Husqvarna 250 XC TPI 2021 Owner's Manual
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Husqvarna 250 XC TPI 2021 Owner's Manual

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OWNER'S MANUAL
2021
250 XC TPI
300 XC TPI
Art. no. 3214211en

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Summary of Contents for Husqvarna 250 XC TPI 2021

  • Page 1 OWNER'S MANUAL 2021 250 XC TPI 300 XC TPI Art. no. 3214211en...
  • Page 3 DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art DEAR KTM CUSTOMER sports vehicle which, with appropriate care, will bring you pleasure for a long time to come. We wish you good and safe riding at all times! Enter the serial numbers of your vehicle below.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS PREPARING FOR USE......... 20 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 5 Advice on preparing for first use ..20 Symbols used ........5 Running in the engine ...... 21 Formats used........5 Starting power of lithium-ion SAFETY ADVICE..........
  • Page 5 TABLE OF CONTENTS 10.10 Adjusting the spring preload of the 11.33 Checking the chain for dirt....68 shock absorber ......41 11.34 Cleaning the chain ......68 10.11 Adjusting the riding sag ....42 11.35 Checking the chain tension ....69 10.12 Checking the basic setting of the 11.36 Adjusting the chain tension....
  • Page 6 TABLE OF CONTENTS 15 COOLING SYSTEM ........102 22.7 Fork..........135 22.8 Shock absorber ......135 15.1 Cooling system ......102 22.9 Chassis tightening torques ....136 15.2 Checking the antifreeze and coolant level ........102 23 SUBSTANCES .......... 138 15.3 Checking the coolant level ....

  • Page 7: Means Of Representation 1

    MEANS OF REPRESENTATION 1 Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop! Your motorcycle will be optimally cared for there by specially trained experts using the auxiliary tools required.

  • Page 8: Safety Advice

    2 SAFETY ADVICE Use definition – intended use This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle com- plies with the currently valid regulations and categories of the top international motorsports organizations. Info This vehicle is designed for use in offroad endurance competition, and not primarily for use in motocross.

  • Page 9: Tampering Warning

    SAFETY ADVICE 2 Tampering warning Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof: 1 The removal or rendering inoperative by any person other than for purposes of servicing, repair, or replace- ment, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any...

  • Page 10: Protective Clothing

    2 SAFETY ADVICE Protective clothing Warning Risk of injury Missing or poor protective clothing presents an increased safety risk. – Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with protectors on all rides. –...

  • Page 11: Important Notes 3

    IMPORTANT NOTES 3 Manufacturer warranty, implied warranty The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and con- firmed in the KTM Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.

  • Page 12: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) V01730-10 Clutch lever ( p. 14) Fuel tank filler cap Air filter box cover Side stand ( p. 18) Shift lever ( p. 17) Engine number ( p. 12)

  • Page 13: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) V01731-10 2-stroke oil tank cap Switch-off button ( p. 14) Start button ( p. 15) Throttle grip ( p. 14) Hand brake lever ( p. 14) Foot brake lever ( p.

  • Page 14: Serial Numbers

    5 SERIAL NUMBERS Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 401945-10 Type label The type label is fixed to the front of the steering head. 401946-10 Engine number The engine number is embossed on the left side of the engine above the engine sprocket.

  • Page 15: Shock Absorber Article Number

    SERIAL NUMBERS 5 Shock absorber article number Shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. 401948-10...

  • Page 16: Controls

    6 CONTROLS Clutch lever Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automati- cally. V01641-10 Hand brake lever Hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever.

  • Page 17: Start Button

    Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an error in the vehicle electronics. Stop, and contact an authorized Husqvarna Motorcycles workshop. The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.

  • Page 18: Closing The Fuel Tank Filler Cap

    6 CONTROLS – Press release button , turn the fuel tank filler cap counter- clockwise, and lift it off. V01646-10 Closing the fuel tank filler cap – Mount filler cap and turn it clockwise until the release but- ton engages. Info Route fuel tank breather hose without kinks.

  • Page 19: Cold Start Button

    CONTROLS 6 6.11 Cold start button The cold start button is fitted on the side of the throttle valve body. If the engine is cold and the ambient temperature is low, the electronic fuel injection system extends the injection time. To help the engine burn the increased fuel quantity, it must be supplied with additional oxygen by pulling the cold start button.

  • Page 20: Foot Brake Lever

    6 CONTROLS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11 6.14 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 401956-10 6.15 Side stand...

  • Page 21: Service Hour Counter

    CONTROLS 6 6.16 Service hour counter The service hour counter is fitted in front of the handlebar. It shows the total number of service hours of the engine. The service hour counter begins counting when the engine is started and stops when the engine is switched off. Info The value indicated by the service hour counter cannot be cleared or adjusted.

  • Page 22: Preparing For Use

    7 PREPARING FOR USE Advice on preparing for first use Danger Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others. – Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication. –...

  • Page 23: Running In The Engine

    PREPARING FOR USE 7 – Adjust the basic position of the foot brake lever. p. 85) – Adjust the basic position of the shift lever. p. 113) – Get used to the handling characteristics of the motorcycle on a suitable surface before undertaking more chal- lenging trips.

  • Page 24: Preparing The Vehicle For Difficult Operating Conditions

    7 PREPARING FOR USE Preparing the vehicle for difficult operating conditions Info Use of the vehicle under difficult conditions, such as on sand or on wet and muddy circuits/surfaces, can lead to considerably more rapid wear of components such as the drive train, brake system, or suspension components.

  • Page 25: Preparing The Vehicle For Riding On Wet Sand

    PREPARING FOR USE 7 – Mount the air filter dust cover. Air filter dust cover (79006920000) Info Observe the fitting instructions for KTM PowerParts. M01104-01 – Mount the air filter sand cover. Air filter sand cover (79006922000) Info Observe the fitting instructions for KTM PowerParts. M01105-01 –...

  • Page 26: Preparing The Vehicle For Riding On Wet And Muddy Circuits

    7 PREPARING FOR USE Warning Danger of scalding During motorcycle oper- ation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operat- ing temperature.

  • Page 27: Preparing Vehicle For High Temperatures Or Slow Riding

    PREPARING FOR USE 7 – Mount the steel sprocket. – Clean motorcycle. ( p. 123) – Straighten the bent radiator fins carefully. 600868-01 Preparing vehicle for high temperatures or slow riding – Check the radiator cap. Value on the radiator cap 1.8 bar (26 psi) »...

  • Page 28: Preparing The Vehicle For Low Temperatures Or Snow

    7 PREPARING FOR USE Preparing the vehicle for low temperatures or snow – Mount the air filter rain cover. Air filter rain cover (79006921000) Info Observe the fitting instructions for KTM PowerParts. M01106-01...

  • Page 29: Riding Instructions 8

    RIDING INSTRUCTIONS 8 Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –...

  • Page 30: Starting Off

    8 RIDING INSTRUCTIONS – Take the motorcycle off side stand and secure the side stand with rubber strap – Shift the transmission to neutral position. Condition Ambient temperature: < 10 °C (< 50 °F) – Pull the cold start button fully out and turn it by a ¼ turn. Info If the engine is warm, the cold start button must be 401944-10...

  • Page 31: Applying The Brakes

    RIDING INSTRUCTIONS 8 – Always open the throttle only as much as the engine can handle – abrupt throttle opening increases fuel con- sumption. – To shift down, apply the brakes and close the throttle at the same time. – Pull the clutch lever and shift into a lower gear, release the clutch lever slowly, and either open the throttle or shift again.

  • Page 32: Transporting

    8 RIDING INSTRUCTIONS – Do not park the vehicle near to materials which are highly flammable or explosive. – Allow the vehicle to cool down before covering it. Note Material damage The vehicle may be damaged by incorrect procedure when parking. Significant damage may be caused if the vehicle rolls away or falls over.

  • Page 33: Adding 2-Stroke Oil

    RIDING INSTRUCTIONS 8 Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – In case of skin contact, rinse the affected area with plenty of water. –...
  • Page 34 8 RIDING INSTRUCTIONS – Fill the 2-stroke oil tank up to the lower edge of the filler neck. Guideline Only use 2-stroke oil which is appropriate for separate lubri- cation. 2-stroke oil tank con- 0.6 l (0.6 qt.) Engine oil, 2-stroke tent approx.

  • Page 35: Service Schedule 9

    SERVICE SCHEDULE 9 Additional information Any further work that results from the compulsory work or from the recommended work must be ordered sepa- rately and invoiced separately. Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments.

  • Page 36: Recommended Work

    9 SERVICE SCHEDULE Every 40 operating hours Every 20 operating hours Every 10 operating hours After 5 operating hours After 1 operating hour ○ ● ● ● Check the antifreeze and coolant level. ( p. 102) ● ● ● Check the cables for damage and for routing without kinks. ○...
  • Page 37 SERVICE SCHEDULE 9 Every 80 operating hours Every 40 operating hours After 20 operating hours / Every 20 operating hours After 10 operating hours / Every 10 operating hours every 48 months every 12 months ● Perform major engine service including removing and installing the engine. Change the piston and check the cylinder.

  • Page 38: 10 Tuning The Chassis

    10 TUNING THE CHASSIS 10.1 Checking the basic chassis setting with rider's weight Info When adjusting the basic chassis setting, first adjust the shock absorber and then the fork. – For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, link fork and frame, the basic settings of the suspension components must match the rider's weight.

  • Page 39: Compression Damping Of The Shock Absorber

    TUNING THE CHASSIS 10 The compression adjuster is located at the upper end of the right fork leg. 10.3 Compression damping of the shock absorber The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed. High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed.

  • Page 40: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    10 TUNING THE CHASSIS 10.5 Adjusting the high-speed compression damping of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. –...

  • Page 41: Measuring The Rear Wheel Dimension Unloaded

    TUNING THE CHASSIS 10 Info Turn clockwise to increase the damping; turn counter- clockwise to reduce damping when the shock absorber rebounds. 10.7 Measuring the rear wheel dimension unloaded Preparatory work – Raise the motorcycle with a lift stand. ( p.

  • Page 42: Checking The Static Sag Of The Shock Absorber

    10 TUNING THE CHASSIS 10.8 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 39) – Hold the motorcycle upright with aid of an assistant. – Measure the distance again between the rear axle and mark- ing SAG on the rear fender using the sag gage.

  • Page 43: Adjusting The Spring Preload Of The Shock Absorber

    TUNING THE CHASSIS 10 10.10 Adjusting the spring preload of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. –...

  • Page 44: Adjusting The Riding Sag

    10 TUNING THE CHASSIS 10.11 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 47) – Remove the shock absorber. p. 56) – After removing the shock absorber, clean it thoroughly. Main work –...

  • Page 45: Adjusting The Fork Air Pressure

    TUNING THE CHASSIS 10 10.13 Adjusting the fork air pressure Warning Danger of accident Modifications to the suspension setting may seriously alter the handling characteris- tic. Extreme modifications to the suspension setting may cause a serious deterioration in the handling char- acteristic and overload components.

  • Page 46: Adjusting The Compression Damping Of The Fork

    10 TUNING THE CHASSIS When disconnecting, excess pressure will escape from the hose – the fork leg itself does not lose any air. The fork airpump indicator switches off automatically after 80 seconds. – Mount the protection cap. Info Only mount the protection cap by hand. Finishing work –...

  • Page 47: Handlebar Position

    TUNING THE CHASSIS 10 Guideline Rebound damping Comfort 23 clicks Standard 18 clicks Sport 13 clicks Info Turn clockwise to increase the damping; turn counter- clockwise to reduce damping when the shock absorber rebounds. – Mount protection cap 10.16 Handlebar position The holes on the handlebar supports are placed at a distance from the center.
  • Page 48 10 TUNING THE CHASSIS Main work – Remove screws . Remove the handlebar clamp. Remove the handlebar and lay it to one side. Info Cover the components to protect them against damage. Do not kink the cables and lines. – Remove screws .

  • Page 49: Service Work On The Chassis 11

    SERVICE WORK ON THE CHASSIS 11 11.1 Raising the motorcycle with a lift stand Note Material damage The vehicle may be damaged by incorrect procedure when parking. Significant damage may be caused if the vehicle rolls away or falls over. The components for parking the vehicle are designed only for the weight of the vehicle. –...

  • Page 50: Cleaning The Dust Boots Of The Fork Legs

    11 SERVICE WORK ON THE CHASSIS Main work – Release bleeder screws Any excess pressure escapes from the interior of the fork. – Tighten the bleeder screws. H01182-12 Finishing work – Remove the motorcycle from the lift stand. ( p. 47) 11.4 Cleaning the dust boots of the fork legs Preparatory work...

  • Page 51: Removing The Fork Legs

    SERVICE WORK ON THE CHASSIS 11 11.5 Removing the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 47) – Remove the front wheel. p. 91) Main work – Remove screws and take off the clamp. –...

  • Page 52: Removing The Fork Protector

    11 SERVICE WORK ON THE CHASSIS – Position the brake caliper. Mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft) Loctite ® 243™ brake caliper – Position the brake line and the clamp. Mount and tighten screws V01693-11 Finishing work –...

  • Page 53: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 11 Main work – Take off cable holder in front of the left radiator. – Remove screw – Remove screw – Remove the upper triple clamp with the handlebar and hang them to the side. Info Cover the components to protect them against damage.
  • Page 54 11 SERVICE WORK ON THE CHASSIS – Position the fork legs. Air bleeder screw of the right fork leg is positioned to the front. Valve of the left fork leg faces the front. Info The air suspension AER valve is located in the left fork leg.

  • Page 55: Checking Steering Head Bearing Play

    SERVICE WORK ON THE CHASSIS 11 – Position the brake caliper. Mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft) Loctite ® 243™ brake caliper – Position the brake line and the clamp. Mount and tighten screws V01693-12 Finishing work –...

  • Page 56: Adjusting Steering Head Bearing Play

    11 SERVICE WORK ON THE CHASSIS Finishing work – Remove the motorcycle from the lift stand. ( p. 47) 11.12 Adjusting steering head bearing play Preparatory work – Raise the motorcycle with a lift stand. ( p. 47) – Remove the handlebar cushion. Main work –...

  • Page 57: Removing The Start Number Plate

    SERVICE WORK ON THE CHASSIS 11 11.14 Removing the start number plate – Remove screw – Disconnect the brake line at the start number plate. Take off the start number plate. V01701-10 11.15 Installing the start number plate – Connect the brake line at the start number plate. –...

  • Page 58: Removing The Shock Absorber

    11 SERVICE WORK ON THE CHASSIS 11.18 Removing the shock absorber Preparatory work – Raise the motorcycle with a lift stand. ( p. 47) Main work – Remove the cable ties. – Remove screws with the washers. – Remove screw –...

  • Page 59: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 11 – Remove nut and pull out the swingarm pivot. – Push the link fork back and secure it against falling over. V01706-10 – Hold the shock absorber and remove screw V01707-10 – Remove the shock absorber carefully at the bottom. V01708-10 11.19 Installing the shock absorber...
  • Page 60 11 SERVICE WORK ON THE CHASSIS – Position the link fork and mount the swingarm pivot. Info Pay attention to flat area – Mount and tighten nut Guideline Nut, fork pivot M16x1.5 100 Nm (73.8 lbf ft) V01709-10 – Mount the chain. –...

  • Page 61: Removing The Seat

    SERVICE WORK ON THE CHASSIS 11 – Position the left frame protector. – Insert the right frame protector from below and push it to the rear. – Mount and tighten screws with the washers. Guideline Screw, frame protec- 3 Nm (2.2 lbf ft) –...

  • Page 62: Removing The Air Filter Box Cover

    11 SERVICE WORK ON THE CHASSIS – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis K01133-10 11.22 Removing the air filter box cover Condition The air filter box cover is secured. – Remove the seat. ( p.

  • Page 63: Installing The Air Filter Box Cover

    SERVICE WORK ON THE CHASSIS 11 11.23 Installing the air filter box cover Condition The air filter box cover is secured. – Insert the air filter box cover in area and clip it into area V01727-12 – Mount and tighten screw Guideline Screw, air filter box EJOT PT...

  • Page 64: Cleaning The Air Filter And Air Filter Box

    11 SERVICE WORK ON THE CHASSIS Main work – Detach retaining tab . Remove air filter with air filter sup- port. – Take off air filter from air filter support. V01658-10 11.25 Cleaning the air filter and air filter box Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 65: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS 11 11.26 Installing the air filter Main work – Mount the clean air filter on the air filter support. – Grease the air filter in area Long-life grease ( p. 140) 102178-10 – Insert the air filter and position the top retaining pin bushing The air filter is correctly positioned.

  • Page 66: Installing The Main Silencer

    11 SERVICE WORK ON THE CHASSIS – Remove screws with the washers. – Pull off the main silencer from the manifold at exhaust sleeve V01659-10 11.29 Installing the main silencer – Position the main silencer in exhaust sleeve – Mount and tighten screws with the washers.

  • Page 67: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 11 Main work – Remove screws . Pull out inner tube with O-ring – Pull glass fiber yarn filling from the inner tube. – Clean the parts that need to be reinstalled and check for dam- age.
  • Page 68 11 SERVICE WORK ON THE CHASSIS Main work – Unplug connector of the fuel pump. – Clean quick release coupling thoroughly with compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve! V01590-10 –...

  • Page 69: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 11 11.32 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 70: Checking The Chain For Dirt

    11 SERVICE WORK ON THE CHASSIS – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis K01189-11 – Plug in connector for the fuel pump. – Remove the wash cap set and thoroughly clean the quick release coupling using compressed air.

  • Page 71: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 11 Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 72: Adjusting The Chain Tension

    11 SERVICE WORK ON THE CHASSIS Main work – Pull the chain at the end of the chain sliding piece upward to measure chain tension Guideline Lower chain section must be taut. Info Chain wear is not always even, so you should repeat this measurement at different chain positions.

  • Page 73: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    SERVICE WORK ON THE CHASSIS 11 Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 55 … 58 mm (2.17 … 2.28 in) Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks...
  • Page 74 11 SERVICE WORK ON THE CHASSIS – Pull on the top section of the chain with the specified weight Guideline Weight, chain wear measure- 10 … 15 kg (22 … 33 lb.) ment – Measure distance of 18 chain rollers in the lower chain section.
  • Page 75 SERVICE WORK ON THE CHASSIS 11 – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check that the chain sliding piece is firmly seated.

  • Page 76: Checking The Frame

    11 SERVICE WORK ON THE CHASSIS 11.38 Checking the frame – Check the frame for cracks and deformation. » If the frame exhibits cracks or deformation due to a mechanical impact: – Change the frame. Info Always replace a frame that has been dam- aged due to a mechanical impact.

  • Page 77: Checking The Rubber Grip

    SERVICE WORK ON THE CHASSIS 11 Main work – Check the throttle cable routing. Both throttle cables must be routed, side by side, on the back of the handlebars, above the fuel tank bracket on the right of the frame to the throttle valve body. Both throttle cables must be secured behind the rubber strap of the fuel tank support.

  • Page 78: Adjusting The Basic Position Of The Clutch Lever

    11 SERVICE WORK ON THE CHASSIS 11.42 Adjusting the basic position of the clutch lever – Adjust the basic position of the clutch lever to your hand size by turning adjusting screw Info Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handle- bar.

  • Page 79: Changing The Hydraulic Clutch Fluid

    SERVICE WORK ON THE CHASSIS 11 Info Clean up overflowed or spilled brake fluid immediately with water. 11.44 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. –...
  • Page 80 11 SERVICE WORK ON THE CHASSIS – Now inject the liquid into the system until it emerges from the drill hole of the master cylinder without bubbles. – Now and then, extract fluid from the master cylinder reservoir to prevent overflow. –...

  • Page 81: Brake System 12

    BRAKE SYSTEM 12 12.1 Checking the free travel of the hand brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. –...

  • Page 82: Checking The Front Brake Fluid Level

    12 BRAKE SYSTEM – Check the front and rear brake disc thickness at multiple points for the dimension Info Wear reduces the thickness of the brake disc around the contact surface of the brake linings. Brake discs - wear limit front 2.5 mm (0.098 in) H00938-10...

  • Page 83: Adding Front Brake Fluid

    BRAKE SYSTEM 12 12.5 Adding front brake fluid Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail. If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.

  • Page 84: Checking The Front Brake Linings

    12 BRAKE SYSTEM Main work – Move the brake reservoir mounted on the handlebar to a hori- zontal position. – Remove screws – Take off cover with membrane – Add brake fluid to level Guideline 5 mm (0.2 in) Level (brake fluid level below reservoir rim) Brake fluid DOT 4 / DOT 5.1 (...
  • Page 85 BRAKE SYSTEM 12 Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing. –...
  • Page 86 12 BRAKE SYSTEM Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons. – Remove cotter pins , pull out pin , and remove the brake linings. – Clean the brake caliper and the brake caliper bracket. V01714-11 –...

  • Page 87: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM 12 – Correct the brake fluid quantity to level Guideline 5 mm (0.2 in) Level (brake fluid level below reservoir rim) Brake fluid DOT 4 / DOT 5.1 ( p. 138) – Position cover with membrane . Mount and tighten screws Info Immediately clean up any brake fluid that has over-...

  • Page 88: Checking The Rear Brake Fluid Level

    12 BRAKE SYSTEM – Detach spring – Loosen nut and, with push rod , turn it back until you have maximum free travel. – To adjust the basic position of the foot brake lever to individ- ual requirements, loosen nut and turn screw accord- ingly.

  • Page 89: Adding Rear Brake Fluid

    BRAKE SYSTEM 12 Main work – Stand the vehicle upright. – Check the brake fluid level in level viewer » If the brake fluid has dropped below marking – Add rear brake fluid. p. 87) V01674-10 12.11 Adding rear brake fluid Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail.

  • Page 90: Checking The Brake Linings Of The Rear Brake

    12 BRAKE SYSTEM Main work – Stand the vehicle upright. – Remove screw cap with membrane and the O-ring. – Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. 138) – Mount the screw cap with the membrane and the O-ring. Info K01185-10 Clean up overflowed or spilled brake fluid immediately...
  • Page 91 BRAKE SYSTEM 12 Warning Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Hazardous substances cause environmental damage.
  • Page 92 12 BRAKE SYSTEM – Insert the new brake linings, insert pin , and mount the cotter pins Info Always change the brake linings in pairs. Make sure that decoupling plate is mounted on the piston side brake lining. – Operate the foot brake lever repeatedly until the brake lin- ings are in contact with the brake disc and there is a pressure M01181-10 point.

  • Page 93: Wheels, Tires 13

    WHEELS, TIRES 13 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 47) Main work – Manually press the brake caliper toward the brake disc to push back the brake pistons. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons.

  • Page 94: Installing The Front Wheel

    13 WHEELS, TIRES 13.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. –...

  • Page 95: Installing The Rear Wheel

    WHEELS, TIRES 13 Main work – Manually press the brake caliper toward the brake disc to push back the brake piston. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston. –...
  • Page 96 13 WHEELS, TIRES Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the rear wheel bearing. – Clean and grease shaft seal rings and contact surfaces of the spacers. Long-life grease ( p.

  • Page 97: Checking The Tire Condition

    WHEELS, TIRES 13 13.5 Checking the tire condition Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on handling characteristics. The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the motorcycle.

  • Page 98: Checking Spoke Tension

    13 WHEELS, TIRES 13.7 Checking spoke tension Warning Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in sec- ondary damage. The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes is too low, then lateral and radial run-out will form in the wheel.

  • Page 99: Electrical System 14

    ELECTRICAL SYSTEM 14 14.1 Removing the 12 V battery Warning Risk of injury 12 V batteries contain harmful substances. – Keep 12 V batteries out of the reach of children. – Keep sparks and open flames away from 12 V batteries. –...

  • Page 100: Charging The 12-V Battery

    14 ELECTRICAL SYSTEM Contact disks must be mounted under screws cable sockets with the claws toward the battery termi- nal. – Slide positive terminal cover over the positive terminal. Finishing work – Mount the seat. ( p. 59) 14.3 Charging the 12-V battery Warning Risk of injury 12 V batteries contain harmful substances.

  • Page 101: Changing Main Fuse

    ELECTRICAL SYSTEM 14 Main work – Check the battery voltage. » Battery voltage: < 9 V – Do not charge the 12 V battery. – Replace the 12 V battery and dispose of the old 12 V battery properly. » If the specifications have been met: Battery voltage: ≥...
  • Page 102 14 ELECTRICAL SYSTEM Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the seat. Preparatory work – Press and hold the switch-off button while the engine is idling until the engine stops. –...

  • Page 103: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM 14 14.5 Changing the fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat. Preparatory work – Press and hold the switch-off button while the engine is idling until the engine stops.

  • Page 104: Cooling System

    15 COOLING SYSTEM 15.1 Cooling system Water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operat- ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 105: Checking The Coolant Level

    COOLING SYSTEM 15 15.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

  • Page 106: Refilling With Coolant

    15 COOLING SYSTEM Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –...
  • Page 107 COOLING SYSTEM 15 – Pour coolant in up to measurement above the radiator fins. Guideline 10 mm (0.39 in) Coolant 1.2 l (1.3 qt.) Coolant ( p. 138) 400243-10 – Push protection cap upward over the thermostat. V01681-10 – Unplug connector –...

  • Page 108: Changing The Coolant

    15 COOLING SYSTEM Finishing work – Check the coolant level. ( p. 103) 15.6 Changing the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
  • Page 109 COOLING SYSTEM 15 – Push protection cap upward over the thermostat. E01426-10 – Unplug connector – Remove thermostat with O-ring and wait until the coolant escapes without bubbles. – Mount thermostat with the O-ring and tighten. Guideline Screw, cylinder head M10x1.25 12 Nm (8.9 lbf ft) temperature sensor...

  • Page 110: 16 Tuning The Engine

    16 TUNING THE ENGINE 16.1 Checking throttle cable play – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable Throttle cable play 2 …...

  • Page 111: Adjusting The Characteristic Map Of

    TUNING THE ENGINE 16 – Unscrew barrel adjuster until the smooth operation or play in the throttle cable deteriorates. – Turn adjusting screw approx. two turns further. – Tighten nut – Tighten nut – Slide on sleeve – Check the throttle grip for smooth operation. Finishing work –...
  • Page 112 16 TUNING THE ENGINE – Clean the outside of the handlebar and the inside of the grip tube. Mount the grip tube on the handlebar. – Attach the throttle cables to the guide plate and route cor- rectly. – Position half-shells , mount and tighten screws Guideline Screw, throttle grip...

  • Page 113: Programming Ambient Pressure

    TUNING THE ENGINE 16 Info Turn clockwise to decrease the idle speed. Turn counterclockwise to increase the idle speed. Make the setting in small steps. An incorrect idle speed can have a negative impact on overall engine running. 16.5 Programming ambient pressure Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.

  • Page 114: Map Adjustment

    16 TUNING THE ENGINE 16.6 Plug-in connector of ignition timing map adjustment Plug-in connector of the ignition timing map adjustment is located on the frame under the fuel tank. Possible states Soft – The plug-in connector of the ignition timing map •...

  • Page 115: Checking The Basic Position Of The Shift Lever

    TUNING THE ENGINE 16 16.8 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the rider's boot when in the basic position. When the shift lever keeps touching the boot, the transmission will be subject to an excessive load. –...

  • Page 116: 17 Service Work On The Engine

    17 SERVICE WORK ON THE ENGINE 17.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 117: Checking 2-Stroke Oil Level

    SERVICE WORK ON THE ENGINE 17 17.2 Checking 2-stroke oil level Warning Engine failure The engine will not be lubricated unless there is 2-stroke oil in the oil tank. If the oil level warning light lights up, the 2-stroke oil is sufficient for the remaining tank of fuel. –...
  • Page 118 17 SERVICE WORK ON THE ENGINE Main work – Pull EFI control unit upward off rubber lugs and hang to the side. – Remove protection cap of the diagnostics connector. V01689-10 – Put throttle grip into full throttle position and secure. V01645-11 –...

  • Page 119: Cleaning The Oil Screen In The Oil Tank

    SERVICE WORK ON THE ENGINE 17 – Check whether air bubbles are visible in the hose » If air bubbles are visible: – Repeat the entire procedure until air bubbles are no longer visible. – Mount protection cap on the diagnostics connector. –...
  • Page 120 17 SERVICE WORK ON THE ENGINE – Loosen clamps of the throttle valve body. – Lift the subframe slightly and secure it. Info Pay attention to intake flange – Pull throttle valve body towards the rear, out of the intake flange, and hang it to the side.
  • Page 121 SERVICE WORK ON THE ENGINE 17 – Mount throttle valve body – Remove the locking piece and position the subframe. Info Pay attention to intake flange – Position and tighten clamps of the throttle valve body. Guideline Screw, intake 6 Nm (4.4 lbf ft) flange/reed valve housing V01726-10...

  • Page 122: Checking The Gear Oil Level

    17 SERVICE WORK ON THE ENGINE 17.5 Checking the gear oil level Info The gear oil level must be checked when the engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Remove gear oil level monitoring screw –...

  • Page 123: Adding The Gear Oil

    SERVICE WORK ON THE ENGINE 17 – Remove filler plug with the O-ring, and fill up with gear oil. Gear oil 0.80 l Engine oil (0.85 qt.) (15W/50) p. 138) – Mount and tighten the filler plug together with the O-ring. Danger Danger of poisoning Exhaust gases are toxic and inhal- 401955-11...
  • Page 124 17 SERVICE WORK ON THE ENGINE Finishing work Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space.

  • Page 125: Cleaning, Care 18

    CLEANING, CARE 18 18.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...
  • Page 126 18 CLEANING, CARE – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p. 140) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

  • Page 127: Storage 19

    STORAGE 19 19.1 Storage Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – In case of skin contact, rinse the affected area with plenty of water. –...

  • Page 128: Preparing For Use After Storage

    19 STORAGE Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Because the engine will not warm up sufficiently, the water vapor produced during combustion will condense, caus- ing engine parts and the exhaust system to rust.

  • Page 129: Troubleshooting 20

    Clean the connector and treat it with loose or oxidized contact spray. – Error in the electronic fuel Read out the fault memory using the injection Husqvarna Motorcycles diagnostics tool. – The engine has no idle speed Spark plug defective Change the spark plug. –...
  • Page 130 Possible cause Action – Engine has too little power Error in the electronic fuel Read out the fault memory using the injection Husqvarna Motorcycles diagnostics tool. – Fuel supply interrupted Check the fuel tank breather. – Exhaust system leaky, Check exhaust system for damage.

  • Page 131: Blink Code

    BLINK CODE 21 Blink code for malfunction indicator lamp 14 Malfunction indicator lamp flashes 1x long, 4x short Crankcase pressure sensor – difference too high between sensor and engine elec- Error level condition tronics control unit Blink code for malfunction indicator lamp 09 Malfunction indicator lamp flashes 9x short Error level condition...
  • Page 132 21 BLINK CODE Blink code for malfunction indicator lamp 37 Malfunction indicator lamp flashes 3x long, 7x short Ignition coil – circuit fault Error level condition Blink code for malfunction indicator lamp 02 Malfunction indicator lamp flashes 2x short Crankshaft speed sensor – synchronization faulty Error level condition Crankshaft speed sensor –...

  • Page 133: Technical Data

    TECHNICAL DATA 22 22.1 Engine Design 1-cylinder 2-stroke engine, water-cooled, with reed intake, exhaust control and transfer duct injection Displacement (250 XC TPI US) 249 cm³ (15.19 cu in) Displacement (300 XC TPI US) 293.15 cm³ (17.8892 cu in) Stroke 72 mm (2.83 in) Hole (250 XC TPI US) 66.4 mm (2.614 in)

  • Page 134: Engine Tightening Torques

    22 TECHNICAL DATA 22.2 Engine tightening torques EJOTDELTA PT Screw, inner membrane sheets ® 35x25 1 Nm (0.7 lbf ft) EJOTDELTA PT Screw, membrane support plate ® 30x12 1 Nm (0.7 lbf ft) EJOTDELTA PT ® Screw, outer membrane sheets 30x6 1 Nm (0.7 lbf ft) Screw, angle lever, exhaust control...

  • Page 135: Capacities

    TECHNICAL DATA 22 Screw, water pump cover 10 Nm (7.4 lbf ft) Vacuum connection, cylinder 4 Nm (3 lbf ft) Loctite ® 2701™ Vacuum connection, housing 2 Nm (1.5 lbf ft) Loctite ® 243™ breather Screw, balancer shaft 30 Nm (22.1 lbf ft) Loctite ®...

  • Page 136: Electrical System

    22 TECHNICAL DATA Brake system Disc brakes, floating brake calipers Brake discs - diameter front 260 mm (10.24 in) rear 220 mm (8.66 in) Brake discs - wear limit front 2.5 mm (0.098 in) rear 3.5 mm (0.138 in) Offroad tire pressure front 1.0 bar (15 psi) rear...

  • Page 137: Fork

    TECHNICAL DATA 22 22.7 Fork Fork article number 34.18.8U.73 WP XACT 5448 Fork Compression damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Rebound damping Comfort 23 clicks Standard 18 clicks Sport 13 clicks Air pressure 9.6 bar (139 psi) Fork length 950 mm (37.4 in) Oil capacity external mechanism...

  • Page 138: Chassis Tightening Torques

    22 TECHNICAL DATA Riding sag 105 mm (4.13 in) Fitted length 477 mm (18.78 in) Shock absorber fluid ( p. 139) SAE 2.5 22.9 Chassis tightening torques Screw, intake air temperature sen- EJOTDELTA PT ® 45x12-Z 0.7 Nm (0.52 lbf ft) Screw, oil fill level sensor G 3/4 "...
  • Page 139 TECHNICAL DATA 22 Screw, chain sliding piece 15 Nm (11.1 lbf ft) Screw, engine brace on engine M8x20 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, engine brace on frame M8x15 25 Nm (18.4 lbf ft) Loctite ® 2701™ Screw, fork stub 15 Nm (11.1 lbf ft) Screw, front brake caliper...

  • Page 140: Substances

    23 SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 MOTOREX ®...
  • Page 141 SUBSTANCES 23 Recommended supplier MOTOREX ® – Cross Power 2T Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 142) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.

  • Page 142: Auxiliary Substances

    24 AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier MOTOREX ® – Racing Bio Dirt Remover Chain cleaner Recommended supplier MOTOREX ® – Chain Clean Fuel additive Recommended supplier MOTOREX ® – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier...
  • Page 143 AUXILIARY SUBSTANCES 24 Silicone spray Recommended supplier MOTOREX ® – Silicone Spray Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier MOTOREX ® – Quick Cleaner Special grease (00062010053) Recommended supplier Klüber Lubrication ® – KLÜBERFOOD NH1 34‑401 Universal oil spray Recommended supplier...

  • Page 144: Standards

    25 STANDARDS JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motor- cycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 145: Index Of Special Terms

    INDEX OF SPECIAL TERMS 26 Injection into transfer ducts (Trans- Electronic fuel injection in which two injection valves fer Port Injection) in the transfer ducts of the cylinders are used On-board diagnosis Vehicle system, which monitors the specified parame- ters of the vehicle electronics...

  • Page 146: List Of Abbreviations

    27 LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 147: List Of Symbols

    Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an error in the vehicle electronics. Stop, and contact an authorized Husqvarna Motorcycles workshop. The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.

  • Page 148: Index

    INDEX rear brake, checking ....88 INDEX 12 V battery Capacity installing ......97 coolant .
  • Page 149 INDEX Environment ......8 Handlebar position ..... . 45 adjusting .
  • Page 150 INDEX checking ......53 Storage ......125 Rear sprocket Switch-off button .
  • Page 151 *3214211en* 3214211en 04/2020 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM http://www.ktm.com...

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