KTM 250 XC TPI User Manual

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18 CLEANING, CARE

122

– Treat bare metal (except for brake discs and the exhaust sys-

tem) with a corrosion inhibitor.

Preserving materials for paints, metal and rubber

( p. 136)

– Treat all plastic parts and powder-coated parts with a mild

cleaning and care product.

Special cleaner for glossy and matte paint finishes, metal

and plastic surfaces ( p. 137)

Default Chapter4
- Table of Contents4
1 Means of Representation 17
- Symbols Used7
- Formats Used7
2 Safety Advice8
- Use Definition - Intended Use8
- Misuse8
- Degrees of Risk and Symbols8
- Tampering Warning9
- Safe Operation9
- Protective Clothing10
- Work Rules10
- Environment10
- Owner's Manual10
3 Important Notes 311
- Manufacturer and Implied Warranty11
- Fuel, Auxiliary Substances11
- Spare Parts, Accessories11
- Service11
- Figures11
- Customer Service11
4 View of Vehicle12
- View of Vehicle, Front Left (Example)12
- View of Vehicle, Rear Right (Example)13
5 Serial Numbers14
- Vehicle Identification Number14
- Type Label14
- Engine Number14
- Fork Part Number14
- Shock Absorber Article Number15
6 Controls16
- Clutch Lever16
- Hand Brake Lever16
- Throttle Grip16
- Switch-Off Button16
- Start Button17
- Overview of Indicator Lamps17
- Opening the Fuel Tank Filler Cap17
- Closing the Fuel Tank Filler Cap18
- Opening 2-Stroke Oil Tank Cap18
- Closing 2-Stroke Oil Tank Cap18
- Cold Start Button19
- Idle Speed Adjusting Screw19
- Shift Lever19
- Foot Brake Lever20
- Side Stand20
- Service Hour Counter21
7 Preparing for Use22
- Advice on Preparing for First Use22
- Running in the Engine23
- Starting Power of Lithium-Ion Batteries at Low Temperatures23
- Preparing the Vehicle for Difficult Operating Conditions24
- Preparing the Vehicle for Riding on Dry Sand24
- Preparing the Vehicle for Riding on Wet Sand25
- Preparing the Vehicle for Riding on Wet and Muddy Circuits26
- Preparing Vehicle for High Temperatures or Slow Riding27
- Preparing the Vehicle for Low Temperatures or Snow28
8 Riding Instructions 829
- Checks and Maintenance Measures When Preparing for Use29
- Starting29
- Starting off30
- Shifting, Riding30
- Applying the Brakes31
- Stopping, Parking31
- Transporting32
- Refueling32
- Adding 2-Stroke Oil33
9 Service Schedule 935
- Additional Information35
- Required Work35
- Recommended Work36
10 Tuning the Chassis38
- Checking the Basic Chassis Setting with Rider's Weight38
- Air Suspension XACT 554838
- Compression Damping of the Shock Absorber39
- Adjusting the Low-Speed Compression Damping of the Shock Absorber39
- Adjusting the High-Speed Compression Damping of the Shock Absorber40
- Adjusting the Rebound Damping of the Shock Absorber40
- Measuring the Rear Wheel Dimension Unloaded41
- Checking the Static Sag of the Shock Absorber42
- Checking the Riding Sag of the Shock Absorber42
- Adjusting the Spring Preload of the Shock Absorber43
- Adjusting the Riding Sag44
- Checking the Basic Setting of the Fork44
- Adjusting the Fork Air Pressure45
- Adjusting the Compression Damping of the Fork46
- Adjusting the Rebound Damping of the Fork46
- Handlebar Position47
- Adjusting the Handlebar Position47
11 Service Work on the Chassis 1149
- Raising the Motorcycle with a Lift Stand49
- Removing the Motorcycle from the Lift Stand49
- Bleeding the Fork Legs49
- Cleaning the Dust Boots of the Fork Legs50
- Removing the Fork Legs51
- Installing the Fork Legs51
- Removing the Fork Protector52
- Installing the Fork Protector52
- Removing the Lower Triple Clamp52
- Installing the Lower Triple Clamp53
- Checking Steering Head Bearing Play55
- Adjusting Steering Head Bearing Play56
- Lubricating the Steering Head Bearing56
- Removing the Start Number Plate57
- Installing the Start Number Plate57
- Removing Front Fender57
- Installing Front Fender57
- Removing the Shock Absorber58
- Installing the Shock Absorber59
- Removing the Seat61
- Mounting the Seat61
- Removing the Air Filter Box Cover62
- Installing the Air Filter Box Cover63
- Removing the Air Filter63
- Cleaning the Air Filter and Air Filter Box64
- Installing the Air Filter65
- Preparing Air Filter Box Cover for Securing65
- Removing the Main Silencer65
- Installing the Main Silencer66
- Changing the Glass Fiber Yarn Filling of the Main Silencer66
- Removing the Fuel Tank67
- Installing the Fuel Tank69
  - Checking the Chain for Dirt70
  - Cleaning the Chain70
  - Checking the Chain Tension71
  - Adjusting the Chain Tension72
  - Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide73
  - Checking the Frame75
  - Checking the Link Fork75
  - Checking the Throttle Cable Routing75
  - Checking the Rubber Grip76
  - Adjusting the Basic Position of the Clutch Lever77
  - Checking/Correcting the Fluid Level of the Hydraulic Clutch77
  - Changing the Hydraulic Clutch Fluid78
12 Brake System80
- Checking the Free Travel of the Hand Brake Lever80
- Adjusting the Basic Position of the Hand Brake Lever80
- Checking the Brake Discs80
- Checking the Front Brake Fluid Level81
- Adding Front Brake Fluid82
- Checking the Front Brake Linings83
- Changing the Brake Linings of the Front Brake83
- Checking the Free Travel of Foot Brake Lever86
- Adjusting the Basic Position of the Foot Brake Lever86
- Checking the Rear Brake Fluid Level87
- Adding Rear Brake Fluid88
- Checking the Brake Linings of the Rear Brake89
- Changing the Rear Brake Linings89
13 Wheels, Tires92
- Removing the Front Wheel92
- Installing the Front Wheel93
- Removing the Rear Wheel93
- Installing the Rear Wheel94
- Checking the Tire Condition96
- Checking Tire Pressure96
- Checking Spoke Tension97
- Diagnostics Connector97
14 Electrical System98
- Removing the 12 V Battery98
- Installing the 12 V Battery98
- Charging the 12-V Battery99
- Changing Main Fuse100
- Changing the Fuses of Individual Power Consumers102
15 Cooling System 15103
- Checking the Antifreeze and103
- Checking the Coolant Level104
- Draining the Coolant104
- Refilling with Coolant105
16 Tuning the Engine108
- Checking Throttle Cable Play108
- Adjusting the Throttle Cable108
  - Play108
- Adjusting the Characteristic Map of109
- Adjusting the Idle Speed110
- Programming Ambient Pressure111
  - Map Adjustment112
- Changing the Ignition Timing Map112
- Checking the Basic Position of the Shift Lever113
- Adjusting the Basic Position of the Shift Lever113
17 Service Work on the Engine114
- Changing the Fuel Screen114
- Checking 2-Stroke Oil Level115
- Priming Oil Pump115
- Cleaning the Oil Screen in the Oil Tank117
- Checking the Gear Oil Level120
- Changing the Gear Oil120
- Adding the Gear Oil121
18 Cleaning, Care 18123
- Cleaning the Motorcycle123
19 Storage 19125
- Preparing for Use after Storage126
20 Troubleshooting127
21 Technical Data129
- Engine129
- Engine Tightening Torques129
- Capacities131
- Gear Oil131
- Coolant131
- Fuel131
- Chassis131
- Electrical System132
- Tires132
- Fork132
- Chassis Tightening Torques133
- Shock Absorber133
  - Substances136
23 Auxiliary Substances138
24 Standards140
25 Index of Special Terms141
26 List of Abbreviations142
27 List of Symbols143
- Yellow and Orange Symbols143
- Index144

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KTM 250 XC TPI Specifications

General

Displacement	249 cc
Bore x Stroke	66.4 mm x 72 mm
Transmission	6-speed
Starter	Electric starter
Front Brake	Disc brake, 260 mm
Rear Brake	Disc brake, 220 mm
Engine Type	2-stroke
Fuel System	TPI (Transfer Port Injection)
Frame	Central Tube Frame, Made of Chrome Molybdenum Steel
Front Suspension	WP Xplor 48, USD fork
Rear Suspension	WP XPLOR Shock with Linkage
Fuel Capacity	8.5 liters