KTM 250 EXC SIX DAYS 2023 Setup Instructions
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KTM 250 EXC SIX DAYS 2023 Setup Instructions

KTM 250 EXC SIX DAYS 2023 Setup Instructions

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SETUP INSTRUCTIONS
2023
250 EXC
250 EXC SIX DAYS
250 XC‑W
300 EXC
300 EXC SIX DAYS
300 XC-W
Art. no. 3214695en

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  • Page 1 SETUP INSTRUCTIONS 2023 250 EXC 250 EXC SIX DAYS 250 XC‑W 300 EXC 300 EXC SIX DAYS 300 XC-W Art. no. 3214695en...
  • Page 3 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.

  • Page 4: Means Of Representation

    1 MEANS OF REPRESENTATION 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.
  • Page 5 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.
  • Page 6 2 SETUP – 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. –...

  • Page 7: Mount And Tighten Screws

    SETUP 2 (All EXC models) – Position the connector board and combination instru- ment on the upper triple clamp. – Mount and tighten screws Guideline Remaining screws, 10 Nm chassis (7.4 lbf ft) H02537-10 (All standard XC-W models) – Position the combination instrument on the upper triple clamp.
  • Page 8 2 SETUP Info Make sure the cables and wiring are positioned cor- rectly. – Position the handlebar clamps. Mount and tighten the screws evenly. Guideline Screw, handlebar 20 Nm clamp (14.8 lbf ft) Info The markings on the handlebar should be at the center of the handlebar clamps.
  • Page 9 SETUP 2 Guideline Screw, handlebar 20 Nm clamp (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 tighten- ing. (All EXC models) – Position the controls on the right half of the handlebar. S03665-01 (All standard XC-W models) –...
  • Page 10 – Position the map switch with the clamp on the right han- dlebar half. Info Read the accompanying KTM PowerParts instruc- tions. E00855-01 Condition Packaging V12 (All EXC models) –...
  • Page 11 SETUP 2 (All standard XC-W models) – Insert indicator lamp in the socket. – Plug in light switch with the yellow and white cables. – Join all plug-in connectors. – Route the cable without tension and secure with the cable ties. F01134-10 –...
  • Page 12 2 SETUP – Preassemble the hand guards on the left and right. E00852-01 – Mount the left hand guard. – Mount the right hand guard. S03689-10 – Secure the handlebar cushion with two cable ties. – Install front fender. ( p.
  • Page 13 SETUP 2 (All EXC models) – Remove connector from the bracket and join with turn signal wiring harness. S03672-10 – 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.
  • Page 14 2 SETUP – Disconnect tail light plug-in connector on the wiring harness. S03678-10 – Remove screws – Remove screws – Remove the license plate holder with the tail light. Info Pay attention to the cable of the tail light. – Feed the cable between the fairing parts.
  • Page 15 SETUP 2 – Position the turn signal on both sides on the license plate holder, mount nuts with washers and tighten. – Position the license plate lamp on the license plate holder, and mount and tighten screws – Mount reflector on license plate holder.
  • Page 16 2 SETUP – Mount and tighten screws Guideline Remaining screws, EJOT PT ® 2 Nm (1.5 lbf ft) chassis K60x25‑Z S03680-10 – Mount and tighten screw Guideline Remaining screws, EJOT PT ® 2 Nm (1.5 lbf ft) chassis K60x25‑Z S03687-10 –...
  • Page 17 SETUP 2 – Join the plug-in connectors of tail light and turn signal cable harness with the wiring harness. Info Pay attention to routing of the wiring harnesses. – Install the rear left side cover. ( p. 33) – Install the air filter box cover. ( p.
  • Page 18 2 SETUP – Mount the washer and splint S03695-10 – Position the left footrest and pin. Info Only insert the pin to the extent that the spring can still be mounted. R00757-10 – Position spring as shown. Spring engages in area S03693-10 –...
  • Page 19 (All special models) – Install the engine guard. ( p. 36) – 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.
  • Page 20 Remove the remaining film, padding, the corrugated card- board, and the other packaging material. – 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.
  • Page 21 WORK 3 Raising the motorcycle with a lift stand 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.

  • Page 22: Mounting The Seat

    3 WORK Mounting the seat – Mount the front of the seat on the two collar bushings of the fuel tank, lower the seat at the rear, and push the seat forward. – Make sure the seat is latched in place correctly. H02218-11 –...
  • Page 23 WORK 3 Main work – Unplug connector of the fuel pump. – Remove tube from the fuel tank breather. S04895-10 – Clean the quick release coupling thoroughly with compressed air. Info Under no circumstances should dirt enter into the fuel line.
  • Page 24 3 WORK 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 25 WORK 3 – Mount and tighten screws with the collar bushings. Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis E00881-11 – Remove the wash cap set. – Clean the quick release coupling thoroughly with compressed air. Info Under no circumstances should dirt enter into the fuel line.
  • Page 26 3 WORK 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 27 WORK 3 Installing the fork legs Main work – Position the fork legs. Bleeder screws are positioned toward the front. Info The rebound damping is located in right fork leg REB (red adjuster). The compression damping is located in left fork leg COMP (white adjuster). Grooves are milled into the side of the upper end of the fork legs.

  • Page 28: Tighten Screws 3 . Guideline

    3 WORK 3.10 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 29 WORK 3 Main work Warning Risk of injury 12 V batteries contain harmful sub- stances. – Keep 12 V batteries out of the reach of children. – Keep sparks and open flames away from 12 V bat- teries. – Only charge 12 V batteries in well-ventilated S04883-10 rooms.

  • Page 30: Charging The 12-V Battery

    3 WORK – Detach wiring harness , disconnect relays and plug and hang to the side. S04884-12 – Remove screw and detach the battery compartment. – Lift out the 12-V battery. S04886-10 3.12 Charging the 12-V battery Warning Risk of injury 12 V batteries contain harmful substances. –...
  • Page 31 WORK 3 Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Even when there is no load on the 12-V battery, it discharges steadily each day. The charging level and the method of charging are very important for the service life of the 12-V battery.
  • Page 32 3 WORK 3.13 Installing the 12-V battery Main work – Insert the 12 V battery into the battery compartment with the terminals facing forward and secure with holding bracket 12-V battery (HJTZ5S-FP-C) – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis S04887-10...
  • Page 33 WORK 3 – Connect positive cable to the 12-V battery. Guideline Screw, battery termi- 2.5 Nm (1.84 lbf ft) Info Contact disk must be mounted under screw cable lug with the claws toward the battery termi- nal. – Slide positive terminal cover over the positive terminal.
  • Page 34 3 WORK 3.16 Removing the air filter box cover Preparatory work – Remove the seat. ( p. 19) Condition The air filter box cover is secured. – Remove screw S03526-10 – Pull off the air filter box cover in area laterally and take it off at the front.
  • Page 35 WORK 3 3.18 Removing the rear left side cover – Remove screw and take off the fairing part to the front. S03671-01 3.19 Installing the rear left side cover – Position side cover and hook it in in areas – Mount and tighten screw Guideline Screw, sub-...
  • Page 36 3 WORK – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V00340-11 Finishing work – Install the headlight mask with the headlight. ( p. 35) – Check the headlight setting. ( p. 35) 3.21 Removing the headlight mask with the headlight –...
  • Page 37 WORK 3 3.22 Installing the headlight mask with the headlight Main work (All EXC models) – Join plug-in connectors E00900-11 (All standard XC-W models) – Join plug-in connector E00357-11 – Position the headlight mask and secure it with rubber straps The holding lugs engage in the fender.
  • Page 38 3 WORK The boundary between light and dark must be exactly on the lower mark for a motorcycle with rider. » If the boundary between light and dark does not meet specifications: – Adjust the headlight range. ( p. 36) 3.24 Adjusting the headlight range Preparatory work...

  • Page 39: Adding 2-Stroke Oil

    WORK 3 3.27 Closing 2-stroke oil tank cap – Put the 2-stroke oil tank cap on and turn it clockwise. – Fold loop down. The 2-stroke oil tank cap engages. E00861-11 3.28 Adding 2-stroke oil 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 40 3 WORK 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 41: Setting Kilometers Or Miles

    WORK 3 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 42 3 WORK Adjusting the Mph – Press the button – Wait 3 - 5 seconds. The settings are stored. Info If no button is pressed for 10–12 seconds, or if an impulse comes from the wheel speed sensor, the settings are automatically saved and the setup menu is closed.

  • Page 43: Setting The Clock

    WORK 3 3.34 Setting the clock Condition The motorcycle is stationary. – Repeatedly press the button briefly until CLK appears at the bottom right of the display. – Press the button for 2–3 seconds. The hour display flashes. – Adjust hour display with the button and/or button –...

  • Page 44: Technical Data

    4 TECHNICAL DATA chassis tightening torques EJOT PT Remaining screws, chassis ® K60x25‑Z 2 Nm (1.5 lbf ft) EJOTDELTA PT Screw, intake air temperature sen- ® 45x12-Z 0.7 Nm (0.52 lbf ft) Screw, oil fill level sensor G 3/4 " 7 Nm (5.2 lbf ft) Screw, oil pump holder on oil tank EJOTDELTA PT 45x12-Z...
  • Page 45 TECHNICAL DATA 4 Nut, foot brake lever 20 Nm (14.8 lbf ft) Nut, foot brake lever stop 20 Nm (14.8 lbf ft) Nut, pull switch (All standard XC- 0.8 Nm (0.59 lbf ft) W models) Nut, rear sprocket screw 35 Nm (25.8 lbf ft) Loctite ®...
  • Page 46 4 TECHNICAL DATA Screw, top shock absorber 80 Nm (59 lbf ft) Loctite ® 2701™ Nut, fork pivot M16x1.5 100 Nm (73.8 lbf ft) Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft) Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft) Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft)
  • Page 47 SUBSTANCES 5 Engine oil, 2-stroke Standard/classification – JASO FD ( p. 47) Guideline – Only use high-grade 2-stroke engine oil from a reputable brand. fully synthetic Recommended supplier MOTOREX ® – Cross Power 2T Super unleaded (ROZ 95) Standard/classification – DIN EN 228 (ROZ 95) Guideline –...

  • Page 48: Auxiliary Substances

    6 AUXILIARY SUBSTANCES Long-life grease Recommended supplier MOTOREX ® – Bike Grease 2000 Silicone spray Recommended supplier MOTOREX ® – Silicone Spray...
  • Page 49 STANDARDS 7 JASO FD JASO FD is a classification 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 achieved even under extreme operating conditions.
  • Page 50 *3214695en* 3214695en 25.03.2022 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM KTM.COM...

This manual is also suitable for:

250 exc 2023250 xc-w 2023300 exc 2023300 exc six days 2023300 xc-w250 exc eu 2023 ... Show all

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