2018-2022 KTM 250 EXC TPI Engine (Gearbox) Oil Capacity Recommended Oil Specs



Comprehensive Guide to Transmission Oil Maintenance for KTM 250 EXC TPI (2018-2022)

Maintaining the gear oil in your KTM 250 EXC TPI 2 stroke is crucial for ensuring the longevity and optimal performance of your motorcycle's transmission. This guide covers the steps for checking, changing, and adding gear oil, as well as some essential safety precautions and tips. This manual is also use for the model: 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 EXC TPI ERZBERGRODEO, 300 XC-W TPI ERZBERGRODEO for the same engine especially gearbox that used for those modoels. Based on the official manual book changing gear oil engine should be Every 40 operating hours.

Checking the Gear Oil Level

Regularly checking the gear oil level is essential to prevent premature wear on the transmission. This should always be done when the engine is cold to get an accurate reading.

Steps to Check Gear Oil Level



  1. Position the Motorcycle: Stand the motorcycle upright on a level surface. This ensures an accurate reading of the gear oil level.

  2. Detach the Foot Brake Lever Spring: Carefully detach the spring to access the gear oil level monitoring screw.

  3. Remove the Gear Oil Level Monitoring Screw: Unscrew the monitoring screw. A small amount of gear oil should flow out of the drilled hole.

    • If No Gear Oil Flows Out: Add the appropriate amount of gear oil until a small amount starts to emerge from the hole.

  4. Reinstall the Gear Oil Level Monitoring Screw: Tighten the screw to the specified torque of 8 Nm (5.9 lbf ft).

  5. Reattach the Foot Brake Lever Spring: Ensure the spring is securely reattached to complete the process.

Changing the Gear Oil

Changing the gear oil at regular intervals is vital for maintaining the health of the transmission. Follow these steps to change the gear oil correctly:

Precautions

  • Danger of Scalding: Engine and gear oil can get extremely hot after riding. Always wear protective clothing and gloves to avoid burns.
  • Environmental Hazard: Dispose of used oil, filters, and other hazardous substances according to local environmental regulations.

Steps to Change Gear Oil

  1. Prepare the Motorcycle:

    • Remove the engine guard if applicable.
    • Position the motorcycle on a level surface.
    • Place a suitable container under the engine to catch the used oil.

  2. Drain the Gear Oil:



    • Remove the gear oil drain plug with the magnet.
    • Allow the oil to drain fully.
    • Clean the drain plug and magnet thoroughly.
    • Clean the sealing surface on the engine.
    • Reinstall the drain plug with a new seal ring, tightening it to 20 Nm (14.8 lbf ft).

  3. Refill with Gear Oil:



    • Remove the filler plug along with the O-ring.
    • Fill the engine with 0.80 liters (0.85 qt.) of the recommended gear oil. For this model, use 15W/50 engine oil, compliant with JASO T903 MA2 standards. Recommended supplier MOTOREX® – Top Speed 4T
    • Reinstall the filler plug with the O-ring, ensuring it is tight.

  4. Start the Engine and Check for Leaks:

    • Ensure adequate ventilation when running the engine indoors.
    • Start the engine and monitor for any oil leaks. If leaks are detected, stop the engine immediately and fix the issue.

  5. Recheck the Gear Oil Level: After running the engine, check the oil level again to ensure it is at the correct level.

Adding Gear Oil

If the gear oil level is low, it is crucial to top it up to prevent damage to the transmission. Only add gear oil when the engine is cold.

Steps to Add Gear Oil

  1. Prepare the Motorcycle: Park the motorcycle on a level surface.

  2. Detach the Foot Brake Lever Spring: This will allow access to the gear oil level monitoring screw.

  3. Remove the Gear Oil Level Monitoring Screw and Filler Plug:

    • Remove the filler plug along with the O-ring.
    • Add gear oil until it begins to emerge from the drilled hole of the gear oil level monitoring screw.

  4. Reinstall the Screws:

    • Tighten the gear oil level monitoring screw to 8 Nm (5.9 lbf ft).
    • Reinstall the filler plug with the O-ring securely.

  5. Reattach the Foot Brake Lever Spring: Ensure it is properly attached to complete the process.

Safety Considerations

  • Danger of Poisoning: Exhaust gases are toxic and can be deadly. Always ensure proper ventilation when running the engine indoors, and use effective exhaust extraction systems.

  • Handling Gear Oil: Always use the recommended gear oil and follow the manufacturer’s guidelines to avoid transmission issues.

Final Steps

After completing any maintenance, it’s important to:

  • Install the Engine Guard: Reinstall any components removed during the process.
  • Clean the Motorcycle: Be cautious when using high-pressure cleaners as they can damage components if used improperly. Maintain a minimum distance of 60 cm (23.6 in) between the nozzle and the motorcycle parts to avoid damage.

By following these detailed steps and precautions, you can ensure that your KTM 250 EXC TPI remains in peak condition, delivering reliable performance on every ride. Regular maintenance not only extends the life of your motorcycle but also enhances your riding experience.

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