KTM 150 EXC TPI 2021 Owner's Manual
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KTM 150 EXC TPI 2021 Owner's Manual

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OWNER'S MANUAL
2021
150 EXC TPI
150 XC‑W TPI
Art. no. 3214218en

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Summary of Contents for KTM 150 EXC TPI 2021

  • Page 1 OWNER'S MANUAL 2021 150 EXC TPI 150 XC‑W TPI Art. no. 3214218en...
  • 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 6.12 Overview of indicator lamps TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 6 (150 EXC TPI EU)......19 Symbols used ........6 6.13 Overview of indicator lamps Formats used........6 (150 XC‑W TPI US)......19 6.14 Opening the fuel tank filler cap ..19 SAFETY ADVICE..........
  • Page 5 TABLE OF CONTENTS PREPARING FOR USE......... 37 11.10 Adjusting the riding sag ....58 11.11 Checking the basic setting of the Advice on preparing for first use ..37 fork ..........58 Running in the engine ...... 38 11.12 Adjusting the compression damping Starting power of lithium-ion of the fork ........
  • Page 6 TABLE OF CONTENTS 12.35 Checking the chain, rear sprocket, 15.6 Removing the headlight mask with engine sprocket, and chain guide ..83 the headlight ......... 117 12.36 Checking the frame ...... 86 15.7 Installing the headlight mask with the headlight ......... 117 12.37 Checking the link fork ....
  • Page 7 TABLE OF CONTENTS 21 TROUBLESHOOTING ........ 147 22 BLINK CODE ..........150 23 TECHNICAL DATA........152 23.1 Engine .......... 152 23.2 Engine tightening torques ....152 23.3 Capacities ........154 23.3.1 Gear oil........154 23.3.2 Coolant ........154 23.3.3 Fuel ......... 154 23.4 Chassis .........

  • Page 8: Means Of Representation

    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 9: Safety Advice 2

    SAFETY ADVICE 2 Use definition – intended use (150 EXC TPI EU) This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies with the currently valid regulations and categories of the top international motorsports organizations. Info This vehicle is only authorized for operation on public roads in the homologated (restricted) version.

  • Page 10: Degrees Of Risk And Symbols

    2 SAFETY ADVICE Degrees of risk and symbols Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

  • Page 11: 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 Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with remote key) or the engine must be at a standstill (models without ignition lock or remote key).

  • Page 12: Owner's Manual

    The Owner's Manual is an important component of the vehicle and must be handed over to the new owner if the vehicle is sold. The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website. International KTM Website: http://www.ktm.com...

  • Page 13: 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 14: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) S03607-10 Hand brake lever ( p. 16) Clutch lever ( p. 16) Light switch ( p. 17) (150 EXC TPI EU) Switch-off button ( p. 16) (150 EXC TPI EU) p.

  • Page 15: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) S03608-10 Fuel tank filler cap Throttle grip ( p. 16) Vehicle identification number ( p. 14) Kick starter lever ( p. 23) Foot brake lever ( p. 23) Level viewer for brake fluid, rear...

  • Page 16: 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 Type label is fixed to the front of the steering head. 401946-10 Key number (150 EXC TPI EU) The key number for the steering lock is stamped onto the key connector.

  • Page 17: Fork Part Number

    SERIAL NUMBERS 5 Fork part number The fork part number is stamped on the inside of the axle clamp. 401947-10 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 18: 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. S03609-10 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 19: Switch-Off Button (150 Xc-Wtpi Us)

    CONTROLS 6 Switch-off button (150 XC‑W TPI US) Switch-off button is fitted on the left side of the handlebar. Possible states is in the basic position – In this • The switch-off button position, the ignition circuit is closed and the engine can be started.

  • Page 20: Turn Signal Switch (150 Exc Tpi Eu)

    6 CONTROLS Turn signal switch (150 EXC TPI EU) Turn signal switch is fitted on the left side of the handlebar. Possible states Turn signal off – The turn signal switch is in the cen- tral position. Left turn signal, on – The turn signal switch is turned to the left.

  • Page 21: Overview Of Indicator Lamps (150 Exc Tpi Eu)

    – The OBD has detected an error in the vehicle elec- tronics. Come safely to a halt, and contact an autho- rized KTM workshop. The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.

  • Page 22: Closing The Fuel Tank Filler Cap

    6 CONTROLS 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 23: Closing 2-Stroke Oil Tank Cap

    CONTROLS 6 6.17 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 6.18 Cold start button The cold start button is fitted on the side of the throttle valve body.

  • Page 24: Idle Speed Adjusting Screw

    6 CONTROLS 6.19 Idle speed adjusting screw The idle setting of the throttle valve body substantially influences the vehicle’s starting behavior, a stable idle speed, and the vehi- cle’s response when the throttle is opened. An engine with a correctly set idle speed is easier to start than an engine with the idle speed set incorrectly.

  • Page 25: Kick Starter Lever

    CONTROLS 6 6.21 Kick starter lever Kick starter lever is fitted on the right side of the engine. The kick starter lever can be swiveled. Info Before riding, swing the kick starter lever inwards towards the engine. 401954-10 6.22 Foot brake lever Foot brake lever is located in front of the right footrest.

  • Page 26: Steering Lock (150 Exc Tpi Eu)

    6 CONTROLS 6.24 Steering lock (150 EXC TPI EU) Steering lock is fitted on the left side of the steering head. The steering lock is used to lock the steering. Steering, and there- fore riding, is no longer possible. E00862-10 6.25 Locking the steering (150 EXC TPI EU) Note...

  • Page 27: Combination Instrument 7

    COMBINATION INSTRUMENT 7 Combination instrument overview – The button is used to select menus and make settings. – The button is used to select menus and make settings. Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. V00799-01 Activation and test Activating combination instrument...

  • Page 28: Adjusting Combination Instrument Function

    7 COMBINATION INSTRUMENT – 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 29: Setting The Clock

    COMBINATION INSTRUMENT 7 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 30: Display Mode Speed (Speed)

    7 COMBINATION INSTRUMENT Display mode SPEED (speed) – Repeatedly press the button briefly until SPEED appears on the left side of the display. The current speed is displayed in the SPEED display mode. The current speed can be displayed in Km/h or Mph. Info Make the setting according to the country.

  • Page 31: Adjusting The Unit Of Measurement

    COMBINATION INSTRUMENT 7 Info Repeatedly press the button briefly until the desired function is reached. If no button is pressed for 20 seconds, the settings are automatically saved. Briefly press Activates the flashing display and changes to the button the next display Press the but- No function for 2–3...

  • Page 32: Display Mode Speed/Clk (Time)

    7 COMBINATION INSTRUMENT 7.11 Display mode SPEED/CLK (time) – Repeatedly press the button briefly until CLK appears at the bottom right of the display. The time is shown in display mode CLK. Press the but- The display changes to the Setup menu of the for 2–3 clock.

  • Page 33: Viewing The Lap Time

    COMBINATION INSTRUMENT 7 Press the but- The stop watch and the lap time are reset. for 2–3 seconds. Briefly press Next display mode the button Press the but- Stops the clock. for 2–3 seconds. Briefly press Starts the stop watch or stop the current lap the button time measurement, stores it and the stop watch starts the next lap.

  • Page 34: Display Mode Speed/Tr1 (Trip Master 1)

    7 COMBINATION INSTRUMENT 7.16 Display mode SPEED/TR1 (trip master 1) – Repeatedly press the button briefly until TR1 appears at the top right of the display. TR1 (trip master 1) runs constantly and counts up to 999.9. You can use it to measure trips or the distance between refueling stops.

  • Page 35: Display Mode Speed/A1 (Average Speed 1)

    COMBINATION INSTRUMENT 7 Info The TR2 value can also be corrected manually during the journey with the button and the button If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0. Press the but- Increases value of TR2. for 2–3 seconds.

  • Page 36: Display Mode Speed/S1 (Stop Watch 1)

    7 COMBINATION INSTRUMENT Press the but- No function for 2–3 seconds. Press the but- No function for 2–3 seconds. Briefly press No function the button 7.21 Display mode SPEED/S1 (stop watch 1) – Repeatedly press the button briefly until S1 appears at the top right of the display.

  • Page 37: Table Of Functions

    COMBINATION INSTRUMENT 7 7.23 Table of functions Display Press the but- Briefly press Press the but- Briefly press Wait 3 - 5 Wait 10 - 12 for 2–3 the button for 2–3 the button seconds. seconds. seconds. seconds. Display mode The display Next display No function...

  • Page 38: Table Of Conditions And Menu Activation

    7 COMBINATION INSTRUMENT Display Press the but- Briefly press Press the but- Briefly press Wait 3 - 5 Wait 10 - 12 for 2–3 the button for 2–3 the button seconds. seconds. seconds. seconds. Display mode Clears the Next display Reduces Reduces SPEED/TR2 (trip...

  • Page 39: Preparing For Use 8

    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 40: Running In The Engine

    8 PREPARING FOR USE (150 EXC TPI EU) – Adjust the free travel of the handbrake lever. ( p. 91) (150 XC‑W TPI US) – Adjust the basic position of the hand brake lever. ( p. 92) – Adjust the basic position of the foot brake lever. p.

  • Page 41: Starting Power Of Lithium-Ion Batteries At Low Temperatures

    PREPARING FOR USE 8 Starting power of lithium-ion batteries at low temperatures Lithium-ion batteries are far lighter than lead batteries, have a low self-discharge rate, and have more starting power at temperatures over 15 °C (60 °F). At low temperatures, however, the starting power of lithium-ion batteries drops to below that of lead batter- ies.
  • Page 42 – Change the radiator cap. – Mount the air filter dust cover. Air filter dust cover (79006920000) Info Observe the KTM PowerParts fitting instructions. M01104-01 – Mount the air filter sand cover. Air filter sand cover (79006922000) Info Observe the KTM PowerParts fitting instructions.

  • Page 43: Preparing The Vehicle For Riding On Wet Sand

    – Change the radiator cap. – Mount the air filter rain cover. Air filter rain cover (79006921000) Info Observe the KTM PowerParts fitting instructions. M01106-01 – Clean the chain. Chain cleaner ( p. 161) –...

  • Page 44: Preparing The Vehicle For Riding On Wet And Muddy Circuits

    Preparing the vehicle for riding on wet and muddy circuits – Mount the air filter rain cover. Air filter rain cover (79006921000) Info Observe the KTM PowerParts fitting instructions. M01106-01 – Mount the steel sprocket. – Clean the motorcycle. ( p.

  • Page 45: Preparing The Vehicle For Low Temperatures Or Snow

    Straighten bent radiator fins carefully. – Check the coolant level. ( p. 123) Preparing the vehicle for low temperatures or snow – Mount the air filter rain cover. Air filter rain cover (79006921000) Info Observe the KTM PowerParts fitting instructions. M01106-01...

  • Page 46: Riding Instructions

    9 RIDING INSTRUCTIONS 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 47: Starting Off

    RIDING INSTRUCTIONS 9 – Take the motorcycle off side stand and secure the side stand with rubber strap – Shift the transmission to neutral position. Condition Ambient temperature: < 10 °C (< 50 °F) – Pull the cold start button fully out and turn it by a ¼ turn. Info If the engine is warm, the cold start button must be 401944-10...

  • Page 48: Braking

    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 49: Stopping, Parking

    RIDING INSTRUCTIONS 9 Stopping, parking Warning Risk of misappropriation People who act without authorization endanger themselves and others. – Do not leave the vehicle unattended if the engine is running. – Protect the vehicle against access by unauthorized persons. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. –...

  • Page 50: Refueling

    In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Improper handling of fuel is a danger to the environment.

  • Page 51: Adding 2-Stroke Oil

    RIDING INSTRUCTIONS 9 – Fill the fuel tank with fuel up to level Guideline 35 mm (1.38 in) Level Total fuel tank 9.25 l Super unleaded capacity, approx. (2.444 US gal) (ROZ 95) p. 160) Info 400382-10 Do not refuel using pre-mixed fuel. –...

  • Page 52: 10 Service Schedule

    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 53: 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 54 10 SERVICE SCHEDULE Every 40 operating hours when used for motorsports Every 10 operating hours when used for motorsports Every 80 operating hours Every 40 operating hours After 20 operating hours After 10 operating hours every 48 months every 12 months ●...

  • Page 55: Tuning The Chassis 11

    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...

  • Page 56: 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 57: Adjusting The Rebound Damping Of The Shock Absorber

    Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) – Turn adjusting screw clockwise up to the last perceptible click.

  • Page 58: Checking The Static Sag Of The Shock Absorber

    11 TUNING THE CHASSIS 11.7 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 55) – 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 59: 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 60: Adjusting The Riding Sag

    11 TUNING THE CHASSIS 11.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 62) – Remove the shock absorber. p. 71) – After removing the shock absorber, clean it thoroughly. Main work –...

  • Page 61: Adjusting The Compression Damping Of The Fork

    TUNING THE CHASSIS 11 11.12 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Turn white adjuster clockwise as far as it will go. Info Adjuster is located at the upper end of the left fork leg.

  • Page 62: Handlebar Position

    11 TUNING THE CHASSIS Info Turn clockwise to increase the damping; turn counter- clockwise to reduce damping when the shock absorber rebounds. 11.14 Handlebar position On the upper triple clamp, there are 2 holes at a distance of each other. Hole distance A 15 mm (0.59 in) The holes on the handlebar support are placed at a distance of...
  • Page 63 TUNING THE CHASSIS 11 – Remove screws . Take off the handlebar clamps. 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 64: 12 Service Work On The Chassis

    12 SERVICE WORK ON THE CHASSIS 12.1 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 65: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS 12 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 62) – Remove the fork protector. ( p. 63) Main work – Push dust boots of both fork legs downward.

  • Page 66: Installing The Fork Protector

    12 SERVICE WORK ON THE CHASSIS 12.6 Installing the fork protector – Position the fork protector on the left fork leg. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Position the brake line, wiring harness, and clamp. Mount and tighten screws –...

  • Page 67: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS 12 12.8 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).

  • Page 68: Installing The Lower Triple Clamp

    12 SERVICE WORK ON THE CHASSIS Main work – Remove screws and hang the combination instrument holder to the side. S03514-10 – Remove screw – Loosen screw . Take off the upper triple clamp with the handlebar and hang them to the side. Info Cover the components to protect them against damage.
  • Page 69 SERVICE WORK ON THE CHASSIS 12 – Position the upper triple clamp with the handlebar. – Position the clutch line and wiring harness. – Mount screw , but do not tighten yet. E00921-11 – Position the combination instrument holder, and mount and tighten screws Guideline Remaining screws,...

  • Page 70: Checking Steering Head Bearing Play

    119) 12.11 Checking steering head bearing play Warning 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.)

  • Page 71: Adjusting The Steering Head Bearing Play

    SERVICE WORK ON THE CHASSIS 12 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. Preparatory work – Raise the motorcycle with a lift stand.

  • Page 72: Lubricating The Steering Head Bearing

    12 SERVICE WORK ON THE CHASSIS 12.13 Lubricating the steering head bearing – Remove the lower triple clamp. p. 65) – Install the lower triple clamp. p. 66) H02387-01 12.14 Removing front fender Preparatory work – Remove the headlight mask with the headlight. ( p.

  • Page 73: Removing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 12 – 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. 117) – Check the headlight setting. ( p.

  • Page 74: Removing The Seat

    12 SERVICE WORK ON THE CHASSIS 12.18 Removing the seat – Remove screws on the left side. S03480-10 – Raise the rear of the seat, pull the seat back, and lift it off. H02218-10 12.19 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.

  • Page 75: Removing The Air Filter Box Cover

    SERVICE WORK ON THE CHASSIS 12 12.20 Removing the air filter box cover Preparatory work – Remove the seat. ( p. 72) 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 76: Removing The Air Filter

    12 SERVICE WORK ON THE CHASSIS 12.22 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine. Dust and dirt will enter the engine without an air filter. – Only operate the vehicle if it is equipped with an air filter. Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 77: Cleaning The Air Filter And Air Filter Box

    SERVICE WORK ON THE CHASSIS 12 12.24 Cleaning the air filter and air filter box 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 Do not clean the air filter with fuel or petroleum since these substances attack the foam.

  • Page 78: Removing The Main Silencer

    12 SERVICE WORK ON THE CHASSIS 12.26 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. –...

  • Page 79: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 12 Main work – Remove screws – Pull out inner tube with O-ring – Remove the glass fiber yarn filling from the inner tube. – Clean the parts that need to be reinstalled and check for dam- age.
  • Page 80 12 SERVICE WORK ON THE CHASSIS 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 81: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 12 12.30 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 82: Checking The Chain For Dirt

    12 SERVICE WORK ON THE CHASSIS – 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.

  • Page 83: Cleaning The Chain

    SERVICE WORK ON THE CHASSIS 12 12.32 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip. – Remove lubricants from the tires using a suitable cleaning agent. Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. –...

  • Page 84: Adjusting The Chain Tension

    12 SERVICE WORK ON THE CHASSIS Main work – Pull the chain at the end of the chain sliding piece upward to measure chain tension Info Lower chain section must be taut. When the chain guard is mounted, it must be possible to pull up the chain at least to the point where it makes contact with chain guard Chain wear is not always even, so you should repeat...

  • Page 85: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    SERVICE WORK ON THE CHASSIS 12 Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 55 … 58 mm (2.17 … 2.28 in) Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks...
  • Page 86 12 SERVICE WORK ON THE CHASSIS – Pull on the top section of the chain with the specified weight Guideline Weight, chain wear measure- 10 … 15 kg (22 … 33 lb.) ment – Measure distance of 18 chain rollers in the lower chain section.
  • Page 87 SERVICE WORK ON THE CHASSIS 12 – Check chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check that the chain sliding piece is firmly seated. »...

  • Page 88: Checking The Frame

    If the link fork shows signs of damage, cracking, or defor- mation: – Change the link fork. Info Always replace a damaged link fork. Repairing the link fork is not authorized by KTM. S01317-10 12.38 Checking throttle cable routing Preparatory work –...

  • Page 89: Checking The Rubber Grip

    SERVICE WORK ON THE CHASSIS 12 – Mount the seat. ( p. 72) 12.39 Checking the rubber grip – Check the rubber grips on the handlebar for damage, wear, and looseness. Info The rubber grips are vulcanized onto a sleeve on the left and onto the handle tube of the throttle grip on the right.

  • Page 90: Checking/Correcting The Fluid Level Of The Hydraulic Clutch

    12 SERVICE WORK ON THE CHASSIS 12.41 Checking/correcting the fluid level of the hydraulic clutch Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. –...

  • Page 91: Changing The Hydraulic Clutch Fluid

    SERVICE WORK ON THE CHASSIS 12 12.42 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing. –...

  • Page 92: Removing Engine Guard

    12 SERVICE WORK ON THE CHASSIS – Now press the fluid into the system until it emerges from the hole of the master cylinder without bubbles. – Now and then, extract fluid from the master cylinder reservoir to prevent overflow. –...

  • Page 93: Brake System 13

    BRAKE SYSTEM 13 13.1 Checking the free travel of the hand brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. –...

  • Page 94: Adjusting The Basic Position Of The Hand Brake Lever (150 Xc-Wtpi Us)

    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.) – Check the front and rear brake disc thickness at multiple...

  • Page 95: Checking The Front Brake Fluid Level

    – 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.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 96: 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 97: Changing The Brake Linings Of The Front Brake

    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 98 13 BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Take off cover with membrane – Manually press the brake caliper toward the brake disc to push back the brake pistons. Ensure that brake fluid does not flow out of the brake fluid reservoir, extract some if necessary.

  • Page 99: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM 13 Info Use water to immediately clean up any brake fluid that has overflowed or spilled. 13.9 Checking the free travel of foot brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.

  • Page 100: 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.) – Stand the vehicle upright.

  • Page 101: 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 102: Checking The Brake Linings Of The Rear Brake

    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 103 BRAKE SYSTEM 13 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 Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.
  • Page 104 13 BRAKE SYSTEM – Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. 159) – Mount screw cap with membrane and O-ring. Info Immediately clean up any brake fluid that has over- flowed or spilled with water. S03487-10...

  • Page 105: Wheels, Tires 14

    WHEELS, TIRES 14 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 62) 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 106: Installing The Front Wheel

    14 WHEELS, TIRES 14.2 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 107: Installing The Rear Wheel

    WHEELS, TIRES 14 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 108 14 WHEELS, TIRES 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 109: 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 110: 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 111: Electrical System 15

    ELECTRICAL SYSTEM 15 15.1 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 112 15 ELECTRICAL SYSTEM – Pull off starter relay and fuse box from the battery compartment and hang to the side. S03491-10 – Detach wiring harness , disconnect relays and plug and hang to the side. S03492-10 – Remove screw and detach the battery compartment. –...

  • Page 113: Installing The 12-V Battery

    ELECTRICAL SYSTEM 15 15.2 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) ( p. 155) – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft)

  • Page 114: Charging The 12-V Battery

    15 ELECTRICAL SYSTEM – 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 115 ELECTRICAL SYSTEM 15 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 S00863-10 rooms.

  • Page 116: Changing Main Fuse

    15 ELECTRICAL SYSTEM Info If the charging current, charging voltage, or charging time is exceeded, the 12-V battery will be destroyed. If the 12-V battery is left in a discharged state for an extended period, it will become deeply discharged and suffer a loss of capacity, destroying the battery.

  • Page 117: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM 15 – Take off protection caps – Remove faulty main fuse Info A faulty fuse has a burned-out fuse wire A spare fuse is located in the starter relay. – Insert a new main fuse. Fuse (58011109120) ( p.
  • Page 118 15 ELECTRICAL SYSTEM Guideline (150 EXC TPI EU) Fuse 1 - 10 A - EFI control unit, lambda sensor, oil pump, combination instrument, electronic fuel injection, diagnostics connector Fuse 2 - 10 A - horn, brake light, radiator fan (optional), turn signal Fuse 3 ‑...

  • Page 119: Removing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM 15 15.6 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 (150 EXC TPI EU) –...

  • Page 120: Changing The Headlight Bulb

    15 ELECTRICAL SYSTEM – 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 121: Changing The Turn Signal Bulb (150 Exc Tpi Eu)

    ELECTRICAL SYSTEM 15 15.9 Changing the turn signal bulb (150 EXC TPI EU) Note Damage to reflector Grease on the reflector reduces the light intensity. Grease on the bulb will evaporate due to the heat and be deposited on the reflector. –...

  • Page 122: Adjusting The Headlight Range

    15 ELECTRICAL SYSTEM 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. 120) 15.11 Adjusting the headlight range Preparatory work...

  • Page 123: Diagnostics Connector

    ELECTRICAL SYSTEM 15 – Position protection cap and turn all the way clockwise using a coin. – Press any button on the combination instrument. The combination instrument is activated. – Position the combination instrument in the holder. – Mount and tighten the screws with washers. V00372-10 Finishing work –...

  • Page 124: 16 Cooling System

    16 COOLING SYSTEM 16.1 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 125: Checking The Coolant Level

    COOLING SYSTEM 16 16.3 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 126: Refilling With Coolant

    16 COOLING SYSTEM 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 127 COOLING SYSTEM 16 – 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. 159) 400243-10 – Push protection cap upward over the thermostat. E00904-10 – Unplug connector –...

  • Page 128: Changing The Coolant

    16 COOLING SYSTEM Finishing work – Check the coolant level. ( p. 123) 16.6 Changing the coolant 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 129 COOLING SYSTEM 16 – Push protection cap upward over the thermostat. S04306-10 – Unplug connector – Remove thermostat with O-ring and wait until the coolant escapes without bubbles. – Mount thermostat with the O-ring and tighten. Guideline Screw, cylinder head M10x1.25 12 Nm (8.9 lbf ft) temperature sensor...

  • Page 130: 17 Tuning The Engine

    17 TUNING THE ENGINE 17.1 Checking the throttle cable play – Check the throttle grip for smooth operation. – Turn handlebar as far as possible to the right. Turn the throttle grip back and forth slightly and determine the play in throttle cable Throttle cable play 3 …...

  • Page 131: Setting The Characteristic Map Of The Throttle Response

    TUNING THE ENGINE 17 – Tighten nut – Tighten nut – Slide on sleeve – Check the throttle grip for smooth operation. Finishing work – Check the throttle cable play. ( p. 128) 17.3 Setting the characteristic map of the throttle response Info On the throttle grip, the characteristic map of the throttle response is changed by changing the guide plate.

  • Page 132: 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 133: Programming Ambient Air Pressure

    TUNING THE ENGINE 17 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. 17.5 Programming ambient air pressure Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.

  • Page 134: Ignition Curve Plug-In Connector

    17 TUNING THE ENGINE 17.6 Ignition curve plug-in connector Plug-in connector of the ignition timing map adjustment is located on the frame under the fuel tank. Info The ignition timing map connector has no function in the homologated (restricted) condition of the motorcycle. Possible states Soft –...

  • Page 135: Checking The Basic Position Of The Shift Lever

    TUNING THE ENGINE 17 Finishing work – Install the fuel tank. p. 79) – Mount the seat. ( p. 72) 17.8 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 136: 18 Service Work On The Engine

    18 SERVICE WORK ON THE ENGINE 18.1 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 fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 137: Checking 2-Stroke Oil Level

    SERVICE WORK ON THE ENGINE 18 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 138 18 SERVICE WORK ON THE ENGINE Preparatory work – Remove the seat. ( p. 72) – Stand the motorcycle upright on a horizontal surface. – Check 2-stroke oil level. ( p. 135) Main work – Pull the EFI control unit upward off the rubber plugs and hang to the side.

  • Page 139: Cleaning The Oil Screen In The Oil Tank

    SERVICE WORK ON THE ENGINE 18 – Plug in wake-up connector for priming the oil pump to the diagnostics connector The combination instrument lighting is activated. Info The connector is included as part of the motorcycle's separate enclosure. – Wait for at least five seconds. –...
  • Page 140 18 SERVICE WORK ON THE ENGINE Main work – Remove screw with the washer. – Remove the cable ties and take off the frame protector. S03626-10 – Remove screws – Loosen screws S03627-10 – Loosen clamps of the throttle valve body. (150 EXC TPI EU) –...
  • Page 141 SERVICE WORK ON THE ENGINE 18 – Remove oil screen and clean it. – Check the oil screen for damage. » If the oil screen is damaged: – Change the oil screen. S03505-10 – Insert the oil screen and mount the angle piece with a new hose clamp.

  • Page 142: Checking The Gear Oil Level

    18 SERVICE WORK ON THE ENGINE – Position the frame protector. – Mount and tighten screw with the washer. Guideline Remaining screws, 5 Nm (3.7 lbf ft) chassis – Mount the cable ties. S03626-10 Finishing work – Install the air filter box cover. ( p.
  • Page 143 SERVICE WORK ON THE ENGINE 18 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 Drain the gear oil while the engine is at operating temperature. Preparatory work –...

  • Page 144: Adding The Gear Oil

    18 SERVICE WORK ON THE ENGINE 18.7 Adding the gear oil Info Too little gear oil or poor-quality gear oil results in premature wear to the transmission. Gear oil must only be topped up when the engine is cold. Preparatory work –...

  • Page 145: Cleaning, Care 19

    CLEANING, CARE 19 19.1 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 146: Checks And Maintenance Steps For Winter Operation

    19 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. 161) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

  • Page 147: Storage 20

    – 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. 62) – Cover the vehicle with a tarp or similar cover that is permeable...

  • Page 148: Preparing For Use After Storage

    20 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 149: Troubleshooting 21

    Check wiring for damage and electrical injection plug-in connectors for corrosion and damage. – Read out the fault memory using the KTM diagnostics tool. – The engine has no idle speed Spark plug defective Change the spark plug. – Faulty ignition Ignition coil - check the primary wind- ing.
  • Page 150 Check wiring for damage and electrical injection plug-in connectors for corrosion and damage. – Read out the fault memory using the KTM diagnostics tool. – Fuel supply interrupted Check the fuel tank breather. – Exhaust system leaky, Check exhaust system for damage.
  • Page 151 – Read out the fault memory using the KTM diagnostics tool. – 12-V battery discharged The 12-V battery is not being Check charging voltage. charged by the alternator –...

  • Page 152: 22 Blink Code

    22 BLINK CODE Info The blink codes are only displayed by the derestricted version of the vehicle. Blink code for malfunction indicator lamp 45 Malfunction indicator lamp flashes 4x long, 5x short Error level condition 150 EXC TPI EU Lamda sensor heater – input signal too low 150 EXC TPI EU Lambda sensor heater - input signal too high Blink code for malfunction...
  • Page 153 BLINK CODE 22 Blink code for malfunction indicator lamp 41 Malfunction indicator lamp flashes 4x long, 1x short Error level condition Fuel pump - short circuit to ground/open circuit Fuel pump – open circuit/short circuit to plus Blink code for malfunction indicator lamp 33 Malfunction indicator lamp flashes 3x long, 3x short Injection valve 0, cylinder 1 –...

  • Page 154: 23 Technical Data

    23 TECHNICAL DATA 23.1 Engine Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 144 cm³ (8.79 cu in) Stroke 54.5 mm (2.146 in) Bore 58 mm (2.28 in) Idle speed 1,400 … 1,500 rpm Exhaust valve - Beginning of adjustment 6,300 rpm Crankshaft bearing 1 grooved ball bearing/1 roller bearing...
  • Page 155 TECHNICAL DATA 23 Screw, retaining bracket, rotary 6 Nm (4.4 lbf ft) Loctite ® 243™ valve Screw, stator 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, water pump wheel 6 Nm (4.4 lbf ft) Loctite ® 243™ Bleeder screw, cylinder head 8 Nm (5.9 lbf ft) Drain plug, water pump cover 10 Nm (7.4 lbf ft)

  • Page 156: Capacities

    23 TECHNICAL DATA Spark plug M14x1.25 25 Nm (18.4 lbf ft) Nut, primary gear wheel M16LHx1.5 130 Nm (95.9 lbf ft) Loctite ® 243™ Nut, inner clutch hub M18x1.5 100 Nm (73.8 lbf ft) Loctite ® 243™ 23.3 Capacities 23.3.1 Gear oil Gear oil 0.80 l (0.85 qt.)

  • Page 157: Electrical System

    (150 XC‑W TPI US) 80/100 - 21 51M TT 110/100 - 18 64M TT Dunlop GEOMAX AT 81 Dunlop GEOMAX AT 81 The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com...

  • Page 158: Fork

    23 TECHNICAL DATA 23.7 Fork Fork article number 14.18.8T.62 WPXPLOR 5548 Fork Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Spring length with preload spacer(s) 474 mm (18.66 in) Spring rate Weight of rider: 65 …...

  • Page 159: Chassis Tightening Torques

    TECHNICAL DATA 23 Fitted length 415 mm (16.34 in) Shock absorber fluid ( p. 160) SAE 2.5 23.9 Chassis tightening torques Remaining screws, chassis EJOT PT ® K60x25‑Z 2 Nm (1.5 lbf ft) Screw, intake air temperature sen- EJOTDELTA PT ®...
  • Page 160 23 TECHNICAL DATA Screw, throttle grip 5 Nm (3.7 lbf ft) Fuel connection on fuel pump 10 Nm (7.4 lbf ft) Nut, foot brake lever 15 Nm (11.1 lbf ft) 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)

  • Page 161: Substances 24

    SUBSTANCES 24 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 162 24 SUBSTANCES Recommended supplier MOTOREX ® – Cross Power 2T Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 163) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.

  • Page 163: Auxiliary Substances 25

    AUXILIARY SUBSTANCES 25 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 164 25 AUXILIARY SUBSTANCES Silicone spray Recommended supplier MOTOREX ® – Silicone Spray Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier MOTOREX ® – Quick Cleaner Universal oil spray Recommended supplier MOTOREX ® – Joker 440 Synthetic...

  • Page 165: Standards 26

    STANDARDS 26 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 166: 27 Index Of Special Terms

    27 INDEX OF SPECIAL TERMS 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 167: List Of Abbreviations 28

    LIST OF ABBREVIATIONS 28 Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 168: 29 List Of Symbols

    Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an error in the vehicle electronics. Come safely to a halt, and contact an authorized KTM workshop. The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.

  • Page 169: Index

    INDEX INDEX Capacity 12-V battery coolant ..... . 125, 154 charging ......112 fuel .
  • Page 170 INDEX slow speed ......42 Gear oil Emergency OFF switch ....18 adding .
  • Page 171 INDEX Service schedule ..... 50-52 Shift lever ......22 Main fuse basic position, adjusting .
  • Page 172 INDEX Tire pressure checking ......107 Transporting ......47 Troubleshooting .
  • Page 173 *3214218en* 3214218en 07/2020 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM http://www.ktm.com...

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