KTM 250 XC-W TPI 2019 Repair Manual

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REPAIR 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. 3206345en

Default Chapter4
- Table of Contents4
1 Means of Representation 19
- Symbols Used9
- Formats Used9
2 Safety Advice10
- Repair Manual10
- Degrees of Risk and Symbols10
- Work Rules10
3 Important Notes 311
- Manufacturer and Implied Warranty11
- Operating and Auxiliary Substances11
- Spare Parts, Accessories11
- Figures11
4 Serial Numbers12
- Chassis Number12
- Type Label12
- Engine Number12
- Fork Part Number12
- Shock Absorber Article Number13
5 Motorcycle14
- Raising the Motorcycle with a Lift Stand14
- Removing the Motorcycle from the Lift Stand14
- Starting the Vehicle14
- Starting the Motorcycle to Check the Function15
6 Fork, Triple Clamp16
- Adjusting the Compression Damping of the Fork16
- Adjusting the Rebound Damping of the Fork17
- Adjusting the Spring Preload of the Fork (All Six Days Models)18
- Bleeding the Fork Legs18
- Cleaning the Dust Boots of the Fork Legs19
- Removing the Fork Legs19
- Installing the Fork Legs20
- Removing the Fork Protector21
- Installing the Fork Protector21
- All Standard EXC/XC-W Models22
- Servicing the Fork22
- Disassembling the Fork Legs22
- Disassembling the Cartridge25
- Disassembling the Tap Compression28
- Checking the Fork Legs29
- Assembling the Tap Compression30
- Assembling the Cartridge31
- Assembling the Fork Legs35
- Lubricating the Steering Head Bearing39
- Removing the Lower Triple Clamp39
- Installing the Lower Triple Clamp40
- Changing the Steering Head Bearing42
- Checking the Play of the Steering Head Bearing44
- Adjusting the Steering Head Bearing Play44
- All Six Days Models45
- Servicing the Fork45
- Disassembling the Fork Legs45
- Disassembling the Cartridge48
- Disassembling the Tap Compression51
- Checking the Fork Legs52
- Assembling the Tap Compression53
- Assembling the Cartridge54
- Assembling the Fork Legs58
- Lubricating the Steering Head Bearing63
- Removing the Lower Triple Clamp63
- Installing the Lower Triple Clamp64
- Changing the Steering Head Bearing66
- Checking the Play of the Steering Head Bearing67
- Adjusting the Steering Head Bearing Play68
7 Handlebar, Controls 769
- Handlebar Position69
- Adjusting the Handlebar Position69
- Adjusting the Basic Position of the Clutch Lever71
- Checking the Rubber Grip72
- Checking Throttle Cable Routing72
- Checking the Play in the Throttle Cable73
- Adjusting the Play in the Throttle Cable73
- Setting the Characteristic Map of the Throttle Response74
8 Frame76
- Checking the Frame76
- Removing the Engine Guard (All Six Days Models)76
- Installing the Engine Guard (All Six Days Models)76
- Changing the Footrests76
9 Shock Absorber, Swingarm80
- Adjusting the High-Speed Compression Damping of the Shock Absorber80
- Adjusting the Low-Speed Compression Damping of the Shock Absorber80
- Adjusting the Rebound Damping of the Shock Absorber81
- Measuring the Rear Wheel Dimension Unloaded82
- Checking the Static Sag of the Shock Absorber82
- Checking the Riding Sag of the Shock Absorber83
- Adjusting the Spring Preload of the Shock Absorber83
- Adjusting the Riding Sag84
- Removing the Shock Absorber85
- Installing the Shock Absorber85
- Servicing the Shock Absorber85
- Removing the Spring86
- Disassembling the Damper87
- Disassembling the Seal Ring Retainer88
- Disassembling the Piston Rod89
- Replacing the Pilot Bushing90
- Checking the Damper91
- Removing the Heim Joint92
- Installing the Heim Joint93
- Assembling Seal Ring Retainer93
- Assembling the Piston Rod94
- Assembling the Damper96
- Bleeding and Filling the Damper98
- Filling Damper with Nitrogen101
- Installing the Spring102
- Checking the Swingarm103
- Checking the Heim Joint for Play103
- Changing the Heim Joint104
- Changing the Heim Joint on the Swingarm105
- Checking the Swingarm Bearing for Play107
- Removing the Swingarm107
- Installing the Swingarm108
- Changing the Swingarm Bearing110
10 Exhaust 10113
- Removing the Manifold113
- Installing the Manifold114
- Removing the Main Silencer115
- Installing the Main Silencer116
- Changing the Glass Fiber Yarn Filling in the Main Silencer116
11 Air Filter118
- Air Filter118
- Removing the Air Filter Box Cover118
- Installing the Air Filter Box Cover118
- Removing the Air Filter119
- Installing the Air Filter119
- Cleaning the Air Filter and Air Filter Box120
- Preparing Air Filter Box Cover for Securing120
- Sealing the Air Filter Box121
12 Fuel Tank, Seat, Trim122
- Opening the Filler Cap122
- Closing the Filler Cap122
- Removing the Seat123
- Mounting the Seat123
- Removing the Fuel Tank124
- Installing the Fuel Tank125
- Changing the Fuel Screen127
- Changing the Fuel Filter128
- Changing the Fuel Pump131
- Checking the Fuel Pressure134
13 Mask, Fender136
- Removing Front Fender136
- Installing Front Fender136
- Removing the Headlight Mask with the Headlight137
- Installing the Headlight Mask with the Headlight137
14 Wheels 14139
- Checking the Tire Air Pressure139
- Checking the Tire Condition139
- Checking the Wheel Bearing for Play140
- Checking the Brake Discs141
- Checking the Rim Run-Out141
- Checking Spoke Tension142
- Front Wheel143
- Removing the Front Wheel143
- Installing the Front Wheel144
- Changing the Front Brake Disc144
- Changing Front Wheel Bearing145
- Rear Wheel146
- Removing the Rear Wheel146
- Installing the Rear Wheel147
- Changing the Rear Brake Disc148
- Changing the Rear Wheel Bearing149
- Checking the Chain for Dirt151
- Cleaning the Chain151
- Checking the Chain Tension152
- Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide153
- Adjusting the Chain Tension155
- Changing the Drivetrain Kit156
15 Wiring Harness, Battery 15159
- Ignition Curve Plug-In Connector159
- Changing the Main Fuse159
- Changing the Fuses of Individual Power Consumers161
- Disconnecting the Negative Cable of the Battery162
- Connecting the Negative Cable of the Battery163
- Removing the Battery163
- Installing the Battery164
- Recharging the Battery165
- Checking the Charging Voltage166
- Checking the Open-Circuit Current167
- Checking the Starter Relay167
- Diagnostics Connector168
16 Brake System 16169
- Checking the Front Brake Linings169
- Changing the Front Brake Linings169
- Checking the Free Travel of the Hand Brake Lever171
- Adjusting Free Travel of Hand Brake Lever (All EXC Models)172
- Adjusting the Basic Position of the Hand Brake Lever (All XC-W Models)172
- Checking the Front Brake Fluid Level172
- Adding Front Brake Fluid173
- Changing the Front Brake Fluid174
- Checking the Brake Linings of the Rear Brake176
- Changing the Rear Brake Linings176
- Checking the Free Travel of Foot Brake Lever178
- Adjusting the Basic Position of the Foot Brake Lever179
- Checking the Rear Brake Fluid Level180
- Adding Rear Brake Fluid180
- Changing the Rear Brake Fluid181
17 Lighting System, Instruments184
- Changing the Headlight Bulb184
- Changing the Turn Signal Bulb (All EXC Models)184
- Checking the Headlight Setting185
- Adjusting the Headlight Range186
- Changing the Combination Instrument186
- Combination Instrument Overview187
- Activation and Test187
- Setting the Kilometers or Miles187
- Adjusting the Combination Instrument Function188
- Setting the Clock189
- Activating Additional Functions189
- Setting the Wheel Circumference190
- Viewing the Lap Time190
18 Engine192
- Cleaning the Pressure Sensor Hose192
- Removing the Engine192
- Installing the Engine198
- Engine Disassembly205
- Clamping the Engine into the Engine Work Stand205
- Removing the Shift Lever205
- Removing the Clutch Push Rod205
- Draining the Gear Oil205
- Removing the Spacer206
- Removing the Alternator Cover206
- Removing the Kick Starter207
- Removing Injection Valves207
- Removing the Cylinder Head207
- Removing the Cylinder208
- Removing the Piston210
- Removing the Water Pump Cover211
- Removing the Clutch Cover211
- Removing the Clutch Discs212
- Removing the Clutch Basket213
- Removing the Balancer Shaft214
- Removing the Kick Starter Shaft215
- Removing the Intermediate Kick Starter Gear215
- Removing the Shift Shaft216
- Removing the Shift Drum Locating Unit216
- Removing the Locking Lever216
- Removing the Rotor216
- Removing the Starter Motor217
- Removing the Reed Valve Housing218
- Removing the Left Engine Case Section219
- Removing the Shift Rails219
- Removing the Shift Drum219
- Removing the Shift Forks220
- Removing the Transmission Shafts220
- Removing the Crankshaft220
- Working on Individual Parts221
- Working on the Right Section of the Engine Case221
- Working on the Left Section of the Engine Case222
- Removing the Crankshaft Bearing Inner Race224
- Installing the Crankshaft Bearing Inner Race224
- Changing the Connecting Rod, Conrod Bearing, and Crank Pin225
- Checking the Crankshaft Run-Out at the Bearing Pin226
- Checking/Measuring the Cylinder226
- Cleaning the Pressure Sensor Cylinder Connection227
- Removing the Exhaust Control227
- Checking the Exhaust Control229
- Installing the Exhaust Control231
- Cylinder - Nikasil Coating234
- Checking/Measuring the Piston234
- Checking the Piston Ring End Gap235
- Measuring the Piston/Cylinder Mounting Clearance235
- Disassemble the Reed Valve Housing236
- Checking the Reed Valve Housing, Reed Valve and Intake Flange237
- Assemble the Reed Valve Housing237
- Working on the Clutch Cover239
- Checking the Clutch242
- Preassembling Shift Shaft243
- Checking the Shift Mechanism244
- Disassembling the Main Shaft245
- Disassembling the Countershaft246
- Checking the Transmission246
- Assembling the Main Shaft248
- Assembling the Countershaft248
- Checking the Kick Starter250
- Preassembling the Kick Starter Shaft250
- Checking the Electric Starter Drive251
- Engine Assembly252
- Installing the Crankshaft252
- Installing the Transmission Shafts253
- Installing the Shift Forks253
- Installing the Shift Drum254
- Installing the Shift Rails254
  - Installing the Left Engine Case Section254
  - Installing the Reed Valve Housing255
  - Installing the Starter Motor256
  - Installing the Rotor257
  - Installing the Locking Lever257
  - Installing the Shift Drum Locating Unit258
  - Installing the Shift Shaft258
  - Installing the Intermediate Kick Starter Gear258
  - Installing the Kick Starter Shaft258
  - Installing the Balancer Shaft259
  - Installing the Clutch Basket260
  - Installing the Clutch Discs261
  - Installing the Clutch Cover263
  - Installing the Water Pump Cover265
  - Installing the Piston266
  - Installing the Cylinder267
  - Checking the X-Distance269
  - Adjusting the X-Distance269
  - Adjusting the Z-Distance271
  - Installing the Cylinder Head273
  - Installing Injection Valves274
  - Installing the Kick Starter274
  - Installing the Alternator Cover274
  - Installing the Spacer275
  - Installing the Gear Oil Drain Plug275
  - Installing the Clutch Push Rod276
  - Installing the Shift Lever276
  - Removing the Engine from the Engine Work Stand276
19 Clutch 19277
- Checking/Correcting the Fluid Level of the Hydraulic Clutch277
- Changing the Hydraulic Clutch Fluid278
- Checking the Clutch279
20 Water Pump, Cooling System288
- Cooling System288
- Checking the Antifreeze and Coolant Level288
- Checking the Coolant Level289
- Draining the Coolant289
- Refilling with Coolant290
21 Exhaust Control 21293
- Checking/Adjusting the Exhaust Control293
22 Lubrication System296
- Changing the Gear Oil296
- Checking the Gear Oil Level297
- Adding Gear Oil297
- Checking 2-Stroke Oil Level298
- Opening 2-Stroke Oil Tank Cap299
- Adding 2-Stroke Oil299
- Closing 2-Stroke Oil Tank Cap299
- Priming the Oil Pump300
- Replacing the Oil Pump301
23 Ignition System304
- Checking the Ignition System304
- Ignition Coil - Checking the Primary Winding305
- Checking the Spark Plug Connector306
- Alternator - Checking the Stator Winding306
- Checking the Crankshaft Position Sensor307
- Changing the Spark Plug308
- Changing the Spark Plug and Spark Plug Connector309
- Removing the Stator309
- Installing the Stator310
24 Electric Starter 24311
- Checking the Starter Motor311
25 Throttle Valve Body312
- Adjusting the Idle Speed312
- Programming Ambient Pressure312
- Cold Start Button313
26 Technical Data314
- Engine314
- All 250 Models314
- All 300 Models314
- Tolerance, Engine Wear Limits315
- Engine Tightening Torques316
- Capacities317
- Gear Oil317
- Engine Oil317
- Coolant317
- Fuel318
- Chassis318
- Electrical System319
- Tires319
- Fork319
- All Standard EXC/XC-W Models319
- All Six Days Models320
- Shock Absorber320
- Chassis Tightening Torques321
27 Cleaning, Care324
- Cleaning, Care324
- Cleaning the Motorcycle324
- Checks and Maintenance Steps for Winter Operation325
28 Storage326
- Preparing for Use after Storage327
29 Service Schedule328
- Additional Information328
- Required Work328
- Recommended Work329
30 Wiring Diagram332
- All EXC Models)332
- All EXC Models)334
- All EXC Models)336
- All EXC Models)338
- All EXC Models)340
- All EXC Models)342
- All EXC Models)344
- All EXC Models)346
- All XC-W Models)348
- All XC-W Models)350
- All XC-W Models)352
- All XC-W Models)354
- All XC-W Models)356
- All XC-W Models)358
31 Substances360
32 Auxiliary Substances362
33 Special Tools364
34 Standards 34379
35 Index of Special Terms380
36 List of Abbreviations 36381
- Index382

Other manuals for KTM 250 XC-W TPI 2019

Owner's Manual176 pages

Setup Instructions45 pages

Questions and Answers:

K
Katie LongAug 3, 2025
How to fix a KTM Motorcycle when the engine cannot be cranked with the electric starter?
- M
  Michael MatthewsAug 3, 2025
  If your KTM Motorcycle engine fails to crank with the electric starter, several issues could be responsible. Begin by ensuring you are following the correct start procedure. A discharged battery is a common cause; recharge it and check the charging voltage, closed current, and alternator stator winding. Inspect the main fuse and replace it if it's blown. Also, the starter relay or the starter motor itself might be faulty and require inspection.
W
William JeffersonAug 14, 2025
Why does my KTM 250 XC-W TPI 2019 engine have no idle?
- J
  Jason OwensAug 14, 2025
  If your KTM Motorcycle engine won't idle, consider these possible causes: a defective spark plug (replace it), faulty ignition (check the ignition coil, spark plug connector, and alternator stator winding), or an incorrectly set idle speed (adjust the idle speed).

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