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.