KTM 150 EXC TPI 2022 User Manual

OWNER'S MANUAL 2022
150 EXC TPI
150 XC‑W TPI
Art. no. 3214420en

KTM 150 EXC TPI 2022 Specifications

General

Bore x Stroke	58 mm x 54.5 mm
Transmission	6-speed
Seat Height	960 mm
Front Suspension	WP XPLOR 48
Rear Suspension	WP XPLOR PDS
Brakes	Disc brakes
Wheel Size (Front)	21 inches
Wheel Size (Rear)	18 inches
Starter	Electric starter
Front Brake	260 mm disc
Rear Brake	220 mm disc
Engine Type	1-cylinder, 2-stroke engine
Displacement	143.99 cc
Fuel System	Transfer Port Injection (TPI)
Cooling	Liquid-cooled
Fuel Tank Capacity	9 l

Summary

Safety Advice

Use Definition - Intended Use

Defines the intended use of the 150 EXC TPI EU and 150 XC-W TPI models.

Misuse

Describes dangers arising from using the vehicle not as intended.

Degrees of Risk and Symbols

Explains the meaning of danger, warning, caution, and note symbols.

Safe Operation

Provides crucial safety advice regarding riding fitness and exhaust fumes.

Protective Clothing

Highlights the increased safety risk from missing or poor protective clothing.

Work Rules

Owner's Manual

Stresses reading the manual carefully for operation, handling, and service.

Important Notes

Service

Emphasizes proper service for operation, wear prevention, and longevity.

Controls

Stop Button (150 EXC TPI EU)

Emergency OFF Switch (150 EXC TPI EU)

Overview of Indicator Lamps (150 EXC TPI EU)

Lists and describes the function of various indicator lamps on the dashboard.

Idle Speed Adjusting Screw

Locking the Steering (150 EXC TPI EU)

Unlocking the Steering (150 EXC TPI EU)

Combination Instrument

Display mode SPEED/ODO (Odometer)

Display mode SPEED/TR1 (Trip Master 1)

Preparing for Use

Advice on Preparing for First Use

Provides critical safety advice and initial checks before first use.

Running in the Engine

Explains the engine break-in procedure and performance limits.

Preparing the Vehicle for Difficult Operating Conditions

Advises on preparing the vehicle for challenging conditions like sand or mud.

Preparing the Vehicle for Riding on Dry Sand

Preparing the Vehicle for Riding on Wet Sand

Preparing Vehicle for High Temperatures or Slow Riding

Preparing the Vehicle for Low Temperatures or Snow

Riding Instructions

Checks and Maintenance Measures When Preparing for Use

Lists essential pre-ride checks for safety and operability.

Starting the Vehicle

Provides instructions and warnings for starting the engine.

Starting Off

Guides on how to safely start moving the motorcycle.

Shifting, Riding

Explains shifting gears and general riding techniques, including warnings.

Braking

Provides important warnings and advice on proper braking techniques.

Stopping, Parking

Refueling

Covers safety warnings and procedures for refueling the vehicle.

Adding 2-Stroke Oil

Explains how to add 2-stroke oil and potential engine failure warnings.

Service Schedule

Required Work

Lists mandatory maintenance tasks at specified intervals.

Recommended Work

Lists recommended maintenance tasks for optimal performance and longevity.

Tuning the Chassis

Checking the Basic Chassis Setting with the Rider's Weight

Adjusting the Low-Speed Compression Damping of the Shock Absorber

Provides instructions for adjusting the shock absorber's low-speed compression.

Adjusting the High-Speed Compression Damping of the Shock Absorber

Details how to adjust the shock absorber's high-speed compression.

Adjusting the Rebound Damping of the Shock Absorber

Explains the procedure for adjusting the shock absorber's rebound damping.

Checking the Static Sag of the Shock Absorber

Checking the Riding Sag of the Shock Absorber

Adjusting the Spring Preload of the Shock Absorber

Provides instructions for adjusting the shock absorber's spring preload.

Adjusting the Compression Damping of the Fork

Details how to adjust the fork's compression damping.

Adjusting the Rebound Damping of the Fork

Explains how to adjust the fork's rebound damping.

Adjusting the Spring Preload of the Fork

Guides on adjusting the spring preload for the fork.

Adjusting the Handlebar Position

Service Work on the Chassis

Checking Steering Head Bearing Play

Adjusting the Steering Head Bearing Play

Removing the Air Filter

Installing the Air Filter

Cleaning the Air Filter and Air Filter Box

Removing the Fuel Tank

Provides detailed instructions and safety warnings for removing the fuel tank.

Installing the Fuel Tank

Details the procedure and safety warnings for installing the fuel tank.

Cleaning the Chain

Checking the Chain Tension

Details the importance of correct chain tension and potential consequences of incorrect tension.

Adjusting the Chain Tension

Provides instructions for adjusting the drive chain tension correctly.

Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide

Checking the chain, rear sprocket, engine sprocket, and chain guide

Checking/Correcting the Fluid Level of the Hydraulic Clutch

Changing the Hydraulic Clutch Fluid

Brake System

Checking the Free Travel of the Hand Brake Lever

Adjusting the Free Travel of the Handbrake Lever (150 EXC TPI EU)

Adjusting the Basic Position of the Hand Brake Lever (150 XC‑W TPI US)

Checking the Brake Discs

Checking the Front Brake Fluid Level

Guides on checking the front brake fluid level and potential issues.

Adding Front Brake Fluid

Provides instructions for adding front brake fluid, including safety warnings.

Checking the Front Brake Linings

Explains how to check front brake lining thickness and for damage.

Changing the Brake Linings of the Front Brake

Details the procedure for changing the front brake linings.

Checking the Free Travel of Foot Brake Lever

Adjusting the Basic Position of the Foot Brake Lever

Checking the Rear Brake Fluid Level

Guides on checking the rear brake fluid level and potential issues.

Adding Rear Brake Fluid

Provides instructions for adding rear brake fluid, including safety warnings.

Checking the Brake Linings of the Rear Brake

Explains how to check rear brake lining thickness and for damage.

Changing the Rear Brake Linings

Details the procedure for changing the rear brake linings.

Wheels, Tires

Checking the Tire Condition

Checking Tire Pressure

Explains how to check and set correct tire pressures for street and offroad.

Checking Spoke Tension

Electrical System

Charging the 12-V Battery

Changing Main Fuse

Guides on how to change the main fuse, with fire hazard warnings.

Changing the Fuses of Individual Electrical Power Consumers

Checking the Headlight Setting

Adjusting the Headlight Range

Cooling System

Checking the Antifreeze and Coolant Level

Guides on checking coolant level and antifreeze protection.

Checking the Coolant Level

Details how to check the coolant level in the radiator.

Draining the Coolant

Refilling with Coolant

Changing the Coolant

Tuning the Engine

Checking the Play in the Throttle Cable

Adjusting the Play in the Throttle Cable

Setting the Characteristic Map of the Throttle Response

Guides on changing the throttle response characteristic map.

Adjusting the Idle Speed

Explains how to adjust the engine's idle speed.

Changing the Ignition Timing Map

Adjusting the Basic Position of the Shift Lever

Service Work on the Engine

Changing the Fuel Screen

Checking 2-Stroke Oil Level

Guides on checking the 2-stroke oil level in the tank.

Priming Oil Pump

Cleaning the Oil Screen in the Oil Tank

Checking the Gear Oil Level

Guides on checking the gear oil level, with specific instructions for cold engines.

Changing the Gear Oil

Provides instructions and warnings for changing the gear oil.

Adding the Gear Oil

Troubleshooting

The engine cannot be cranked (starter motor)

Lists possible causes and actions for engine cranking issues.

The engine turns but does not start

Lists possible causes and actions for engine starting failures.

The engine has no idle speed

Lists possible causes and actions for lack of engine idle speed.

Engine does not speed up

Lists possible causes and actions for engine not accelerating.

Engine has too little power

Lists possible causes and actions for reduced engine power.

The engine dies during the trip

Lists possible causes and actions for the engine stopping while riding.

Engine overheats

Lists possible causes and actions for engine overheating.

Malfunction indicator lamp lights up or flashes

Lists causes and actions for the malfunction indicator lamp.

Blink Code

Blink Code for Malfunction Indicator Lamp 45

Explains malfunction code 45 and its error level conditions.

Blink Code for Malfunction Indicator Lamp 14

Explains malfunction code 14 and its error level conditions.

Blink Code for Malfunction Indicator Lamp 13

Explains malfunction code 13 and its error level conditions.

Blink Code for Malfunction Indicator Lamp 12

Explains malfunction code 12 and its error level conditions.

Blink Code for Malfunction Indicator Lamp 33

Explains malfunction code 33 and its error level conditions.

Blink Code for Malfunction Indicator Lamp 34

Explains malfunction code 34 and its error level conditions.

Blink Code for Malfunction Indicator Lamp 06

Explains malfunction code 06 and its error level conditions.

Blink Code for Malfunction Indicator Lamp 17

Explains malfunction code 17 and its error level conditions.

Blink Code for Malfunction Indicator Lamp 41

Explains malfunction code 41 and its error level conditions.

Blink Code for Malfunction Indicator Lamp 21

Blink Code for Malfunction Indicator Lamp (Tilt Sensor)

Technical Data

Engine

Engine Tightening Torques

Fork

Shock Absorber

Chassis Tightening Torques