KTM 250 XC TPI 2020 Manual

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

INTRODUCTION

*3214037en*

3214037en

08/2019

INTRODUCTION

Perform the work described in these setup instructions before the vehicle is delivered to the customer.

Read the setup instructions in their entirety before beginning work.

These setup instructions were written to correspond to the latest state of this series. We reserve the right to make

changes in the interest of technical advancement without at the same time updating this manual.

We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop

are not specified here. It is assumed that the work will be performed by a fully trained mechanic.

All specifications contained herein are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right

to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc.,

without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop produc-

tion of a particular model without prior notice. 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.

Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission

of the copyright owner.

ISO 9001(12 100 6061)

KTM applies quality assurance processes that lead to the highest possible product quality as

defined in the ISO 9001 international quality management standard.

Issued by: TÜV Management Service

KTM Sportmotorcycle GmbH

Stallhofnerstraße 3

5230 Mattighofen, Austria

This document is valid for the following models:

250 EXC TPI EU (F7303T7)

250 EXC Six Days TPI EU (F7303T2)

250 XC‑W TPI US (F7375T4)

300 EXC TPI EU (F7403T7)

300 EXC Six Days TPI EU (F7403T2)

300 XC‑W TPI US (F7475T3)

300 XC‑W Six Days TPI US (F7475T2)

300 EXC TPI ERZBERGRODEO EU (F7403T3)

1 MEANS OF REPRESENTATION

1.1 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.

Indicates the result of a testing step.

Indicates a voltage measurement.

Indicates a current measurement.

Indicates a resistance measurement.

Indicates the end of an activity including potential rework.

1.2 Formats used

The typographical formats used in this document are explained below.

Proprietary name Indicates a proprietary name.

Name®Indicates a protected name.

Brand™ Indicates a brand available on the open market.

Underlined terms Refer to technical details of the vehicle or indicate technical terms, which

are explained in the glossary.

SETUP 2

2.1 Transport mode

H02712-01

This vehicle was blocked for transport in the software.

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.

Info

Make sure that the vehicle is permanently enabled before

handing it over to the customer.

2.2 Unpacking and setting up the vehicle

E00851-10

Condition

Packaging V2

–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 have finished.

–Remove the separate enclosure and unpack it. Check that

the scope of supply is complete using the enclosed pack-

ing list.

Info

The procedure in the event of missing parts is

described in the customer service manual.

–Have a lift stand available.

Lift stand (78129955100)

–Carefully loosen and remove the tension belt of the footrest

mount.

Info

An assistant prevents the motorcycle from falling

over.

402050-01

–Together with an assistant, take the vehicle off the pallet.

–Position the vehicle on a lift stand.

–Check the vehicle for transport damage.

Info

The procedure in the event of transport damage is

described in the customer service manual.

–Remove the headlight mask with the headlight. ( p. 35)

2 SETUP

H02474-10

(All EXC models)

–Position the turn signal indicator lamp 1in the com-

bination instrument bracket.

E00850-10

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

have finished.

–Remove the separate enclosure and unpack it. Check that

the scope of supply is complete using the enclosed pack-

ing list.

Info

The procedure in the event of missing parts is

described in the customer service manual.

–Have a lift stand available.

Lift stand (78129955100)

–Remove the two cable ties on the triple clamp.

402051-01

–Together with an assistant, take the vehicle off the pallet.

–Position the vehicle on a lift stand.

–Check the vehicle for transport damage.

Info

The procedure in the event of transport damage is

described in the customer service manual.

–Install the shock absorber. ( p. 24)

H02537-10

(All EXC models)

–Position the connector retainer and combination instru-

ment on the upper triple clamp.

–Mount and tighten screws 2.

Guideline

Remaining screws,

chassis

M6 10 Nm

(7.4 lbf ft)

SETUP 2

H02538-10

(All XC‑W models)

–Position the combination instrument on the upper

triple clamp.

–Mount and tighten screws 2with the collar bushings.

Guideline

Remaining screws,

chassis

M6 10 Nm

(7.4 lbf ft)

–Route the clutch line with the clutch master cylinder

toward the front between the upper and lower triple

clamps.

–Install the fork legs. ( p. 25)

S01414-10

(All standard EXC/XC-W models)

–Remove screws 3and take off the handlebar supports.

–Move the handlebar supports to the desired position and

mount and tighten screws 3.

Guideline

Screw, handle-

bar support

M10 40 Nm (29.5 lbf ft)

Loctite®243™

Info

Position the left and right handlebar supports

evenly.

E00483-01

Warning

Danger of accidents A repaired handlebar poses a

safety risk.

If the handlebar is bent or straightened, the mate-

rial becomes fatigued. The handlebar may break

as a result.

–Change the handlebar if the handlebar is dam-

aged or bent.

–Position the handlebar.

Info

Make sure the cables and wiring are positioned cor-

rectly.

–Position the handlebar clamps. Mount and tighten the

screws evenly.

2 SETUP

Guideline

Screw, handlebar

clamp

M8 20 Nm

(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.

S01415-10

(All Six Days models, 300 EXC TPI ERZBERGRODEO EU)

–Remove screws 3and take off the handlebar supports.

–Move the handlebar supports to the desired position and

mount and tighten screws 3.

Guideline

Screw, handle-

bar support

M10 40 Nm (29.5 lbf ft)

Loctite®243™

Info

Position the left and right handlebar supports

evenly.

S01413-01

Warning

Danger of accidents A repaired handlebar poses a

safety risk.

If the handlebar is bent or straightened, the mate-

rial becomes fatigued. The handlebar may break

as a result.

–Change the handlebar if the handlebar is dam-

aged or bent.

–Position the handlebar.

Info

Make sure the cables and wiring are positioned cor-

rectly.

–Position the handlebar clamps. Mount and tighten the

screws evenly.

Guideline

Screw, handlebar

clamp

M8 20 Nm

(14.8 lbf ft)

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.

S03665-01

(All EXC models)

–Position the controls on the right half of the handlebar.

S03667-01

(All XC‑W models)

–Position the controls on the right half of the handlebar.

S03664-01

(All EXC models)

–Position the controls on the left handlebar half.

S03666-01

(All XC‑W models)

–Position the controls on the left handlebar half.

2 SETUP

402148-01

(All EXC models)

–Mount the turn signal switch.

E00855-01

(All Six Days models)

Warning

Voiding of the government approval for road use and

the insurance coverage If the map switch is

installed, the vehicle's approval for road use is

invalidated.

–Only operate the vehicle in closed-off areas

away from public road traffic if the map switch

is installed.

–Position the map switch with the clamp on the right han-

dlebar half.

Info

Read the accompanying KTM PowerParts instruc-

tions.

F01133-10

Condition

Packaging V12

(All EXC models)

–Insert indicator lamp 4in the socket.

–Join all plug-in connectors to the plug-in holder.

–Route the cable without tension and secure with cable

ties.

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