KTM 250 XC-W TPI User Manual

180 pages

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VIEW OF VEHICLE 4

4.2 View of vehicle, rear right (example)

S03467-10

Fuel tank filler cap

Throttle grip ( p. 16)

Vehicle identification number ( p. 14)

Foot brake lever ( p. 23)

Level viewer for brake fluid, rear

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

Questions and Answers:

C
Craig HernandezAug 19, 2025
What to do if my KTM Motorcycle engine cannot be cranked (starter motor)?
- D
  Darlene JonesAug 19, 2025
  If your KTM Motorcycle engine cannot be cranked, start by ensuring you are following the correct start procedure. Then, check the 12-V battery, charging it if discharged, and verify the charging voltage, closed current, and stator winding of the alternator. Inspect the main fuse and replace it if blown. Also, the starter relay or the starter motor itself could be faulty, so check them accordingly.
J
James TaylorAug 21, 2025
What to do if my KTM 250 XC-W TPI engine does not speed up?
- R
  Roberto CoxAug 22, 2025
  If your KTM Motorcycle engine does not speed up, there might be a defect in the fuel injection system, so check the cabling for damage and the electrical plug-in connections for corrosion and damage. Also, faulty ignition could be the cause, so check the ignition coil, spark plug connector, and the stator winding of the alternator. Another possibility is that the ambient pressure is incorrectly stored, so program ambient pressure.

KTM 250 XC-W TPI Specifications

General

Displacement	249 cc
Cooling	Liquid cooled
Transmission	6-speed
Starter	Electric starter
Front Brake	Disc brake
Rear Brake	Disc brake
Bore x Stroke	66.4 mm x 72 mm
Seat Height	960 mm
Ground Clearance	370 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 liters
Frame	Chromium-Molybdenum steel central tube frame
Weight (without fuel)	103 kg