KTM 250 EXC TPI 2019 Manual

SETUP INSTRUCTIONS 2019
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
Art. no. 3213896en

INTRODUCTION
*3213896en*
3213896en
03/2018
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 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 production of a particular
model without prior notice. KTM accepts no liability for delivery options, deviations from figures and descriptions,
misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the
regular scope of supply.
© 2018 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)
According to the international quality management standard ISO 9001, KTM uses quality assur-
ance processes that lead to the maximum possible quality of the products.
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 (F7303S7)
250 EXC Six Days TPI EU (F7303S2)
250 XC‑W TPI US (F7375S4)
300 EXC TPI EU (F7403S7)
300 EXC Six Days TPI EU (F7403S2)
300 XC‑W TPI US (F7475S3)
300 XC‑W Six Days TPI US (F7475S2)

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. 30)

2 SETUP
4
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 and unpack the separate enclosure and attach-
ments. 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 attachments for transport damage.
–Install the shock absorber. ( p. 24)
H02474-10
(All EXC models)
–Position the turn signal indicator lamp 1in the com-
bination instrument bracket.

SETUP 2
5
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)
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 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.

2 SETUP
6
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)
Info
The markings on the handlebar should be at the
center of the handlebar clamps.
Keep the gap widths equal when tightening.
S01415-10
(All Six Days models)
–Remove screws 3and take off 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.

SETUP 2
7
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 gap widths equal when tightening.
F01132-01
(All EXC models)
–Position the controls on the right half of the handlebar.
F01136-01
(All XC‑W models)
–Position the controls on the right half of the handlebar.
S01453-01
(All EXC models)
–Position the controls on the left half of the handlebar.
S01454-01
(All XC‑W models)
–Position the controls on the left half of the handlebar.

2 SETUP
8
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
tie.

SETUP 2
9
F01134-10
(All XC‑W models)
–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 cable
tie.
S01457-10
–Route the cable without tension and secure with cable ties and
cable holder.
H01060-01
(All EXC models)
–Mount the mirror clamps on both sides.
E01231-10
–Mount both rear mirrors with the adapter.

2 SETUP
10
E00852-01
–Preassemble the hand guards on the left and right.
E01232-10
–Mount the left hand guard.
–Mount the right hand guard.
F01135-10
–Secure the handlebar cushion with two cable ties.
–Install front fender. ( p. 29)
–Install the front wheel. ( p. 26)
–Remove the battery. ( p. 26)
–Recharge the battery. ( p. 27)
(All XC‑W models)
–Install the headlight mask with the headlight. ( p. 30)
–Install the battery. ( p. 29)
(All EXC models)
–Remove the fuel tank. ( p. 20)

SETUP 2
11
F01140-10
–Position turn signal cable harness.
–Insert the indicator lamp with the black and violet cable
colors into socket 6.
F01139-10
–Position turn signal on the headlight mask on both sides,
mount nuts with washers and tighten.
–Connect the plug-in connector 7of the left turn signal
using the violet and brown cable colors of the turn signal
cable harness.
–Connect the plug-in connector 8of the right turn signal
using the black and brown cable colors of the turn signal
cable harness.
Info
Pay attention to where the brake line is routed when
doing so.
–Connect 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. 30)
F01141-10
–Pull the EFI control unit bm upward off the rubber
plugs bn and hang to the side.
–Remove holding bracket bo and hang to the side.
F01142-10
–Route the turn signal cable harness from the front to the
rear as far as the battery compartment.
–Position and secure turn signal cable harness using cable
ties to the main wiring harness under the rubber bands of
fuel tank support.

2 SETUP
12
F01143-10
–Remove screw bp.
–Remove screw bq.
–Pull off the side cover in area Aand area Band remove
it toward the rear.
F01144-10
–Remove screws br with the washers.
–Pull off the main silencer at the rubber sleeve bs and the
spring ring from the manifold.
F01157-10
–Disconnect the plug-in connector bt on the main wiring
harness.
–Join turn signal cable harness plug-in connector to the
main wiring harness plug-in connector.
F01145-10
–Remove screw ck with the collar bushing.
–Remove screw cl.
–Remove screw cm with negative cable and contact disk.

SETUP 2
13
F01146-10
–Remove screws cn.
–Remove screws co with the washers.
–Carefully pull the tail light cable out of the frame, paying
attention to the plug as you do so.
–Take off license plate holder with tail light toward the rear.
F01147-10
–Remove screws cp and hang the tail light to the side.
–Drill a hole at the marking Cto the size of the marking.
F01158-10
–Route the turn signal cable harness toward the rear and
pass through the frame paying attention to the plugs as
you do so.
–Route turn signal cable harness on the license plate holder
and pass turn signal cable harness through the drill hole.
–Position tail light on license plate holder, and mount and
tighten screws cp.

2 SETUP
14
F01148-10
–Carefully pass the tail light cable through the frame, pay-
ing attention to the plug as you do so.
–Position license plate holder on the rear.
–Mount and tighten screws co with the washers.
F01145-10
–Mount and tighten screw ck with the collar bushing.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
–Mount and tighten screw cl.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
–Mount and tighten screw cm with negative cable and con-
tact disk.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
F01159-10
–Connect the tail light plug-in connector to the main wiring
harness plug-in connector.

SETUP 2
15
F01141-10
–Mount holding bracket bo.
–Mount the EFI control unit bmon the rubber lugs bn.
Info
The wiring harness runs under the EFI control unit.
–Position the turn signal cable harness and main wiring har-
ness and secure with cable ties.
F01144-10
–Mount the main silencer with the rubber sleeve bs and
spring ring.
–Mount and tighten screws br with the washers.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
F01143-10
–Attach the side cover in area Aand engage it in area B.
–Mount and tighten screw bq.
Guideline
Screw, sub-
frame
M8 35 Nm (25.8 lbf ft)
Loctite®2701™
–Mount and tighten screw bp.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
–Install the battery. ( p. 29)
–Install the fuel tank. ( p. 22)
F01149-10
–Position turn signal on both sides, mount nuts with wash-
ers and tighten.
–Position license plate lamp on the license plate holder,
and mount and tighten screws cq.
–Mount reflector cr on license plate holder.
–Pass cable through the license plate holder.
F01150-10
–Position license plate holder on the license plate holder.
–Join the plug-in connector of the license plate lamp.
–Connect the plug-in connector of the left turn signal which
is marked red.
–Connect the plug-in connector of the right turn signal
which is marked green.
–Mount and tighten screws cn.

2 SETUP
16
R01229-10
–Position the right footrest and pin.
Info
When inserting the pin, leave enough space to mount
the spring.
F01151-10
–Position spring as shown.
Spring Dengages in area E.
F01152-10
–Press the spring with special tool cs.
Footrest spring plier (79029083000)
The special tool is applied to area Fon the footrest.
–Mount pin ct.
F01153-10
–Mount the washer and split pin dk.

SETUP 2
17
R00757-10
–Position the left footrest and pin.
Info
When inserting the pin, leave enough space to mount
the spring.
F01154-10
–Position spring as shown.
Spring Gengages in area H.
F01155-10
–Press the spring with special tool cs.
Footrest spring plier (79029083000)
The special tool is applied to area Ion the footrest.
–Mount pin dl.
F01156-10
–Mount the washer and split pin dm.

2 SETUP
18
F01160-10
–Position the frame protectors on both sides.
–Mount and tighten screws dn.
Guideline
Screw, frame protec-
tor
M5 3 Nm (2.2 lbf ft)
–Mount and tighten screws do with the washers.
Guideline
Screw, frame protec-
tor
M5 3 Nm (2.2 lbf ft)
–Mount the cable tie(s).
(All Six Days models)
–Install the engine guard. ( p. 32)
–Unpack and mount the KTM PowerParts included in the deliv-
ery (optional).
Info
Read the accompanying KTM PowerParts fitting instruc-
tions.
–Apply the sticker included in the delivery (optional).
–Set kilometers or miles. ( p. 35)
–Adjust the combination instrument function. ( p. 36)
–Set the clock. ( p. 37)
–Add 2-stroke oil. ( p. 33)
–Refuel. ( p. 34)
–Position all controls in their exact positions on the handlebar.
Tighten all screws.
–Prepare the vehicle according to the specifications in the
KTM Dealer.net for handover to the customer.
Info
Transport mode must be deactivated to be able to start
the motorcycle.