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KTM 250 XC TPI 2020 Setup Instructions
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KTM 250 XC TPI 2020 Setup Instructions

KTM 250 XC TPI 2020 Setup Instructions

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SETUP INSTRUCTIONS
2020
250 EXC Six Days TPI
250 XC‑W TPI
300 EXC Six Days TPI
300 XC-W TPI
300 XC-W Six Days TPI
300 EXC TPI ERZBERGRODEO
250 EXC TPI
300 EXC TPI
Art. no. 3214037en

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Summary of Contents for KTM 250 XC TPI 2020

  • Page 1 SETUP INSTRUCTIONS 2020 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 XC-W Six Days TPI 300 EXC TPI ERZBERGRODEO Art. no. 3214037en...
  • 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 (All EXC models) – 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 have finished.

  • Page 7: Mount And Tighten Screws

    SETUP 2 (All XC‑W models) – 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 clamp (14.8 lbf ft) Info The markings on the handlebar should be at the center of the handlebar clamps. Keep the installed gap widths equal when tighten- ing. (All Six Days models, 300 EXC TPI ERZBERGRODEO EU) –...
  • Page 9 SETUP 2 Info The markings on the handlebar should be at the center of the handlebar clamps. Keep the installed gap widths equal when tighten- ing. (All EXC models) – Position the controls on the right half of the handlebar. S03665-01 (All XC‑W models) –...
  • Page 10 – Position the map switch with the clamp on the right han- dlebar half. Info Read the accompanying KTM PowerParts instruc- tions. E00855-01 Condition Packaging V12 (All EXC models) –...
  • Page 11 SETUP 2 (All XC‑W models) – Insert indicator lamp in the socket. – Plug in light pull switch with the yellow and white cables. – Join all plug-in connectors. – Route the cable without tension and secure with cable ties. F01134-10 –...
  • Page 12 2 SETUP – Preassemble the hand guards on the left and right. E00852-01 – Mount the left hand guard. – Mount the right hand guard. S03689-10 – Secure the handlebar cushion with two cable ties. – Install front fender. ( p.
  • Page 13 SETUP 2 (All EXC models) – 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 14 2 SETUP – 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 15 SETUP 2 – Position the turn signal on both sides on the license plate holder, mount nuts with washers and tighten. – Position license plate lamp on the license plate holder, and mount and tighten screws – Mount reflector on license plate holder. S03681-10 –...
  • Page 16 2 SETUP – 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 17 SETUP 2 – 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. 34) – Install the air filter box cover. ( p.
  • Page 18 2 SETUP – Mount the washer and splint S03695-10 – 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 19 (All Six Days models, 300 EXC TPI ERZBERGRODEO EU) – Install the engine guard. ( p. 38) – Unpack and mount the KTM PowerParts included in the deliv- ery (optional). Info Read the accompanying KTM PowerParts fitting instruc- tions. –...
  • Page 20 2 SETUP Info Transport mode must be deactivated to be able to start the motorcycle.
  • 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 locked in correctly. H02218-11 –...
  • Page 23 WORK 3 Main work – Unplug connector of the fuel pump. – Remove tube from the fuel tank breather. S03485-10 – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel line.
  • Page 24 3 WORK Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –...
  • Page 25 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. – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel line.
  • Page 26 3 WORK Main work – Check throttle cable routing. Both throttle cables must be routed, side by side, on the back of the handlebars, above the fuel tank bracket on the right of the frame to the throttle valve body. Both throttle cables must be secured behind the 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 S03463-10 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 Six Days models, All standard EXC/XC-W models, All XC‑W models) –...

  • Page 29: Tighten Screws

    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 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 31: 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 32 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 if there is no load on the 12-V battery, it discharges each day. The charging level and the method of charging are very important for the service life of the 12-V battery.
  • Page 33 WORK 3 – Mount the seat. ( p. 20) 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,...
  • Page 34 3 WORK – Secure EFI control unit with the rubber lugs S03490-11 – 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.
  • Page 35 WORK 3 3.15 Connecting the negative cable of the 12-V battery Main work – Connect negative cable of the 12-V battery. Guideline Screw, battery termi- 2.5 Nm (1.84 lbf ft) R01414-10 Finishing work – Mount the seat. ( p. 20) 3.16 Removing the air filter box cover Preparatory work...
  • Page 36 3 WORK Condition The air filter box cover is secured. – Mount and tighten screw Guideline Screw, air filter box EJOT PT ® 3 Nm (2.2 lbf ft) cover K60x20-Z S03526-10 Finishing work – Mount the seat. ( p. 20) 3.18 Removing the rear left side cover –...
  • Page 37 WORK 3 3.20 Installing front fender Main work – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V00341-11 – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V00340-11 Finishing work –...
  • Page 38 3 WORK (All XC‑W models) – Disconnect plug-in connector and take off the head- light mask together with the headlight. E00357-10 3.22 Installing the headlight mask with the headlight Main work (All EXC models) – Join plug-in connectors E00900-11 (All XC‑W models) –...

  • Page 39: Tighten Screw

    WORK 3 3.23 Checking the headlight setting – Park the vehicle on a horizontal surface in front of a light- colored wall and make a mark at the height of the center of the low beam headlight. – Make another mark at a distance under the first marking.
  • Page 40 3 WORK 3.25 Installing the engine guard (All Six Days models, 300 EXC TPI ERZBERGRODEO EU) – Attach the engine guard on the frame at the rear and swing up at the front. – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis H01638-10...
  • Page 41 WORK 3 – Fill the 2-stroke oil tank up to the lower edge of the filler neck. 2-stroke oil tank con- 0.6 l (0.6 qt.) Engine oil, 2-stroke tent approx. p. 46) – Close 2-stroke oil tank cap. ( p. 38) M01516-10 3.29 Opening the fuel tank filler cap...
  • Page 42 3 WORK 3.30 Closing the fuel tank filler cap – Mount the fuel tank filler cap and turn it clockwise until release button engages. Info Route fuel tank breather hose without kinks. E00930-10 3.31 Refueling Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled.
  • Page 43 WORK 3 – Fill the fuel tank with fuel up to level Guideline 35 mm (1.38 in) Level Total fuel tank Super unleaded capacity, approx. (2.4 US gal) (ROZ 95/RON 95/PON 91) p. 46) 400382-10 Info Do not refuel using pre-mixed fuel. –...
  • Page 44 3 WORK 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 45 WORK 3 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 46: 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 PT 45x12-Z Screw, oil pump holder on oil tank...
  • Page 47 TECHNICAL DATA 4 Screw, bottom triple clamp (All 15 Nm (11.1 lbf ft) standard EXC/XC-W models) Screw, bottom triple clamp (All 15 Nm (11.1 lbf ft) Six Days models, 300 EXC TPI ERZBERGRODEO EU) Screw, chain sliding piece 15 Nm (11.1 lbf ft) Screw, engine brace M8x15 25 Nm (18.4 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 of a reputable brand. Fully synthetic Recommended supplier MOTOREX ® – Cross Power 2T Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification –...

  • Page 49: Auxiliary Substances

    AUXILIARY SUBSTANCES 6 Long-life grease Recommended supplier MOTOREX ® – Bike Grease 2000...
  • 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 *3214037en* 3214037en 08/2019 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM http://www.ktm.com...

This manual is also suitable for:

250 xc six days tpi 2020250 xc-w tpi 2020300 exc tpi 2020300 exc six days tpi 2020300 xc-w tpi 2020300 xc-w six days tpi 2020 ... Show all