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.