KTM 150 EXC TPI 2021

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Table of Contents4
Means of Representation8
Symbols Used8
Formats Used8
Safety Advice 29
Use Definition - Intended Use9
Misuse9
Degrees of Risk and Symbols10
Tampering Warning10
Safe Operation10
Protective Clothing11
Work Rules11
Environment11
Owner's Manual12
Important Notes 313
Manufacturer and Implied Warranty13
Fuel, Auxiliary Substances13
Spare Parts, Accessories13
Service13
Figures13
Customer Service13
View of Vehicle14
View of Vehicle, Front Left (Example)14
View of Vehicle, Rear Right (Example)15
Serial Numbers16
Vehicle Identification Number16
Type Label16
Key Number (150 EXC TPI EU)16
Engine Number16
Fork Part Number17
Shock Absorber Article Number17
Controls18
Clutch Lever18
Hand Brake Lever18
Throttle Grip18
Switch-Off Button (150 EXC TPI EU)18
Switch-Off Button (150 XC-WTPI US)19
Horn Button (150 EXC TPI EU)19
Light Switch (150 EXC TPI EU)19
Light Switch (150 XC-W TPI US)19
Turn Signal Switch (150 EXC TPI EU)20
Emergency off Switch (150 EXC TPI EU)20
Start Button20
Overview of Indicator Lamps (150 EXC TPI EU)21
Overview of Indicator Lamps (150 XC-W TPI US)21
Opening the Fuel Tank Filler Cap21
Closing the Fuel Tank Filler Cap22
Opening 2-Stroke Oil Tank Cap22
Closing 2-Stroke Oil Tank Cap23
Cold Start Button23
Idle Speed Adjusting Screw24
Shift Lever24
Kick Starter Lever25
Foot Brake Lever25
Side Stand25
Steering Lock (150 EXC TPI EU)26
Locking the Steering (150 EXC TPI EU)26
Unlocking the Steering (150 EXC TPI EU)26
Combination Instrument 727
Combination Instrument Overview27
Activation and Test27
Setting the Kilometers or Miles27
Adjusting Combination Instrument Function28
Setting the Clock29
Viewing the Lap Time29
Display Mode SPEED (Speed)30
Display Mode SPEED/H (Operating Hours)30
Setup Menu30
Adjusting the Unit of Measurement31
Display Mode SPEED/CLK (Time)32
Setting the Clock32
Display Mode SPEED/LAP (Lap Time)32
Viewing the Lap Time33
Display Mode SPEED/ODO (Odometer)33
Display Mode SPEED/TR1 (Trip Master 1)34
Display Mode SPEED/TR2 (Trip Master 2)34
Adjusting TR2 (Trip Master 2)34
Display Mode SPEED/A1 (Average Speed 1)35
Display Mode SPEED/A2 (Average Speed 2)35
Display Mode SPEED/S1 (Stop Watch 1)36
Display Mode SPEED/S2 (Stop Watch 2)36
Table of Functions37
Table of Conditions and Menu Activation38
Preparing for Use 839
Advice on Preparing for First Use39
Running in the Engine40
Starting Power of Lithium-Ion Batteries at Low Temperatures41
Preparing the Vehicle for Difficult Operating Conditions41
Preparing the Vehicle for Riding on Dry Sand41
Preparing the Vehicle for Riding on Wet Sand43
Preparing the Vehicle for Riding on Wet and Muddy Circuits44
Preparing Vehicle for High Temperatures or Slow Riding44
Preparing the Vehicle for Low Temperatures or Snow45
Riding Instructions46
Checks and Maintenance Measures When Preparing for Use46
Starting the Vehicle46
Starting off47
Shifting, Riding47
Braking48
Stopping, Parking49
Transporting49
Refueling50
Adding 2-Stroke Oil51
10 Service Schedule52
Additional Information52
Required Work52
Recommended Work53
Tuning the Chassis 1155
Checking the Basic Chassis Setting with the Rider's Weight55
Compression Damping of the Shock Absorber55
Adjusting the Low-Speed Compression Damping of the Shock Absorber55
Adjusting the High-Speed Compression Damping of the Shock Absorber56
Adjusting the Rebound Damping of the Shock Absorber57
Measuring the Dimension of the Rear Wheel Unloaded57
Checking the Static Sag of the Shock Absorber58
Checking the Riding Sag of the Shock Absorber58
Adjusting the Spring Preload of the Shock Absorber59
Adjusting the Riding Sag60
Checking the Basic Setting of the Fork60
Adjusting the Compression Damping of the Fork61
Adjusting the Rebound Damping of the Fork61
Handlebar Position62
Adjusting the Handlebar Position62
12 Service Work on the Chassis64
Raising the Motorcycle with a Lift Stand64
Removing the Motorcycle from the Lift Stand64
Bleeding the Fork Legs64
Cleaning the Dust Boots of the Fork Legs65
Removing the Fork Protector65
Installing the Fork Protector66
Removing the Fork Legs66
Installing the Fork Legs67
Removing the Lower Triple Clamp67
Installing the Lower Triple Clamp68
Checking Steering Head Bearing Play70
Adjusting the Steering Head Bearing Play71
Lubricating the Steering Head Bearing72
Removing Front Fender72
Installing Front Fender72
Removing the Shock Absorber73
Installing the Shock Absorber73
Removing the Seat74
Mounting the Seat74
Removing the Air Filter Box Cover75
Installing the Air Filter Box Cover75
Removing the Air Filter76
Installing the Air Filter76
Cleaning the Air Filter and Air Filter Box77
Preparing Air Filter Box Cover for Securing77
Removing the Main Silencer78
Installing the Main Silencer78
Changing the Glass Fiber Yarn Filling in the Main Silencer78
Removing the Fuel Tank79
Installing the Fuel Tank81
Checking the Chain for Dirt82
Cleaning the Chain83
Checking the Chain Tension83
Adjusting the Chain Tension84
Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide85
Checking the Frame88
Checking the Link Fork88
Checking Throttle Cable Routing88
Checking the Rubber Grip89
Adjusting the Basic Position of the Clutch Lever89
Checking/Correcting the Fluid Level of the Hydraulic Clutch90
Changing the Hydraulic Clutch Fluid91
Removing Engine Guard92
Installing the Engine Guard92
Brake System 1393
Checking the Free Travel of the Hand Brake Lever93
Adjusting the Free Travel of the Handbrake Lever (150 EXC TPI EU)93
Adjusting the Basic Position of the Hand Brake Lever (150 XC-WTPI US)94
Checking the Brake Discs94
Checking the Front Brake Fluid Level95
Adding Front Brake Fluid95
Checking the Front Brake Linings96
Changing the Brake Linings of the Front Brake97
Checking the Free Travel of Foot Brake Lever99
Adjusting the Basic Position of the Foot Brake Lever99
Checking the Rear Brake Fluid Level100
Adding Rear Brake Fluid101
Checking the Brake Linings of the Rear Brake102
Changing the Brake Linings of the Rear Brake102
Wheels, Tires 14105
Removing the Front Wheel105
Installing the Front Wheel106
Removing the Rear Wheel106
Installing the Rear Wheel107
Checking the Tire Condition109
Checking Tire Pressure109
Checking Spoke Tension110
Electrical System 15111
Removing the 12-V Battery111
Installing the 12-V Battery113
Charging the 12-V Battery114
Changing Main Fuse116
Changing the Fuses of Individual Power Consumers117
Removing the Headlight Mask with the Headlight119
Installing the Headlight Mask with the Headlight119
Changing the Headlight Bulb120
Changing the Turn Signal Bulb (150 EXC TPI EU)121
Checking the Headlight Setting121
Adjusting the Headlight Range122
Changing the Combination Instrument Battery122
Diagnostics Connector123
16 Cooling System124
Checking the Antifreeze and Coolant Level124
Checking the Coolant Level125
Draining the Coolant125
Refilling with Coolant126
Changing the Coolant128
17 Tuning the Engine130
Checking the Throttle Cable Play130
Adjusting the Throttle Cable Play130
Setting the Characteristic Map of the Throttle Response131
Adjusting the Idle Speed132
Programming Ambient Air Pressure133
Ignition Curve Plug-In Connector134
Changing the Ignition Timing Map134
Checking the Basic Position of the Shift Lever135
Adjusting the Basic Position of the Shift Lever135
18 Service Work on the Engine136
Changing the Fuel Screen136
Checking 2-Stroke Oil Level137
Priming Oil Pump137
Cleaning the Oil Screen in the Oil Tank139
Checking the Gear Oil Level142
Changing the Gear Oil142
Adding the Gear Oil144
Cleaning, Care 19145
Cleaning the Motorcycle145
Checks and Maintenance Steps for Winter Operation146
Storage 20147
Preparing for Use after Storage148
Troubleshooting 21149
22 Blink Code152
23 Technical Data154
Engine154
Engine Tightening Torques154
Capacities156
Gear Oil156
Coolant156
Fuel156
Chassis156
Electrical System157
Tires157
Fork158
Shock Absorber158
Chassis Tightening Torques159
Substances 24161
Auxiliary Substances 25163
Standards 26165
27 Index of Special Terms166
List of Abbreviations 28167
29 List of Symbols168
Red Symbols168
Yellow and Orange Symbols168
Green and Blue Symbols168
Index169

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KTM 150 EXC TPI 2021 - Page 2

Table of Contents

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