KTM 150 EXC TPI 2021 Setup Instructions
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KTM 150 EXC TPI 2021 Setup Instructions

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SETUP INSTRUCTIONS
2021
150 EXC TPI
150 XC‑W TPI
Art. no. 3214371en

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Summary of Contents for KTM 150 EXC TPI 2021

  • Page 1 SETUP INSTRUCTIONS 2021 150 EXC TPI 150 XC‑W TPI Art. no. 3214371en...
  • 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 (150 EXC TPI EU) – Position the turn signal indicator lamp in the com- bination instrument bracket. H02474-10 Condition Packaging V12 – 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 E00850-10...

  • Page 7: Mount And Tighten Screws

    SETUP 2 (150 XC‑W TPI US) – Position the combination instrument on the upper triple clamp. – Mount and tighten screws with the collar bushings. Guideline Remaining screws, 10 Nm chassis (7.4 lbf ft) – Route the clutch line with the clutch master cylinder H02538-10 toward the front between the upper and lower triple clamps.
  • Page 8 2 SETUP Guideline Screw, handlebar 20 Nm (14.8 lbf ft) clamp Info The markings on the handlebar should be at the center of the handlebar clamps. Keep the installed gap widths equal when tightening. (150 EXC TPI EU) – Position the controls on the right half of the handlebar. S03665-01 (150 XC‑W TPI US) –...
  • Page 9 SETUP 2 (150 EXC TPI EU) – Mount the turn signal switch. 402148-01 Condition Packaging V12 (150 EXC TPI EU) – Insert indicator lamp in the socket. – Join all plug-in connectors to the plug-in holder. – Route the cable without tension and secure with the cable ties.
  • Page 10 2 SETUP (150 EXC TPI EU) – Mount the mirror clamps on both sides. H01060-01 – Mount both rear mirrors with the adapter. E01231-10 – Preassemble the hand guards on the left and right. E00852-01...
  • Page 11 SETUP 2 – Mount the left hand guard. – Mount the right hand guard. S03689-10 – Secure the handlebar cushion with two cable ties. – Install front fender. ( p. 31) – Install the front wheel. ( p. 23) – Remove the 12-V battery.
  • Page 12 2 SETUP – Insert the black and violet cables of bulb included in the separate enclosure into the socket and position it in the turn signal indicator lamp. S03673-01 – Position the turn signal on the headlight mask on both sides, mount nuts with washers and tighten.
  • Page 13 SETUP 2 – Remove screws – Remove screws – Remove the license plate holder with the tail light. Info Pay attention to the cable of the tail light. – Feed the cable between the fairing parts. S03679-10 – Remove screws on the license plate holder and hang the tail light to the side.
  • Page 14 2 SETUP – Drill a hole at marking on the license plate holder to the size of the marking. S03682-01 – Position the tail light together with the license plate holder on the license plate bracket. Info Ensure that the cables are routed correctly. S03683-10 –...
  • Page 15 SETUP 2 – Feed the wiring harnesses through the opening. – Position the license plate holder on the rear. S03684-01 – Mount and tighten screw with the collar bushing. Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Mount and tighten screw Guideline Remaining screws, EJOT PT...
  • Page 16 2 SETUP – 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 S03691-10 – Mount the washer and splint S03692-10 –...
  • Page 17 SETUP 2 – 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 S03694-10 – Mount the washer and splint S03695-10 –...
  • Page 18 2 SETUP – 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 19 WORK 3 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 20: Mounting The Seat

    3 WORK Mounting the seat – Mount the front of the seat on the two collar bushings of the fuel tank, lower the seat at the rear, and push the seat forward. – Make sure the seat is latched in place correctly. H02218-11 –...
  • Page 21 WORK 3 Main work – Unplug connector of the fuel pump. – Remove tube from the fuel tank breather. S03485-10 – Clean the quick release coupling thoroughly with compressed air. Info Under no circumstances should dirt enter into the fuel line.
  • Page 22 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 fuel the vehicle in the vicinity of open flames or lit cigarettes. –...
  • Page 23 WORK 3 – 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. – Clean the quick release coupling thoroughly with compressed air. Info Under no circumstances should dirt enter into the fuel line.
  • Page 24 3 WORK 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 25 WORK 3 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 adjuster). The compression damping is located in left fork leg COMP (white adjuster). Grooves are milled into the side of the upper end of the H01595-10 fork legs.

  • Page 26: Tighten Screws 3 . Guideline

    3 WORK – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change front wheel bearing. – Clean and grease shaft seal rings and contact surfaces of the spacers. Long-life grease ( p.
  • Page 27 WORK 3 Main work Warning Risk of injury 12 V batteries contain harmful sub- stances. – Keep 12 V batteries out of the reach of children. – Keep sparks and open flames away from 12 V bat- teries. – Only charge 12 V batteries in well-ventilated S03489-10 rooms.

  • Page 28: Charging The 12-V Battery

    3 WORK – Detach wiring harness , disconnect relays and plug and hang to the side. S03492-10 – Remove screw and detach the battery compartment. – Lift out the 12-V battery. S03493-10 3.12 Charging the 12-V battery Warning Risk of injury 12 V batteries contain harmful substances. –...
  • Page 29 WORK 3 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 Even when there is no load on the 12-V battery, it discharges steadily each day. The charging level and the method of charging are very important for the service life of the 12-V battery.
  • Page 30 3 WORK 3.13 Installing the 12-V battery Main work – Insert the 12-V battery into the battery compartment with the terminals facing forward and secure with holding bracket 12-V battery (HJTZ5S-FP-C) – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis S03494-10 –...
  • Page 31 WORK 3 – Connect positive cable to the 12-V battery. Guideline Screw, battery termi- 2.5 Nm (1.84 lbf ft) Info Contact disk must be mounted under screw cable lug with the claws toward the battery termi- nal. – Slide positive terminal cover over the positive terminal.
  • Page 32 3 WORK 3.16 Removing the air filter box cover Preparatory work – Remove the seat. ( p. 17) Condition The air filter box cover is secured. – Remove screw S03632-10 – Pull off the air filter box cover in area laterally and take it off at the front.
  • Page 33 WORK 3 3.18 Removing the rear left side cover – Remove screw and take off the fairing part to the front. S03671-01 3.19 Installing the rear left side cover – Position side cover and hook it in in areas – Mount and tighten screw Guideline Screw, sub-...
  • Page 34 3 WORK – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V00340-11 Finishing work – Install the headlight mask with the headlight. ( p. 33) – Check the headlight setting. ( p. 33) 3.21 Removing the headlight mask with the headlight –...
  • Page 35 WORK 3 3.22 Installing the headlight mask with the headlight Main work (150 EXC TPI EU) – Join plug-in connectors E00900-11 (150 XC‑W TPI US) – Join plug-in connector E00357-11 – Position the headlight mask and secure it with rubber straps The holding lugs engage in the fender.

  • Page 36: Tighten Screw

    3 WORK The boundary between light and dark must be exactly on the lower mark for a motorcycle with rider. » If the boundary between light and dark does not meet specifications: – Adjust the headlight range. ( p. 34) 3.24 Adjusting the headlight range Preparatory work...

  • Page 37: Adding 2-Stroke Oil

    WORK 3 3.27 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 3.28 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 38 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 39 WORK 3 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 40 3 WORK Adjusting the Mph – Press the button – Wait 3 - 5 seconds. The settings are stored. Info If no button is pressed for 10–12 seconds, or if an impulse comes from the wheel speed sensor, the settings are automatically saved and the setup menu is closed.

  • Page 41: Setting The Clock

    WORK 3 3.34 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. – Adjust hour display with the button and/or button –...

  • Page 42: Technical Data

    4 TECHNICAL DATA Chassis tightening torques EJOT PT Remaining screws, chassis ® K60x25‑Z 2 Nm (1.5 lbf ft) EJOTDELTA PT Screw, intake air temperature sen- ® 45x12-Z 0.7 Nm (0.52 lbf ft) G 3/4 " Screw, oil fill level sensor 7 Nm (5.2 lbf ft) EJOTDELTA PT45x12-Z Screw, oil pump holder on oil tank...
  • Page 43 TECHNICAL DATA 4 Nut, foot brake lever stop 20 Nm (14.8 lbf ft) Nut, pull switch (150 XC‑W 0.4 Nm (0.3 lbf ft) TPI US) Nut, rear sprocket screw 35 Nm (25.8 lbf ft) Loctite ® 2701™ Nut, rim lock 12 Nm (8.9 lbf ft) Remaining nuts, chassis 25 Nm (18.4 lbf ft)
  • Page 44 5 SUBSTANCES Engine oil, 2-stroke Standard/classification – JASO FD ( p. 44) 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 45: Auxiliary Substances

    AUXILIARY SUBSTANCES 6 Long-life grease Recommended supplier MOTOREX ® – Bike Grease 2000...
  • Page 46 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 47 *3214371en* 3214371en 02/2021 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM KTM.com...

This manual is also suitable for:

150 xc‑w tpi 2021F7103u6F7175u36

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