Contents

1 MEANS OF REPRESENTATION
- 1.1 Symbols used
- 1.2 Formats used
2 SAFETY ADVICE
- 2.1 Use definition intended use
- 2.2 Misuse
- 2.3 Safety advice
- 2.4 Degrees of risk and symbols
- 2.5 Tampering warning
- 2.6 Safe operation
- 2.7 Protective clothing
- 2.8 Work rules
- 2.9 Environment
- 2.10 Owner's Manual
3 IMPORTANT NOTES
- 3.1 Manufacturer and implied warranty
- 3.2 Fuel, auxiliary substances
- 3.3 Spare parts, accessories
- 3.4 Service
- 3.5 Figures
- 3.6 Customer service
4 VIEW OF VEHICLE
- 4.1 View of vehicle, front left (example)
- 4.2 View of vehicle, rear right (example)
5 SERIAL NUMBERS
- 5.1 Vehicle identification number
- 5.2 Type label
- 5.3 Key number (All EXC models)
- 5.4 Engine number
- 5.5 Fork part number
- 5.6 Shock absorber article number
6 CONTROLS
- 6.1 Clutch lever
- 6.2 Hand brake lever
- 6.3 Throttle grip
- 6.4 Switch-off button (All EXC models)
- 6.5 Switch-off button (All XCW models)
- 6.6 Horn button (All EXC models)
- 6.7 Light switch (All EXC models)
- 6.8 Light switch (All XCW models)
- 6.9 Turn signal switch (All EXC models)
- 6.10 Emergency OFF switch (All EXC models)
- 6.11 Start button
- 6.12 Map switch (All special models)
- 6.13 Overview of indicator lamps (All EXC models)
- 6.14 Overview of indicator lamps (All XCW models)
- 6.15 Opening the fuel tank filler cap
- 6.16 Closing the fuel tank filler cap
- 6.17 Opening 2-stroke oil tank cap
- 6.18 Closing 2-stroke oil tank cap
- 6.19 Straps (All ERZBERGRODEO)
- 6.20 Cold start button
- 6.21 Idle speed adjusting screw
- 6.22 Shift lever
- 6.23 Foot brake lever
- 6.24 Side stand
- 6.25 Steering lock (All EXC models)
- 6.26 Locking the steering (All EXC models)
- 6.27 Unlocking the steering (All EXC models)
7 COMBINATION INSTRUMENT
- 7.1 Combination instrument overview
- 7.2 Activation and test
- 7.3 Setting the kilometers or miles
- 7.4 Adjusting combination instrument function
- 7.5 Setting the clock
- 7.6 Viewing the lap time
- 7.7 Display mode SPEED (speed)
- 7.8 Display mode SPEED/H (operating hours)
- 7.9 Setup menu
- 7.10 Adjusting the unit of measurement
- 7.11 Display mode SPEED/CLK (time)
- 7.12 Setting the clock
- 7.13 Display mode SPEED/LAP (lap time)
- 7.14 Viewing the lap time
- 7.15 Display mode SPEED/ODO (odometer)
- 7.16 Display mode SPEED/TR1 (trip master 1)
- 7.17 Display mode SPEED/TR2 (trip master 2)
- 7.18 Setting TR2 (trip master 2)
- 7.19 Display mode SPEED/A1 (average speed 1)
- 7.20 Display mode SPEED/A2 (average speed 2)
- 7.21 Display mode SPEED/S1 (stop watch 1)
- 7.22 Display mode SPEED/S2 (stop watch 2)
- 7.23 Table of functions
- 7.24 Table of conditions and menu activation
8 PREPARING FOR USE
- 8.1 Advice on preparing for first use
- 8.2 Running in the engine
- 8.3 Starting power of lithium-ion batteries at low temperatures
- 8.4 Preparing the vehicle for difficult riding conditions
- 8.5 Preparing the vehicle for riding on dry sand
- 8.6 Preparing the vehicle for riding on wet sand
- 8.7 Preparing the vehicle for riding on wet and muddy circuits
- 8.8 Preparing vehicle for high temperatures or slow riding
- 8.9 Preparing the vehicle for low temperatures or snow
9 RIDING INSTRUCTIONS
- 9.1 Checks and maintenance measures when preparing for use
- 9.2 Starting the vehicle
- 9.3 Starting off
- 9.4 Shifting, riding
- 9.5 Braking
- 9.6 Stopping, parking
- 9.7 Transporting
- 9.8 Refueling
- 9.9 Adding 2-stroke oil
10 SERVICE SCHEDULE
- 10.1 Additional information
- 10.2 Required work
- 10.3 Recommended work
11 TUNING THE CHASSIS
- 11.1 Checking the basic chassis setting with rider's weight
- 11.2 Compression damping of the shock absorber
- 11.3 Adjusting the low-speed compression damping of the shock absorber
- 11.4 Adjusting the high-speed compression damping of the shock absorber
- 11.5 Adjusting the rebound damping of the shock absorber
- 11.6 Measuring the dimension of the rear wheel unloaded
- 11.7 Checking the static sag of the shock absorber
- 11.8 Checking the riding sag of the shock absorber
- 11.9 Adjusting the spring preload of the shock absorber
- 11.10 Adjusting the riding sag
- 11.11 Checking the basic setting of the fork
- 11.12 Adjusting the compression damping of the fork
- 11.13 Adjusting the rebound damping of the fork
- 11.14 Adjusting the spring preload of the fork (All Six Days models)
- 11.15 Handlebar position
- 11.16 Adjusting the handlebar position
12 SERVICE WORK ON THE CHASSIS
- 12.1 Raising the motorcycle with a lift stand
- 12.2 Removing the motorcycle from the lift stand
- 12.3 Bleeding the fork legs
- 12.4 Cleaning the dust boots of the fork legs
- 12.5 Removing the fork protector
- 12.6 Installing the fork protector
- 12.7 Removing the fork legs
- 12.8 Installing the fork legs
- 12.9 Removing the lower triple clamp (All standard EXC/XC-W models)
- 12.10 Removing the lower triple clamp (All special models)
- 12.11 Installing the lower triple clamp (All standard EXC/XC-W models)
- 12.12 Installing the lower triple clamp (All special models)
- 12.13 Checking steering head bearing play
- 12.14 Adjusting the steering head bearing play
- 12.15 Lubricating the steering head bearing
- 12.16 Removing front fender
- 12.17 Installing front fender
- 12.18 Removing the shock absorber
- 12.19 Installing the shock absorber
- 12.20 Removing the seat
- 12.21 Mounting the seat
- 12.22 Removing the air filter box cover
- 12.23 Installing the air filter box cover
- 12.24 Removing the air filter
- 12.25 Installing the air filter
- 12.26 Cleaning the air filter and air filter box
- 12.27 Preparing air filter box cover for securing
- 12.28 Removing the main silencer
- 12.29 Installing the main silencer
- 12.30 Changing the glass fiber yarn filling of the main silencer
- 12.31 Removing the fuel tank
- 12.32 Installing the fuel tank
- 12.33 Checking the chain for dirt
- 12.34 Cleaning the chain
- 12.35 Checking the chain tension
- 12.36 Adjusting the chain tension
- 12.37 Checking the chain, rear sprocket, engine sprocket, and chain guide
- 12.38 Checking the frame
- 12.39 Checking the link fork
- 12.40 Checking throttle cable routing
- 12.41 Checking the rubber grip
- 12.42 Adjusting the basic position of the clutch lever
- 12.43 Checking/correcting the fluid level of the hydraulic clutch
- 12.44 Changing the hydraulic clutch fluid
- 12.45 Removing the engine guard (All special models)
- 12.46 Installing the engine guard (All special models)
13 BRAKE SYSTEM
- 13.1 Checking the free travel of the hand brake lever
- 13.2 Adjusting the free travel of the handbrake lever (All EXC models)
- 13.3 Adjusting the basic position of the hand brake lever (All XCW models)
- 13.4 Checking the brake discs
- 13.5 Checking the front brake fluid level
- 13.6 Adding front brake fluid
- 13.7 Checking the front brake linings
- 13.8 Changing the brake linings of the front brake
- 13.9 Checking the free travel of foot brake lever
- 13.10 Adjusting the basic position of the foot brake lever
- 13.11 Checking the rear brake fluid level
- 13.12 Adding rear brake fluid
- 13.13 Checking the brake linings of the rear brake
- 13.14 Changing the brake linings of the rear brake
14 WHEELS, TIRES
- 14.1 Removing the front wheel
- 14.2 Installing the front wheel
- 14.3 Removing the rear wheel
- 14.4 Installing the rear wheel
- 14.5 Checking the tire condition
- 14.6 Checking tire pressure
- 14.7 Checking spoke tension
15 ELECTRICAL SYSTEM
- 15.1 Removing the 12-V battery
- 15.2 Installing the 12-V battery
- 15.3 Charging the 12-V battery
- 15.4 Changing main fuse
- 15.5 Changing the fuses of individual power consumers
- 15.6 Removing the headlight mask with the headlight
- 15.7 Installing the headlight mask with the headlight
- 15.8 Changing the headlight bulb
- 15.9 Changing the turn signal bulb (All EXC models)
- 15.10 Checking the headlight setting
- 15.11 Adjusting the headlight range
- 15.12 Changing the combination instrument battery
- 15.13 Diagnostics connector
16 COOLING SYSTEM
- 16.1 Cooling system
- 16.2 Checking the antifreeze and coolant level
- 16.3 Checking the coolant level
- 16.4 Draining the coolant
- 16.5 Refilling with coolant
17 TUNING THE ENGINE
- 17.1 Checking the throttle cable play
- 17.2 Adjusting the throttle cable play
- 17.3 Setting the characteristic map of the throttle response
- 17.4 Adjusting the idle speed
- 17.5 Programming ambient pressure
- 17.6 Ignition curve plug-in connector
- 17.7 Changing the ignition timing map (All standard EXC/XC-W models)
- 17.8 Checking the basic position of the shift lever
- 17.9 Adjusting the basic position of the shift lever
18 SERVICE WORK ON THE ENGINE
- 18.1 Changing the fuel screen
- 18.2 Checking 2-stroke oil level
- 18.3 Priming oil pump
- 18.4 Cleaning the oil screen in the oil tank
- 18.5 Checking the gear oil level
- 18.6 Changing the gear oil
- 18.7 Adding the gear oil
19 CLEANING, CARE
- 19.1 Cleaning the motorcycle
- 19.2 Checks and maintenance steps for winter operation
20 STORAGE
- 20.1 Storage
- 20.2 Preparing for use after storage
21 TROUBLESHOOTING
22 TECHNICAL DATA
- 22.1 Engine
  - 22.1.1 All 250 models
  - 22.1.2 All 300 models
- 22.2 Engine tightening torques
- 22.3 Capacities
  - 22.3.1 Gear oil
  - 22.3.2 Coolant
  - 22.3.3 Fuel
- 22.4 Chassis
- 22.5 Electrical system
- 22.6 Tires
- 22.7 Fork
  - 22.7.1 All standard EXC/XC-W models, All ERZBERGRODEO
  - 22.7.2 All Six Days models
- 22.8 Shock absorber
- 22.9 Chassis tightening torques
23 SUBSTANCES
24 AUXILIARY SUBSTANCES
25 STANDARDS
26 INDEX OF SPECIAL TERMS
27 LIST OF ABBREVIATIONS
28 LIST OF SYMBOLS
- 28.1 Red symbols
- 28.2 Yellow and orange symbols
- 28.3 Green and blue symbols
INDEX
- 1
- 2
- A
- B
- C
- D
- E
- F
- G
- H
- I
- K
- L
- M
- O
- P
- R
- S
- T
- U
- V
- W

KTM EXC 250 TPI 2020 Owner's Manual

KTM EXC 250 TPI 2020 Motorcycle manual cover

Pages 180

Year 2020

Language(s)

of 180

KTM EXC 250 TPI 2020 Motorcycle Specification

The KTM EXC 250 TPI 2020 is a state-of-the-art enduro motorcycle, characterized by its advanced two-stroke engine technology and innovative design. At its core lies the 249cc, single-cylinder, two-stroke, liquid-cooled engine featuring Transfer Port Injection (TPI) technology. This system optimizes fuel efficiency and reduces emissions while ensuring consistent power delivery across various terrains. The engine is paired with an electric starter and a six-speed transmission, offering seamless gear shifts and enhanced performance.

The chassis is constructed from high-strength chromium-molybdenum steel, providing a lightweight yet robust frame that enhances agility and stability. The suspension system consists of WP XPLOR 48 front forks and a WP XPLOR PDS rear shock absorber, both fully adjustable to accommodate diverse riding conditions. The braking system is equipped with Brembo hydraulic brakes, ensuring precise and responsive stopping power. The wheels are fitted with Metzeler 6 Days Extreme tires, designed to offer exceptional grip and durability in off-road environments.

Ergonomically, the KTM EXC 250 TPI 2020 features a comfortable seat, a slim profile, and an adjustable handlebar, catering to a wide range of rider preferences. The bike's bodywork is designed for easy maneuverability and includes a high-mounted front fender and minimalistic graphics, reflecting KTM's signature aesthetic. The fuel tank capacity is 9.5 liters, providing ample range for long rides. The KTM EXC 250 TPI 2020 is also equipped with a digital display that provides essential information such as speed, engine hours, and trip distance, ensuring riders are well-informed during their adventures. This motorcycle stands out as a technologically advanced and versatile choice for enduro enthusiasts.

KTM EXC 250 TPI 2020 Motorcycle F.A.Q.

What is the recommended oil type for the KTM EXC 250 TPI 2020?

The recommended oil for the KTM EXC 250 TPI 2020 is a high-quality two-stroke oil, such as Motorex Cross Power 2T.

How often should I change the air filter on my KTM EXC 250 TPI 2020?

The air filter should be checked after every ride and cleaned or replaced as necessary, especially if riding in dusty or muddy conditions.

What is the procedure for bleeding the brakes on the KTM EXC 250 TPI 2020?

To bleed the brakes, first ensure the brake fluid reservoir is full. Attach a clear hose to the bleeder valve, pump the brake lever, and open the valve to release air and old fluid. Close the valve and repeat until only fluid comes out.

How can I adjust the suspension on my KTM EXC 250 TPI 2020 for better performance?

Suspension can be adjusted by setting the preload, rebound, and compression damping according to your weight and riding style. Consult the owner's manual for specific adjustment settings.

What is the correct spark plug gap for the KTM EXC 250 TPI 2020?

The correct spark plug gap for the KTM EXC 250 TPI 2020 is 0.6 to 0.7 mm.

How do I troubleshoot starting issues with my KTM EXC 250 TPI 2020?

Check the battery charge, ensure the fuel supply is adequate, inspect the spark plug, and verify that the kill switch is in the 'run' position.

What tire pressure should I maintain for optimal performance on my KTM EXC 250 TPI 2020?

For off-road use, a tire pressure of 12-15 psi is typical, but always adjust according to the terrain and riding conditions.

How often should I replace the drive chain on my KTM EXC 250 TPI 2020?

The drive chain should be inspected regularly and replaced if there is excessive wear, rust, or damage. Typically, this is every 5,000 to 10,000 miles.

What is the best way to clean the KTM EXC 250 TPI 2020 after a ride?

Use a gentle stream of water to remove mud and dirt. Avoid high-pressure washers on bearings and seals. Use a mild detergent if necessary and dry the bike thoroughly to prevent rust.

How do I adjust the clutch lever on my KTM EXC 250 TPI 2020?

Loosen the lock nut on the clutch lever, adjust the screw to set the desired lever position, and then tighten the lock nut to secure the adjustment.