KTM 200 EXC 2000-2016 Manual

KTM 200 EXC · 2000–2016 · manual · 171 pages

KTM 200 EXC
2000–2016
Manual
171 pages
Powersport

Technical data

Numbers below were extracted automatically from the document. Verify them against the original manual before you order parts or apply torque.

Tightening torque

Values extracted from the document text. Check against the original before service work.

Item	Value	Also	PDF page
Screw, handle	40 N·m	29.5 ft·lb	p. 59
Screw, top steering	12 N·m	8.9 ft·lb	p. 65
Screw, seat fixing	8 N·m	5.9 ft·lb	p. 71
Screw, frame protec	3 N·m	2.2 ft·lb	p. 72
Screw, air filter box	3 N·m	2.2 ft·lb	p. 73
Screws on main	7 N·m	5.2 ft·lb	p. 77
Nut, wheel spindle	80 N·m	59 ft·lb	p. 83
Screw, chain slid	15 N·m		p. 85
Screw, front wheel	35 N·m	25.8 ft·lb	p. 104
Screw, fork stub	15 N·m	11.1 ft·lb	p. 104
Screw, battery sup	6 N·m	4.4 ft·lb	p. 110
Screw, battery termi	2.5 N·m		p. 110
Bleeder screw, cylin	8 N·m	5.9 ft·lb	p. 122
Screw, throttle grip	5 N·m	3.7 ft·lb	p. 129
Screw, shift	14 N·m	10.3 ft·lb	p. 131
Screw, sub	30 N·m	22.1 ft·lb	p. 138
I00456-10 Screw, sub	35 N·m	25.8 ft·lb	p. 138
Gear oil drain plug	20 N·m	14.8 ft·lb	p. 140
Nut, adjusting screw, control flap	6 N·m	4.4 ft·lb	p. 151
Screw, actuator, exhaust control	6 N·m	4.4 ft·lb	p. 151
Screw, bearing retainer	6 N·m	4.4 ft·lb	p. 151
Screw, clutch spring retainer	6 N·m	4.4 ft·lb	p. 151
Screw, control flap lever, exhaust	8 N·m	5.9 ft·lb	p. 152
Screw, cover, actuator	6 N·m	4.4 ft·lb	p. 152
Screw, crankshaft speed sensor	6 N·m	4.4 ft·lb	p. 152
Screw, exhaust control cover	6 N·m	4.4 ft·lb	p. 152
Screw, locking lever	6 N·m	4.4 ft·lb	p. 152
Screw, retaining bracket, rotary	6 N·m	4.4 ft·lb	p. 152
Screw, stator	6 N·m	4.4 ft·lb	p. 152
Screw, water pump wheel	6 N·m	4.4 ft·lb	p. 152
Bleeder screw, cylinder head	8 N·m	5.9 ft·lb	p. 152
Bleeder screw, water pump cover	8 N·m	5.9 ft·lb	p. 152
Coolant drain plug	10 N·m	7.4 ft·lb	p. 152
Screw, alternator cover	8 N·m	5.9 ft·lb	p. 152
Screw, clutch cover	10 N·m	7.4 ft·lb	p. 152
Screw, clutch slave cylinder	10 N·m	7.4 ft·lb	p. 152
Screw, cover, starter motor	8 N·m	5.9 ft·lb	p. 152
Screw, engine case	10 N·m	7.4 ft·lb	p. 152
Screw, exhaust flange	10 N·m	7.4 ft·lb	p. 152
Screw, gear oil level monitoring	8 N·m	5.9 ft·lb	p. 152
Screw, intake flange/reed valve M6	8 N·m	5.9 ft·lb	p. 152
Screw, intake flange/reed valve	6 N·m	4.4 ft·lb	p. 152
Housing Screw, outer clutch cover	8 N·m	5.9 ft·lb	p. 152
Screw, shift drum locating	10 N·m	7.4 ft·lb	p. 152
Screw, water pump cover	10 N·m	7.4 ft·lb	p. 152
Vacuum connection, housing	2 N·m	1.5 ft·lb	p. 152
Nut, cylinder base	23 N·m	17 ft·lb	p. 152
Screw, cylinder base	10 N·m	7.4 ft·lb	p. 152
Screw, engine sprocket	60 N·m	44.3 ft·lb	p. 152
Nut, rotor	50 N·m	36.9 ft·lb	p. 153
Spark plug	25 N·m	18.4 ft·lb	p. 153
Nut, inner clutch hub	120 N·m	88.5 ft·lb	p. 153
Nut, primary gear wheel	120 N·m	88.5 ft·lb	p. 153
Mushroom head screw for spoiler	2.5 N·m	1.84 ft·lb	p. 156
Screw, emergency OFF switch	2 N·m	1.5 ft·lb	p. 156
Screw, fuel pump on fuel tank	2.5 N·m	1.84 ft·lb	p. 156
Screw, hose clip, inlet sleeve	2.8 N·m	2.07 ft·lb	p. 156
Screw, oil fill level sensor	2.5 N·m	1.84 ft·lb	p. 156
Screw, oil pump holder on oil tank EJOTDELTA	0.7 N·m	0.52 ft·lb	p. 156
Screw, pressure regulator	2.3 N·m	1.7 ft·lb	p. 156
Screw, radiator hoses clip	2.4 N·m	1.77 ft·lb	p. 156
Screw, fixed grip	5 N·m	3.7 ft·lb	p. 156
Screw, throttle valve body cover	2.6 N·m	1.92 ft·lb	p. 156
Spoke nipple, front wheel	6 N·m	4.4 ft·lb	p. 156
Spoke nipple, rear wheel	6 N·m	4.4 ft·lb	p. 156
Screw, battery terminal	2.5 N·m	1.84 ft·lb	p. 156
Screw, light switch	1 N·m	0.7 ft·lb	p. 156
Screw, shock absorber adjusting	5 N·m	3.7 ft·lb	p. 156
Screw, turn signal switch (150 EXC EU)	1 N·m	0.7 ft·lb	p. 156
Nut, cable on starter motor	4 N·m	3 ft·lb	p. 156
Nut, throttle cable wire on throttle	3 N·m	2.2 ft·lb	p. 156
Screw, battery support bracket	6 N·m	4.4 ft·lb	p. 156
Screw, brake lever	5 N·m	3.7 ft·lb	p. 156
Screw, brake line guide for link	4.5 N·m	3.32 ft·lb	p. 156
Screw, cable on starter relay	6 N·m	4.4 ft·lb	p. 156
Screw, chain guide on link fork	10 N·m	7.4 ft·lb	p. 156
Screw, chain sliding guard	10 N·m	7.4 ft·lb	p. 157
Screw, clutch lever	5 N·m	3.7 ft·lb	p. 157
Screw, front brake disc	14 N·m	10.3 ft·lb	p. 157
Screw, fuel tank spoiler on radiator	6 N·m	4.4 ft·lb	p. 157
Screw, oil pump	6 N·m	4.4 ft·lb	p. 157
Screw, oil tank cap	6 N·m	4.4 ft·lb	p. 157
Screw, oil tank on frame	5 N·m	3.7 ft·lb	p. 157
Screw, push rod ball joint	10 N·m	7.4 ft·lb	p. 157
Screw, rear brake disc	14 N·m	10.3 ft·lb	p. 157
Screw, silent block on frame	6 N·m	4.4 ft·lb	p. 157
Nut, pull switch	0.8 N·m	0.59 ft·lb	p. 157
Nut, rear sprocket screw	35 N·m	25.8 ft·lb	p. 157
Nut, rim lock	12 N·m	8.9 ft·lb	p. 157
Rear brake lever stop nut	20 N·m	14.8 ft·lb	p. 157
Screw, bottom triple clamp	15 N·m	11.1 ft·lb	p. 157
Screw, chain sliding piece	15 N·m	11.1 ft·lb	p. 157
Screw, engine brace	25 N·m	18.4 ft·lb	p. 157
Screw, engine sprocket cover	15 N·m	11.1 ft·lb	p. 157
Screw, front brake caliper	25 N·m	18.4 ft·lb	p. 157
Screw, handlebar clamp	20 N·m	14.8 ft·lb	p. 157
Screw, manifold	15 N·m	11.1 ft·lb	p. 157
Screw, side stand attachment	33 N·m	24.3 ft·lb	p. 157
Screw, subframe bottom	30 N·m	22.1 ft·lb	p. 157
Screw, subframe, top	35 N·m	25.8 ft·lb	p. 158
Screw, top steering stem	20 N·m	14.8 ft·lb	p. 158
Screw, top triple clamp	20 N·m	14.8 ft·lb	p. 158
Screw, wheel speed sensor	4.5 N·m	3.32 ft·lb	p. 158
Engine bracket screw	60 N·m	44.3 ft·lb	p. 158
Nut, foot brake lever	45 N·m	33.2 ft·lb	p. 158

Spark plugs

Values extracted from the document text. Check against the original before service work.

Item	Value	Also	PDF page
BR9	—		p. 151

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