KTM 150 XC-W TPI 2022 Setup Instructions
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KTM 150 XC-W TPI 2022 Setup Instructions

KTM 150 XC-W TPI 2022 Setup Instructions

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SETUP INSTRUCTIONS
2022
150 EXC TPI
150 XC‑W TPI
Art. no. 3214484en

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Summary of Contents for KTM 150 XC-W TPI 2022

  • Page 1 SETUP INSTRUCTIONS 2022 150 EXC TPI 150 XC‑W TPI Art. no. 3214484en...
  • 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 and components 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 damaged E00483-01 or bent.
  • Page 9 SETUP 2 (150 EXC TPI EU) – Position the controls on the left handlebar half. S03664-01 (150 XC‑W TPI US) – Position the controls on the left handlebar half. S03666-01 (150 EXC TPI EU) – Mount the turn signal switch. 402148-01 Condition Packaging V12...
  • Page 10 2 SETUP (150 XC‑W TPI US) – Insert indicator lamp in the socket. – Plug in light switch with the yellow and white cables. – Join all plug-in connectors. – Route the cable without tension and secure with the cable ties. F01134-10 –...
  • Page 11 SETUP 2 – Preassemble the hand guards on the left and right. E00852-01 – Mount the left hand guard. – Mount the right hand guard. S03689-10 – Secure the handlebar cushion with two cable ties. – Install front fender. ( p.
  • Page 12 2 SETUP (150 EXC TPI EU) – Remove connector from the bracket and join with turn signal wiring harness. S03672-10 – 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.
  • Page 13 SETUP 2 – Disconnect tail light plug-in connector on the wiring harness. S03678-10 – 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.
  • Page 14 2 SETUP – Position the turn signal on both sides on the license plate holder, mount nuts with washers and tighten. – Position the license plate lamp on the license plate holder, and mount and tighten screws – Mount reflector on license plate holder.
  • Page 15 SETUP 2 – Mount and tighten screws Guideline Remaining screws, EJOT PT ® 2 Nm (1.5 lbf ft) chassis K60x25‑Z S03680-10 – Mount and tighten screw Guideline Remaining screws, EJOT PT ® 2 Nm (1.5 lbf ft) chassis K60x25‑Z S03687-10 –...
  • Page 16 2 SETUP – Join the plug-in connectors of tail light and turn signal cable harness with the wiring harness. Info Pay attention to routing of the wiring harnesses. – Install the rear left side cover. ( p. 32) – Install the air filter box cover. ( p.
  • Page 17 SETUP 2 – Mount the washer and splint S03692-10 – Position the left footrest and pin. Info Only insert the pin to the extent that the spring can still be mounted. R00757-10 – Position spring as shown. Spring engages in area S03693-10 –...
  • Page 18 – Mount the cable ties. – Install the engine guard. ( p. 35) – 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 Remove the remaining film, padding, the corrugated card- board, and the other packaging material. – Prepare the vehicle according to the specifications in KTM Dealer.net for handover to the customer. Info Transport mode must be deactivated to be able to start the motorcycle.
  • Page 20 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 21: Mounting The Seat

    WORK 3 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 22 3 WORK 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 23 WORK 3 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 24 3 WORK – Mount and tighten screws with the collar bushings. Guideline Screw, fuel tank 6 Nm (4.4 lbf ft) spoiler on radiator 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 25 WORK 3 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 26 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 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 27: Tighten Screws 3 . Guideline

    WORK 3 – 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 28 3 WORK 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 29: Charging The 12-V Battery

    WORK 3 – 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 30 3 WORK 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 31 WORK 3 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 Screw, battery sup- 6 Nm (4.4 lbf ft) port bracket S03494-10...
  • Page 32 3 WORK – 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 33 WORK 3 3.16 Removing the air filter box cover Preparatory work – Remove the seat. ( p. 18) 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 34 3 WORK 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 35 WORK 3 – 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. 34) – Check the headlight setting. ( p. 34) 3.21 Removing the headlight mask with the headlight –...
  • Page 36 3 WORK 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 37: Tighten Screw

    WORK 3 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. 35) 3.24 Adjusting the headlight range Preparatory work...

  • Page 38: Adding 2-Stroke Oil

    3 WORK 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 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: Setting Kilometers Or Miles

    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 41 WORK 3 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 42: Setting The Clock

    3 WORK 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 43: Technical Data

    TECHNICAL DATA 4 Chassis tightening torques EJOT PT Remaining screws, chassis ® K60x25‑Z 2 Nm (1.5 lbf ft) Screw, activated carbon filter 5 Nm (3.7 lbf ft) (150 EXC TPI EU) EJOT PT Screw, fuel pump on fuel tank ® K60x25‑Z 2.5 Nm (1.84 lbf ft) Screw, hose clip, inlet sleeve...
  • Page 44 4 TECHNICAL DATA Screw, clutch lever 5 Nm (3.7 lbf ft) Screw, front brake disc 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, fuel tank spoiler on radiator 6 Nm (4.4 lbf ft) Screw, manifold on silent block 6 Nm (4.4 lbf ft) Screw, oil pump 6 Nm (4.4 lbf ft) Screw, oil tank on frame...
  • Page 45 TECHNICAL DATA 4 Screw, handlebar support 40 Nm (29.5 lbf ft) Loctite ® 243™ Nut, fuel pump 15 Nm (11.1 lbf ft) Screw, bottom shock absorber 80 Nm (59 lbf ft) Loctite ® 2701™ Screw, top shock absorber 80 Nm (59 lbf ft) Loctite ®...
  • Page 46 5 SUBSTANCES Engine oil, 2-stroke Standard/classification – JASO FD ( p. 46) 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 47: Auxiliary Substances

    AUXILIARY SUBSTANCES 6 Long-life grease Recommended supplier MOTOREX ® – Bike Grease 2000 Silicone spray Recommended supplier MOTOREX ® – Silicone Spray...
  • Page 48 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 49 *3214484en* 3214484en 04/2021 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM KTM.COM...

This manual is also suitable for:

150 exc tpi 2022

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