2004-2010 KTM 250 / 300 SX, SXS, MXC, EXC, EXC SIX DAYS, XC, XC-W Workshop Manual • P/N C4085-91017
KTM Models Covered & Key Technical Specifications
Models: KTM 250 SX, KTM 250 SXS, KTM 250 MXC, KTM 250 EXC, KTM 250 EXC-E, KTM 250 EXC SIX DAYS, KTM 250 EXC-E SIX DAYS, KTM 250 XC, KTM 250 XC-W, KTM 300 SX, KTM 300 SXS, KTM 300 MXC, KTM 300 EXC, KTM 300 EXC-E, KTM 300 EXC SIX DAYS, KTM 300 EXC-E SIX DAYS, KTM 300 XC, KTM 300 XC-W
Sub-models / Variants: 250cc, 300cc, SX, SXS, MXC, EXC, EXC-E, EXC SIX DAYS, EXC-E SIX DAYS, XC, XC-W
Model Years: 2004–2010
Serial Numbers: Engine numbers beginning with 4 (2004), 5 (2005), 6 (2006), 7/8/9 (2007–2009), 0 (2010)
Technical Data:
- Engine type: Liquid-cooled, single-cylinder, two-stroke
- Piston displacement: 249 ccm (250 models), 293.15 ccm (300 models)
- Gearbox oil: 0.7 liters of Motorex Top Speed 4T 15W50
- Generator output (EXC/EXC SIX DAYS): 12V / 110W
- Cooling system capacity: 1.2 liters (50% anti-freeze, 50% pure water, rated to -25°C)
- Fuel tank capacity: 7.5 to 11 liters depending on model
- Carburetor type: Keihin PWK 36S AG or PWK 38S AG
KTM Manual Features & Content Preview
2004–2010 KTM 250 and 300 Series Workshop Manual
- Covers the 2004–2010 KTM 250 and 300 series including SX, SXS, MXC, EXC, EXC-E, EXC SIX DAYS, XC, and XC-W variants equipped with liquid-cooled two-stroke single-cylinder engines.
- Official KTM publication (Art.-No. 3.206.088-E, edition 02/2010) serving as the final technical update for this production run.
- Contains 233 pages of technical specifications, exploded-view assembly diagrams, and maintenance schedules.
- Instant download provides immediate access to the repair data from any laptop or mobile device.
- Optimized for the shop floor: features a full-text search to locate specific part numbers in seconds and allows printing of individual component sections.
Technical Documentation Overview
This official workshop publication documents the internal components and systems of the KTM 250 and 300 platforms. It comprehensively outlines internal engine repair, chassis maintenance, and electrical diagnostics. The manual provides detailed reference material for the disassembly and assembly of the engine housing, transmission components, and crankshaft. It also lists the factory parameters for adjusting the TVC exhaust control system and optimizing carburetor tuning across varying altitudes. Always verify equipment stability and reference the specified factory tolerances before handling high-tension ignition modules or pressurized cooling systems to ensure a secure workspace.
Specifications and Shop Data
Technical sections catalog strict engine clearances and electrical thresholds specifically for the 2K-1, 2K-2, and 2K-3 ignition components. Mechanics can quickly reference fluid specifications, which explicitly require a transmission oil capacity of 0.7 liters (15W50) and a cooling system capacity of 1.2 liters using a standard 50/50 mixture. Furthermore, the carburetor tuning guide provides the exact intake and exhaust port settings required for both displacement variants. Critical torque values are documented throughout the assembly chapters to guarantee components are tightened exactly to factory standards.
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