2004-2006 KTM 250/300 SX / EXC / XC Repair Manual (P/N 3.206.032-E)
159 Pages • 11.34 MB • Instant, Printable PDF
KTM Models Covered & Key Technical Specifications
Models: KTM 250 SX, KTM 300 SX, KTM 250 SXS, KTM 300 SXS, KTM 250 MXC, KTM 300 MXC, KTM 250 EXC, KTM 300 EXC, KTM 250 EXC SIX DAYS, KTM 300 EXC SIX DAYS, KTM 250 XC, KTM 300 XC, KTM 250 XC-W, KTM 300 XC-W
Sub-models / Variants: SXS, MXC, EXC, EXC Six Days, XC, XC-W
Trade Names: Racing, Six Days
Model Years: 2004–2006
Serial Numbers: 4xxxx, 5xxxx, 6xxxx (Engine number series)
Technical Data:
- Engine Displacement (250 models): 249 ccm
- Engine Displacement (300 models): 293.15 ccm
- Piston Bore (250 models): 66.4 mm
- Piston Bore (300 models): 72 mm
- Stroke: 72 mm
- Coolant Capacity: 1.2 liters (50% antifreeze, 50% water)
- Transmission Oil Capacity: 0.7 liters
- Generator Output (EU models): 12V / 110 W
- Generator Output (USA models): 12V / 40 W
KTM Manual Features & Content Preview
- Covers 2004–2006 KTM 250 and 300 two-stroke motocross and enduro models, including the SX, SXS, MXC, EXC, EXC Six Days, XC, and XC-W variants
- Official KTM publication P/N 3.206.032-E, revision dated November 2005
- Features 159 pages of technical specifications, exploded component diagrams, and factory maintenance schedules
- Includes factory-authorized setup and tolerance data for the 2006 engine updates, highlighting clutch and brake bleeding procedures not detailed in earlier editions
Engine Teardown and Assembly Sequence
When you are splitting the cases on a two-stroke, you need exact tolerances. This publication details the entire removal and refitting process for the 2004–2006 KTM 250/300 engine series. It walks through comprehensive disassembly instructions for the top end, transmission, and internal crankcase components. You will find the absolute service limits for critical internal parts, such as piston ring end gaps, crankshaft web dimensions, and transmission gear inspections. The layout provides a logical flow from complete engine teardown straight through to the precise assembly protocols required to restore factory-level performance.
Specifications and Maintenance Data
Having the right numbers on hand speeds up any bench work. Detailed tables outline the torque requirements, fluid capacities, and electrical reference values necessary for professional maintenance. For example, the cooling system capacity is listed at 1.2 liters, while the transmission requires precisely 0.7 liters of oil. Intake system data covers carburetor settings for both the Keihin PWK 36S AG and 38S AG, detailing jet needle ranges and air control screw configurations. Electrical reference values for the Kokusan ignition systems are also broken down by model year, covering stator output voltages and coil resistances. Multi-stage cylinder head bolt torque sequences are mapped out to ensure a proper gasket seal across all 250 and 300 displacement models. Always rely on the original OEM documentation and standard workshop safety practices before turning a wrench, as the reference data discussed here is meant to support professional judgment and proper tools rather than replace them.
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