KTM 250 XC-W TPI 2019 User Manual

OWNER'S MANUAL 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. 3213853en

KTM 250 XC-W TPI 2019 Specifications

General

Displacement	249 cm³
Bore x Stroke	66.4 mm x 72 mm
Transmission	6-speed
Seat Height	960 mm
Fuel Tank Capacity	9.5 liters
Rear Suspension	WP Xplor PDS
Cooling System	Liquid cooled
Starting System	Electric starter
Front Brake	260 mm disc
Rear Brake	220 mm disc
Ground Clearance	370 mm
Engine Type	Single cylinder, 2-stroke
Front Suspension	WP Xplor 48
Brakes	Disc brakes
Frame	Chromium-molybdenum steel

Summary

2 SAFETY ADVICE

2.3 Safety advice

Provides essential safety instructions for operating the product safely.

2.4 Degrees of risk and symbols

Explains the different degrees of risk and associated warning symbols.

2.5 Tampering warning

2.6 Safe operation

Provides essential safety guidelines for operating the vehicle.

6 CONTROLS

6.1 Clutch lever

6.2 Hand brake lever

6.3 Throttle grip

6.4 Kill switch (All EXC models)

Explains the function and states of the kill switch for engine operation.

6.5 Kill switch (All XC-W models)

Explains the function and states of the kill switch for engine operation.

6.7 Light switch (All EXC models)

6.8 Light switch (All XC-W models)

6.9 Turn signal switch (All EXC models)

6.10 Emergency OFF switch (All EXC models)

Details the function of the emergency OFF switch for stopping the engine.

6.11 Electric starter button

6.12 Map switch (All Six Days models)

Explains the function of the map switch for altering engine characteristics.

6.13 Indicator lamps overview (All EXC models)

Explains the meaning of various indicator lamps on the instrument panel.

6.14 Indicator lamps overview (All XC-W models)

Explains the meaning of various indicator lamps on the instrument panel.

6.15 Opening the filler cap

6.19 Cold start button

Explains the function of the cold start button for cold engines.

6.20 Idle speed adjusting screw

Describes the idle speed adjusting screw and its function.

6.21 Shift lever

6.22 Kick starter

6.23 Foot brake lever

6.25 Steering lock (All EXC models)

Describes the function and operation of the steering lock.

6.26 Locking the steering (All EXC models)

Provides instructions and warnings for locking the steering.

6.27 Unlocking the steering (All EXC models)

7 COMBINATION INSTRUMENT

8 PREPARING FOR USE

8.1 Advice on first use

8.2 Running in the engine

Details the procedure and recommendations for the engine's running-in phase.

8.4 Preparing the vehicle for difficult riding conditions

8.5 Preparing vehicle for rides on dry sand

8.6 Preparing vehicle for rides on wet sand

8.7 Preparing vehicle for rides on wet and muddy circuits

9 RIDING INSTRUCTIONS

9.1 Checks and maintenance measures when preparing for use

Outlines essential checks and maintenance before every trip for safety.

9.2 Starting the vehicle

Provides instructions and safety warnings for starting the motorcycle's engine.

9.3 Starting off

9.4 Shifting, riding

9.5 Braking

Provides important safety warnings and techniques for braking.

9.6 Stopping, parking

9.8 Refueling

Gives instructions and safety warnings for refueling the motorcycle.

9.9 Adding 2-stroke oil

Provides instructions and warnings for adding 2-stroke oil.

10 SERVICE SCHEDULE

10.2 Required work

Lists mandatory maintenance tasks at specified operating hour intervals.

10.3 Recommended work

Lists recommended maintenance tasks for optimal performance and longevity.

11 TUNING THE CHASSIS

11.1 Checking the basic chassis setting with the rider's weight

Explains how to adjust suspension based on rider weight for optimal handling.

11.2 Compression damping of the shock absorber

Explains high-speed and low-speed compression damping for rear suspension.

11.3 Adjusting the low-speed compression damping of the shock absorber

Guides on adjusting the low-speed compression damping of the rear shock absorber.

11.4 Adjusting the high-speed compression damping of the shock absorber

Guides on adjusting the high-speed compression damping of the rear shock absorber.

11.5 Adjusting the rebound damping of the shock absorber

Details how to adjust the rebound damping of the rear shock absorber.

11.6 Measuring the rear wheel dimension unloaded

11.7 Checking the static sag of the shock absorber

Guides on checking the static sag of the rear shock absorber.

11.8 Checking the riding sag of the shock absorber

Explains how to check the riding sag of the rear shock absorber.

11.9 Adjusting the spring preload of the shock absorber

Provides instructions for adjusting the spring preload of the rear shock absorber.

11.10 Adjusting the riding sag

Details how to adjust the riding sag by selecting a suitable spring.

11.11 Checking the basic setting of the fork

11.12 Adjusting the compression damping of the fork

Guides on adjusting the compression damping of the front fork.

11.13 Adjusting the rebound damping of the fork

Details how to adjust the rebound damping of the front fork.

11.14 Adjusting the spring preload of the fork (All Six Days models)

Provides instructions for adjusting fork spring preload on Six Days models.

12 SERVICE WORK ON THE CHASSIS

12.3 Bleeding the fork legs

12.7 Removing the fork legs

12.8 Installing the fork legs

12.9 Removing the lower triple clamp (All standard EXC/XC-W models)

12.10 Removing the lower triple clamp (All Six Days models)

12.11 Installing the lower triple clamp (All standard EXC/XC-W models)

12.12 Installing the lower triple clamp (All Six Days models)

12.13 Checking the play of the steering head bearing

Explains how to check for play in the steering head bearing.

12.14 Adjusting the steering head bearing play

Guides on adjusting the steering head bearing play.

12.18 Removing the shock absorber

12.19 Installing the shock absorber

12.24 Removing the air filter

12.25 Installing the air filter

12.26 Cleaning the air filter and air filter box

Details the process for cleaning the air filter and air filter box.

12.29 Removing the main silencer

12.30 Installing the main silencer

12.31 Changing the glass fiber yarn filling in the main silencer

12.32 Removing the fuel tank

12.33 Installing the fuel tank

12.35 Cleaning the chain

12.36 Checking the chain tension

Explains how to check the chain tension for proper alignment.

12.37 Adjusting the chain tension

Guides on how to adjust the chain tension correctly.

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

Details how to check wear on the chain, sprockets, and chain guide.

12.39 Checking the frame

12.40 Checking the swingarm

12.41 Checking throttle cable routing

12.43 Adjusting the basic position of the clutch lever

12.44 Checking/correcting the fluid level of the hydraulic clutch

Explains how to check and correct the hydraulic clutch fluid level.

12.45 Changing the hydraulic clutch fluid

Provides instructions for changing the hydraulic clutch fluid.

13 BRAKE SYSTEM

13.1 Checking the free travel of the hand brake lever

Guides on checking the hand brake lever's free travel for proper function.

13.2 Adjusting free travel of hand brake lever (All EXC models)

Details how to adjust the free travel of the hand brake lever for EXC models.

13.3 Adjusting the basic position of the hand brake lever (All XC-W models)

Explains how to adjust the hand brake lever position for XC-W models.

13.4 Checking the brake discs

Details how to check brake disc thickness for wear and damage.

13.5 Checking the front brake fluid level

Guides on checking the front brake fluid level.

13.6 Adding front brake fluid

Provides instructions for adding front brake fluid.

13.7 Checking the front brake linings

Explains how to check the front brake linings for minimum thickness.

13.8 Changing the front brake linings

Provides instructions for changing the front brake linings.

13.9 Checking the free travel of foot brake lever

Guides on checking the free travel of the foot brake lever.

13.10 Adjusting the basic position of the foot brake lever

Explains how to adjust the basic position of the foot brake lever.

13.11 Checking the rear brake fluid level

Guides on checking the rear brake fluid level.

13.12 Adding rear brake fluid

Provides instructions for adding rear brake fluid.

13.13 Checking the brake linings of the rear brake

Explains how to check rear brake linings for minimum thickness.

13.14 Changing the rear brake linings

Provides instructions for changing the rear brake linings.

14 WHEELS, TIRES

14.1 Removing the front wheel

14.2 Installing the front wheel

14.3 Removing the rear wheel

14.4 Installing the rear wheel

14.5 Checking the tire condition

Explains how to check tires for cuts, damage, and tread depth.

14.6 Checking the tire air pressure

Guides on checking tire air pressure for optimal riding comfort and safety.

14.7 Checking spoke tension

Explains how to check spoke tension for wheel integrity and handling.

15 ELECTRICAL SYSTEM

15.1 Removing the battery

15.2 Installing the battery

15.3 Recharging the battery

Provides instructions and recommendations for safely recharging the battery.

15.4 Changing the main fuse

Details the steps for changing the main fuse to protect electrical systems.

15.5 Changing the fuses of individual power consumers

Explains how to change fuses for various electrical components.

15.6 Removing the headlight mask with the headlight

15.7 Installing the headlight mask with the headlight

15.8 Changing the headlight bulb

Explains how to replace the headlight bulb.

15.9 Changing the turn signal bulb (All EXC models)

15.10 Checking the headlight setting

15.11 Adjusting the headlight range

15.12 Changing the combination instrument

16 COOLING SYSTEM

16.2 Checking the antifreeze and coolant level

Guides on checking the antifreeze and coolant level for engine protection.

16.3 Checking the coolant level

Details how to check the coolant level in the radiator.

16.4 Draining the coolant

16.5 Refilling with coolant

17 TUNING THE ENGINE

17.1 Checking the play in the throttle cable

17.2 Adjusting the play in the throttle cable

17.3 Setting the characteristic map of the throttle response

Details how to change the throttle response characteristic map.

17.4 Adjusting the idle speed

Guides on adjusting the engine's idle speed for proper running.

17.5 Programming ambient pressure

17.6 Ignition curve plug-in connector

17.7 Changing the ignition timing map

17.8 Checking the basic position of the shift lever

17.9 Adjusting the basic position of the shift lever

18 SERVICE WORK ON THE ENGINE

18.1 Changing the fuel screen

18.2 Checking 2-stroke oil level

Explains how to check the 2-stroke oil level in the oil tank.

18.3 Priming the oil pump

18.4 Checking the gear oil level

Guides on checking the gear oil level when the engine is cold.

18.5 Changing the gear oil

Provides instructions for changing the engine gear oil.

18.6 Adding gear oil

19 CLEANING, CARE

19.2 Checks and maintenance steps for winter operation

20 STORAGE

20.1 Storage

20.2 Preparing for use after storage

21 TROUBLESHOOTING

The engine cannot be cranked (electric starter)

Lists possible causes and actions for the engine not cranking.

The engine turns but does not start

Addresses potential causes and solutions when the engine cranks but doesn't start.

Engine has no idle

Provides troubleshooting steps for when the engine lacks a stable idle.

Engine does not speed up

Lists causes and solutions for the engine not reaching expected speeds.

Engine has too little power

Troubleshoots issues related to the engine producing insufficient power.

The engine dies during the trip

Addresses reasons why the engine might stop running during a trip.

Engine overheats

Lists possible causes and solutions for engine overheating.

White smoke emission (steam in exhaust gas)

Troubleshoots white smoke from the exhaust, potentially indicating gasket issues.

Gear oil exits at the vent hose

Water in the gear oil

Malfunction indicator lamp lights up or flashes

Explains causes for the malfunction indicator lamp and related actions.

The battery is discharged

Troubleshoots battery discharge issues related to charging system faults.

22 TECHNICAL DATA

22.2 Engine tightening torques

Provides torque specifications for various engine screws and bolts.

22.6 Tires

22.7 Fork

22.8 Shock absorber

22.9 Chassis tightening torques

Provides torque specifications for various chassis screws and bolts.