2004–2006 KTM 250 SX/SXS & 250/300 MXC/EXC/EXC Six Days/XC/XC-W Repair Manual (P/N 3.206.032-E)

This KTM repair manual, P/N 3.206.032-E, is the November 2005 revision for the 2004–2006 KTM 250/300 two-stroke range. It covers 250 SX/SXS and the 250/300 MXC, EXC, EXC Six Days, XC, and XC-W variants.

Search, navigation, and wiring detail: Repair text and specification tables are searchable, with embedded bookmarks for chapters and procedures. Some wiring-diagram labels are not searchable; small wire-color codes and connector labels require zooming.

• Engine repair: Engine removal and refitting, crankcase disassembly, crankshaft and piston inspection, and top-end reassembly.

• Transmission and clutch: Mainshaft and countershaft assembly, shift-mechanism inspection, kickstarter service, primary-drive repair, and outer clutch-hub replacement.

• TVC and cooling: Twin Valve Control inspection and adjustment, control-flap assembly, centrifugal-timer service, water-pump seal replacement, and coolant refilling.

• Carburetor service: Keihin PWK 36S AG and PWK 38S AG removal, disassembly, component inspection, reassembly, float-level checks, and jetting tables.

• Electrical diagnosis: Kokusan ignition testing with a peak voltage adapter, stator and pickup checks, voltage-regulator and capacitor tests, and model-specific wiring diagrams.

• Hydraulic clutch and brakes: Separate clutch-bleeding procedures for the two fluid systems, plus front and rear brake-fluid replacement and compatibility guidance.

KTM specifies qualified, professionally trained mechanics and assumes familiarity with normal workshop procedures.

Engine Teardown and Assembly Sequence

Internal repair coverage includes crankshaft-bearing replacement, crankshaft-web measurements, piston-ring end-gap checks, and transmission gear and bearing inspections. Exploded views of the cylinder exhaust-control assembly and shift mechanism show how their components fit together.

Assembly references: Dimension X describes the position of the piston crown relative to the cylinder's upper edge at top dead center. The manual explains base-gasket selection and identifies adjusting plate 548.29.001.000 for 250 SX/SXS and all 2006 250 models. Dimension Z concerns the exhaust-control flap, with separate settings for the updated 250 engine.

The reed-valve section distinguishes 250 SX/SXS housings from the EXC, MXC, XC, and XC-W arrangement. Cylinder-head assembly includes the staged tightening sequence, supported by engine torque tables, fluid capacities, fitting clearances, and gasket specifications.

Keihin Carburetor Adjustment and Inspection

The carburetor operating-range diagram and jet-needle range-of-action charts link mixture behavior to the relevant circuit. Inspection covers the throttle slide, starting piston, float needle valve, jets, and gaskets.

Jetting tables distinguish model, temperature, and altitude. The 2006 SX/SXS data uses the PWK 36S AG, while earlier SX/SXS tables cover the PWK 38S AG. EXC unrestricted settings are identified for off-road use.

Kokusan Ignition and Electrical Troubleshooting

Kokusan 2K-1, 2K-2, and 2K-3 sections provide coil-resistance specifications and configuration-specific static ignition and generator tests. Model-specific connector and wire-color references help trace a no-spark fault through the pickup, stator, and wiring without mixing test data from different systems.

Main-harness schematics, CDI/charging-circuit diagrams, and light-system/instrument circuits accompany the electrical checks. Troubleshooting charts also cover poor idling, power loss, high-rpm misfiring, overheating, and coolant-related symptoms.

CDI function testing requires an ignition test bench; the manual warns that ordinary measuring instruments can damage its electronic components.

Clutch Fluids, Brakes, and Chassis References

Separate clutch sections distinguish mineral-oil systems through 2005 from Brembo systems using DOT 5.1 brake fluid from 2006. The compatibility warnings identify silicone-based DOT 5 as damaging to seals and brake hoses.

Chassis coverage includes WP fork and PDS shock setup tables, fastener torques, and competition-versus-hobby maintenance schedules. Suspension settings and scheduled service are included, but internal fork and shock rebuild procedures are outside this manual's scope. Brake-pad and disc inspection refers to the owner's manual.

Follow the factory procedures and established workshop safety practices, particularly for brake work and engine handling.

A Preview of Piston Fit and Power-Valve Settings

These are a few examples from the manual's internal-engine fitting and adjustment data.

For the covered 250/300 engines, piston fitting clearance is 0.06–0.10 mm, measured as the difference between the smallest measured cylinder bore and the piston diameter.

Dimension Z runs from the control flap's lower edge to the cylinder's upper edge at the center of the exhaust port. It is 47.5 mm (+0/−0.2 mm) for 2006 250 models and 48.5 mm (+0/−0.2 mm) for 2004–2005 250/300 models and 2006 300 models.

Printable PDF and Included Pages

The English manual is supplied as one 159-page printable PDF: 129 technical and chapter-index pages, seven front-matter pages, and 23 blank pages. The front matter includes the cover, binder spine, main contents, updating instructions, revision history, introduction, and reply form; all are already included in the total.