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KTM 250 EXC TPI 2022 Setup Instructions
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KTM 250 EXC TPI 2022 Setup Instructions

KTM 250 EXC TPI 2022 Setup Instructions

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SETUP INSTRUCTIONS
2022
250 EXC SIX DAYS TPI
300 EXC SIX DAYS TPI
300 EXC TPI ERZBERGRODEO
300 XC‑W TPI ERZBERGRODEO
250 EXC TPI
250 XC‑W TPI
300 EXC TPI
300 XC-W TPI
Art. no. 3214497en

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Summary of Contents for KTM 250 EXC TPI 2022

  • Page 1 SETUP INSTRUCTIONS 2022 250 EXC TPI 250 EXC SIX DAYS TPI 250 XC‑W TPI 300 EXC TPI 300 EXC SIX DAYS TPI 300 XC-W TPI 300 EXC TPI ERZBERGRODEO 300 XC‑W TPI ERZBERGRODEO Art. no. 3214497en...
  • 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 Info An assistant prevents the motorcycle from falling over. – 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: Mount And Tighten Screws

    SETUP 2 – 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 8 2 SETUP Warning Danger of accidents A repaired handlebar poses a safety risk. If the handlebar is bent or straightened, the mate- rial becomes fatigued. The handlebar may break as a result. – Change the handlebar if the handlebar is dam- E00483-01 aged or bent.
  • Page 9 SETUP 2 Warning Danger of accidents A repaired handlebar poses a safety risk. If the handlebar is bent or straightened, the mate- rial becomes fatigued. The handlebar may break as a result. – Change the handlebar if the handlebar is dam- S01413-01 aged or bent.
  • Page 10 2 SETUP (All EXC models) – Position the controls on the left handlebar half. S03664-01 (All XC‑W models) – Position the controls on the left handlebar half. S03666-01 (All EXC models) – Mount the turn signal switch. 402148-01...
  • Page 11 – 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 12 2 SETUP (All EXC models) – 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 13 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. 34) – Install the front wheel. ( p. 26) – Remove the 12-V battery.
  • Page 14 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 15 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 16 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 17 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 18 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 S03695-10 –...
  • Page 19 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 20 (All special models) – Install the engine guard. ( p. 37) – 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 21 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 22: 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 23 WORK 3 Main work – Unplug connector of the fuel pump. – Remove tube from the fuel tank breather. S04895-10 – Clean the quick release coupling thoroughly with compressed air. Info Under no circumstances should dirt enter into the fuel line.
  • Page 24 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 25 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 26 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 27 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 S04824-13 fork legs.
  • Page 28 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. (All Standard and SIX DAYS models) –...
  • Page 29 WORK 3 – Mount and tighten screw Guideline Screw, front wheel M20x1.5 35 Nm (25.8 lbf ft) spindle – Operate the hand brake lever several times until the brake lin- ings are seated correctly against the brake disc. – Remove the motorcycle from the lift stand. ( p.
  • Page 30 3 WORK – Pull back positive terminal cover and disconnect the posi- tive cable from the 12-V battery. – Pull EFI control unit upward off rubber lugs and hang to the side. S04884-10 – Pull off starter relay and fuse box from the battery compartment and hang to the side.

  • Page 31: Charging The 12-V Battery

    WORK 3 3.12 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. – Keep sparks and open flames away from 12 V batteries. – Only charge 12 V batteries in well-ventilated rooms. –...
  • Page 32 3 WORK Info Follow the instructions of the charger and the manual. – Disconnect the battery charger after charging the 12-V battery. Guideline The charging current, charging voltage, and charging time must not be exceeded. Recharge the 12-V battery 3 months regularly when the motorcy- cle is not being used Finishing work...
  • Page 33 WORK 3 – Attach starter relay and fuse box to the battery com- partment. S04884-14 – Secure EFI control unit with the rubber lugs S04884-15 – 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...
  • Page 34 3 WORK 3.14 Disconnecting the negative cable of the 12-V battery Preparatory work – Remove the seat. ( p. 19) Main work – Disconnect negative cable of the 12-V battery. R01414-10 3.15 Connecting the negative cable of the 12-V battery Main work –...
  • Page 35 WORK 3 3.17 Installing the air filter box cover Main work – Insert the air filter box cover in area and clip it into area S03526-12 Condition The air filter box cover is secured. – Mount and tighten screw Guideline Screw, air filter box EJOT PT ®...
  • Page 36 3 WORK 3.19 Installing the rear left side cover – Position side cover and hook it in in areas – Mount and tighten screw Guideline Screw, sub- 30 Nm (22.1 lbf ft) Loctite ® 2701™ frame bottom S03688-10 3.20 Installing front fender Main work –...
  • Page 37 WORK 3 3.21 Removing the headlight mask with the headlight – Detach the brake line and wiring harness from the headlight mask. – Loosen rubber strap . Slide the headlight mask up and swing it forward. E00899-10 (All EXC models) –...
  • Page 38 3 WORK – Position the headlight mask and secure it with rubber straps The holding lugs engage in the fender. – Position the brake line and wiring harness in the brake line guide. E00899-11 Finishing work – Check the headlight setting. ( p.

  • Page 39: Tighten Screw

    WORK 3 Info If you have a payload, you may have to correct the headlight range. – Tighten screw 3.25 Installing the engine guard (All special models) – Attach the engine guard on the frame at the rear and swing up at the front.

  • Page 40: Adding 2-Stroke Oil

    3 WORK 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 41 WORK 3 – Press release button , turn the fuel tank filler cap counter- clockwise, and lift it off. E00929-10 3.30 Closing the fuel tank filler cap – Mount the fuel tank filler cap and turn it clockwise until release button engages.
  • Page 42 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. 38) – Fill the fuel tank with fuel up to level Guideline 35 mm (1.38 in)
  • Page 43 WORK 3 3.33 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 44 3 WORK Info The seconds can only be set to zero. If no button is pressed for 15–20 seconds, or if an impulse comes from the wheel speed sensor, the settings are automatically saved and the setup menu is closed.

  • Page 45: Technical Data

    TECHNICAL DATA 4 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 PT 45x12-Z Screw, oil pump holder on oil tank...
  • Page 46 4 TECHNICAL DATA Nut, foot brake lever 20 Nm (14.8 lbf ft) Nut, foot brake lever stop 20 Nm (14.8 lbf ft) Nut, pull switch (All XC‑W models) 0.8 Nm (0.59 lbf ft) Nut, rear sprocket screw 35 Nm (25.8 lbf ft) Loctite ®...
  • Page 47 TECHNICAL DATA 4 Nut, fork pivot M16x1.5 100 Nm (73.8 lbf ft) Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft) Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft) Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) Screw-in fitting, cooling system M24x1.5 18 Nm (13.3 lbf ft)
  • Page 48 5 SUBSTANCES Engine oil, 2-stroke Standard/classification – JASO FD ( p. 48) 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 49: Auxiliary Substances

    AUXILIARY SUBSTANCES 6 Long-life grease Recommended supplier MOTOREX ® – Bike Grease 2000 Silicone spray Recommended supplier MOTOREX ® – Silicone Spray...
  • Page 50 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 51 *3214497en* 3214497en 05/2021 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM KTM.COM...

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