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 warranty, 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 Adjusting 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 the 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 Standard and 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 the 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
- 16.6 Changing the coolant
17 TUNING THE ENGINE
- 17.1 Checking the play in the throttle cable
- 17.2 Adjusting the play in the throttle cable
- 17.3 Setting the characteristic map of the throttle response
- 17.4 Adjusting the idle speed
- 17.5 Programming ambient air 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 BLINK CODE
23 TECHNICAL DATA
- 23.1 Engine
  - 23.1.1 All 250 models
  - 23.1.2 All 300 models
- 23.2 Engine tightening torques
- 23.3 Capacities
  - 23.3.1 Gear oil
  - 23.3.2 Coolant
  - 23.3.3 Fuel
- 23.4 Chassis
- 23.5 Electrical system
- 23.6 Tires
- 23.7 Fork
- 23.8 Shock absorber
- 23.9 Chassis tightening torques
24 SUBSTANCES
25 AUXILIARY SUBSTANCES
26 STANDARDS
27 INDEX OF SPECIAL TERMS
28 LIST OF ABBREVIATIONS
29 LIST OF SYMBOLS
- 29.1 Red symbols
- 29.2 Yellow and orange symbols
- 29.3 Green and blue symbols
INDEX
- 1
- 2
- A
- B
- C
- D
- E
- F
- G
- H
- I
- K
- L
- M
- O
- P
- R
- S
- T
- V
- W

KTM EXC 250 TPI 2021 Owner's Manual

KTM EXC 250 TPI 2021 Motorcycle manual cover

Pages 182

Year 2021

Language(s)

of 182

KTM EXC 250 TPI 2021 Motorcycle Specification

The KTM EXC 250 TPI 2021 is a high-performance enduro motorcycle engineered for demanding off-road conditions. It is powered by a 249cc, single-cylinder, two-stroke engine equipped with Transfer Port Injection (TPI) technology. This advanced fuel injection system enhances fuel efficiency and ensures smoother power delivery while minimizing emissions. The engine features a counter-balancer shaft to reduce vibrations, improving rider comfort.

The bike's chassis is constructed from lightweight chromium-molybdenum steel, providing an optimal balance of rigidity and flexibility. The frame design allows for precise handling and stability on challenging terrains. The suspension system includes WP XPLOR front forks and a WP XPLOR PDS rear shock, both fully adjustable to accommodate different riding styles and conditions.

Braking is handled by high-performance Brembo calipers paired with wave discs, offering exceptional stopping power and control. The KTM EXC 250 TPI 2021 is equipped with an electric starter and a lithium-ion battery, ensuring reliable and quick engine ignition. The motorcycle also features a robust 6-speed transmission optimized for enduro riding, facilitating smooth gear transitions and maintaining power across various speeds.

The bodywork is ergonomically designed to provide maximum rider comfort and ease of movement. The bike includes a compact headlight and a multifunctional digital display for essential riding information. The airbox design allows for quick and easy filter changes, enhancing maintenance efficiency. The KTM EXC 250 TPI 2021 is finished with high-quality graphics and a durable seat cover, combining aesthetics with functionality. This motorcycle represents a blend of cutting-edge technology and practical design, making it a top choice for enduro enthusiasts.

KTM EXC 250 TPI 2021 Motorcycle F.A.Q.

How do I perform a basic oil change on the KTM EXC 250 TPI 2021?

To perform an oil change on your KTM EXC 250 TPI, first warm up the engine for a few minutes. Turn the engine off and place the bike on a stand. Remove the oil drain bolt located underneath the engine and drain the oil into a pan. Replace the drain bolt and tighten it securely. Remove the oil filter cover and replace the oil filter with a new one. Refill the engine with the recommended oil type and quantity. Start the engine and check for leaks.

What type of fuel should I use for the KTM EXC 250 TPI 2021?

The KTM EXC 250 TPI 2021 is designed to run on high-octane, premium unleaded gasoline with a minimum octane rating of 91 RON / 87 AKI. Using the correct fuel type ensures optimal performance and engine longevity.

How can I troubleshoot starting issues with my KTM EXC 250 TPI 2021?

If your KTM EXC 250 TPI is having trouble starting, check the following: ensure the fuel tank has fuel, verify the battery charge, check the spark plug for wear or fouling, ensure the fuel pump is functioning, and inspect the air filter for clogs. If the issue persists, consult a professional mechanic.

What is the recommended maintenance schedule for the KTM EXC 250 TPI 2021?

The recommended maintenance schedule includes: checking and cleaning the air filter every ride, changing the oil and oil filter every 15 hours or 500 km, inspecting the brake system every 30 hours, checking the chain tension and lubrication every ride, and performing a full service every 100 hours. Always consult the owner's manual for specific intervals and procedures.

How do I adjust the suspension on my KTM EXC 250 TPI 2021?

To adjust the suspension, start by setting the sag for your weight. Use the compression and rebound adjusters on the front forks and rear shock to fine-tune the ride. For the front forks, adjust the clickers at the top and bottom of the fork legs. For the rear shock, adjust the compression and rebound using the clickers on the shock body. Refer to the owner's manual for detailed settings based on your riding style and conditions.

What should I do if the KTM EXC 250 TPI 2021 engine overheats?

If the engine overheats, stop the bike immediately and let it cool down. Check the coolant level and top up if necessary. Inspect the radiator for blockages and clean if needed. Ensure the radiator cap is functioning properly. Additionally, check for any leaks in the cooling system. If the problem continues, have the cooling system inspected by a professional.

How do I clean the air filter on my KTM EXC 250 TPI 2021?

To clean the air filter, remove the seat and take out the air filter from the airbox. Wash the filter in warm, soapy water and rinse thoroughly. Allow it to dry completely before applying air filter oil evenly across the surface. Reinstall the air filter in the airbox and secure it properly. Regular cleaning ensures optimal engine performance.

How can I improve the fuel efficiency of my KTM EXC 250 TPI 2021?

To improve fuel efficiency, ensure the bike is properly maintained: keep the air filter clean, use the recommended oil, ensure the tires are inflated to the correct pressure, and adjust the chain tension correctly. Riding smoothly and avoiding aggressive throttle inputs can also help increase fuel efficiency.

What are some common issues with the electrical system of the KTM EXC 250 TPI 2021?

Common electrical issues may include a dead battery, faulty connections, or a malfunctioning starter. Regularly check the battery terminals for corrosion, inspect wiring for damage, and ensure all connections are secure. Keep the battery charged and consider using a battery tender for prolonged periods of inactivity.

How do I properly store the KTM EXC 250 TPI 2021 during winter?

For winter storage, clean the bike thoroughly and apply a protective wax. Drain the fuel tank or add a fuel stabilizer. Change the oil and oil filter. Remove the battery and keep it on a trickle charger. Store the bike in a cool, dry place and cover it to protect against dust. Check tire pressure and consider placing the bike on a stand to prevent flat spots on the tires.