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KTM 250 XC TPI 2022 User Manual

KTM 250 XC TPI 2022
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OWNER'S MANUAL 2022
250 XC TPI
300 XC TPI
Art. no. 3214413en

Table of Contents

Questions and Answers:

KTM 250 XC TPI 2022 Specifications

General IconGeneral
Displacement249 cc
Bore x Stroke66.4 mm x 72 mm
Transmission6-speed
Seat Height950 mm
Fuel Tank Capacity9.5 liters
Front SuspensionWP XPLOR 48
Rear SuspensionWP XPLOR PDS
StarterElectric starter
Front Brake260 mm disc
Rear Brake220 mm disc
Ground Clearance370 mm
Engine Type2-stroke
Fuel SystemElectronic Fuel Injection
FrameChrome-molybdenum frame

Summary

Means of Representation

Symbols Used

Explains the meaning of symbols used in the manual for clarity and safety.

Formats Used

Details typographical formats like proprietary names, brands, and underlined terms for document comprehension.

Safety Advice

Use Definition – Intended Use

Defines the intended offroad endurance competition use for the vehicle, excluding public roads.

Degrees of Risk and Symbols

Classifies dangers into Danger, Warning, Caution, and Note, explaining associated symbols and their implications.

Safety Advice

Safe Operation

Provides essential guidelines for safe vehicle operation, including rider fitness and environmental considerations.

Tampering Warning

Warns against tampering with the noise control system, outlining prohibited acts under federal law.

Safety Advice

Protective Clothing

Emphasizes the importance of wearing appropriate protective clothing for injury prevention during operation.

Owner's Manual

Stresses the importance of reading the Owner's Manual for essential operating, handling, and servicing information.

Important Notes

Manufacturer Warranty, Implied Warranty

Outlines conditions for maintaining manufacturer warranty, voiding claims due to unauthorized work or conversions.

Fuel, Auxiliary Substances

Advises on the correct use of fuels and auxiliary substances, noting environmental hazards of improper handling.

View of Vehicle

View of Vehicle, Front Left (Example)

Illustrates the front-left view of the motorcycle, labeling key components like clutch lever and fuel tank cap.

View of Vehicle

View of Vehicle, Rear Right (Example)

Shows the rear-right view of the motorcycle, identifying components such as the stop button and foot brake lever.

Serial Numbers

Vehicle Identification Number

Details the location and method for identifying the unique Vehicle Identification Number (VIN).

Engine Number

Specifies the location where the engine number is embossed on the left side of the engine.

Controls

Clutch Lever

Describes the handlebar-mounted clutch lever, its hydraulic activation, and automatic adjustment.

Stop Button

Explains the function and states of the stop button for engine ignition control and shutdown.

Controls

Start Button

Details the function of the start button for actuating the starter motor.

Opening the Fuel Tank Filler Cap

Provides safety warnings and instructions for safely opening the fuel tank filler cap, emphasizing fire and poisoning hazards.

Preparing for Use

Advice on Preparing for First Use

Offers critical advice for first-time use, covering rider fitness, protective gear, and initial checks before riding.

Preparing for Use

Running in the Engine

Provides guidelines for the engine running-in phase, specifying maximum engine performance limits.

Starting Power of Lithium-Ion Batteries at Low Temperatures

Explains the behavior of lithium-ion batteries at low temperatures and how to manage starting attempts.

Preparing for Use

Preparing the Vehicle for Difficult Operating Conditions

Details preparations for operating the vehicle in challenging conditions like sand or mud, emphasizing air filter and connector checks.

Preparing the Vehicle for Riding on Dry Sand

Provides specific preparation steps for riding on dry sand, including checking the radiator cap and air filter dust cover.

Preparing for Use

Preparing the Vehicle for Riding on Wet Sand

Outlines preparations for riding on wet sand, including chain maintenance and radiator fin checks.

Preparing the Vehicle for Riding on Wet and Muddy Circuits

Details preparations for riding on wet and muddy circuits, focusing on air filter and chain maintenance.

Preparing for Use

Preparing Vehicle for High Temperatures or Slow Riding

Advises on preparing the vehicle for high temperatures or slow riding, including radiator and chain checks.

Preparing the Vehicle for Low Temperatures or Snow

Provides guidance on preparing the vehicle for operation in low temperatures or snowy conditions.

Riding Instructions

Checks and Maintenance Measures When Preparing for Use

Lists essential pre-ride checks and maintenance tasks to ensure safe and optimal vehicle operation.

Starting

Covers the procedure for starting the engine, including safety precautions related to exhaust gases and cold engine operation.

Riding Instructions

Starting Off

Guides on the procedure for starting off, including clutch and throttle control for smooth engagement.

Shifting, Riding

Guides the rider on proper shifting techniques, speed adaptation, and handling the motorcycle during operation.

Riding Instructions

Applying the Brakes

Explains correct brake application techniques, warning about excessive force, spongy points, and the effects of moisture and dirt.

Stopping, Parking

Provides guidelines for safely stopping and parking the motorcycle, including safety warnings about hot components and unauthorized access.

Riding Instructions

Transporting

Details safe practices for transporting the motorcycle, emphasizing securing it properly to prevent damage or accidents.

Refueling

Covers safe refueling procedures, including fire hazard warnings and correct fuel level indication.

Riding Instructions

Adding 2-Stroke Oil

Explains how to add 2-stroke oil to the tank, highlighting the importance for engine lubrication and preventing failure.

Service Schedule

Required Work

Details routine maintenance tasks categorized by operating hours, ensuring the vehicle's upkeep and performance.

Recommended Work

Lists recommended maintenance tasks based on time intervals (months/years), complementing the required work schedule.

Tuning the Chassis

Checking the Basic Chassis Setting with Rider's Weight

Explains how rider weight affects chassis settings and the importance of matching suspension to rider weight for optimal handling.

Air Suspension XACT 5448

Introduces the WP XACT 5448 air suspension system used in the fork, highlighting its advantages and basic functionality.

Tuning the Chassis

Compression Damping of the Shock Absorber

Explains the division of shock absorber compression damping into high-speed and low-speed ranges.

Adjusting the Low-Speed Compression Damping of the Shock Absorber

Provides instructions on adjusting the low-speed compression damping on the rear shock absorber for tailored ride comfort and performance.

Tuning the Chassis

Adjusting the High-Speed Compression Damping of the Shock Absorber

Details how to adjust the high-speed compression damping on the rear shock absorber for improved handling during impacts.

Adjusting the Rebound Damping of the Shock Absorber

Guides on adjusting the rebound damping of the shock absorber to control the suspension's return speed after compression.

Tuning the Chassis

Measuring the Rear Wheel Dimension Unloaded

Explains how to measure the rear wheel's unloaded dimension using a sag gauge for suspension setup.

Tuning the Chassis

Checking the Static Sag of the Shock Absorber

Describes how to check the static sag of the shock absorber, a key parameter for initial suspension setup.

Checking the Riding Sag of the Shock Absorber

Details how to check the riding sag of the shock absorber with rider weight applied, critical for proper suspension performance.

Tuning the Chassis

Adjusting the Spring Preload of the Shock Absorber

Details the procedure for adjusting the shock absorber spring preload to achieve the correct static and riding sag.

Tuning the Chassis

Adjusting the Riding Sag

Guides on adjusting the riding sag by selecting or adjusting the spring rate for optimal suspension performance.

Checking the Basic Setting of the Fork

Explains how to check the basic settings of the front fork, considering factors like air pressure and rider weight.

Tuning the Chassis

Adjusting the Fork Air Pressure

Provides instructions for adjusting front fork air pressure to tune suspension response to rider weight and conditions.

Tuning the Chassis

Adjusting the Compression Damping of the Fork

Details how to adjust the front fork's compression damping to control suspension movement and improve handling.

Adjusting the Rebound Damping of the Fork

Explains how to adjust the front fork's rebound damping to control suspension extension after compression.

Tuning the Chassis

Handlebar Position

Describes how the handlebar can be mounted in two positions to optimize rider comfort.

Adjusting the Handlebar Position

Provides instructions for adjusting the handlebar position and warns against using bent or repaired handlebars.

Service Work on the Chassis

Raising the Motorcycle with a Lift Stand

Explains the correct method for safely lifting the motorcycle using a lift stand for maintenance.

Removing the Motorcycle from the Lift Stand

Details the procedure for safely lowering and removing the motorcycle from a lift stand.

Service Work on the Chassis

Bleeding the Fork Legs

Guides on bleeding the fork legs to remove air, ensuring proper suspension function.

Cleaning the Dust Boots of the Fork Legs

Explains how to clean fork dust boots to prevent dirt accumulation and oil seal leaks.

Service Work on the Chassis

Removing the Fork Legs

Guides on the step-by-step process for safely removing the front fork legs from the motorcycle.

Installing the Fork Legs

Details the procedure for correctly installing the front fork legs, including tightening torque specifications.

Service Work on the Chassis

Removing the Fork Protector

Explains how to remove the fork protectors before servicing the fork legs.

Installing the Fork Protector

Guides on reinstalling the fork protectors after servicing the fork legs.

Removing the Lower Triple Clamp

Details the steps required to remove the lower triple clamp assembly from the steering head.

Service Work on the Chassis

Installing the Lower Triple Clamp

Provides instructions for installing the lower triple clamp, including greasing and alignment.

Service Work on the Chassis

Checking the Steering Head Bearing Play

Describes how to check for play in the steering head bearing, crucial for safe handling and preventing damage.

Service Work on the Chassis

Adjusting Steering Head Bearing Play

Details the procedure for adjusting steering head bearing play to eliminate looseness and ensure smooth steering.

Lubricating the Steering Head Bearing

Explains that the steering head bearing is lubricated during removal and installation.

Service Work on the Chassis

Removing the Start Number Plate

Guides on removing the start number plate, including disconnecting the brake line.

Removing Front Fender

Explains how to remove the front fender for access to other components.

Installing Front Fender

Guides on reinstalling the front fender after maintenance or component replacement.

Service Work on the Chassis

Removing the Shock Absorber

Provides detailed steps for the removal of the rear shock absorber unit.

Service Work on the Chassis

Installing the Shock Absorber

Details the procedure for correctly installing the rear shock absorber, including tightening torques.

Service Work on the Chassis

Removing the Seat

Explains how to remove the motorcycle seat.

Mounting the Seat

Guides on correctly mounting the motorcycle seat.

Service Work on the Chassis

Removing the Air Filter Box Cover

Details how to remove the air filter box cover for access to the air filter.

Service Work on the Chassis

Installing the Air Filter Box Cover

Guides on correctly installing the air filter box cover.

Removing the Air Filter

Explains how to remove the air filter for cleaning or replacement, emphasizing engine protection.

Service Work on the Chassis

Cleaning the Air Filter and Air Filter Box

Provides instructions for cleaning the air filter and its box, crucial for engine performance and longevity.

Service Work on the Chassis

Installing the Air Filter

Guides on correctly installing the clean air filter, ensuring proper engine air intake.

Preparing Air Filter Box Cover for Securing

Details preparing the air filter box cover by drilling a hole for securing purposes.

Removing the Main Silencer

Explains how to remove the main silencer, warning about hot exhaust system components.

Service Work on the Chassis

Installing the Main Silencer

Guides on installing the main silencer, ensuring it's correctly positioned and tightened.

Changing the Glass Fiber Yarn Filling of the Main Silencer

Details the process of changing the glass fiber yarn filling in the main silencer to maintain performance and noise levels.

Service Work on the Chassis

Removing the Fuel Tank

Provides step-by-step instructions for safely removing the fuel tank, emphasizing fire and poisoning hazards.

Service Work on the Chassis

Installing the Fuel Tank

Details the procedure for correctly installing the fuel tank, ensuring secure connections and proper routing of lines.

Service Work on the Chassis

Checking the Chain for Dirt

Explains how to check the drive chain for dirt and soiling.

Cleaning the Chain

Guides on cleaning the drive chain, emphasizing the importance of proper lubrication for longevity.

Service Work on the Chassis

Checking the Chain Tension

Explains how to check the drive chain tension, warning about the consequences of incorrect tension.

Service Work on the Chassis

Adjusting the Chain Tension

Details the procedure for adjusting the drive chain tension to the specified measurement, ensuring proper alignment.

Service Work on the Chassis

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

Instructs on checking the wear of the chain, sprockets, and chain guide, recommending replacement if worn.

Service Work on the Chassis

Checking the Frame

Guides on checking the motorcycle frame for damage, cracks, or deformation, stating that repairs are not permitted.

Checking the Link Fork

Instructs on checking the link fork for damage, cracks, or deformation, stating that repairs are not permitted.

Service Work on the Chassis

Checking the Throttle Cable Routing

Explains how to check the throttle cable routing to ensure it is correct and prevents unintended acceleration.

Checking the Rubber Grip

Guides on checking the rubber grips on the handlebar for damage, wear, and looseness.

Service Work on the Chassis

Adjusting the Basic Position of the Clutch Lever

Details how to adjust the clutch lever's basic position to suit the rider's hand size and comfort.

Checking/Correcting the Fluid Level of the Hydraulic Clutch

Explains how to check and correct the hydraulic clutch fluid level, warning about skin irritation from brake fluid.

Service Work on the Chassis

Changing the Hydraulic Clutch Fluid

Provides instructions for changing the hydraulic clutch fluid, emphasizing safety and correct fluid type.

Brake System

Checking the Free Travel of the Hand Brake Lever

Explains how to check the free travel of the hand brake lever, essential for proper front brake function.

Adjusting the Basic Position of the Hand Brake Lever

Details how to adjust the hand brake lever's position for optimal rider comfort and control.

Checking the Brake Discs

Guides on checking the brake discs for wear, damage, and cracking, emphasizing replacement of worn discs.

Brake System

Checking the Front Brake Fluid Level

Details the procedure for checking the front brake fluid level, warning about insufficient levels and system failure.

Brake System

Adding Front Brake Fluid

Provides instructions for adding front brake fluid, emphasizing safety and correct fluid type.

Brake System

Checking the Front Brake Linings

Guides on checking the minimum thickness and condition of front brake linings for safe braking performance.

Changing the Brake Linings of the Front Brake

Details the procedure for changing the front brake linings, stressing the importance of professional servicing.

Brake System

Checking the Free Travel of Foot Brake Lever

Explains how to check the free travel of the foot brake lever, crucial for proper rear brake function.

Adjusting the Basic Position of the Foot Brake Lever

Details how to adjust the foot brake lever's position for optimal rider comfort and control.

Brake System

Checking the Rear Brake Fluid Level

Outlines the steps to check the rear brake fluid level, highlighting potential issues like leaks or worn linings.

Brake System

Adding Rear Brake Fluid

Provides instructions for adding rear brake fluid, emphasizing safety and correct fluid type.

Brake System

Checking the Brake Linings of the Rear Brake

Guides on checking the minimum thickness and condition of rear brake linings for safe braking performance.

Changing the Rear Brake Linings

Details the procedure for changing the rear brake linings, stressing the importance of professional servicing.

Wheels, Tires

Removing the Front Wheel

Provides step-by-step instructions for safely removing the front wheel, including brake caliper and spindle procedures.

Wheels, Tires

Installing the Front Wheel

Details the process of correctly installing the front wheel, including brake and fork considerations.

Removing the Rear Wheel

Guides on the procedure for removing the rear wheel, including chain and brake considerations.

Wheels, Tires

Installing the Rear Wheel

Details the process of correctly installing the rear wheel, including chain and brake system considerations.

Wheels, Tires

Checking the Tire Condition

Explains how to check tires for damage, wear, and age, emphasizing the impact on handling and safety.

Checking Tire Pressure

Guides on checking tire pressure when cold, stressing its importance for optimal riding comfort and tire longevity.

Wheels, Tires

Checking Spoke Tension

Explains how to check spoke tension by sound, ensuring wheel integrity and handling.

Electrical System

Removing the 12-V Battery

Covers the safe disconnection and removal of the 12-V battery, emphasizing safety precautions.

Installing the 12-V Battery

Details the procedure for safely installing the 12-V battery, ensuring correct terminal connections.

Electrical System

Charging the 12-V Battery

Provides instructions and safety advice for charging the 12-V battery, noting its importance for battery life.

Electrical System

Changing Main Fuse

Details the procedure for locating and replacing the main fuse, a critical component for the vehicle's electrical system.

Electrical System

Changing the Fuses of Individual Electrical Power Consumers

Explains how to identify and replace fuses for specific electrical components, ensuring system integrity.

Electrical System

Diagnostics Connector

Identifies the location of the diagnostics connector used for vehicle electronic system checks.

Cooling System

Cooling System

Briefly explains the function of the water pump and radiator cap in the cooling system.

Checking the Antifreeze and Coolant Level

Guides on checking coolant antifreeze and level, with warnings about hot coolant and its toxicity.

Cooling System

Checking the Coolant Level

Details how to check the coolant level in the radiator, with safety warnings and procedures for correction.

Cooling System

Draining the Coolant

Provides instructions for safely draining the coolant from the cooling system, emphasizing safety precautions.

Refilling with Coolant

Details the process of refilling the cooling system with coolant, including safety warnings and correct procedures.

Cooling System

Changing the Coolant

Provides instructions for changing the coolant, including safety warnings and correct procedures.

Tuning the Engine

Checking the Play in the Throttle Cable

Explains how to check throttle cable play, essential for smooth throttle operation and preventing unintended engine speed changes.

Adjusting the Play in the Throttle Cable

Details the procedure for adjusting throttle cable play to ensure optimal throttle response and smooth operation.

Tuning the Engine

Adjusting the Characteristic Map of the Throttle Response

Describes how to change the throttle response by swapping guide plates on the throttle grip, affecting acceleration characteristics.

Tuning the Engine

Adjusting the Idle Speed

Guides on adjusting the engine's idle speed using the adjusting screw, crucial for stable engine running and preventing spontaneous stalling.

Tuning the Engine

Programming Ambient Air Pressure

Explains how to reprogram the ambient air pressure setting for optimal engine performance at different altitudes.

Tuning the Engine

Plug-in Connector of Ignition Timing Map Adjustment

Identifies the plug-in connector for adjusting ignition timing maps, affecting engine performance and rideability.

Changing the Ignition Timing Map

Details switching between ignition timing maps (Soft/Performance) to alter engine characteristics.

Tuning the Engine

Checking the Basic Position of the Shift Lever

Explains how to check the shift lever's basic position to prevent interference with the rider's boot and transmission load.

Adjusting the Basic Position of the Shift Lever

Details the procedure for adjusting the shift lever's basic position for optimal rider comfort and shift operation.

Service Work on the Engine

Changing the Fuel Screen

Details the procedure for replacing the fuel screen, emphasizing safety during fuel handling and system disconnection.

Service Work on the Engine

Checking 2-Stroke Oil Level

Explains how to check the 2-stroke oil level in the tank, critical for engine lubrication and preventing failure.

Priming Oil Pump

Guides on priming the oil pump after it has been drained or disconnected, ensuring proper lubrication.

Service Work on the Engine

Cleaning the Oil Screen in the Oil Tank

Details how to clean the oil screen in the oil tank to ensure proper oil flow and filtration.

Service Work on the Engine

Checking the Gear Oil Level

Describes how to check the gear oil level, ensuring proper lubrication for the transmission.

Changing the Gear Oil

Provides instructions for changing the gear oil, emphasizing draining while the engine is warm.

Service Work on the Engine

Adding the Gear Oil

Guides on adding gear oil, specifying the correct type and level, and warning about premature transmission wear from low oil.

Cleaning, Care

Cleaning the Motorcycle

Provides instructions on how to clean the motorcycle, including warnings about pressure washers and environmental considerations.

Storage

Storage

Outlines the steps and precautions for storing the motorcycle for extended periods to maintain its condition.

Storage

Preparing for Use After Storage

Details the procedures required to prepare the motorcycle for operation after a period of storage.

Troubleshooting

Blink Code

Technical Data

Engine

Lists technical specifications related to the motorcycle's engine, including design, dimensions, and ignition system.

Technical Data

Engine Tightening Torques

Provides a comprehensive list of tightening torques for various engine components, crucial for proper assembly and safety.

Technical Data

Capacities

Details the fluid capacities for essential systems like gear oil, coolant, and fuel, important for maintenance.

Chassis

Lists technical data related to the motorcycle's chassis, including frame, fork, and shock absorber specifications.

Technical Data

Electrical System

Lists technical specifications for the motorcycle's electrical system, including battery and fuses.

Tires

Provides specifications for front and rear tires, including recommended brands and types.

Technical Data

Fork

Lists technical data for the front fork, including article number, suspension settings, and oil capacities.

Shock Absorber

Details technical data for the rear shock absorber, including article number, damping settings, and spring rates.

Technical Data

Chassis Tightening Torques

Lists specific tightening torques for chassis components, ensuring correct assembly and structural integrity.

Substances

Auxiliary Substances

Standards

List of Symbols

Red Symbols

Explains red symbols indicating error conditions requiring immediate intervention and their associated meanings.

Yellow and Orange Symbols

Describes yellow and orange symbols indicating prompt intervention requirements and active driving aids.

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