KTM 250 EXC TPI EU 2018 Setup Instructions
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KTM 250 EXC TPI EU 2018 Setup Instructions

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SETUP INSTRUCTIONS
2018
250 EXC TPI
250 EXC Six Days TPI
250 XC‑W TPI
300 EXC TPI
300 EXC Six Days TPI
Art. no. 3213730en

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  • Page 1 SETUP INSTRUCTIONS 2018 250 EXC TPI 250 EXC Six Days TPI 250 XC‑W TPI 300 EXC TPI 300 EXC Six Days TPI Art. no. 3213730en...
  • Page 3 KTM accepts no liability for delivery options, deviations from figures 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 2 SETUP Unpacking and setting up the vehicle Condition Packaging V2 – Remove the box and the plastic packaging. Info An assistant prevents the motorcycle from falling over. To avoid damaging the motorcycle during the setup, leave the protective film on the vehicle until you have finished.

  • Page 6: Mount And Tighten Screws

    2 SETUP Info An assistant prevents the motorcycle from falling over. To avoid damaging the motorcycle during the setup, leave the protective film on the vehicle until you have finished. – Remove and unpack the separate enclosure and attach- ments. Check that the scope of supply is complete using the enclosed packing list.
  • Page 7 2 SETUP – Route the clutch line with the clutch master cylinder toward the front between the upper and lower triple clamps. – Install the fork legs. ( p. 25) (All standard EXC/XC-W models) – Remove screws and take off handlebar supports. –...
  • Page 8 2 SETUP (All Six Days models) – Remove screws and take off handlebar supports. – Move the handlebar supports to the desired position and mount and tighten screws Guideline Screw, handle- 40 Nm (29.5 lbf ft) Loctite ® 243™ bar support Info Position the left and right handlebar supports evenly.
  • Page 9 2 SETUP (All EXC models) – Position the controls on the right half of the handlebar. F01132-01 (250 XC‑W TPI US) – Position the controls on the right half of the handlebar. F01136-01 (All EXC models) – Position the controls on the left half of the handlebar. S01453-01 (250 XC‑W TPI US) –...
  • Page 10 – Position the map switch with the clamp on the right han- dlebar half. Info Read the accompanying KTM PowerParts instruc- tions. E00855-01 Condition Packaging V12 (All EXC models) –...
  • Page 11 2 SETUP (250 XC‑W TPI US) – Insert indicator lamp in the socket. – Plug in light pull switch with the yellow and white cables. – Join all plug-in connectors. – Route the cable without tension and secure with cable tie.
  • Page 12 2 SETUP – Preassemble the hand guards on the left and right. E00852-01 – Mount the left hand guard. – Mount the right hand guard. F01138-10 – Secure the handlebar cushion with two cable ties. – Install front fender. ( p.
  • Page 13 2 SETUP – Position turn signal cable harness. – Insert the indicator lamp with the black and violet cable colors into socket F01140-10 – Position turn signal on the headlight mask on both sides, mount nuts with washers and tighten. –...
  • Page 14 2 SETUP – Remove screw – Remove screw – Pull off the side cover in area and area and remove it toward the rear. F01143-10 – Remove screws with the washers. – Pull off the main silencer at the rubber sleeve and the spring ring from the manifold.
  • Page 15 2 SETUP – Remove screws – Remove screws with the washers. – Carefully pull the tail light cable out of the frame, paying attention to the plug as you do so. – Take off license plate holder with tail light toward the rear. F01146-10 –...
  • Page 16 2 SETUP – Carefully pass the tail light cable through the frame, pay- ing attention to the plug as you do so. – Position license plate holder on the rear. – Mount and tighten screws with the washers. F01148-10 – Mount and tighten screw with the collar bushing.
  • Page 17 2 SETUP – Mount holding bracket – Mount the EFI control unit on the rubber lugs Info The wiring harness runs under the EFI control unit. – Position the turn signal cable harness and main wiring har- ness and secure with cable ties. F01141-10 –...
  • Page 18 2 SETUP – Position the right footrest and pin. Info When inserting the pin, leave enough space to mount the spring. R01229-10 – Position spring as shown. Spring engages in area F01151-10 – Press the spring with special tool Footrest spring plier (79029083000) The special tool is applied to area on the footrest.
  • Page 19 2 SETUP – Position the left footrest and pin. Info When inserting the pin, leave enough space to mount the spring. R00757-10 – Position spring as shown. Spring engages in area F01154-10 – Press the spring with special tool Footrest spring plier (79029083000) The special tool is applied to area on the footrest.
  • Page 20 Mount the cable tie(s). (All Six Days models) – Install the engine guard. ( p. 32) – Unpack and mount the KTM PowerParts included in the deliv- ery (optional). Info Read the accompanying KTM PowerParts fitting instruc- tions. – Apply the sticker included in the delivery (optional).

  • Page 21: Remove Screws

    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 22 3 WORK Mounting the seat – Hook in the front of the seat on the collar bushing of the fuel tank, lower it at the rear and push it forward. – Make sure that the seat is correctly locked in. E00872-10 –...
  • Page 23 3 WORK Main work – Unplug connector of the fuel pump. – Remove tube from the fuel tank breather. E00879-10 – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel line.

  • Page 24: Mount And Tighten Screw

    3 WORK 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 25 3 WORK – Mount and tighten screws with the collar bushings. Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis E00881-11 – Remove the wash cap set. – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel line.
  • Page 26 3 WORK Main work – Check 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 fuel tank contact area rubber band.
  • Page 27 3 WORK Installing the fork legs Main work – Position the fork legs. Bleeder screws are positioned toward the front. Info The rebound damping is located in right fork leg REB (red adjusting screw). The compression damping is located in left fork leg COM (white adjusting screw). Grooves are milled into the side of the upper end of the H01595-10 fork legs.

  • Page 28: Tighten Screws 3 . Guideline

    3 WORK 3.10 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 29 3 WORK Preparatory work (All EXC models) – Press and hold the kill switch while the engine is idling until the engine stops. (250 XC‑W TPI US) – Press and hold the kill switch while the engine is idling until the engine stops. –...
  • Page 30 3 WORK Warning Environmental hazard Batteries contain environmentally-hazardous materials. – Do not dispose of batteries as household waste. – Dispose of batteries at a collection point for used batteries. Warning 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.
  • Page 31 3 WORK 3.13 Installing the battery Main work – Insert the battery into the battery compartment with the termi- nals facing forward and secure with holding bracket Battery (HJTZ5S-FP) – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis –...
  • Page 32 3 WORK Finishing work – Install the headlight mask with the headlight. ( p. 30) – Check the headlight setting. ( p. 31) 3.15 Removing the headlight mask with the headlight – Detach the brake line and wiring harness from the headlight mask.
  • Page 33 3 WORK (250 XC‑W TPI US) – Connect plug-in connector E00357-11 – Position the headlight mask and fix it with rubber bands The holding lugs engage in the fender. – Position the brake line and wiring harness in the brake line guide.
  • Page 34 3 WORK 3.18 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 31) Main work – Loosen screw – Adjust the headlight range by pivoting the headlight. Guideline The boundary between light and dark must be exactly on the lower marking for a motorcycle with rider (instructions on how to apply the marking: Checking the headlight setting).

  • Page 35: Adding 2-Stroke Oil

    3 WORK 3.21 Closing 2-stroke oil tank cap – Put the 2-stroke oil tank cap on and turn it clockwise. – Fold loop down. The 2-stroke oil tank cap engages. E00861-11 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 36 3 WORK 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 37 3 WORK 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 38 3 WORK – Repeatedly press the button briefly until H appears at the bottom right of the display. – Press the button for 2–3 seconds. The Setup menu is displayed and the active functions are shown. – Repeatedly press the button briefly until Km/h/Mph flashes.

  • Page 39: Setting The Clock

    3 WORK 3.28 Setting the clock Condition The motorcycle is stationary. – Repeatedly press the button briefly until CLK appears at the bottom right of the display. – Press the button for 2–3 seconds. The hour display flashes. – Set the hour display with the button and/or button –...

  • Page 40: Technical Data

    4 TECHNICAL DATA Chassis tightening torques EJOT PT Remaining screws, chassis ® K60x25‑Z 2 Nm (1.5 lbf ft) EJOT PT Screw, fuel pump ® 2.3 Nm (1.7 lbf ft) G 3/4 " Screw, oil fill level sensor 7 Nm (5.2 lbf ft) Screw, pressure regulator EJOT PT ®...
  • Page 41 4 TECHNICAL DATA Screw, bottom triple clamp (All 15 Nm (11.1 lbf ft) standard EXC/XC-W models) Screw, bottom triple clamp (All 15 Nm (11.1 lbf ft) Six Days models) Screw, chain sliding piece 15 Nm (11.1 lbf ft) Screw, engine brace 25 Nm (18.4 lbf ft) Loctite ®...
  • Page 42 5 SUBSTANCES Engine oil, 2-stroke Standard/classification – JASO FD ( p. 42) Guideline – Only use high grade 2-stroke engine oil of a reputable brand. Fully synthetic Recommended supplier Motorex ® – Cross Power 2T Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification –...

  • Page 43: Auxiliary Substances

    6 AUXILIARY SUBSTANCES Long-life grease Recommended supplier Motorex ® – Bike Grease 2000...
  • Page 44 7 STANDARDS 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 45 *3213730en* 3213730en 06/2017 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

This manual is also suitable for:

250 exc six days tpi eu 2018250 xc-w tpi us 2018300 exc tpi eu 2018300 exc six days tpi eu 2018F7303r7F7303r2 ... Show all

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