KTM F7303S2 Setup Instructions Download

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*3213896en*

3213896en

03/2018

KTM Sportmotorcycle GmbH

5230 Mattighofen/Austria

http://www.ktm.com

Photo: Mitterbauer/KTM

Summary of Contents for F7303S2

Page 1: ...SETUP INSTRUCTIONS 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 3213896en...

Page 2: ......

Page 3: ...ecifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice KTM accepts no liability for delivery options deviations from figures and d...

Page 4: ...or tips Indicates the result of a testing step Indicates a voltage measurement Indicates a current measurement Indicates a resistance measurement Indicates the end of an activity including potential r...

Page 5: ...1 10 Condition Packaging V2 Remove the box and the plastic packaging Info An assistant prevents the motorcycle from falling over To avoid damaging the motorcycle during the setup leave the protective...

Page 6: ...you have finished Remove and unpack the separate enclosure and attach ments Check that the scope of supply is complete using the enclosed packing list Have a lift stand available Lift stand 781299551...

Page 7: ...toward the front between the upper and lower triple clamps Install the fork legs p 25 S01414 10 All standard EXC XC W models Remove screws 3 and take off handlebar supports Move the handlebar supports...

Page 8: ...he handlebar supports to the desired position and mount and tighten screws 3 Guideline Screw handle bar support M10 40 Nm 29 5 lbf ft Loctite 243 Info Position the left and right handlebar supports ev...

Page 9: ...widths equal when tightening F01132 01 All EXC models Position the controls on the right half of the handlebar F01136 01 All XC W models Position the controls on the right half of the handlebar S0145...

Page 10: ...e is invalidated Only operate the vehicle in closed off areas away from public road traffic if the map switch is installed Position the map switch with the clamp on the right han dlebar half Info Read...

Page 11: ...yellow and white cables Join all plug in connectors Route the cable without tension and secure with cable tie S01457 10 Route the cable without tension and secure with cable ties and cable holder H01...

Page 12: ...e right hand guard F01135 10 Secure the handlebar cushion with two cable ties Install front fender p 29 Install the front wheel p 26 Remove the battery p 26 Recharge the battery p 27 All XC W models I...

Page 13: ...cable harness Info Pay attention to where the brake line is routed when doing so Connect plug in connector 9 of the headlight Connect plug in connector bk of the turn signal switch Secure turn signal...

Page 14: ...ull off the main silencer at the rubber sleeve bs and the spring ring from the manifold F01157 10 Disconnect the plug in connector bt on the main wiring harness Join turn signal cable harness plug in...

Page 15: ...0 Remove screws cp and hang the tail light to the side Drill a hole at the marking C to the size of the marking F01158 10 Route the turn signal cable harness toward the rear and pass through the frame...

Page 16: ...45 10 Mount and tighten screw ck with the collar bushing Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount and tighten screw cl Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount...

Page 17: ...frame M8 35 Nm 25 8 lbf ft Loctite 2701 Mount and tighten screw bp Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Install the battery p 29 Install the fuel tank p 22 F01149 10 Position turn s...

Page 18: ...e enough space to mount the spring F01151 10 Position spring as shown Spring D engages in area E F01152 10 Press the spring with special tool cs Footrest spring plier 79029083000 The special tool is a...

Page 19: ...enough space to mount the spring F01154 10 Position spring as shown Spring G engages in area H F01155 10 Press the spring with special tool cs Footrest spring plier 79029083000 The special tool is ap...

Page 20: ...rts included in the deliv ery optional Info Read the accompanying KTM PowerParts fitting instruc tions Apply the sticker included in the delivery optional Set kilometers or miles p 35 Adjust the combi...

Page 21: ...2 Removing the motorcycle from the lift stand Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 401943 10 Remove the motorcycle from the...

Page 22: ...witch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refuelin...

Page 23: ...line Dirt in the fuel line clogs the injection valve Disconnect the plug in connection of the fuel line Info Remaining fuel may flow out of the fuel hose Mount wash cap set 3 Wash cap set 81212016100...

Page 24: ...ye 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 Rinse the eyes thoroug...

Page 25: ...ircumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Lubricate the O ring and connect plug in connection 3 for the fuel line Info Route the cable and fuel...

Page 26: ...p 22 Mount the seat p 20 3 8 Installing the shock absorber E00870 10 Main work Push splash protector 1 to the side and position the shock absorber Mount and tighten screw 2 Guideline Screw top shock a...

Page 27: ...ls Tighten screws 2 Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Tighten screws 3 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft E00919 11 All Six Days models Tighten screws 2 Guide...

Page 28: ...ositioned V00364 11 Mount and tighten screw 2 Guideline Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Operate the hand brake lever several times until the brake lin ings are seated correctly aga...

Page 29: ...m voltage before the start of the charge 9 V Dispose of batteries with less than the minimum voltage correctly Disconnect negative cable 1 from the battery Pull back positive terminal cover 2 and disc...

Page 30: ...estroyed If the battery is depleted by repeated starting the battery must be charged immediately If the battery is left in a discharged state for an extended period it will become over discharged and...

Page 31: ...ew 5 and the cable lug 6 with the claws toward the battery terminal Slide positive terminal cover 7 over the positive terminal Connect negative cable 4 to the battery Guideline Screw battery termi nal...

Page 32: ...the headlight mask Release rubber bands 1 Slide the headlight mask up and swing it forward E00900 10 All EXC models Detach plug in connectors 2 and take off the headlight mask with the headlight E0035...

Page 33: ...tal surface in front of a light wall and make a marking at the height of the center of the low beam headlight Make another mark at a distance B under the first marking Guideline Distance B 5 cm 2 in P...

Page 34: ...uctions on how to apply the marking Checking the headlight setting Info If you have a payload you may have to correct the headlight range Tighten screw 1 3 19 Installing the engine guard All Six Days...

Page 35: ...refuel Time the oil pump if the 2 stroke oil hose has been removed or the 2 stroke oil tank has been fully depleted in error Open 2 stroke oil tank cap p 32 M01516 10 Fill the 2 stroke oil tank up to...

Page 36: ...to the environment Do not allow fuel to enter the groundwater the soil or the sewage system E00929 10 Press release button 1 turn the filler cap counterclockwise and lift it free 3 24 Closing the fil...

Page 37: ...ot be sufficient This will result in problems with the fuel system Refuel only with clean fuel that meets the specified standards Note Environmental hazard Improper handling of fuel is a danger to the...

Page 38: ...d SPEED ODO display modes are activated Condition The motorcycle is stationary 400318 01 Repeatedly press the button briefly until H appears at the bottom right of the display Press the button for 2 3...

Page 39: ...s Set the hour display with the button and or button Wait 3 5 seconds The next segment of the display flashes and can be set You can set the following segments in the same way as the hours by pressing...

Page 40: ...Nm 3 7 lbf ft Screw turn signal switch All EXC models M5 1 Nm 0 7 lbf ft Nut cable on starter motor M6 4 Nm 3 lbf ft Remaining nuts chassis M6 10 Nm 7 4 lbf ft Remaining screws chassis M6 10 Nm 7 4 l...

Page 41: ...stem All Six Days models M8 17 Nm 12 5 lbf ft Loctite 243 Screw top triple clamp All stan dard EXC XC W models M8 20 Nm 14 8 lbf ft Screw top triple clamp All Six Days models M8 17 Nm 12 5 lbf ft Engi...

Page 42: ...Motorex Cross Power 2T Super unleaded ROZ 95 RON 95 PON 91 Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specifie...

Page 43: ...AUXILIARY SUBSTANCES 6 41 Long life grease Recommended supplier Motorex Bike Grease 2000...

Page 44: ...fication for a 2 stroke engine oil that was specifically developed for the extreme demands of racing Thanks to first rate synthetic esters and specially designed additives superb combustion is achieve...

Page 45: ...3213896en 3213896en 03 2018 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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