Bike Build | 2024 Gnarly Routes KTM 300 XC-W

Published 2024-02-14
In this video I take a brand new 2024 KTM 300 XC-W and build it up for racing in Texas and upcoming Gnarly Routes tours this spring and summer. I've logged about twenty hours on a 2024 KTM 250 XC-W so I already know what adjustments I wanted to make on the 300 XC-W.

I swapped out the 45t stock gearing ( 13/45) for a 48t rear sprocket and a generous amount of lock-tite goes on the bolts. This tightens up the gears for racing and allows me to use third in most enduro race situations. The rear brake caliper is outfitted with an Enduro Engineering disc guard to keep rocks out of the way of the rear disc. Enduro Engineering front and rear axle pulls are installed to make wheel removal easier and an Enduro Engineering brake pedal tip increases durability and feel over the stock tip. Silicone is added to the shifter and chain slider to prevent it getting packed with debris. I use the Enduro Engineering start and stop buttons because they have a much more positive feel than the OEM start button. I also added a map switch on the bar. A fan will be added at a later date and I like to run one to keep the engine temps down when the going gets slow. An Enduro Engineering skid plate is added to protect the frame and under belly of the KTM power plant and the OEM bolt holes from KTM make mounting a breeze. I've been using Enduro Engineering products since 2000. The XC Gear Mako 360 SX is mounted in place of the stock bar mounts and does exactly what it advertises. It reduces hand fatigue and the impact felt in the wrists on large trail chatter. This bike came with billet triple clamps but I opted for the cast version as I like the comfort it provides in the roots and square edge bumps. A lot of XC-W models are starting to show up with billet clamps in stock form due to supplier shortages. The OEM odometer will be removed and replaced with a Trail Tech Voyager Pro unit that is mounted to a homemade mount (I'm planning on racing this bike this weekend and didn't want to mount up the Voyager Pro quite yet). The tires and tubes are removed and replaced with Michelin Bib Mousse front and rear mounted inside of Michelin StarCross 6 tires. I normally run a StarCross 6 med/soft front and rear in DFW this time of year because the dirt is typically soft. Gnarly Routes graphics from Bike Graphix are installed and they add at least five horse power to the build. Look fast go fast! An Akrapovic slip-on line silencer is mounted up in place of the stock unit and adds bottom end and reduces weight over the stock silencer. I do plan on testing the shorter SX/XC version of this silencer to see how it performs. The Akrapovic stuff is second to none, the quality and craftsman ship is truly impressive. I've logged hundreds and hundreds of hours on numerous bikes and have yet to have one fail or show sign of fatigue. WP XPLOR Pro 7548 cone valve forks tuned by Solid Performance replace the stock version and a WP XPLOR PRO 8946 PDS shock replaces the stock rear unit. Finally, a seat concept seat is installed and a MotoMinded headlight will be added once they are available.

Bike: 2024 KTM 300 XC-W
Exhaust: Akrapovic slip on
Tires: Michelin StarCross 6 Med/Soft with Michelin Bib Mousse
Bar Clamp: XC Gear Mako 360sx
Suspension: WP XPLOR PRO Cone Valve Fork (4.6 springs) and Trax Shock (6.9 spring)
Suspenion Tuned by: Solid Performance
Gearing: 13/48
Protection Parts: Enduro Engineering
Lubricants: Motorex
Seat: Seat Concepts
Graphics: Bike Graphix
Bars: OEM (Renthal twinwalls are shown at the start but it's the same bend as OEM)

All Comments (21)
  • This was by far the most soothing thing I could have started my morning with. Awesome job on both the bike and the production!
  • @Captain250FX
    I only gave this video one thumbs up because it wouldn’t let me give MORE! Beautiful bike bro!
  • @jaredandersen82
    This has to be one of the best and most satisfying build videos to watch! Excellent job, that bike looks like a beast!
  • If you haven't watched this guy ride, it's a real treat. This guy can shred with the best of them!!! Great build video, nicely done, great show!!
  • @BraaapoholicBob
    Cole, you are a bad ass rider...love your racing vids! Three more things I wud do because I'm super OCD...fork lug guards, pipe guard and swingarm guards.
  • @Hendy711
    Awesome Thanks Cole. Love the build vidoes. Helps a guy like me get pointed in a good direction.
  • @troybond706
    Thoughts on a bike for a teenage rider, a little background then some questions. Great build, I will have to watch it closer and look at the pile of parts I have ready to go for my 24 300 xcw hard enduro edition and see what else I want. I rode the 23 300 xc all last year and love it, very playful and fun reminds me of all my 2 strokes I grew up on, so much more responsive than my 21 TPI 300 xcw. My buddy picked up his 24 300 xcw in Oct of 23 and I was able to jump on it for a weekend before the snow started to fly up here in Canada. The gearing felt very similar or same as my xc which I love, I have had many xc bikes over the years and like them over the w, a massive improvement over my 21 300 xcw which was way too gapped out, It was my first and I thought my last w model. I've put some track time on the 24 300 xcw as well and for stock suspension and no engine mods the thing rips and is a pretty fun bike everywhere. So now I have seat time on both new 300's it is probably just the engine responsiveness but somehow the xcw feels a bit lighter when trail riding which I didn't think was possible as the new 300 xc feels very light and nibble. My teenage son has been on a 150 xcw (21 TPI) but he's now 17 and 170lbs so moving up. Before I got my 24 300 xcw I was getting him a 24 250 xc as I love my 300 xc. Then riding the 24 300 xcw I was feeling like maybe a 250 xcw would be a better fit, a bit more manageable as he is still figuring out controlling his traction with the clutch in real time. In watching many reviews it sounds like you need to be on the pipe on the 250 a lot more. I am pretty sure I want him on a 24 xcw as I like the no linkage on the trails and easy to put on a real light and a rad fan with the bigger stator though I think I would like the xc motors power better. He has jumped on my 300 a few times and does really well but gets off and says it feels heavy and compared to his 150 he is correct. Does the 250 xcw feel significantly lighter than the 300, on paper they are the same weight. I am tempted to get him a 300 and just buy some 250 decals for it so he doesn't know. We have a track for practice and fun but we mainly ride single track. He is not a super aggressive rider I just don't want to buy the 250 and be disappointed in the power but also want him to have to learn how to make it work and not ride lazy. Any thoughts? if the 250 does feel lighter maybe a fmf gnarly pipe for more bottom and mid? Btw I ran into you in riding in green river this past October
  • @paulg7964
    Great content. Most people blather on and on. I'm stoked on this build as my son and I are picking up a couple of these. I tried to convince him into getting th TX 300 over the TE because we live in San Diego and primarily ride desert. I've been riding here from 86 to present. I'm coming off a RFS 450xc with pds. Can't decide between the TE or TX 300. Nice to have choices right 😊. Please keep the content coming. Great source of information. Btw foam ear plugs and silicone for larger voids.
  • @pepemotores
    Te ha quedado de cine, imagino que no la tirarás por los aires como los locos de hard enduro.
  • @jasonshurtz2235
    That’s an awesome build! Great job on the edit man👌 Any thoughts on the 450xcw? Have you ridden one?
  • @randytidwell5836
    Any chance you and some of your racing partners may make the 24 hour hare scramble in Plantersville Al. at Perry Mountain Motorcycle Club this June 1st and 2nd. I think you have been there before right.
  • Can you huneslty notice a sound & power difference between stock and Akropovic exhuast?
  • @michaelwalas5948
    Looks like you own a TBI 250 and 300 xc-w What are your pros and cons of both? Is there much power differences in bottom and top end.. and which bike do you choose for riding types? Hope you hear from you 🙏🏻🙏🏻