling the damper with nitrogen .......................
8.27 Installing the spring ........................................
8.28 Changing the heim joint...................................
9
EXHAUST ..................................................................
9.1
Removing the main silencer .............................
9.2
Installing the main silencer..............................
9.3
Changing the glass fiber yarn filling of the
main silencer..................................................
10 AIR FILTER ...............................................................
10.1 Removing the air filter box lid ..........................
10.2 Installing the air filter box lid ...........................
10.3 Removing the air filter .....................................
10.4 Installing the air filter......................................
10.5 Cleaning the air filter and air filter box ..............
11 FUEL TANK, SEAT, TRIM ...........................................
11.1 Opening the filler cap......................................
11.2 Closing the filler cap .......................................
11.3 Removing the seat ..........................................
11.4 Mounting the seat ...........................................
11.5 Removing the fuel tank....................................
11.6 Installing the fuel tank ....................................
11.7 Fuel tap .........................................................
12 MASK, FENDER.........................................................
12.1 Removing the front fender ...............................
12.2 Installing the front fender ................................
12.3 Removing the headlight mask with the
headlight (All 125/200 EXC models).................
12.4 Refitting the headlight mask with the headlight
(All 125/200 EXC models) ...............................
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1
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7
MEANS OF REPRESENTATION ..................................... 6
1.1
Symbols used ................................................... 6
1.2
Formats used.................................................... 6
SAFETY ADVICE........................................................... 7
2.1
Repair Manual .................................................. 7
2.2
Safety advice.................................................... 7
2.3
Degrees of risk and symbols ............................... 7
2.4
Work rules........................................................ 7
IMPORTANT INFORMATION ......................................... 8
3.1
Guarantee, warranty .......................................... 8
3.2
Operating and auxiliary substances ..................... 8
3.3
Spare parts, accessories .................................... 8
3.4
Figures ............................................................ 8
SERIAL NUMBERS ...................................................... 9
4.1
Chassis number ................................................ 9
4.2
Type label ........................................................ 9
4.3
Engine number ................................................. 9
4.4
Fork part number ............................................ 10
4.5
Shock absorber part number ............................ 10
MOTORCYCLE ........................................................... 11
5.1
Raising the motorcycle with the lift stand.......... 11
5.2
Removing the motorcycle from the lift stand...... 11
5.3
Starting.......................................................... 11
5.4
Starting the motorcycle for checking ................. 12
FORK, TRIPLE CLAMP ............................................... 13
6.1
Adjusting the compression damping of the
fork ............................................................... 13
6.2
Adjusting the rebound damping of the fork ........ 13
6.3
Adjusting the spring preload of the fork............. 13
6.4
Bleeding the fork legs...................................... 14
6.5
Cleaning the dust boots of the fork legs............. 14
6.6
Loosening the fork protection ........................... 15
6.7
Positioning the fork protection.......................... 15
6.8
Removing the fork legs .................................... 15
6.9
Installing the fork legs ..................................... 16
6.10 Removing the fork protector ............................. 17
6.11 Installing the fork protector.............................. 17
6.12 Performing a fork service ................................. 18
6.13 Disassembling the fork legs.............................. 18
6.14 Cartridge disassembly...................................... 21
6.15 Disassembling the compression damping
fitting ............................................................ 23
6.16 Checking the fork legs ..................................... 23
6.17 Assembling the compression damping fitting ..... 24
6.18 Assembling the cartridge ................................. 25
6.19 Assembling the fork legs.................................. 27
6.20 Greasing the steering head bearing ................... 31
6.21 Removing the lower triple clamp (EXC, XC‑W) .... 31
6.22 Removing the lower triple clamp
(125 EXC SIX DAYS EU).................................. 31
6.23 Installing the lower triple clamp (EXC, XC‑W)..... 32
6.24 Installing the lower triple clamp
(125 EXC SIX DAYS EU).................................. 34
6.25 Checking the play of the steering head
bearing .......................................................... 35
6.26 Adjusting the play of the steering head
bearing .......................................................... 36
HANDLEBAR, CONTROLS........................................... 37
7.1
Handlebar position.......................................... 37
7.2
Adjusting the handlebar position ...................... 37
7.3
Adjusting the basic position of the clutch
lever .............................................................. 37
TABLE OF CONTENTS
12.5
Removing the start number plate
(200 XC‑W USA)............................................. 72
12.6 Installing the start number plate
(200 XC‑W USA)............................................. 72
WHEELS ................................................................... 73
13.1 Checking the tire air pressure........................... 73
13.2 Checking the tire condition .............................. 73
13.3 Checking the brake discs ................................. 74
13.4 Checking the spoke tension.............................. 74
13.5 Front wheel .................................................... 75
13.5.1
Removing the front wheel ............................ 75
13.5.2
Installing the front wheel ............................. 75
13.5.3
Removing the brake disc of the front brake.... 76
13.5.4
Installing the brake disc of the front brake .... 76
13.6 Rear wheel ..................................................... 76
13.6.1
Removing the rear wheel ............................. 76
13.6.2
Installing the rear wheel .............................. 77
13.6.3
Removing the brake disc of the rear brake ..... 78
13.6.4
Installing the brake disc of the rear brake...... 78
13.6.5
Checking the chain for dirt .......................... 78
13.6.6
Cleaning the chain ...................................... 79
13.6.7
Checking the chain tension.......................... 79
13.6.8
Checking the chain, rear sprocket, engine
sprocket and chain guide............................. 80
13.6.9
Adjusting the chain tension ......................... 81
13.6.10 Adjusting the chain guide ............................ 82
WIRING HARNESS..................................................... 83
14.1 Plug-in connection, ignition timing map ............ 83
14.2 Checking the capacitor .................................... 83
BRAKE SYSTEM ........................................................ 84
15.1 Checking the front brake linings ....................... 84
15.2 Changing the front brake linings ....................... 84
15.3 Checking free travel of hand brake lever ............ 86
15.4 Adjusting free travel of hand brake lever (All
125/200 EXC models)..................................... 86
15.5 Adjusting the basic position of the hand brake
lever (200 XC‑W USA) ..................................... 86
15.6 Checking the front brake fluid level .................. 87
15.7 Adding front brake fluid................................... 87
15.8 Changing the front brake fluid .......................... 88
15.9 Checking the rear brake linings ........................ 89
15.10 Changing the rear brake linings ........................ 90
15.11 Checking the free travel of foot brake lever ........ 91
15.12 Adjusting the basic position of the foot brake
lever .............................................................. 91
15.13 Checking the rear brake fluid level.................... 92
15.14 Adding brake fluid for the rear brake................. 92
15.15 Changing the rear brake fluid ........................... 93
LIGHTING SYSTEM, INSTRUMENTS ........................... 95
16.1 Adjusting the speedometer functions ................ 95
16.2 Setting kilometers or miles............................... 95
16.3 Activating the additional functions.................... 96
16.4 Setting the wheel circumference ...................... 96
16.5 Setting the clock............................................. 97
16.6 Changing the speedometer battery .................... 97
16.7 Checking the headlight setting (All
125/200 EXC models)..................................... 98
16.8 Adjusting the headlight range (All
125/200 EXC models)..................................... 99
ENGINE .................................................................. 100
17.1 Removing the engine..................................... 100
17.2 Installing the engine...................................... 103
17.3 Engine disassembly.......................................
17.3.1
Clamping the engine into the engine work
stand .......................................................
17.3.2
Draining the gear oil..................................
17.3.3
Removing the shift lever ............................
17.3.4
Removing the engine sprocket....................
17.3.5
Removing the clutch push rod....................
17.3.6
Removing the spacer.................................
17.3.7
Removing the alternator cover ....................
17.3.8
Removing the kick starter ..........................
17.3.9
Removing the cylinder head .......................
17.3.10 Removing the cylinder...............................
17.3.11 Removing the piston .................................
17.3.12 Removing the water pump cover.................
17.3.13 Removing the clutch cover.........................
17.3.14 Removing the clutch discs .........................
17.3.15 Removing the outer clutch hub ..................
17.3.16 Removing the primary gear ........................
17.3.17 Removing the kick starter shaft ..................
17.3.18 Removing the shift shaft............................
17.3.19 Removing the shift drum locating unit ........
17.3.20 Removing the rotor....................................
17.3.21 Removing the stator ..................................
17.3.22 Removing the reed valve housing................
17.3.23 Removing the left engine case section ........
17.3.24 Removing the shift rails.............................
17.3.25 Removing the shift drum ...........................
17.3.26 Removing the shift forks............................
17.3.27 Removing the transmission shafts...............
17.3.28 Removing the crankshaft ...........................
17.4 Work on individual parts ................................
17.4.1
Work on the right section of the engine
case ........................................................
17.4.2
Work on the left section of the engine
case ........................................................
17.4.3
Removing the crankshaft bearing inner
race.........................................................
17.4.4
Installing the crankshaft bearing inner
race.........................................................
17.4.5
Changing the connecting rod, conrod
bearing, and crank pin ..............................
17.4.6
Checking the crankshaft run-out at the
bearing pin...............................................
17.4.7
Checking/measuring the cylinder ................
17.4.8
Removing the exhaust control ....................
17.4.9
Checking the exhaust control in the
cylinder ...................................................
17.4.10 Installing the exhaust control .....................
17.4.11 Cylinder - Nikasil
®
coating .........................
17.4.12 Checking/measuring the piston...................
17.4.13 Checking the piston ring end gap ...............
17.4.14 Piston/cylinder - measuring the mounting
clearance .................................................
17.4.15 Checking the reed valve housing, reed
valve and intake flange..............................
17.4.16 Changing the water pump bearing ..............
17.4.17 Removing the exhaust control in the clutch
cover .......................................................
17.4.18 Checking the exhaust control in the clutch
cover .......................................................
17.4.19 Installing the exhaust control in the clutch
cover .......................................................
17.4.20 Checking the clutch ..................................
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