2004-2010 KTM 250 / 300 SX, SXS, MXC, EXC, EXC SIX DAYS, XC, XC-W Workshop Manual
Comprehensive repair manual for KTM 250 SX, 300 SX, 250 EXC, 300 EXC, 250 SXS, 300 SXS, 250 XC, 300 XC, 250 EXC SIX DAYS, 300 EXC SIX DAYS models. Publication C4085-91017.
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Sample pages from the 2004-2010 KTM 250 / 300 SX, SXS, MXC, EXC, EXC SIX DAYS, XC, XC-W Workshop Manual manual
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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
Build 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 2004–2010 KTM 250 and 300 series including SX, SXS, MXC, EXC, EXC-E, EXC SIX DAYS, XC, and XC-W variants with liquid-cooled two-stroke single-cylinder engines
- Official KTM publication Art.- No. 3.206.088-E, edition 02/2010
- Contains 233 pages of technical specifications, exploded-view assembly diagrams, and maintenance schedules
- Accessible from your device as soon as the order is placed
- Suitable for printing individual sections for shop-floor use
- Full-text search finds any part number or setting in seconds
- This 2010 edition serves as the final update in the 2004–2010 series, incorporating technical revisions for all 250 and 300 models across the production range
Technical Documentation Scope
This 2004–2010 KTM 250/300 workshop publication details internal engine repair, chassis maintenance, and electrical system diagnostics. The manual provides guidance for disassembling and assembling the engine housing, transmission components, and crankshaft assembly, alongside instructions for adjusting the TVC exhaust control system and carburetor tuning for varying altitudes and conditions.
Specification and Data Preview
Technical sections document specific engine clearances, torque values, and electrical system thresholds for the 2K-1, 2K-2, and 2K-3 ignition components. The transmission oil capacity is listed at 0.7 liters of 15W50 oil in the assembly section. Cooling system capacity is documented at 1.2 liters for the standard 50/50 coolant mixture in the technical specifications chapter. Intake and exhaust port settings are provided for 250 and 300 displacement variants in the carburetor tuning guide. Reference what factory workshop documentation is structured for a detailed breakdown of service procedures included in this document.
An official 233-page KTM workshop manual covering the 2004–2010 250 and 300 series SX, EXC, XC, and MXC models, documenting engine, drivetrain, electrical, and fuel system specifications for all variants within the series.
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