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KTM
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250 EXC TPI
KTM 250 EXC TPI User Manual
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ELECTRIC
AL
SYSTEM
15
119
15.2
Installing
the
12-V
battery
S03494-10
Main
work
–
Insert
the
12
V
battery
into
the
b
attery
compartment
with
the
terminals
facing
f
orward
and
secure
w
ith
holding
bracket
1
.
12-V
battery
(HJT
Z5S-FP-C)
(
p.
161)
–
Mount
and
tighten
screw
2
.
Guideline
Remaining
screws
,
chassis
M6
10
Nm
(7.4
lbf
ft)
S03492-11
–
Place
relays
3
and
connector
4
on
the
battery
com
part-
ment
and
attach
t
he
wiring
harness
5
.
S03491-11
–
Attach
starter
rela
y
6
and
fuse
box
7
to
the
battery
com
-
partment.
S03490-11
–
Secure
EFI
contro
l
unit
8
with
the
rubber
lug
s
9
.
120
122
Table of Contents
Default Chapter
4
Table of Contents
4
1 Means of Representation
8
Symbols Used
8
Formats Used
8
2 Safety Advice 2
9
Use Definition - Intended Use
9
Misuse
9
Degrees of Risk and Symbols
10
Tampering Warning
10
Safe Operation
10
Protective Clothing
11
Work Rules
11
Environment
11
Owner's Manual
12
3 Important Notes 3
13
Manufacturer and Implied Warranty
13
Fuel, Auxiliary Substances
13
Spare Parts, Accessories
13
Service
13
Figures
13
Customer Service
13
4 View of Vehicle
14
View of Vehicle, Front Left (Example)
14
View of Vehicle, Rear Right (Example)
15
5 Serial Numbers
16
Vehicle Identification Number
16
Type Label
16
Key Number (All EXC Models)
16
Engine Number
16
Fork Part Number
17
Shock Absorber Article Number
17
6 Controls
18
Clutch Lever
18
Hand Brake Lever
18
Throttle Grip
18
Switch-Off Button (All EXC Models)
18
Switch-Off Button (All XC-W Models)
19
Horn Button (All EXC Models)
19
Light Switch (All EXC Models)
19
Light Switch (All XC-W Models)
19
Turn Signal Switch (All EXC Models)
20
Emergency off Switch (All EXC Models)
20
Start Button
20
Map Switch (All Special Models)
20
Overview of Indicator Lamps (All EXC Models)
21
Overview of Indicator Lamps (All XC-W Models)
21
Opening the Fuel Tank Filler Cap
21
Closing the Fuel Tank Filler Cap
22
Opening 2-Stroke Oil Tank Cap
22
Closing 2-Stroke Oil Tank Cap
23
Straps
23
(300 EXC Erzberg Edition TPI EU)
23
Cold Start Button
23
Idle Speed Adjusting Screw
24
Shift Lever
24
Foot Brake Lever
25
Side Stand
25
Steering Lock (All EXC Models)
25
Locking the Steering (All EXC Models)
26
Unlocking the Steering (All EXC Models)
26
7 Combination Instrument 7
27
Combination Instrument Overview
27
Activation and Test
27
Setting the Kilometers or Miles
27
Adjusting Combination Instrument Function
28
Setting the Clock
29
Viewing the Lap Time
29
Display Mode SPEED (Speed)
30
Display Mode SPEED/H (Operating Hours)
30
Setup Menu
30
Adjusting the Unit of Measurement
31
Display Mode SPEED/CLK (Time)
32
Setting the Clock
32
Display Mode SPEED/LAP (Lap Time)
32
Viewing the Lap Time
33
Display Mode SPEED/ODO (Odometer)
33
Display Mode SPEED/TR1 (Trip Master 1)
34
Display Mode SPEED/TR2 (Trip Master 2)
34
Setting TR2 (Trip Master 2)
34
Display Mode SPEED/A1 (Average Speed 1)
35
Display Mode SPEED/A2 (Average Speed 2)
35
Display Mode SPEED/S1 (Stop Watch 1)
36
Display Mode SPEED/S2 (Stop Watch 2)
36
Table of Functions
37
Table of Conditions and Menu Activation
38
8 Preparing for Use 8
39
Advice on Preparing for First Use
39
Running in the Engine
40
Starting Power of Lithium-Ion Batteries at Low Temperatures
41
Preparing the Vehicle for Difficult Riding Conditions
41
Preparing the Vehicle for Riding on Dry Sand
41
Preparing the Vehicle for Riding on Wet Sand
43
Preparing the Vehicle for Riding on Wet and Muddy Circuits
44
Preparing Vehicle for High Temperatures or Slow Riding
44
Preparing the Vehicle for Low Temperatures or Snow
45
9 Riding Instructions
46
Checks and Maintenance Measures When Preparing for Use
46
Starting the Vehicle
46
Starting off
47
Shifting, Riding
47
Braking
48
Stopping, Parking
49
Transporting
49
Refueling
50
Adding 2-Stroke Oil
51
10 Service Schedule
52
Additional Information
52
Required Work
52
Recommended Work
53
11 Tuning the Chassis 11
55
Checking the Basic Chassis Setting with Rider's Weight
55
Compression Damping of the Shock Absorber
55
Adjusting the Low-Speed Compression Damping of the Shock Absorber
55
Adjusting the High-Speed Compression Damping of the Shock Absorber
56
Adjusting the Rebound Damping of the Shock Absorber
57
Measuring the Dimension of the Rear Wheel Unloaded
57
Checking the Static Sag of the Shock Absorber
58
Checking the Riding Sag of the Shock Absorber
58
Adjusting the Spring Preload of the Shock Absorber
59
Adjusting the Riding Sag
60
Checking the Basic Setting of the Fork
60
Adjusting the Compression Damping of the Fork
61
Adjusting the Rebound Damping of the Fork
62
Adjusting the Spring Preload of the Fork (All Six Days Models)
63
Handlebar Position
64
Adjusting the Handlebar Position
64
12 Service Work on the Chassis 12
67
Raising the Motorcycle with a Lift Stand
67
Removing the Motorcycle from the Lift Stand
67
Bleeding the Fork Legs
67
Cleaning the Dust Boots of the Fork Legs
68
Removing the Fork Protector
68
Installing the Fork Protector
69
Removing the Fork Legs
69
Installing the Fork Legs
70
(All Standard EXC/XC-W Models)
71
(All Special Models)
71
Installing the Lower Triple Clamp (All Standard EXC/XC-W Models)
72
Installing the Lower Triple Clamp
72
(All Special Models)
75
Checking Steering Head Bearing Play
77
Adjusting the Steering Head Bearing Play
77
Lubricating the Steering Head Bearing
79
Removing Front Fender
79
Installing Front Fender
79
Removing the Shock Absorber
80
Installing the Shock Absorber
80
Removing the Seat
81
Mounting the Seat
81
Removing the Air Filter Box Cover
82
Installing the Air Filter Box Cover
82
Removing the Air Filter
83
Installing the Air Filter
83
Cleaning the Air Filter and Air Filter Box
84
Preparing Air Filter Box Cover for Securing
84
Removing the Main Silencer
85
Installing the Main Silencer
85
Changing the Glass Fiber Yarn Filling of the Main Silencer
85
Removing the Fuel Tank
86
Installing the Fuel Tank
88
Checking the Chain for Dirt
89
Cleaning the Chain
90
Checking the Chain Tension
90
Adjusting the Chain Tension
91
Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide
92
Checking the Frame
95
Checking the Link Fork
95
Checking Throttle Cable Routing
95
Checking the Rubber Grip
96
Adjusting the Basic Position of the Clutch Lever
96
Checking/Correcting the Fluid Level of the Hydraulic Clutch
97
Changing the Hydraulic Clutch Fluid
98
Removing the Engine Guard (All Special Models)
99
Installing the Engine Guard (All Special Models)
99
13 Brake System
100
Checking the Free Travel of the Hand Brake Lever
100
Adjusting the Free Travel of the Handbrake Lever (All EXC Models)
100
Adjusting the Basic Position of the Hand Brake Lever (All XC-W Models)
101
Checking the Brake Discs
101
Checking the Front Brake Fluid Level
102
Adding the Front Brake Fluid
102
Checking the Front Brake Linings
103
Changing the Brake Linings of the Front Brake
104
Checking the Free Travel of Foot Brake Lever
106
Adjusting the Basic Position of the Foot Brake Lever
106
Checking the Rear Brake Fluid Level
107
Adding Rear Brake Fluid
108
Checking the Brake Linings of the Rear Brake
109
Changing the Brake Linings of the Rear Brake
109
14 Wheels, Tires
112
Removing the Front Wheel
112
Installing the Front Wheel
113
Removing the Rear Wheel
114
Installing the Rear Wheel
115
Checking the Tire Condition
116
Checking Tire Pressure
117
Checking Spoke Tension
117
15 Electrical System 15
119
Removing the 12-V Battery
119
Installing the 12-V Battery
121
Charging the 12-V Battery
122
Changing Main Fuse
124
Changing the Fuses of Individual Power Consumers
125
Removing the Headlight Mask with the Headlight
127
Installing the Headlight Mask with the Headlight
127
Changing the Headlight Bulb
128
Changing the Turn Signal Bulb (All EXC Models)
129
Checking the Headlight Setting
129
Adjusting the Headlight Range
130
Changing the Combination Instrument Battery
130
Diagnostics Connector
131
16 Cooling System
132
Checking the Antifreeze and Coolant Level
132
Checking the Coolant Level
133
Draining the Coolant
133
Refilling with Coolant
134
17 Tuning the Engine 17
137
Checking the Throttle Cable Play
137
Adjusting the Throttle Cable Play
137
Setting the Characteristic Map of the Throttle Response
138
Adjusting the Idle Speed
139
Programming Ambient Pressure
140
Ignition Curve Plug-In Connector
141
Changing the Ignition Timing Map (All Standard EXC/XC-W Models)
141
Checking the Basic Position of the Shift Lever
142
Adjusting the Basic Position of the Shift Lever
142
18 Service Work on the Engine 18
143
Changing the Fuel Screen
143
Checking 2-Stroke Oil Level
144
Priming Oil Pump
144
Cleaning the Oil Screen in the Oil Tank
146
Checking the Gear Oil Level
149
Changing the Gear Oil
149
Adding the Gear Oil
150
19 Cleaning, Care
152
Cleaning the Motorcycle
152
Checks and Maintenance Steps for Winter Operation
153
20 Storage
154
Preparing for Use after Storage
155
21 Troubleshooting
156
22 Technical Data 22
159
Engine
159
All 250 Models
159
All 300 Models
159
Engine Tightening Torques
160
Capacities
162
Gear Oil
162
Coolant
162
Fuel
162
Chassis
162
Electrical System
163
Tires
163
Fork
164
All Standard EXC/XC-W Models, 300 EXC Erzberg Edition TPI EU
164
All Six Days Models
164
Shock Absorber
165
Chassis Tightening Torques
165
23 Substances
168
24 Auxiliary Substances
170
25 Standards
172
26 Index of Special Terms 26
173
27 List of Abbreviations
174
28 List of Symbols 28
175
Red Symbols
175
Yellow and Orange Symbols
175
Green and Blue Symbols
175
Index
176
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KTM 250 EXC TPI Specifications
General
Brand
KTM
Model
250 EXC TPI
Category
Motorcycle
Language
English
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