KTM 250 EXC TPI User Manual

KTM 250 EXC TPI

180 pages

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27 LIST OF ABBREVIATIONS

172

Art. no. Article number

ca. circa

cf. compare

e.g. for example

etc. et cetera

i.a. inter alia

no. number

poss. possibly

Table of Contents

Default Chapter4
- Table of Contents4
1 Means of Representation8
- Symbols Used8
- Formats Used8
2 Safety Advice 29
- Use Definition - Intended Use9
- Misuse9
- Degrees of Risk and Symbols10
- Tampering Warning10
- Safe Operation10
- Protective Clothing11
- Work Rules11
- Environment11
- Owner's Manual12
3 Important Notes 313
- Manufacturer and Implied Warranty13
- Fuel, Auxiliary Substances13
- Spare Parts, Accessories13
- Service13
- Figures13
- Customer Service13
4 View of Vehicle14
- View of Vehicle, Front Left (Example)14
- View of Vehicle, Rear Right (Example)15
5 Serial Numbers16
- Vehicle Identification Number16
- Type Label16
- Key Number (All EXC Models)16
- Engine Number16
- Fork Part Number17
- Shock Absorber Article Number17
6 Controls18
- Clutch Lever18
- Hand Brake Lever18
- Throttle Grip18
- 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 Button20
- 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 Cap21
- Closing the Fuel Tank Filler Cap22
- Opening 2-Stroke Oil Tank Cap22
- Closing 2-Stroke Oil Tank Cap23
- Straps23
- (300 EXC Erzberg Edition TPI EU)23
- Cold Start Button23
- Idle Speed Adjusting Screw24
- Shift Lever24
- Foot Brake Lever25
- Side Stand25
- Steering Lock (All EXC Models)25
- Locking the Steering (All EXC Models)26
- Unlocking the Steering (All EXC Models)26
7 Combination Instrument 727
- Combination Instrument Overview27
- Activation and Test27
- Setting the Kilometers or Miles27
- Adjusting Combination Instrument Function28
- Setting the Clock29
- Viewing the Lap Time29
- Display Mode SPEED (Speed)30
- Display Mode SPEED/H (Operating Hours)30
- Setup Menu30
- Adjusting the Unit of Measurement31
- Display Mode SPEED/CLK (Time)32
- Setting the Clock32
- Display Mode SPEED/LAP (Lap Time)32
- Viewing the Lap Time33
- 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 Functions37
- Table of Conditions and Menu Activation38
8 Preparing for Use 839
- Advice on Preparing for First Use39
- Running in the Engine40
- Starting Power of Lithium-Ion Batteries at Low Temperatures41
- Preparing the Vehicle for Difficult Riding Conditions41
- Preparing the Vehicle for Riding on Dry Sand41
- Preparing the Vehicle for Riding on Wet Sand43
- Preparing the Vehicle for Riding on Wet and Muddy Circuits44
- Preparing Vehicle for High Temperatures or Slow Riding44
- Preparing the Vehicle for Low Temperatures or Snow45
9 Riding Instructions46
- Checks and Maintenance Measures When Preparing for Use46
- Starting the Vehicle46
- Starting off47
- Shifting, Riding47
- Braking48
- Stopping, Parking49
- Transporting49
- Refueling50
- Adding 2-Stroke Oil51
10 Service Schedule52
- Additional Information52
- Required Work52
- Recommended Work53
11 Tuning the Chassis 1155
- Checking the Basic Chassis Setting with Rider's Weight55
- Compression Damping of the Shock Absorber55
- Adjusting the Low-Speed Compression Damping of the Shock Absorber55
- Adjusting the High-Speed Compression Damping of the Shock Absorber56
- Adjusting the Rebound Damping of the Shock Absorber57
- Measuring the Dimension of the Rear Wheel Unloaded57
- Checking the Static Sag of the Shock Absorber58
- Checking the Riding Sag of the Shock Absorber58
  - Adjusting the Spring Preload of the Shock Absorber59
- Adjusting the Riding Sag60
- Checking the Basic Setting of the Fork60
- Adjusting the Compression Damping of the Fork61
- Adjusting the Rebound Damping of the Fork62
- Adjusting the Spring Preload of the Fork (All Six Days Models)63
- Handlebar Position64
- Adjusting the Handlebar Position64
12 Service Work on the Chassis 1267
- Raising the Motorcycle with a Lift Stand67
- Removing the Motorcycle from the Lift Stand67
- Bleeding the Fork Legs67
- Cleaning the Dust Boots of the Fork Legs68
- Removing the Fork Protector68
- Installing the Fork Protector69
- Removing the Fork Legs69
- Installing the Fork Legs70
  - (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 Clamp72
  - (All Special Models)75
- Checking Steering Head Bearing Play77
- Adjusting the Steering Head Bearing Play77
- Lubricating the Steering Head Bearing79
- Removing Front Fender79
- Installing Front Fender79
- Removing the Shock Absorber80
- Installing the Shock Absorber80
- Removing the Seat81
- Mounting the Seat81
- Removing the Air Filter Box Cover82
- Installing the Air Filter Box Cover82
- Removing the Air Filter83
- Installing the Air Filter83
- Cleaning the Air Filter and Air Filter Box84
- Preparing Air Filter Box Cover for Securing84
  - Removing the Main Silencer85
  - Installing the Main Silencer85
  - Changing the Glass Fiber Yarn Filling of the Main Silencer85
  - Removing the Fuel Tank86
  - Installing the Fuel Tank88
  - Checking the Chain for Dirt89
  - Cleaning the Chain90
  - Checking the Chain Tension90
  - Adjusting the Chain Tension91
  - Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide92
  - Checking the Frame95
  - Checking the Link Fork95
  - Checking Throttle Cable Routing95
  - Checking the Rubber Grip96
  - Adjusting the Basic Position of the Clutch Lever96
  - Checking/Correcting the Fluid Level of the Hydraulic Clutch97
  - Changing the Hydraulic Clutch Fluid98
  - Removing the Engine Guard (All Special Models)99
  - Installing the Engine Guard (All Special Models)99
13 Brake System100
- Checking the Free Travel of the Hand Brake Lever100
- 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 Discs101
- Checking the Front Brake Fluid Level102
- Adding the Front Brake Fluid102
- Checking the Front Brake Linings103
  - Changing the Brake Linings of the Front Brake104
- Checking the Free Travel of Foot Brake Lever106
- Adjusting the Basic Position of the Foot Brake Lever106
- Checking the Rear Brake Fluid Level107
- Adding Rear Brake Fluid108
- Checking the Brake Linings of the Rear Brake109
- Changing the Brake Linings of the Rear Brake109
14 Wheels, Tires112
- Removing the Front Wheel112
- Installing the Front Wheel113
- Removing the Rear Wheel114
- Installing the Rear Wheel115
- Checking the Tire Condition116
- Checking Tire Pressure117
- Checking Spoke Tension117
15 Electrical System 15119
- Removing the 12-V Battery119
- Installing the 12-V Battery121
- Charging the 12-V Battery122
- Changing Main Fuse124
- Changing the Fuses of Individual Power Consumers125
- Removing the Headlight Mask with the Headlight127
- Installing the Headlight Mask with the Headlight127
- Changing the Headlight Bulb128
- Changing the Turn Signal Bulb (All EXC Models)129
- Checking the Headlight Setting129
- Adjusting the Headlight Range130
- Changing the Combination Instrument Battery130
- Diagnostics Connector131
16 Cooling System132
- Checking the Antifreeze and Coolant Level132
- Checking the Coolant Level133
- Draining the Coolant133
- Refilling with Coolant134
17 Tuning the Engine 17137
- Checking the Throttle Cable Play137
- Adjusting the Throttle Cable Play137
- Setting the Characteristic Map of the Throttle Response138
- Adjusting the Idle Speed139
- Programming Ambient Pressure140
- Ignition Curve Plug-In Connector141
- Changing the Ignition Timing Map (All Standard EXC/XC-W Models)141
- Checking the Basic Position of the Shift Lever142
- Adjusting the Basic Position of the Shift Lever142
18 Service Work on the Engine 18143
- Changing the Fuel Screen143
- Checking 2-Stroke Oil Level144
- Priming Oil Pump144
- Cleaning the Oil Screen in the Oil Tank146
- Checking the Gear Oil Level149
- Changing the Gear Oil149
- Adding the Gear Oil150
19 Cleaning, Care152
- Cleaning the Motorcycle152
- Checks and Maintenance Steps for Winter Operation153
20 Storage154
- Preparing for Use after Storage155
21 Troubleshooting156
22 Technical Data 22159
- Engine159
- All 250 Models159
- All 300 Models159
- Engine Tightening Torques160
- Capacities162
- Gear Oil162
- Coolant162
- Fuel162
- Chassis162
- Electrical System163
- Tires163
- Fork164
- All Standard EXC/XC-W Models, 300 EXC Erzberg Edition TPI EU164
- All Six Days Models164
- Shock Absorber165
- Chassis Tightening Torques165
23 Substances168
24 Auxiliary Substances170
25 Standards172
26 Index of Special Terms 26173
27 List of Abbreviations174
28 List of Symbols 28175
- Red Symbols175
- Yellow and Orange Symbols175
- Green and Blue Symbols175
- Index176

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KTM 250 EXC TPI Specifications

General

Displacement	249 cm³
Cooling	Liquid cooled
Transmission	6-speed
Starter	Electric starter
Front Brake	Disc brake
Rear Brake	Disc brake
Ground Clearance	370 mm
Seat Height	960 mm
Bore x Stroke	66.4 mm x 72 mm
Engine Type	1-cylinder, 2-stroke
Fuel System	TPI
Front Suspension	WP XPLOR-USD, Ø 48 mm
Rear Suspension	WP Xplor shock absorber
Fuel Capacity	9 l
Frame	Central tube frame made of chrome molybdenum steel

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