Market Segment:
High-performance off-road enduro motorcycle, specifically targeting riders participating in competitive enduro events and demanding trail riding.
Key Competitors:
Similar era Yamaha WR250, Honda CRF250X, Kawasaki KLX250, Suzuki RMX250, Husqvarna TE250.
Ktm Offroad Heritage:
KTM's strong reputation in off-road racing and durability is a primary selling point for this model.
Six Days Edition Features:
The 'Six Days' designation typically indicates enhanced features and graphics commemorating the International Six Days Enduro (ISDE), often including upgraded components like different exhaust, triple clamps, seat, and special graphics.
Manual Coverage Summary:
Comprehensive service, maintenance, and troubleshooting for the specified KTM 250 EXC-E Six Days models.
Page Count:
Estimated 300-400+ pages (typical for this type of comprehensive workshop manual)
Manual Type:
Workshop Service Repair Manual
Engine Systems:
Engine assembly, disassembly, lubrication, cooling system, fuel system (carburetor), ignition system, exhaust system, starting system.
Transmission Systems:
Clutch operation and adjustment, gearbox (gear selection, inspection), final drive (chain and sprockets).
Chassis Systems:
Frame inspection and repair, suspension (forks, rear shock absorber - including adjustments and seal replacement), steering system, wheels and tires, braking system (hydraulic discs front and rear).
Electrical Systems:
Wiring diagrams, lighting (headlight, taillight, indicators), battery, charging system (alternator), starter motor, fuses, switches, sensors.
Bodywork And Ergonomics:
Seat, fuel tank, fenders, handlebars, levers, footpegs, graphics, Six Days specific components.
Maintenance Procedures:
Routine checks, oil changes, filter replacements (air, oil), spark plug service, chain adjustment and lubrication, brake fluid flush, coolant flush, valve clearance adjustment.
Troubleshooting Procedures:
Diagnostic charts for common running issues (starting problems, poor performance, electrical faults), symptom-based troubleshooting.
Repair Procedures:
Detailed step-by-step instructions for component removal, overhaul, repair, and reinstallation (e.g., engine rebuild, carburetor tuning, suspension rebuild, brake caliper service).
Special Tool Requirements:
Identification of specific KTM or aftermarket tools required for certain operations.
Technical Depth:
In-depth technical information suitable for professional mechanics and experienced DIY enthusiasts. Covers full engine teardown and rebuild, advanced suspension tuning, and detailed electrical diagnostics.
File Format Quality:
High-resolution PDF with searchable text and clear, legible diagrams. Printable pages.
Print Quality Recommendation:
Optimized for digital viewing and home printing. Diagrams and text are clear.
Binding Type:
N/A (Digital PDF Download)
Paper Type:
N/A (Digital PDF Download)
Engine Type:
Four-stroke, liquid-cooled, single-cylinder
Displacement:
249 cc (approx. 15.2 cu in)
Bore X Stroke:
76 mm x 54.5 mm (typical for this generation LC4 250)
Compression Ratio:
Approximately 11.5:1
Horsepower Estimate:
Around 30-35 HP (subject to tuning and specific variant)
Torque Estimate:
Approximately 24-26 Nm
Carburetor Type:
Keihin FCR 39 (typical for this era)
Fuel Type:
Unleaded gasoline (95 RON recommended)
Engine Oil Capacity:
Approximately 1.1 - 1.2 Liters (check manual for precise amount with filter change)
Engine Oil Specification:
SAE 10W-50 or 15W-50, JASO MA certified motorcycle oil
Coolant Type:
Ethylene glycol-based coolant with anti-corrosion additives (typically 50/50 mix with distilled water)
Ignition Type:
Digital electronic ignition
Safety Ratings:
N/A (Off-road motorcycles typically not subject to formal crash ratings like road vehicles)
Braking System:
Hydraulic disc brakes front and rear. Brembo components were common.
Front Brake Specs:
260 mm disc, twin-piston caliper
Rear Brake Specs:
220 mm disc, single-piston caliper
Suspension Adjustability:
Adjustable compression and rebound damping on front forks and rear shock absorber (typical for EXC models).
Handguards:
Standard on Six Days models to protect hands and levers.
Skid Plate:
Often included or available as an upgrade for under-engine protection.
Infotainment System:
N/A (Off-road motorcycle, no infotainment system in the conventional sense)
Driver Assistance Features:
N/A (No electronic driver aids like ABS, traction control, etc., typical for this era and type of bike)
Lighting System:
Halogen headlight, LED taillight and brake light, standard turn signals.
Oil Change Interval:
Every 10-15 hours of riding or annually, whichever comes first (typical for off-road use). Refer to manual for exact mileage/hours.
Air Filter Cleaning Interval:
Every 5-10 hours of riding, or more frequently in dusty conditions.
Spark Plug Replacement Interval:
Every 20-30 hours of riding or annually.
Valve Clearance Check Interval:
Every 30-40 hours of riding or annually.
Chain And Sprocket Inspection Lubrication:
Check and lubricate every 5-10 hours of riding. Adjust tension as needed.
Engine Oil Viscosity:
SAE 10W-50 or 15W-50
Coolant Mixture:
50% distilled water, 50% ethylene glycol-based coolant
Brake Fluid Type:
DOT 4 hydraulic brake fluid
Clutch Fluid Type:
DOT 4 hydraulic clutch fluid
Carburetor Tuning Sensitivity:
The Keihin FCR carburetor can be sensitive to altitude and temperature changes, requiring periodic adjustments for optimal performance.
Cooling System Maintenance:
Regular coolant flushes and ensuring proper radiator fin condition are crucial for preventing overheating.
Chain And Sprocket Wear:
Due to off-road use, chain and sprocket wear can be accelerated; regular inspection and lubrication are vital.
Suspension Seals:
Fork seals and rear shock seals can degrade over time and with harsh use, requiring periodic inspection and replacement.
Ktm Offroad Legacy:
KTM has a rich history in off-road motorcycling, particularly in enduro and motocross, since its founding in 1934.
Exc Series Lineage:
The EXC series has been KTM's flagship line for enduro competition and aggressive trail riding for decades, continuously evolving with engine technology, chassis design, and suspension.
250Cc Four Stroke Development:
The introduction of the 250cc four-stroke engine (LC4) marked a significant step for KTM in this displacement class, competing with established Japanese manufacturers.
Production Period:
2004-2010 for this specific generation of 250 EXC-E Six Days.
Manufacturing Location:
Austria (KTM's primary manufacturing base)
