KTM 250 XC TPI Owner's Manual
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KTM 250 XC TPI Owner's Manual

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OWNER'S MANUAL
2020
250 XC TPI
300 XC TPI
Art. no. 3214002en

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Summary of Contents for KTM 250 XC TPI

  • Page 1 OWNER'S MANUAL 2020 250 XC TPI 300 XC TPI Art. no. 3214002en...
  • Page 3 KTM accepts no liability for delivery options, deviations from fig- ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS PREPARING FOR USE......... 20 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 5 Advice on preparing for first use ..20 Symbols used ........5 Running in the engine ...... 21 Formats used........5 Starting power of lithium-ion SAFETY ADVICE..........
  • Page 5 TABLE OF CONTENTS 10.10 Adjusting the spring preload of the 11.33 Checking the chain for dirt....68 shock absorber ......41 11.34 Cleaning the chain ......68 10.11 Adjusting the riding sag ....42 11.35 Checking the chain tension ....69 10.12 Checking the basic setting of the 11.36 Adjusting the chain tension....
  • Page 6 TABLE OF CONTENTS 15 COOLING SYSTEM ........101 21.9 Chassis tightening torques ....131 15.1 Cooling system ......101 22 SUBSTANCES .......... 134 15.2 Checking the antifreeze and 23 AUXILIARY SUBSTANCES ......136 coolant level ........101 15.3 Checking the coolant level ....102 24 STANDARDS ..........

  • Page 7: Means Of Representation 1

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop! Your motorcycle will be optimally cared for there by specially trained experts using the auxiliary tools required.

  • Page 8: Safety Advice

    2 SAFETY ADVICE Use definition – intended use This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle com- plies with the currently valid regulations and categories of the top international motorsports organizations. Info This vehicle is designed for use in offroad endurance competition, and not primarily for use in motocross.

  • Page 9: Tampering Warning

    Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. The vehicle should only be used by trained persons. Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop. Adhere to the information and warning labels on the vehicle.

  • Page 10: Protective Clothing

    – Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. Work rules Special tools are necessary for certain tasks.

  • Page 11: Important Notes 3

    Manufacturer and implied warranty The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and con- firmed in the KTM Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.

  • Page 12: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) V01730-10 Clutch lever ( p. 14) Fuel tank filler cap Air filter box cover Side stand ( p. 18) Shift lever ( p. 17) Engine number ( p. 12)

  • Page 13: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) V01731-10 2-stroke oil tank cap Switch-off button ( p. 14) Start button ( p. 15) Throttle grip ( p. 14) Hand brake lever ( p. 14) Foot brake lever ( p.

  • Page 14: Serial Numbers

    5 SERIAL NUMBERS Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 401945-10 Type label The type label is fixed to the front of the steering head. 401946-10 Engine number The engine number is embossed on the left side of the engine above the engine sprocket.

  • Page 15: Shock Absorber Article Number

    SERIAL NUMBERS 5 Shock absorber article number Shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. 401948-10...

  • Page 16: Controls

    6 CONTROLS Clutch lever Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automati- cally. V01641-10 Hand brake lever Hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever.

  • Page 17: Start Button

    CONTROLS 6 Start button Start button is fitted on the right side of the handlebar. Possible states • The start button is in the basic position is pressed – In this position, the starter • The start button motor is actuated. V01643-10 Overview of indicator lamps Possible states...

  • Page 18: Closing The Fuel Tank Filler Cap

    6 CONTROLS – Press release button , turn the fuel tank filler cap counter- clockwise, and lift it off. V01646-10 Closing the fuel tank filler cap – Mount filler cap and turn it clockwise until the release but- ton engages. Info Route fuel tank breather hose without kinks.

  • Page 19: Cold Start Button

    CONTROLS 6 6.11 Cold start button The cold start button is fitted on the side of the throttle valve body. If the engine is cold and the ambient temperature is low, the electronic fuel injection system extends the injection time. To help the engine burn the increased fuel quantity, it must be supplied with additional oxygen by pulling the cold start button.

  • Page 20: Foot Brake Lever

    6 CONTROLS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11 6.14 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 401956-10 6.15 Side stand...

  • Page 21: Service Hour Counter

    CONTROLS 6 6.16 Service hour counter The service hour counter is fitted in front of the handlebar. It shows the total number of service hours of the engine. The service hour counter begins counting when the engine is started and stops when the engine is switched off. Info The value indicated by the service hour counter cannot be cleared or adjusted.

  • Page 22: Preparing For Use

    When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-sales inspection work has been carried out by an authorized KTM workshop. You will receive a delivery certificate when the vehicle is handed over.

  • Page 23: Running In The Engine

    PREPARING FOR USE 7 – Adjust the basic position of the foot brake lever. p. 84) – Adjust the basic position of the shift lever. p. 111) – Get used to the handling characteristics of the motorcycle on a suitable surface before undertaking more chal- lenging trips.

  • Page 24: Preparing The Vehicle For Difficult Operating Conditions

    7 PREPARING FOR USE Preparing the vehicle for difficult operating conditions Info Use of the vehicle under difficult conditions, such as on sand or on wet and muddy circuits/surfaces, can lead to considerably more rapid wear of components such as the drive train, brake system, or suspension components.

  • Page 25: Preparing The Vehicle For Riding On Wet Sand

    PREPARING FOR USE 7 – Mount the air filter dust cover. Air filter dust cover (79006920000) Info Observe the fitting instructions for KTM PowerParts. M01104-01 – Mount the air filter sand cover. Air filter sand cover (79006922000) Info Observe the fitting instructions for KTM PowerParts.

  • Page 26: Preparing The Vehicle For Riding On Wet And Muddy Circuits

    – Change the radiator cap. – Mount the air filter rain cover. Air filter rain cover (79006921000) Info Observe the fitting instructions for KTM PowerParts. M01106-01 – Clean the chain. Chain cleaner ( p. 136) –...

  • Page 27: Preparing Vehicle For High Temperatures Or Slow Riding

    PREPARING FOR USE 7 – Mount the steel sprocket. – Clean motorcycle. ( p. 121) – Straighten the bent radiator fins carefully. 600868-01 Preparing vehicle for high temperatures or slow riding – Check the radiator cap. Value on the radiator cap 1.8 bar (26 psi) »...

  • Page 28: Preparing The Vehicle For Low Temperatures Or Snow

    7 PREPARING FOR USE Preparing the vehicle for low temperatures or snow – Mount the air filter rain cover. Air filter rain cover (79006921000) Info Observe the fitting instructions for KTM PowerParts. M01106-01...

  • Page 29: Riding Instructions 8

    RIDING INSTRUCTIONS 8 Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –...

  • Page 30: Starting Off

    Do not change into a low gear at high engine speed. Info If you hear unusual noises while riding, stop immediately, switch off the engine, and contact an autho- rized KTM workshop. First gear is used for starting off and for steep inclines. –...

  • Page 31: Applying The Brakes

    Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Moisture and dirt impair the brake system.

  • Page 32: Transporting

    8 RIDING INSTRUCTIONS – Do not park the vehicle near to materials which are highly flammable or explosive. – Allow the vehicle to cool down before covering it. Note Material damage The vehicle may be damaged by incorrect procedure when parking. Significant damage may be caused if the vehicle rolls away or falls over.

  • Page 33: Adding 2-Stroke Oil

    RIDING INSTRUCTIONS 8 Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – In case of skin contact, rinse the affected area with plenty of water. –...
  • Page 34 8 RIDING INSTRUCTIONS – Fill the 2-stroke oil tank up to the lower edge of the filler neck. 2-stroke oil tank con- 0.6 l (0.6 qt.) Engine oil, 2-stroke tent approx. p. 134) – Close 2-stroke oil tank cap. ( p.

  • Page 35: Service Schedule 9

    Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise you.

  • Page 36: Recommended Work

    Final check: Check the vehicle for operating safety and take a test ride. ○ ○ ● ● ● Read out the error memory after the test ride using the KTM diagnostics tool. ○ ○ ● ● ● Make a service entry in KTM Dealer.net.
  • Page 37 SERVICE SCHEDULE 9 Every 80 operating hours Every 40 operating hours After 20 operating hours / Every 20 operating hours After 10 operating hours / Every 10 operating hours every 12 months ● Perform major engine service including removing and installing the engine. Change the piston and check the cylinder.

  • Page 38: 10 Tuning The Chassis

    – As delivered, KTM offroad motorcycles are adjusted for an average rider's weight (with full protective clothing). Guideline Standard rider weight 75 …...

  • Page 39: Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the low-speed compression adjuster can be seen in slow to normal compression of the shock absorber.

  • Page 40: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the high-speed compression adjuster can be seen in fast compression of the shock absorber.

  • Page 41: Measuring The Rear Wheel Dimension Unloaded

    TUNING THE CHASSIS 10 Info Turn clockwise to increase the damping; turn counter- clockwise to reduce damping when the shock absorber rebounds. 10.7 Measuring the rear wheel dimension unloaded Preparatory work – Raise the motorcycle with a lift stand. ( p.

  • Page 42: Checking The Static Sag Of The Shock Absorber

    10 TUNING THE CHASSIS 10.8 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 39) – Hold the motorcycle upright with aid of an assistant. – Measure the distance again between the rear axle and mark- ing SAG on the rear fender using the sag gage.

  • Page 43: Adjusting The Spring Preload Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the spring length.

  • Page 44: Adjusting The Riding Sag

    10 TUNING THE CHASSIS 10.11 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 47) – Remove the shock absorber. p. 56) – After removing the shock absorber, clean it thoroughly. Main work –...

  • Page 45: Adjusting The Fork Air Pressure

    A little air escapes from the fork leg when connecting. Info This is due to the volume of the hose and not due to a defect in the fork airpump or the fork. Read the accompanying KTM PowerParts instructions. – Adjust the air pressure as specified. Guideline Air pressure 9.6 bar (139 psi)

  • Page 46: Adjusting The Compression Damping Of The Fork

    10 TUNING THE CHASSIS When disconnecting, excess pressure will escape from the hose – the fork leg itself does not lose any air. The fork airpump indicator switches off automatically after 80 seconds. – Mount the protection cap. Info Only mount the protection cap by hand. Finishing work –...

  • Page 47: Handlebar Position

    TUNING THE CHASSIS 10 Guideline Rebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Info Turn clockwise to increase the damping; turn counter- clockwise to reduce damping when the shock absorber rebounds. – Mount protection cap 10.16 Handlebar position The holes on the handlebar supports are placed at a distance from the center.
  • Page 48 10 TUNING THE CHASSIS Main work – Remove screws . Remove the handlebar clamp. Remove the handlebar and lay it to one side. Info Cover the components to protect them against damage. Do not kink the cables and lines. – Remove screws .

  • Page 49: Service Work On The Chassis 11

    SERVICE WORK ON THE CHASSIS 11 11.1 Raising the motorcycle with a lift stand Note Material damage The vehicle may be damaged by incorrect procedure when parking. Significant damage may be caused if the vehicle rolls away or falls over. The components for parking the vehicle are designed only for the weight of the vehicle. –...

  • Page 50: Cleaning The Dust Boots Of The Fork Legs

    11 SERVICE WORK ON THE CHASSIS Main work – Release bleeder screws Any excess pressure escapes from the interior of the fork. – Tighten the bleeder screws. H01182-12 Finishing work – Remove the motorcycle from the lift stand. ( p. 47) 11.4 Cleaning the dust boots of the fork legs Preparatory work...

  • Page 51: Removing The Fork Legs

    SERVICE WORK ON THE CHASSIS 11 11.5 Removing the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 47) – Remove the front wheel. p. 90) Main work – Remove screws and take off the clamp. –...

  • Page 52: Removing The Fork Protector

    11 SERVICE WORK ON THE CHASSIS – Position the brake caliper. Mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft) Loctite ® 243™ brake caliper – Position the brake line and the clamp. Mount and tighten screws V01693-11 Finishing work –...

  • Page 53: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 11 Main work – Take off cable holder in front of the left radiator. – Remove screw – Remove screw – Remove the upper triple clamp with the handlebar and hang them to the side. Info Cover the components to protect them against damage.
  • Page 54 11 SERVICE WORK ON THE CHASSIS – Position the fork legs. Air bleeder screw of the right fork leg is positioned to the front. Valve of the left fork leg faces the front. Info The air suspension AER valve is located in the left fork leg.

  • Page 55: Checking Steering Head Bearing Play

    Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam- ages components. – Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.) Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time.

  • Page 56: Adjusting Steering Head Bearing Play

    11 SERVICE WORK ON THE CHASSIS Finishing work – Remove the motorcycle from the lift stand. ( p. 47) 11.12 Adjusting steering head bearing play Preparatory work – Raise the motorcycle with a lift stand. ( p. 47) – Remove the handlebar cushion. Main work –...

  • Page 57: Removing The Start Number Plate

    SERVICE WORK ON THE CHASSIS 11 11.14 Removing the start number plate – Remove screw – Disconnect the brake line at the start number plate. Take off the start number plate. V01701-10 11.15 Installing the start number plate – Connect the brake line at the start number plate. –...

  • Page 58: Removing The Shock Absorber

    11 SERVICE WORK ON THE CHASSIS 11.18 Removing the shock absorber Preparatory work – Raise the motorcycle with a lift stand. ( p. 47) Main work – Remove the cable ties. – Remove screws with the washers. – Remove screw –...

  • Page 59: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 11 – Remove nut and pull out the swingarm pivot. – Push the link fork back and secure it against falling over. V01706-10 – Hold the shock absorber and remove screw V01707-10 – Remove the shock absorber carefully at the bottom. V01708-10 11.19 Installing the shock absorber...
  • Page 60 11 SERVICE WORK ON THE CHASSIS – Position the link fork and mount the swingarm pivot. Info Pay attention to flat area – Mount and tighten nut Guideline Nut, fork pivot M16x1.5 100 Nm (73.8 lbf ft) V01709-10 – Mount the chain. –...

  • Page 61: Removing The Seat

    SERVICE WORK ON THE CHASSIS 11 – Position the left frame protector. – Insert the right frame protector from below and push it to the rear. – Mount and tighten screws with the washers. Guideline Screw, frame protec- 3 Nm (2.2 lbf ft) –...

  • Page 62: Removing The Air Filter Box Cover

    11 SERVICE WORK ON THE CHASSIS – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis K01133-10 11.22 Removing the air filter box cover Condition The air filter box cover is secured. – Remove the seat. ( p.

  • Page 63: Installing The Air Filter Box Cover

    SERVICE WORK ON THE CHASSIS 11 11.23 Installing the air filter box cover Condition The air filter box cover is secured. – Insert the air filter box cover in area and clip it into area V01727-12 – Mount and tighten screw Guideline Screw, air filter box EJOT PT...

  • Page 64: Cleaning The Air Filter And Air Filter Box

    11 SERVICE WORK ON THE CHASSIS Main work – Detach retaining tab . Remove air filter with air filter sup- port. – Take off air filter from air filter support. V01658-10 11.25 Cleaning the air filter and air filter box Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 65: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS 11 11.26 Installing the air filter Main work – Mount the clean air filter on the air filter support. – Grease the air filter in area Long-life grease ( p. 136) 102178-10 – Insert the air filter and position the top retaining pin bushing The air filter is correctly positioned.

  • Page 66: Installing The Main Silencer

    11 SERVICE WORK ON THE CHASSIS – Remove screws with the washers. – Pull off the main silencer from the manifold at exhaust sleeve V01659-10 11.29 Installing the main silencer – Position the main silencer in exhaust sleeve – Mount and tighten screws with the washers.

  • Page 67: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 11 Main work – Remove screws . Pull out inner tube with O-ring – Pull glass fiber yarn filling from the inner tube. – Clean the parts that need to be reinstalled and check for dam- age.
  • Page 68 11 SERVICE WORK ON THE CHASSIS Main work – Unplug connector of the fuel pump. – Clean plug-in connection of the fuel line thoroughly with compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve! V01590-10 –...

  • Page 69: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 11 11.32 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 70: Checking The Chain For Dirt

    11 SERVICE WORK ON THE CHASSIS – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis K01189-11 – Plug in connector for the fuel pump. – Remove the wash cap set and thoroughly clean the plug-in connection of the fuel line using compressed air.

  • Page 71: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 11 Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info The service life of the chain depends largely on its maintenance. Preparatory work –...

  • Page 72: Adjusting The Chain Tension

    11 SERVICE WORK ON THE CHASSIS Finishing work – Remove the motorcycle from the lift stand. ( p. 47) 11.36 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly.

  • Page 73: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    SERVICE WORK ON THE CHASSIS 11 11.37 Checking the chain, rear sprocket, engine sprocket, and chain guide Preparatory work – Raise the motorcycle with a lift stand. ( p. 47) Main work – Shift the transmission into neutral. – Check the chain, rear sprocket, and engine sprocket for wear. »...
  • Page 74 11 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the lower edge of the chain pins is in line with, or below, the chain sliding guard: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated.

  • Page 75: Checking The Frame

    If the link fork exhibits damage, cracking, or deformation: – Change the link fork. Info Always replace a damaged link fork. Repairing the link fork is not authorized by KTM. S02305-01 11.40 Checking the throttle cable routing Warning Danger of accidents The throttle cable may slip out of the guide if routed incorrectly.

  • Page 76: Checking The Rubber Grip

    11 SERVICE WORK ON THE CHASSIS Main work – Check the throttle cable routing. Both throttle cables must be routed, side by side, on the back of the handlebars, above the fuel tank bracket on the right of the frame to the throttle valve body. Both throttle cables must be secured behind the rubber strap of the fuel tank support.

  • Page 77: Adjusting The Basic Position Of The Clutch Lever

    SERVICE WORK ON THE CHASSIS 11 11.42 Adjusting the basic position of the clutch lever – Adjust the basic position of the clutch lever to your hand size by turning adjusting screw Info Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handle- bar.

  • Page 78: Changing The Hydraulic Clutch Fluid

    11 SERVICE WORK ON THE CHASSIS Info Clean up overflowed or spilled brake fluid immediately with water. 11.44 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. –...
  • Page 79 SERVICE WORK ON THE CHASSIS 11 – Now inject the liquid into the system until it emerges from the drill hole of the master cylinder without bubbles. – Now and then, extract fluid from the master cylinder reservoir to prevent overflow. –...

  • Page 80: 12 Brake System

    Do not make any adjustments while riding. 12.3 Checking the brake discs Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.)

  • Page 81: Checking The Front Brake Fluid Level

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Preparatory work –...

  • Page 82: Adding Front Brake Fluid

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 83: Checking The Front Brake Linings

    Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...
  • Page 84 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 85 BRAKE SYSTEM 12 Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons. – Remove cotter pins , pull out pin , and remove the brake linings. – Clean the brake caliper and the brake caliper bracket. V01714-11 –...

  • Page 86: Checking The Free Travel Of Foot Brake Lever

    12 BRAKE SYSTEM – Correct the brake fluid quantity to level Guideline 5 mm (0.2 in) Level (brake fluid level below reservoir rim) Brake fluid DOT 4 / DOT 5.1 ( p. 134) – Position cover with membrane . Mount and tighten screws Info Immediately clean up any brake fluid that has over-...

  • Page 87: Checking The Rear Brake Fluid Level

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Preparatory work –...

  • Page 88: Adding Rear Brake Fluid

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 89: Checking The Brake Linings Of The Rear Brake

    Checking the brake linings of the rear brake Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...
  • Page 90 Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Hazardous substances cause environmental damage.
  • Page 91 BRAKE SYSTEM 12 – Insert the new brake linings, insert pin , and mount the cotter pins Info Always change the brake linings in pairs. Make sure that decoupling plate is mounted on the piston side brake lining. – Operate the foot brake lever repeatedly until the brake lin- ings are in contact with the brake disc and there is a pressure M01181-10 point.

  • Page 92: 13 Wheels, Tires

    13 WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 47) Main work – Manually press the brake caliper toward the brake disc to push back the brake pistons. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons.

  • Page 93: Installing The Front Wheel

    WHEELS, TIRES 13 13.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. –...

  • Page 94: Installing The Rear Wheel

    13 WHEELS, TIRES Main work – Manually press the brake caliper toward the brake disc to push back the brake piston. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston. –...
  • Page 95 WHEELS, TIRES 13 Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the rear wheel bearing. – Clean and grease shaft seal rings and contact surfaces of the spacers. Long-life grease ( p.

  • Page 96: Checking The Tire Condition

    DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manu- facture. KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of H01144-01 wear.

  • Page 97: Checking Spoke Tension

    Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized KTM workshop will be glad to help.) –...

  • Page 98: 14 Electrical System

    14 ELECTRICAL SYSTEM 14.1 Removing the 12 V battery Warning Risk of injury 12 V batteries contain harmful substances. – Keep 12 V batteries out of the reach of children. – Keep sparks and open flames away from 12 V batteries. –...

  • Page 99: Charging The 12-V Battery

    ELECTRICAL SYSTEM 14 Contact disks must be mounted under screws cable sockets with the claws toward the battery termi- nal. – Slide positive terminal cover over the positive terminal. Finishing work – Mount the seat. ( p. 59) 14.3 Charging the 12-V battery Warning Risk of injury 12 V batteries contain harmful substances.

  • Page 100: Changing Main Fuse

    It is also impossible to overcharge the 12-V battery with this battery charger. The charging time may be longer at low temperatures. This battery charger is only suitable for lithium iron phosphate batteries. Read the accompanying KTM Pow- erParts instructions. Info Never remove cover –...
  • Page 101 ELECTRICAL SYSTEM 14 Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the seat. Preparatory work – Press and hold the switch-off button while the engine is idling until the engine stops. –...

  • Page 102: Changing The Fuses Of Individual Power Consumers

    14 ELECTRICAL SYSTEM 14.5 Changing the fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat. Preparatory work – Press and hold the switch-off button while the engine is idling until the engine stops.

  • Page 103: Cooling System 15

    COOLING SYSTEM 15 15.1 Cooling system Water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operat- ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 104: Checking The Coolant Level

    15 COOLING SYSTEM 15.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

  • Page 105: Refilling With Coolant

    COOLING SYSTEM 15 Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –...
  • Page 106 15 COOLING SYSTEM – Pour coolant in up to measurement above the radiator fins. Guideline 10 mm (0.39 in) Coolant 1.2 l (1.3 qt.) Coolant ( p. 134) 400243-10 – Push protection cap upward over the thermostat. V01681-10 – Unplug connector –...
  • Page 107 COOLING SYSTEM 15 Finishing work – Check the coolant level. ( p. 102)

  • Page 108: 16 Tuning The Engine

    16 TUNING THE ENGINE 16.1 Checking throttle cable play – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable Throttle cable play 2 …...

  • Page 109: Adjusting The Characteristic Map Of

    TUNING THE ENGINE 16 – Unscrew barrel adjuster until the smooth operation or play in the throttle cable deteriorates. – Turn adjusting screw approx. two turns further. – Tighten nut – Tighten nut – Slide on sleeve – Check the throttle grip for smooth operation. Finishing work –...

  • Page 110: Adjusting The Idle Speed

    Danger of accidents The engine may go out spontaneously if the idle speed is set too low. – Set the idle speed to the specified value. (Your authorized KTM workshop will be glad to help.) – Run the engine until warm.

  • Page 111: Programming Ambient Pressure

    TUNING THE ENGINE 16 Info Turn clockwise to decrease the idle speed. Turn counterclockwise to increase the idle speed. Make the setting in small steps. An incorrect idle speed can have a negative impact on overall engine running. 16.5 Programming ambient pressure Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.

  • Page 112: Map Adjustment

    16 TUNING THE ENGINE 16.6 Plug-in connector of ignition timing map adjustment Plug-in connector of the ignition timing map adjustment is located on the frame under the fuel tank. Possible states Soft – The plug-in connector of the ignition timing map •...

  • Page 113: Checking The Basic Position Of The Shift Lever

    TUNING THE ENGINE 16 16.8 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the rider's boot when in the basic position. When the shift lever keeps touching the boot, the transmission will be subject to an excessive load. –...

  • Page 114: 17 Service Work On The Engine

    17 SERVICE WORK ON THE ENGINE 17.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 115: Checking 2-Stroke Oil Level

    SERVICE WORK ON THE ENGINE 17 17.2 Checking 2-stroke oil level Warning Engine failure The engine will not be lubricated unless there is 2-stroke oil in the oil tank. If the oil level warning light lights up, the 2-stroke oil is sufficient for the remaining tank of fuel. –...
  • Page 116 17 SERVICE WORK ON THE ENGINE Main work – Pull EFI control unit upward off rubber lugs and hang to the side. – Remove protection cap of the diagnostics connector. V01689-10 – Put throttle grip into full throttle position and secure. V01645-11 –...

  • Page 117: Cleaning The Oil Screen In The Oil Tank

    SERVICE WORK ON THE ENGINE 17 – Check whether air bubbles are visible in the hose » If air bubbles are visible: – Repeat the entire procedure until air bubbles are no longer visible. – Mount protection cap on the diagnostics connector. –...
  • Page 118 17 SERVICE WORK ON THE ENGINE – Loosen clamps of the throttle valve body. – Lift the subframe slightly and secure it. Info Pay attention to intake flange – Pull throttle valve body towards the rear, out of the intake flange, and hang it to the side.
  • Page 119 SERVICE WORK ON THE ENGINE 17 – Mount throttle valve body – Remove the locking piece and position the subframe. Info Pay attention to intake flange – Position and tighten clamps of the throttle valve body. Guideline Screw, intake 6 Nm (4.4 lbf ft) flange/reed valve housing V01726-10...

  • Page 120: Checking The Gear Oil Level

    17 SERVICE WORK ON THE ENGINE 17.5 Checking the gear oil level Info The gear oil level must be checked when the engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Remove gear oil level monitoring screw –...

  • Page 121: Adding The Gear Oil

    SERVICE WORK ON THE ENGINE 17 – Remove filler plug with the O-ring, and fill up with gear oil. Gear oil 0.80 l Engine oil (0.85 qt.) (15W/50) p. 134) – Mount and tighten the filler plug together with the O-ring. Danger Danger of poisoning Exhaust gases are toxic and inhal- 401955-11...
  • Page 122 17 SERVICE WORK ON THE ENGINE Finishing work Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space.

  • Page 123: Cleaning, Care 18

    CLEANING, CARE 18 18.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...
  • Page 124 18 CLEANING, CARE – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p. 136) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

  • Page 125: Storage 19

    – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with a lift stand. ( p. 47) – Cover the vehicle with a tarp or a similar cover that is perme-...

  • Page 126: Preparing For Use After Storage

    19 STORAGE Info 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, caus- ing engine parts and the exhaust system to rust.

  • Page 127: Troubleshooting

    TROUBLESHOOTING 20 Faults Possible cause Action – The engine cannot be cranked Operating error Carry out the start procedure. (starter motor) p. 27) – 12-V battery discharged Charge the 12-V battery. p. 97) – Check the charging voltage. – Check the closed current. –...
  • Page 128 20 TROUBLESHOOTING Faults Possible cause Action – Engine has too little power Error in the electronic fuel Read out the fault memory using the injection Husqvarna Motorcycles diagnostics tool. – Fuel supply interrupted Check the fuel tank breather. – Exhaust system leaky, Check exhaust system for damage.

  • Page 129: Technical Data

    X distance (upper edge of piston to upper edge of 0 … 0.10 mm (0 … 0.0039 in) cylinder) Z distance (height of control flap) (250 XC TPI US) 49.0 mm (1.929 in) Z distance (height of control flap) (300 XC TPI US) 49.5 mm (1.949 in)
  • Page 130 21 TECHNICAL DATA Screw, crankshaft speed sensor 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, exhaust control bearing 6 Nm (4.4 lbf ft) Loctite ® 243™ support Screw, exhaust control cap 5 Nm (3.7 lbf ft) Screw, exhaust control cover 4 Nm (3 lbf ft) Screw, injection valve holder 5 Nm (3.7 lbf ft)

  • Page 131: Capacities

    TECHNICAL DATA 21 Screw, cylinder head temperature M10x1.25 12 Nm (8.9 lbf ft) sensor Nut, rotor M12x1 55 Nm (40.6 lbf ft) Gear oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) Spark plug M14x1.25 25 Nm (18.4 lbf ft) Nut, inner clutch hub M18x1.5 100 Nm (73.8 lbf ft)

  • Page 132: Electrical System

    80/100 - 21 51M TT 110/100 - 18 64M TT Dunlop GEOMAX AT81F Dunlop GEOMAX AT81 The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com 21.7 Fork Fork article number 34.18.8T.73 Fork...

  • Page 133: Chassis Tightening Torques

    TECHNICAL DATA 21 Grease capacity, left cartridge 5 g (0.18 oz) Special grease (00062010053) p. 137) Oil capacity, right cartridge 380 ml (12.85 fl. oz.) Fork oil (SAE 4) (48601166S1) p. 135) 21.8 Shock absorber Shock absorber article number 18.18.7T.73 Shock absorber WP XACT 5750 Lowspeed compression damping...
  • Page 134 21 TECHNICAL DATA Screw, throttle valve body hose 5 Nm (3.7 lbf ft) clamp Spoke nipple, front wheel M4.5 6 Nm (4.4 lbf ft) Spoke nipple, rear wheel M4.5 6 Nm (4.4 lbf ft) Remaining nuts, chassis 5 Nm (3.7 lbf ft) Remaining screws, chassis 5 Nm (3.7 lbf ft) Screw, battery terminal...
  • Page 135 TECHNICAL DATA 21 Screw, top triple clamp 17 Nm (12.5 lbf ft) Engine bracket screw 60 Nm (44.3 lbf ft) Remaining nuts, chassis 45 Nm (33.2 lbf ft) Remaining screws, chassis 45 Nm (33.2 lbf ft) Screw, bottom shock absorber 60 Nm (44.3 lbf ft) Loctite ®...

  • Page 136: Substances

    22 SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 MOTOREX ®...
  • Page 137 SUBSTANCES 22 Recommended supplier MOTOREX ® – Cross Power 2T Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 138) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.

  • Page 138: Auxiliary Substances

    23 AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier MOTOREX ® – Racing Bio Dirt Remover Chain cleaner Recommended supplier MOTOREX ® – Chain Clean Fuel additive Recommended supplier MOTOREX ® – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier...
  • Page 139 AUXILIARY SUBSTANCES 23 Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier MOTOREX ® – Quick Cleaner Special grease (00062010053) Recommended supplier Klüber Lubrication ® – KLÜBERFOOD NH1 34‑401 Universal oil spray Recommended supplier MOTOREX ®...

  • Page 140: Standards

    24 STANDARDS JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motor- cycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 141: Index Of Special Terms

    INDEX OF SPECIAL TERMS 25 Injection into transfer ducts (Trans- Electronic fuel injection in which two injection valves fer Port Injection) in the transfer ducts of the cylinders are used On-board diagnosis Vehicle system, which monitors the specified parame- ters of the vehicle electronics...

  • Page 142: List Of Abbreviations

    26 LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 143: List Of Symbols

    LIST OF SYMBOLS 27 27.1 Red symbols Red symbols indicate an error condition that requires immediate intervention. The oil level warning lamp lights up red – Oil level has reached the MINmarking. Ride for no more than until the remaining fuel in the tank is depleted and at the next opportunity refuel with 2-stroke oil.

  • Page 144: Index

    INDEX INDEX Capacity 12 V battery coolant ..... . 104, 129 installing ......96 gear oil .
  • Page 145 INDEX Handlebar position ..... . 45 adjusting ......45 Figures .
  • Page 146 INDEX checking ......53 Storage ......123 Rear sprocket Switch-off button .
  • Page 147 *3214002en* 3214002en 05/2019 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM http://www.ktm.com...

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300 xc tpiF6375t5F6475t5

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