KTM 250 EXC 2024 Parts list manual

SETUP INSTRUCTIONS 2024
250 EXC
250 EXC SIX DAYS
250 XC‑W
300 EXC
300 EXC SIX DAYS
300 XC-W
300 EXC HARDENDURO
300 XC-W HARDENDURO
Art. no. 3214968en

INTRODUCTION
*3214968en*
3214968en
11.07.2023
INTRODUCTION
Perform the work described in these setup instructions before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
These setup instructions were written to correspond to the latest state of this model series. We reserve the right
to make modifications in the interest of technical advancement without at the same time updating these setup
instructions.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop
are not specified here. It is assumed that the work will be performed by a fully trained mechanic.
All specifications contained herein are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right
to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc.,
without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop produc-
tion of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from fig-
ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that
does not belong to the regular scope of supply.
© 2023 KTM Sportmotorcycle GmbH, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission
of the copyright owner.
ISO 9001(12 100 6061)
KTM applies quality assurance processes that lead to the highest possible product quality as
defined in the ISO 9001 international quality management standard.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
Stallhofnerstraße 3
5230 Mattighofen, Austria
This document is valid for the following models:
250 EXC EU (F7303X7)
250 EXC SIX DAYS EU (F7303X2)
250 XC‑W US (F7375X4)
300 EXC EU (F7403X7)
300 EXC BR (F7440X6)
300 EXC SIX DAYS EU (F7403X2)
300 EXC SIX DAYS ASEAN (F7488X2)
300 EXC SIX DAYS BR (F7440X2)
300 EXC SIX DAYS CN (F7487X2)
300 XC‑W US (F7475X3)
300 EXC HARDENDURO EU (F7403X3)
300 EXC HARDENDURO CN (F7487X6)
300 XC‑W HARDENDURO US (F7475X6)

1 MEANS OF REPRESENTATION
2
1.1 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).
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details 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 rework.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.
Name®Indicates a protected name.
Brand™ Indicates a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which
are explained in the glossary.

SETUP 2
3
2.1 Transport mode
H02712-01
This vehicle was blocked for transport in the software.
To operate the vehicle, the vehicle electronics must be enabled.
This process is conducted during initial setup in KTM Dealer.net.
Enabling ensures that the initial setup in KTM Dealer.net is docu-
mented.
Enabling can be performed either temporarily, e.g. for a test ride,
or permanently for vehicle handover.
Info
Make sure that the vehicle is permanently enabled before
handing it over to the customer.
2.2 Diagnostics connector
H00933-12
Diagnostics connector 1is located under the seat below the EFI
control unit.
2.3 Unpacking and setting up the vehicle
V02692-01
Condition
Packaging V3
–Remove the box and the plastic packaging.
Info
To avoid damaging the motorcycle during the setup,
leave the protective film on the vehicle until you
have finished.
–Remove the separate enclosure and unpack it. Check
that the scope of supply is complete on the basis of the
enclosed packing list.
Info
The procedure for missing components is described
in the Customer Service Manual.
–Carefully loosen and remove the tension belts around the
fork legs.
–Remove the attachment on the rear wheel.
Info
An assistant prevents the motorcycle from falling over.
–Have a lift stand available.
Lift stand (A54029955100)

2 SETUP
4
V02693-01
–Together with an assistant, take the vehicle off the pallet.
–Position the vehicle on a lift stand.
–Check the vehicle for transport damage.
Info
The procedure in the event of transport damage is
described in the Customer Service Manual.
–Remove the headlight mask with the headlight. ( p. 28)
H02474-10
–Position the turn signal indicator lamp 1in the combina-
tion instrument bracket.
W00383-10
(All standard EXC models)
–Loosen and lift upper triple clamp.
–Position steering lock 2.
–Mount upper triple clamp on the ignition lock.
Guideline
Screw, top triple
clamp
M8 20 Nm
(14.8 lbf ft)
Screw, top steering
stem
M8 20 Nm
(14.8 lbf ft)
(All SIX DAYS models, 300 EXC HARDENDURO EU, 300 EXC HARDEN-
DURO CN)
–Loosen and lift upper triple clamp.
–Position steering lock 2.
–Mount upper triple clamp on the ignition lock.
Guideline
Screw, top
triple clamp
M8 17 Nm (12.5 lbf ft)
Screw, top
steering stem
M8 17 Nm (12.5 lbf ft)
Loctite®243™

SETUP 2
5
W00324-11
(All standard models)
–Remove screws 3and take off the handlebar support.
–Move the handlebar support in 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 handlebar support so that it is even.
W00323-11
(All special models)
–Remove screws 3and take off the handlebar support.
–Move the handlebar support in 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 handlebar support so that it is even.
W00384-10
Warning
Danger of accidents A repaired handlebar poses a
safety risk.
If the handlebar is bent or straightened, the mate-
rial becomes fatigued. The handlebar may break as a
result.
–Change the handlebar if the handlebar is damaged
or bent.
–Position the handlebar.

2 SETUP
6
Info
Make sure the cables and wiring are routed correctly.
–Position the handlebar clamps. Mount and tighten the screws
evenly.
Guideline
Screw, handlebar
clamp
M8 20 Nm (14.8 lbf ft)
Info
The markings on the handlebar should be at the center
of the handlebar clamps.
Keep the installed gap widths equal when tightening.
W00385-10
(All EXC models)
–Position the controls on the right half of the handlebar.
W00386-10
(All XC‑W models)
–Position the controls on the right half of the handlebar.
W00387-10
(All EXC models)
–Position the controls on the left handlebar half.
W00388-10
(All XC‑W models)
–Position the controls on the left handlebar half.

SETUP 2
7
W00389-10
(All special models)
Caution
Voiding of the government approval for road use and
the insurance coverage If the combination switch
is mounted, the vehicle’s road permit, if any,
expires.
–Only operate the vehicle in closed-off areas
remote from public road traffic if the combina-
tion switch is installed.
–(Optional) Mount combination switch on the left side.
Info
The figure shows a possible installation position of
the left side combination switch.
402148-01
(All EXC models)
–Mount the turn signal switch.
W00390-10
–Join all plug-in connectors to the connector board.
–Route the cable without tension and secure with quick release.

2 SETUP
8
S01411-01
(All special models)
Caution
Voiding of the government approval for road use and
the insurance coverage If the combination switch
is mounted, the vehicle’s road permit, if any,
expires.
–Only operate the vehicle in closed-off areas
remote from public road traffic if the combina-
tion switch is installed.
–(Optional) Remove the protection cap and join the plug-in
connector of the left combination switch.
H01060-01
(All EXC models)
–Mount the mirror clamps on both sides.
E01231-10
–Mount both rear mirrors with the adapter.

SETUP 2
9
E00852-01
–Preassemble the hand guards on the left and right.
S03689-10
–Mount the left hand guard.
–Mount the right hand guard.
W00392-10
–Fix the handlebar cushion to the handlebar clamp.
–Install front fender. ( p. 28)
–Remove the 12-V battery. ( p. 22)
–Charge the 12-V battery. ( p. 24)
Guideline
The 12-V battery must be fully charged before it is handed
over to the customer.
(All XC‑W models)
–Install the headlight mask with the headlight. ( p. 29)
–Install the 12-V battery. ( p. 26)
–Mount the seat. ( p. 18)

2 SETUP
10
W00393-10
(All EXC models)
–Connect plug 4with turn signal wiring harness.
S03673-01
–Insert the black and violet cables of the bulb included in
the separate enclosure into the socket and position it in
the turn signal indicator lamp.
W00395-10
–Position the turn signal on the headlight mask on both
sides, mount nuts with washers and tighten.
–Join plug-in connector 5of the left turn signal using the
violet and brown cable colors of the turn signal cable har-
ness.
–Join plug-in connector 6of the right turn signal using
the black and brown cable colors of the turn signal cable
harness.
–Join plug-in connector 7of the headlight.
–Connect plug-in connector 8of the turn signal switch.
–Install the headlight mask with the headlight. ( p. 29)
W00396-10
–Disconnect tail light plug-in connector 9on the wiring
harness.
–Remove screws bk.

SETUP 2
11
W00397-10
–Remove screws bl.
–Remove screws bm.
–Remove the license plate holder with the tail light.
Info
Pay attention to the cable of the tail light.
W00398-10
–Loosen screws bn and remove license plate holder from
fender.
–Loosen screws bo and hang the tail light to the side.
W00399-10
–Position the turn signal on both sides on the license plate
holder, mount nuts bp with washers and tighten.
–Position the license plate lamp on the license plate holder,
and mount and tighten screws bq.
–Connect the plug-in connections of the turn signals and
the license plate lamp with the wiring harness.
W00401-10
–Drill a hole at marking Aon the license plate holder to
the size of the marking.

2 SETUP
12
W00400-10
–Position the tail light together with the license plate holder
on the license plate bracket.
Info
Ensure that the cables are routed correctly.
–Position the fender on the license plate holder.
W00398-10
–Mount and tighten screws bo.
Guideline
Remaining screws,
chassis
EJOT PT®
K60x25‑Z
2 Nm (1.5 lbf ft)
–Mount and tighten screws bn.
Guideline
Remaining screws,
chassis
EJOT PT®
K60x25‑Z
2 Nm (1.5 lbf ft)
V01867-10
–Mount and tighten screw br.
Guideline
Remaining screws,
chassis
EJOT PT®
K60x25‑Z
2 Nm (1.5 lbf ft)
W00397-10
–Slide license plate holder onto tail section and position.
Info
Ensure that the cables are routed correctly.
–Mount and tighten screws bm.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
–Mount and tighten screws bl.
Guideline
Remaining screws,
chassis
EJOT PT®
K60x25‑Z
2 Nm (1.5 lbf ft)

SETUP 2
13
W00402-10
–Mount and tighten screws bk.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
–Join the plug-in connectors of tail light bs and turn signal
cable harness bt with the wiring harness.
Info
Pay attention to routing of the wiring harnesses.
–Install the 12-V battery. ( p. 26)
–Mount the seat. ( p. 18)
R01229-10
–Position the right footrest and pin.
Info
Only insert the pin to the extent that the spring can still
be mounted.
S03690-10
–Position spring as shown.
Spring Bengages in area C.
I00468-10
–Press the spring with special tool ck.
Footrest spring plier (79029083000)
The special tool is applied to area Don the footrest.
–Mount pin cl.

2 SETUP
14
I00469-10
–Mount the washer and splint cm.
R00757-10
–Position the left footrest and pin.
Info
Only insert the pin to the extent that the spring can still
be mounted.
S03693-10
–Position spring as shown.
Spring Eengages in area F.
I00470-10
–Press the spring with special tool ck.
Footrest spring plier (79029083000)
The special tool is applied to area Gon the footrest.
–Mount pin cn.

SETUP 2
15
I00471-10
–Mount the washer and splint co.
I00472-10
–Stick displacement sticker on the left and right of the side
cover.
(All special models)
–Install the engine guard. ( p. 31)
–Install the frame protector. ( p. 31)
–Unpack and mount the KTM PowerParts included in the deliv-
ery (optional).
Info
Read the accompanying KTM PowerParts fitting instruc-
tions.
–Make sure that the reflectors are glued on to the left and right
fork leg.
H02556-01
Info
The reflectors must not be covered by trim parts.
–Attach the stickers included in the scope of supply (optional).
–Charge the 12-V battery. ( p. 24)
Guideline
The 12-V battery must be fully charged before it is handed
over to the customer.
Info
The first charging process may take longer with a new
12-V battery.
–Set kilometers or miles. ( p. 34)
–Adjust combination instrument function. ( p. 35)
–Set the clock. ( p. 35)
–Add 2-stroke oil. ( p. 32)
–Refuel. ( p. 33)
–Position all controls in their exact positions on the handlebar.
Tighten all screws.
–Remove the remaining film, padding, the corrugated card-
board, and the other packaging material.

2 SETUP
16
–Prepare the vehicle according to the specifications in
KTM Dealer.net for handover to the customer.
Info
Transport mode must be deactivated to be able to start
the motorcycle.

WORK 3
17
3.1 Raising the motorcycle with a lift stand
401942-01
Note
Danger of damage The parked vehicle can roll away or fall
over.
–Park the vehicle on a firm and level surface.
–Raise the motorcycle at the frame underneath the engine.
Lift stand (78129955100)
Neither wheel is in contact with the ground.
–Secure the motorcycle against falling over.
3.2 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 lift stand.
–Remove the lift stand.
–To park the motorcycle, press side stand 1to the ground
with your foot and lean the motorcycle on it.
Info
When you are riding, the side stand must be folded up
and secured with the rubber strap.
3.3 Removing the seat
W00301-10
–Remove screw 1.
W00311-10
–Pull seat toward the fuel tank and lift it off.

3 WORK
18
3.4 Mounting the seat
W00314-10
–Mount the front of the seat on the collar bushings of the fuel
tank, lower the seat at the rear, and push the seat to the rear.
The holding lugs engage in the recesses at the back.
–Make sure the seat is latched in place correctly.
W00301-10
–Mount and tighten screw 1.
Guideline
Screw, seat fixing M6 8 Nm (5.9 lbf ft)
3.5 Removing 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.
–Switch 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 refueling.