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KTM 150 EXC 2024 Setup Instructions
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KTM 150 EXC 2024 Setup Instructions

KTM 150 EXC 2024 Setup Instructions

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SETUP INSTRUCTIONS
2024
150 EXC
150 XC‑W
Art. no. 3214967en

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Summary of Contents for KTM 150 EXC 2024

  • Page 1 SETUP INSTRUCTIONS 2024 150 EXC 150 XC‑W Art. no. 3214967en...
  • 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: Means Of Representation

    1 MEANS OF REPRESENTATION Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). Indicates a page reference (more information is provided on the specified page). Indicates information with more details or tips.
  • Page 5 To operate the vehicle, the vehicle electronics must be enabled. This process is conducted during initial setup in KTM Dealer.net. Enabling ensures that the initial setup in KTM Dealer.net is docu- mented. Enabling can be performed either temporarily, e.g. for a test ride, or permanently for vehicle handover.
  • Page 6 2 SETUP – Together with an assistant, take the vehicle off the pallet. – Position the vehicle on a lift stand. – Check the vehicle for transport damage. Info The procedure in the event of transport damage is described in the Customer Service Manual. –...
  • Page 7 SETUP 2 – Remove screws and take off the handlebar support. – Move the handlebar support in the desired position and mount and tighten screws Guideline Screw, handle- 40 Nm (29.5 lbf ft) bar support Loctite ® 243™ Info Position the handlebar support so that it is even. W00324-11 Warning Danger of accidents A repaired handlebar poses a...
  • Page 8 2 SETUP (150 EXC EU) – Position the controls on the right half of the handlebar. W00385-10 (150 XC‑W US) – Position the controls on the right half of the handlebar. W00386-10 (150 EXC EU) – Position the controls on the left handlebar half. W00387-10 (150 XC‑W US) –...
  • Page 9 SETUP 2 (150 EXC EU) – Mount the turn signal switch. 402148-01 – Join all plug-in connectors to the connector board. – Route the cable without tension and secure with quick release. W00390-10 (150 EXC EU) – Mount the mirror clamps on both sides. H01060-01...
  • Page 10 2 SETUP – Mount both rear mirrors with the adapter. E01231-10 – Preassemble the hand guards on the left and right. E00852-01 – Mount the left hand guard. – Mount the right hand guard. S03689-10...
  • Page 11 SETUP 2 – Fix the handlebar cushion to the handlebar clamp. – Install front fender. ( p. 26) – Remove the 12-V battery. ( p. 22) – Charge the 12-V battery. ( p. 23) Guideline The 12-V battery must be fully charged before it is handed over to the customer.
  • Page 12 2 SETUP – Disconnect tail light plug-in connector on the wiring harness. – Remove screws W00396-10 – Remove screws – Remove screws – Remove the license plate holder with the tail light. Info Pay attention to the cable of the tail light. W00397-10 –...
  • Page 13 SETUP 2 – Drill a hole at marking on the license plate holder to the size of the marking. W00401-10 – Position the tail light together with the license plate holder on the license plate bracket. Info Ensure that the cables are routed correctly. –...
  • Page 14 2 SETUP – Slide license plate holder onto tail section and position. Info Ensure that the cables are routed correctly. – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis W00397-10 – Mount and tighten screws Guideline Remaining screws, EJOT PT...
  • Page 15 SETUP 2 – Position spring as shown. Spring engages in area S03690-10 – Press the spring with special tool Footrest spring plier (79029083000) The special tool is applied to area on the footrest. – Mount pin I00468-10 – Mount the washer and splint I00469-10 –...
  • Page 16 2 SETUP – Position spring as shown. Spring engages in area S03693-10 – Press the spring with special tool Footrest spring plier (79029083000) The special tool is applied to area on the footrest. – Mount pin I00470-10 – Mount the washer and splint I00471-10...
  • Page 17 Install the engine guard. ( p. 29) – Install the frame protector. ( p. 29) – Unpack and mount the KTM PowerParts included in the deliv- ery (optional). Info Read the accompanying KTM PowerParts fitting instruc- tions. – Make sure that the reflectors are glued on to the left and right fork leg.
  • Page 18 3 WORK Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (78129955100) Neither wheel is in contact with the ground.

  • Page 19: Mounting The Seat

    WORK 3 Mounting the seat – Mount the front of the seat on the collar bushings of the fuel tank, lower the seat at the rear, and push the seat to the rear. The holding lugs engage in the recesses at the back. –...
  • Page 20 3 WORK Warning Danger of poisoning Fuel is harmful to health. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – Rinse the affected area immediately with plenty of water in the event of contact with the skin. –...
  • Page 21 WORK 3 – Remove screws with the collar bushings. S05360-10 – Pull both spoilers off laterally from the radiator bracket and lift off the fuel tank. S05361-10 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. –...
  • Page 22 3 WORK – Position the fuel tank and fit the two spoilers to the sides in front of the radiator bracket. – Make sure that no cables or throttle cables are trapped or dam- aged. I00434-10 – Mount and tighten screw with the rubber bushing.
  • Page 23 WORK 3 – Attach fuel tank breather hose – Plug in fuel pump connector I00437-10 Finishing work – Mount the seat. ( p. 17) Checking the throttle cable routing Warning Danger of accidents The throttle cable can become kinked, trapped or blocked if it is not routed cor- rectly.
  • Page 24 3 WORK Removing the 12-V battery Note Environmental hazard 12 V batteries contain environmentally hazardous materials. – Do not dispose of 12 V batteries as household waste. – Dispose of 12 V batteries at a collection point for used batteries. Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 25: Charging The 12-V Battery

    WORK 3 – Pull up battery holding bracket and remove the 12-V bat- tery to the rear. Info Pay attention to the wiring harness. W00358-10 Charging the 12-V battery Warning Risk of injury 12 V batteries contain harmful substances. – Keep 12 V batteries out of the reach of children. –...
  • Page 26 3 WORK Main work – Connect a battery charger to the 12-V battery. Adjust the bat- tery charger. EU battery charger XCharge‑professional (00029095050) Alternative 1 US battery charger XCharge‑professional (00029095051) Alternative 2 311910-10 UK battery charger XCharge‑professional (00029095052) Info Follow the instructions of the charger and the manual. –...
  • Page 27 WORK 3 – Connect positive cable to the 12-V battery. Guideline Screw, battery termi- 2.5 Nm (1.84 lbf ft) – Connect negative cable to the 12 V battery. Guideline Screw, battery termi- 2.5 Nm (1.84 lbf ft) Contact disks must be mounted under screws cable sockets with the claws toward the battery termi- nal.
  • Page 28 3 WORK 3.13 Installing front fender Main work – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V00341-11 – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V00340-11 Finishing work –...
  • Page 29 WORK 3 (150 XC‑W US) – Disconnect plug-in connector and take off the head- light mask together with the headlight. W00351-10 3.15 Installing the headlight mask with the headlight Main work (150 EXC EU) – Join plug-in connectors W00350-11 (150 XC‑W US) –...
  • Page 30 3 WORK 3.16 Checking the headlight setting – Park the vehicle on a horizontal surface in front of a light- colored wall and make a mark at the height of the center of the low beam headlight. – Make another mark at a distance under the first marking.
  • Page 31 WORK 3 3.18 Installing the engine guard – Attach the engine guard on the frame at the rear and swing up at the front. – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis H01638-10 3.19 Installing the frame protector –...

  • Page 32: Adding 2-Stroke Oil

    3 WORK 3.22 Adding 2-stroke oil 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 33 WORK 3 – Press release button , turn the fuel tank filler cap counter- clockwise, and lift it off. E00929-10 3.24 Closing the fuel tank filler cap – Mount the fuel tank filler cap and turn it clockwise until release button engages.
  • Page 34 3 WORK Note Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to enter the groundwater, the soil, or the sewage system. – Open the fuel tank filler cap. ( p. 30) – Fill the fuel tank with fuel up to level Guideline 35 mm (1.38 in)
  • Page 35 WORK 3 3.27 Adjusting combination instrument function Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. Condition The motorcycle is stationary. – Repeatedly press the button briefly until H appears at the bottom right of the display. –...

  • Page 36: Technical Specifications

    4 TECHNICAL SPECIFICATIONS chassis tightening torques Hose connector, active carbon fil- 3.8 Nm (2.8 lbf ft) Mushroom head screw for spoiler 2.5 Nm (1.84 lbf ft) and seat Remaining screws, chassis EJOT PT ® K60x25‑Z 2 Nm (1.5 lbf ft) Screw, emergency OFF switch EJOT PT ®...
  • Page 37 TECHNICAL SPECIFICATIONS 4 Screw, connector board incl. com- 5 Nm (3.7 lbf ft) bination instrument Screw, fender to triple clamp 12 Nm (8.9 lbf ft) Screw, front brake disc 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, fuel tank spoiler on radiator 6 Nm (4.4 lbf ft) Screw, ground wire in tail section 10 Nm (7.4 lbf ft)
  • Page 38 4 TECHNICAL SPECIFICATIONS Engine bracket screw 60 Nm (44.3 lbf ft) Nut, foot brake lever 45 Nm (33.2 lbf ft) Remaining nuts, chassis 45 Nm (33.2 lbf ft) Remaining screws, chassis 45 Nm (33.2 lbf ft) Screw, brake caliper on brake 45 Nm (33.2 lbf ft) caliper bracket Loctite...
  • Page 39 SUBSTANCES 5 Engine oil, 2-stroke Standard/classification – JASO FD ( p. 39) Guideline – Only use high-grade 2-stroke engine oil from a reputable brand. fully synthetic Recommended supplier MOTOREX ® – Cross Power 2T Super unleaded (ROZ 95) Standard/classification – DIN EN 228 (ROZ 95) Guideline –...

  • Page 40: Auxiliary Substances

    6 AUXILIARY SUBSTANCES Silicone spray Recommended supplier MOTOREX ® – Silicone Spray...
  • Page 41 STANDARDS 7 JASO FD JASO FD 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.
  • Page 42 *3214967en* 3214967en 11.07.2023 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM KTM.COM...

This manual is also suitable for:

150 xc-w 2024