KTM 250 300 EXC XC-W 2017 Repair Manual – Workshop Service PDF

Description

File Details

• Manual type: Repair manual (workshop service manual)
• Brand: KTM
• Model series: 250 EXC, 250 XC-W, 300 EXC, 300 XC-W
• Model year: 2017
• Language: English
• Page count: 309
• File format: PDF
• Document number: 3206285en
• Date of issue: 07/2016
• Publisher: KTM Sportmotorcycle GmbH

Models Covered by the KTM 250 300 EXC XC-W 2017 Repair Manual

This manual is valid for the following machine codes across the 2017 two-stroke enduro line-up:

• 250 EXC EU – F7303Q6
• 250 EXC AU – F7360Q6
• 250 EXC Six Days EU – F7303Q2
• 250 XC-W US – F7375Q3
• 300 EXC EU – F7403Q6
• 300 EXC AU – F7460Q6
• 300 EXC Six Days EU – F7403Q2
• 300 EXC BR – F7440Q6
• 300 XC-W US – F7475Q3
• 300 XC-W Six Days US – F7475Q2

IMAGES PREVIEW

Chapters Covered

• Means of representation
• Safety advice
• Important notes
• Serial numbers – chassis number, type label, engine number, fork part number, shock absorber article number
• Motorcycle – raising with a lift stand, removing from the lift stand, starting
• Fork, triple clamp – compression and rebound damping, spring preload on Six Days models, bleeding, dust boot cleaning, removing and installing fork legs, fork protector, servicing the fork, steering head bearing
• Handlebar, controls – handlebar position, clutch lever, throttle cable routing and play
• Frame – checking the frame, engine guard, footrests
• Shock absorber, swingarm – high and low speed compression damping, rebound damping, static and riding sag, spring preload, removing and installing the shock absorber, servicing, heim joints, swingarm and bearings
• Exhaust – main silencer removal and installation, glass fibre yarn filling
• Air filter – box cover, filter removal and installation, cleaning, sealing the box
• Fuel tank, seat, trim – filler cap, seat, fuel tank, fuel tap
• Mask, fender – front fender, headlight mask with headlight
• Wheels – tire air pressure and condition, wheel bearing play, brake discs, rim run-out, spoke tension, front wheel, rear wheel, chain
• Wiring harness, battery – ignition curve connector, main fuse, battery, charging voltage, closed current, starter relay
• Brake system – front and rear linings, brake fluid, free travel, hand and foot brake levers
• Lighting system, instruments – headlight setting and range, speedometer overview and settings
• Engine – removal and installation, disassembly, working on individual parts, assembly
• Carburetor – choke, idle speed, float chamber, removal and installation, components, float level
• Clutch – fluid level, changing fluid, checking the clutch
• Water pump, cooling system – antifreeze and coolant level, draining and refilling
• Exhaust control – setting the auxiliary spring
• Lubrication system – changing, draining, refilling and checking gear oil
• Ignition system – checking the ignition system, ignition coil, spark plug connector, alternator, crankshaft position sensor, spark plug, stator
• Electric starter – checking the starter motor
• Technical data – engine, tolerance and wear limits, engine tightening torques, capacities, chassis, electrical system, tires, fork, shock absorber, chassis tightening torques, carburetor, carburetor tuning
• Cleaning, care – cleaning the motorcycle, checks for winter operation
• Storage – storage, preparing for use after storage
• Service schedule – required work, recommended work
• Wiring diagram – EU/AU/BR and US variants
• Substances, auxiliary substances, special tools, standards, index of special terms, list of abbreviations, index

Taken as a whole, the KTM 250 300 EXC XC-W 2017 Repair Manual gives a trained mechanic a complete working reference for the 2017 model year two-stroke enduro range. It opens with the practical basics – how to raise the bike on a lift stand, how to start it, where every identification number sits – and then moves systematically through the machine, system by system. Suspension work is covered in unusual depth: both the MXMA 4860 fork used on the 250/300 EXC EU/AU, 300 EXC BR and 250/300 XC-W and the Xplor 48 fork used on the Six Days models are stripped down to individual shims, tap compression, cartridges and seal rings. The shock absorber chapter follows the same pattern, covering damper disassembly, bleeding with a vacuum pump, nitrogen filling, heim joint replacement and spring rate selection by rider weight. The engine chapter is just as complete, from removal and installation through full disassembly of the cases, crankshaft and transmission, piston and cylinder measurement, X-distance and Z-distance adjustment, and reassembly. Electrical diagnostics include resistance and peak-voltage values for the ignition coil, stator, crankshaft position sensor and spark plug connector, plus a complete wiring diagram set for the EU/AU/BR and US variants. The technical data chapter closes the loop with capacities, wear limits, tightening torques and carburetor jetting charts keyed to altitude and temperature.

What This KTM 250 300 EXC XC-W Workshop Manual Enables You to Do

With the KTM 250 300 EXC XC-W 2017 Repair Manual open in front of you, the following jobs are fully supported from start to finish:

• Adjusting fork compression and rebound damping and the Six Days spring preload
• Bleeding the fork legs, cleaning dust boots and rebuilding the fork down to cartridge and tap compression
• Lubricating or changing the steering head bearing and setting bearing play
• Adjusting the handlebar position and clutch lever, checking throttle cable routing and play
• Checking the frame, changing footrests and removing or installing the engine guard
• Adjusting shock absorber high and low speed compression damping and rebound damping
• Measuring static and riding sag, adjusting spring preload and choosing the correct spring rate
• Removing, servicing and reassembling the shock absorber and replacing the heim joints on the shock and swingarm
• Removing and installing the swingarm and changing its bearings
• Removing and installing the main silencer and changing the glass fibre yarn filling
• Servicing the air filter and sealing the air filter box
• Removing and installing the fuel tank, seat and trim
• Removing and installing the front and rear wheels, changing wheel bearings and brake discs, checking rim run-out and spoke tension
• Checking and adjusting chain tension and changing the drivetrain kit
• Working on the wiring harness, battery, main fuse and starter relay
• Checking and changing front and rear brake linings, brake fluid and free travel
• Adjusting the headlight range and configuring the speedometer functions
• Removing and installing the engine and rebuilding it completely, including crankshaft, transmission, piston and cylinder
• Servicing the Mikuni TMX 38 carburetor and adjusting the float level
• Checking the clutch and changing the hydraulic clutch fluid
• Draining, refilling and checking the coolant circuit
• Setting the exhaust control auxiliary spring
• Changing gear oil and checking the gear oil level
• Checking the ignition system, stator, crankshaft position sensor and starter motor
• Reading torque values, wear limits and capacities from the technical data chapter

Why Correct Procedures and Specifications Matter

A 2017 KTM 250 or 300 two-stroke enduro is not a machine that tolerates guesswork. The X-distance and Z-distance on the cylinder, the fork oil volume per leg, the nitrogen pressure in the shock reservoir, the carburetor jetting relative to altitude and temperature, the engine case tightening sequence and the peak-voltage values for the ignition – each of these directly affects how the bike runs, how long it lasts and whether it is safe to ride. Working without the correct figures invites burnt pistons, leaking fork seals, warped engine cases, poor jetting or an electrical fault that is chased rather than diagnosed. This manual gives the exact numbers, the correct disassembly order and the special-tool references needed to do the job properly the first time.

Instant PDF Delivery

This KTM 250 300 EXC XC-W 2017 Repair Manual is delivered as an instant-download PDF once payment is complete – no shipping, no waiting and no physical book to lose in the workshop. Read it on a laptop, tablet or phone, search within the document, zoom into the illustrations and print the pages you need for the bench. Whether you are servicing your own 250 EXC, rebuilding the top end on a 300 XC-W Six Days, or running a workshop that sees the whole 2017 EXC and XC-W range, this is the reference that keeps every job within KTM specifications.