2004–2010 KTM 250 SX/SXS, 300 MXC & 250/300 EXC, EXC-E, SIX DAYS, XC, XC-W Workshop Manual (P/N 3.206.088-E)

This KTM repair manual (Art.-No. 3.206.088-E, edition 02/2010) covers the 2004–2010 250 and 300 series, including SX, SXS, MXC, EXC, EXC-E, EXC SIX DAYS, EXC-E SIX DAYS, XC, and XC-W variants with liquid-cooled two-stroke single-cylinder engines. SX/SXS specifications apply to the 250; the MXC specification tables identify the 300.

Text search, bookmarks, and wiring detail: The PDF is partially searchable; the 2010 maintenance tables and several wiring diagrams lack searchable body text. Chapter bookmarks are included, although some engine-disassembly entries open one page early. Small wiring labels require zooming, and some fine connector labels in the 2010 diagrams remain soft.

• Engine repair: Engine removal and installation, crankcase separation, bearing replacement, cylinder and piston inspection, crankshaft checks, and reassembly.

• Transmission and clutch: Mainshaft and countershaft inspection, shift-mechanism service, wet-clutch repair, outer-clutch-hub replacement, and hydraulic clutch bleeding.

• TVC and cooling: Exhaust-control inspection and adjustment, control-flap setup, water-pump component service, and coolant refilling and bleeding.

• Fuel system: Keihin PWK carburetor disassembly, jet and float-needle inspection, float-level checks, reassembly, and reed-valve housing inspection.

• Electrical diagnosis: Ignition-coil, stator, pickup, regulator, capacitor, and charging tests, with peak-voltage measurements and model-specific wiring diagrams.

• Starting systems: Kickstarter-shaft service, electric-starter removal and installation, Bendix and drive-gear wear checks, and starter-drive backlash adjustment.

Written for qualified, professionally trained mechanics, this manual assumes familiarity with general workshop procedures and safety practices.

Engine Clearances, TVC, and Transmission Repair

Illustrated piston-and-cylinder measuring procedures establish piston mounting clearance. Separately, dimension “X” defines piston position relative to the cylinder’s upper edge at top dead center; dimension “Z” defines exhaust-control flap height. The TVC section documents operating checks and auxiliary-spring options.

Crankshaft and transmission inspection sections include wear limits, fitting clearances, gasket-thickness data, and component-specific torque tables. Exploded views show the mainshaft and countershaft assemblies.

Special-tool references identify the dimension-X adjusting plate 548.29.001.000 and clutch riveting tool 546.29.027.000. The crankcase section warns that prying between the housing halves can damage their sealing faces.

Clutch Hydraulics and Electric-Start Variants

The hydraulic-clutch sections distinguish the mineral-oil system used through 2005 from the Brembo DOT 5.1 system introduced for 2006. This distinction helps technicians select the appropriate bleeding procedure and fluid specification before clutch service.

Electric-start coverage includes the Bendix, starter idler gear, bearing bushings, and backlash shims. It covers removal, inspection, and drive adjustment. Internal starter-motor rebuild procedures are not included.

Keihin PWK Carburetor Settings and Troubleshooting

The fuel chapter covers PWK 36S AG and PWK 38S AG carburetors. The “Operating Ranges of the Carburetor” diagram and “Jet Needle Range of Action” charts explain which metering components affect idle, part-throttle, and full-throttle behavior.

Setting tables distinguish temperature and altitude adjustments, regional jetting, and restricted versus unrestricted EXC configurations. The 2010 250 SX specifications also list separate sand-track settings. Troubleshooting charts address starting problems, poor idle, power loss, high-rpm misfire, and overheating.

Kokusan Ignition Tests and Wiring Diagrams

Electrical sections provide test specifications for 2K-1, 2K-2, and 2K-3 ignition systems, plus static and dynamic generator tests for EXC-E variants. The peak-voltage adapter is identified as 584.29.042.000.

CDI/charging-circuit and lighting/instrument diagrams include connector identifiers and wire-color legends. Switch tables and separate positive and ground connections support circuit tracing.

CDI coverage is limited to inspection and test-bench diagnosis. The manual warns that ordinary measuring devices can damage the unit’s sensitive electronic components.

Chassis Maintenance and Suspension Specifications

Brake-fluid replacement procedures, WP 4860 fork and WP 5018 PDS shock settings, fluid specifications, and model-specific maintenance schedules are included. Full fork and shock overhaul procedures are not included; brake-pad and disc inspection is referred to the owner’s manual.

Always verify equipment stability and follow the manual’s precautions for ignition testing and brake-fluid handling.

English PDF and Included Pages

Supplied as one printable English PDF with 233 pages total: 202 technical and section-index pages, seven preliminary pages, and 24 blank pages. The preliminary pages comprise two cover/title pages, a contents overview, two updating pages, an introduction, and a repair-manual feedback form; all are already included in the total.