KTM 150 EXC TPI 2021 Manual

SETUP INSTRUCTIONS 2021
150 EXC TPI
150 XC‑W TPI
Art. no. 3214371en

INTRODUCTION
*3214371en*
3214371en
02/2021
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.
© 2021 KTM Sportmotorcycle GmbH, Mattighofen Austria
All rights reserved
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:
150 EXC TPI EU (F7103U6)
150 XC‑W TPI US (F7175U3)

1 MEANS OF REPRESENTATION
2
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
3
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.
–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.
–Remove the headlight mask with the headlight. ( p. 32)

2 SETUP
4
H02474-10
(150 EXC TPI EU)
–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 and unpack the separate enclosure and compo-
nents. Check that the scope of supply is complete using
the enclosed packing list.
–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 and components for transport damage.
–Install the shock absorber. ( p. 22)
H02537-10
(150 EXC TPI EU)
–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
5
H02538-10
(150 XC‑W TPI US)
–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. 23)
S01414-10
–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 damaged
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
6
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 tightening.
S03665-01
(150 EXC TPI EU)
–Position the controls on the right half of the handlebar.
S03667-01
(150 XC‑W TPI US)
–Position the controls on the right half of the handlebar.
S03664-01
(150 EXC TPI EU)
–Position the controls on the left handlebar half.
S03666-01
(150 XC‑W TPI US)
–Position the controls on the left handlebar half.

SETUP 2
7
402148-01
(150 EXC TPI EU)
–Mount the turn signal switch.
F01133-10
Condition
Packaging V12
(150 EXC TPI EU)
–Insert indicator lamp 4in the socket.
–Join all plug-in connectors to the plug-in holder.
–Route the cable without tension and secure with the
cable ties.
F01134-10
(150 XC‑W TPI US)
–Insert indicator lamp 4in the socket.
–Plug in light pull switch 5with the yellow and white
cables.
–Join all plug-in connectors.
–Route the cable without tension and secure with the
cable ties.
S01457-10
–Route the cable without tension and secure with cable ties and
cable holders.

2 SETUP
8
H01060-01
(150 EXC TPI EU)
–Mount the mirror clamps on both sides.
E01231-10
–Mount both rear mirrors with the adapter.
E00852-01
–Preassemble the hand guards on the left and right.

SETUP 2
9
S03689-10
–Mount the left hand guard.
–Mount the right hand guard.
F01135-10
–Secure the handlebar cushion with two cable ties.
–Install front fender. ( p. 31)
–Install the front wheel. ( p. 23)
–Remove the 12-V battery. ( p. 24)
–Charge the 12-V battery. ( p. 26)
(150 XC‑W TPI US)
–Install the headlight mask with the headlight. ( p. 33)
–Install the 12-V battery. ( p. 28)
S03672-10
(150 EXC TPI EU)
–Remove connector 6from the bracket and join with turn
signal wiring harness.

2 SETUP
10
S03673-01
–Insert the black and violet cables of bulb included in the
separate enclosure into the socket and position it in the
turn signal indicator lamp.
S03677-10
–Position the turn signal on the headlight mask on both
sides, mount nuts with washers and tighten.
–Join plug-in connector 7of the left turn signal using the
violet and brown cable colors of the turn signal cable har-
ness.
–Join plug-in connector 8of the right turn signal using
the black and brown cable colors of the turn signal cable
harness.
–Join plug-in connector 9of the headlight.
–Connect plug-in connector bk of the turn signal switch.
–Secure turn signal relay bl with a cable tie and plug in
the connector.
–Install the headlight mask with the headlight. ( p. 33)
–Remove the air filter box cover. ( p. 30)
–Remove the rear left side cover. ( p. 31)
S03678-10
–Disconnect tail light plug-in connector bm on the wiring
harness.

SETUP 2
11
S03679-10
–Remove screws bn.
–Remove screws bo.
–Remove the license plate holder with the tail light.
Info
Pay attention to the cable of the tail light.
–Feed the cable between the fairing parts.
S03680-10
–Remove screws bp on the license plate holder and hang
the tail light to the side.
S03681-10
–Position the turn signal on both sides on the license plate
holder, mount nuts with washers and tighten.
–Position the license plate lamp on the license plate holder,
and mount and tighten screws bq.
–Mount reflector br on license plate holder.

2 SETUP
12
S03682-01
–Drill a hole at marking Aon the license plate holder to
the size of the marking.
S03683-10
–Position the tail light together with the license plate holder
on the license plate bracket.
Info
Ensure that the cables are routed correctly.
S03680-10
–Mount and tighten screws bp.
Guideline
Remaining screws,
chassis
EJOT PT®
K60x25‑Z
2 Nm (1.5 lbf ft)
S03687-10
–Mount and tighten screw bs.
Guideline
Remaining screws,
chassis
EJOT PT®
K60x25‑Z
2 Nm (1.5 lbf ft)

SETUP 2
13
S03684-01
–Feed the wiring harnesses through the opening.
–Position the license plate holder on the rear.
S03685-10
–Mount and tighten screw bn with the collar bushing.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
–Mount and tighten screw bo.
Guideline
Remaining screws,
chassis
EJOT PT®
K60x25‑Z
2 Nm (1.5 lbf ft)
S03686-10
–Join the plug-in connectors of tail light bt and turn signal
cable harness ck with the wiring harness.
Info
Pay attention to routing of the wiring harnesses.
–Install the rear left side cover. ( p. 31)
–Install the air filter box cover. ( p. 30)
–Install the 12-V battery. ( p. 28)
R01229-10
–Position the right footrest and pin.
Info
Only insert the pin to the extent that the spring can still
be mounted.

2 SETUP
14
S03690-10
–Position spring as shown.
Spring Bengages in area C.
S03691-10
–Press the spring with special tool cl.
Footrest spring plier (79029083000)
The special tool is applied to area Don the footrest.
–Mount pin cm.
S03692-10
–Mount the washer and splint cn.
R00757-10
–Position the left footrest and pin.
Info
Only insert the pin to the extent that the spring can still
be mounted.

SETUP 2
15
S03693-10
–Position spring as shown.
Spring Eengages in area F.
S03694-10
–Press the spring with special tool cl.
Footrest spring plier (79029083000)
The special tool is applied to area Gon the footrest.
–Mount pin cm.
S03695-10
–Mount the washer and splint cn.
S03696-10
–Position the frame protectors on both sides.
–Hook in the frame protector in area J.
–Mount and tighten screws co.
Guideline
Screw, frame protec-
tor
M5 3 Nm (2.2 lbf ft)
–Mount and tighten screws cp with washers.
Guideline
Screw, frame protec-
tor
M5 3 Nm (2.2 lbf ft)
–Mount the cable ties.
–Install the engine guard. ( p. 34)

2 SETUP
16
–Unpack and mount the KTM PowerParts included in the deliv-
ery (optional).
Info
Read the accompanying KTM PowerParts fitting instruc-
tions.
–Make sure that the reflectors are glued on to the left and right
fork leg.
H02556-01
Info
The reflectors must not be covered by trim parts.
–Attach the stickers included in the scope of supply (optional).
–Set the kilometers or miles. ( p. 37)
–Adjust combination instrument function. ( p. 38)
–Set the clock. ( p. 39)
–Add 2-stroke oil. ( p. 35)
–Refuel. ( p. 36)
–Position all controls in their exact positions on the handlebar.
Tighten all screws.
–Remove the remaining film, padding, the corrugated card-
board, and the other packaging material.
–Prepare the vehicle according to the specifications in
KTM Dealer.net for handover to the customer.
Info
Transport mode must be deactivated to be able to start
the motorcycle.

WORK 3
17
3.1 Raising the motorcycle with a lift stand
401942-01
Note
Danger of damage The parked vehicle can roll away or fall
over.
–Park the vehicle on a firm and level surface.
–Raise the motorcycle at the frame underneath the engine.
Lift stand (78129955100)
Neither wheel is in contact with the ground.
–Secure the motorcycle against falling over.
3.2 Removing the motorcycle from the lift stand
Note
Danger of damage The parked vehicle can roll away or fall over.
–Park the vehicle on a firm and level surface.
401943-10
–Remove the motorcycle from the lift stand.
–Remove the lift stand.
–To park the motorcycle, press side stand 1to the ground
with your foot and lean the motorcycle on it.
Info
When you are riding, the side stand must be folded up
and secured with the rubber strap.
3.3 Removing the seat
S03480-10
–Remove screws 1on the left side.
H02218-10
–Raise the rear of the seat, pull the seat back, and lift it off.

3 WORK
18
3.4 Mounting the seat
H02218-11
–Mount the front of the seat on the two collar bushings of the
fuel tank, lower the seat at the rear, and push the seat forward.
–Make sure the seat is latched in place correctly.
S03480-10
–Mount and tighten screw 1on the left side.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
3.5 Removing the fuel tank
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.
–Keep fuels correctly in a suitable canister, and out of the reach of children.
Preparatory work
–Remove the seat. ( p. 17)