KTM 250 XC TPI 2020 Manual

SETUP INSTRUCTIONS 2020
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
300 EXC TPI ERZBERGRODEO
Art. no. 3214037en

INTRODUCTION
*3214037en*
3214037en
08/2019
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.
© 2019 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:
250 EXC TPI EU (F7303T7)
250 EXC Six Days TPI EU (F7303T2)
250 XC‑W TPI US (F7375T4)
300 EXC TPI EU (F7403T7)
300 EXC Six Days TPI EU (F7403T2)
300 XC‑W TPI US (F7475T3)
300 XC‑W Six Days TPI US (F7475T2)
300 EXC TPI ERZBERGRODEO EU (F7403T3)

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.
Info
The procedure in the event of missing parts is
described in the customer service manual.
–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.
Info
The procedure in the event of transport damage is
described in the customer service manual.
–Remove the headlight mask with the headlight. ( p. 35)

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 the separate enclosure and unpack it. Check that
the scope of supply is complete using the enclosed pack-
ing list.
Info
The procedure in the event of missing parts is
described in the customer service manual.
–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 for transport damage.
Info
The procedure in the event of transport damage is
described in the customer service manual.
–Install the shock absorber. ( p. 24)
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)

SETUP 2
5
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 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 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.

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 tighten-
ing.
S01415-10
(All Six Days models, 300 EXC TPI ERZBERGRODEO EU)
–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.
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.
Guideline
Screw, handlebar
clamp
M8 20 Nm
(14.8 lbf ft)

SETUP 2
7
Info
The markings on the handlebar should be at the
center of the handlebar clamps.
Keep the installed gap widths equal when tighten-
ing.
S03665-01
(All EXC models)
–Position the controls on the right half of the handlebar.
S03667-01
(All XC‑W models)
–Position the controls on the right half of the handlebar.
S03664-01
(All EXC models)
–Position the controls on the left handlebar half.
S03666-01
(All XC‑W models)
–Position the controls on the left handlebar half.

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
ties.

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
ties.
S01457-10
–Route the cable without tension and secure with cable ties and
cable holders.
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.
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. 35)
–Install the front wheel. ( p. 26)
–Remove the 12-V battery. ( p. 27)
–Charge the 12-V battery. ( p. 29)
(All XC‑W models)
–Install the headlight mask with the headlight. ( p. 36)
–Install the 12-V battery. ( p. 31)

SETUP 2
11
S03672-10
(All EXC models)
–Remove connector 6from the bracket and join with turn
signal wiring harness.
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.
–Connect the 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. 36)
–Remove the air filter box cover. ( p. 33)
–Remove the rear left side cover. ( p. 34)

2 SETUP
12
S03678-10
–Disconnect tail light plug-in connector bm on the wiring
harness.
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 bpon the license plate holder and hang
the tail light to the side.

SETUP 2
13
S03681-10
–Position the turn signal on both sides on the license plate
holder, mount nuts with washers and tighten.
–Position license plate lamp on the license plate holder,
and mount and tighten screws bq.
–Mount reflector br on license plate holder.
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.

2 SETUP
14
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)
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)

SETUP 2
15
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. 34)
–Install the air filter box cover. ( p. 33)
–Install the 12-V battery. ( p. 31)
R01229-10
–Position the right footrest and pin.
Info
Only insert the pin to the extent that the spring can still
be mounted.
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.

2 SETUP
16
S03695-10
–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.
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.

SETUP 2
17
S03695-10
–Mount the washer and splint cn.
S03696-11
–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 the washers.
Guideline
Screw, frame protec-
tor
M5 3 Nm (2.2 lbf ft)
–Mount the cable ties.
(All Six Days models, 300 EXC TPI ERZBERGRODEO EU)
–Install the engine guard. ( p. 38)
–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. 41)
–Adjust combination instrument function. ( p. 42)
–Set the clock. ( p. 42)
–Add 2-stroke oil. ( p. 38)
–Refuel. ( p. 40)
–Position all controls in their exact positions on the handlebar.
Tighten all screws.
–Remove the remaining plastic packaging, corrugated card-
board, and other packaging material.
–Prepare the vehicle according to the specifications in
KTM Dealer.net for handover to the customer.

2 SETUP
18
Info
Transport mode must be deactivated to be able to start
the motorcycle.