Target Audience:
Professional technicians and advanced DIY enthusiasts undertaking comprehensive maintenance, repair, and restoration.
Value Proposition:
Provides the same level of detail as professional service manuals, offering a cost-effective alternative to dealership service or expensive physical manuals.
Delivery Method:
Instant download, eliminating shipping costs and wait times.
Usability:
Features numbered instructions, bold figure numbers, detailed illustrations, and a numbered table of contents for efficient navigation.
General Coverage:
Complete service and repair for KTM 250, 300, and 380 SX, MXC, and EXC models from 1999-2003.
Estimated Page Count:
Extensive (Specific count not provided, but described as 'very detailed' and covering 'everything').
Type:
Full Service Repair Manual
Engine:
Detailed engine overhaul, rebuild, troubleshooting, and diagnostics for 2-stroke engines.
Transmission:
Clutch, gearbox, and drivetrain maintenance and repair procedures.
Electrical:
Complete electrical system diagnostics, troubleshooting, and wiring diagrams.
Suspension:
Front and rear suspension system service, including forks and shock absorbers.
Brakes:
Hydraulic brake system service, maintenance, and troubleshooting.
Fuel System:
Carburetor (likely Keihin PWK or similar for the era) disassembly, cleaning, adjustment, and jetting.
Cooling System:
Radiator, coolant, and associated plumbing service (if applicable, though most SX/MXC/EXC of this era were air-cooled or had minimal liquid cooling for specific models).
Frame And Bodywork:
Chassis, subframe, plastics, and seat maintenance and repair.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustment, and general upkeep.
Repair:
Component-level repair and replacement for all major vehicle systems.
Rebuild:
Complete engine rebuild procedures, including piston, ring, cylinder, crankshaft, and connecting rod servicing.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues.
Diagnostics:
Detailed diagnostic flowcharts and fault finding guidance.
Wiring Diagrams:
Comprehensive and detailed electrical wiring diagrams for all circuits.
Depth:
Professional level, suitable for experienced technicians and advanced DIY mechanics. Covers detailed sub-steps, notes, cautions, and warnings.
Engine Type:
2-Stroke, single-cylinder (typical for SX/MXC/EXC models of this era).
Bore Stroke 250:
Approx. 66.4mm x 72mm (typical for 250cc 2-stroke KTM).
Bore Stroke 300:
Approx. 72mm x 72mm (typical for 300cc 2-stroke KTM).
Bore Stroke 380:
Approx. 82mm x 72mm (typical for 380cc 2-stroke KTM).
Horsepower 250:
Estimated 40-45 HP (varies by specific model and tuning).
Horsepower 300:
Estimated 45-50 HP (varies by specific model and tuning).
Horsepower 380:
Estimated 50-55 HP (varies by specific model and tuning).
Carburetor Type:
Likely Keihin PWK (e.g., 38mm for SX/MXC, potentially 36mm for EXC variants).
Fuel Octane Rating:
91-98 RON (unleaded premium gasoline recommended for optimal performance and engine longevity).
Premix Ratio:
Typically 1:32 to 1:50 with quality 2-stroke synthetic oil (consult manual for exact recommendation).
Type:
6-speed constant mesh manual transmission.
Clutch Type:
Hydraulic actuation, multi-plate wet clutch.
Transmission Fluid:
Dedicated transmission oil (e.g., SAE 75W/90 or SAE 10W/40 motorcycle-specific, consult manual for precise specification).
Ground Clearance:
Varies by model (SX: ~350mm, EXC: ~370mm typical).
Dry Weight 250:
Approx. 98-102 kg (varies by model SX/MXC/EXC).
Dry Weight 300:
Approx. 100-104 kg (varies by model SX/MXC/EXC).
Dry Weight 380:
Approx. 103-107 kg (varies by model SX/MXC/EXC).
Oil Change Interval:
Transmission oil: Every 10-15 hours of riding, or annually. (Refer to manual for exact interval).
Air Filter Cleaning:
Frequent cleaning recommended, typically after every few rides or in dusty conditions.
Spark Plug Replacement:
Variable, typically every 20-40 hours of riding, depending on plug type and usage.
Top End Rebuild Interval:
Highly variable based on usage and tuning, often 50-100 hours for competitive use.
Engine Oil Type:
Specific 2-stroke premix oil (e.g., Motorex, Castrol TTS, etc., refer to manual).
Transmission Oil Spec:
Refer to manual for specific SAE viscosity and API rating (e.g., SAE 75W/90 or SAE 10W/40 motorcycle specific).
Power Valve Sticking:
Common issue in 2-strokes; requires regular cleaning and lubrication of the power valve mechanism.
Clutch Drag:
Can occur with worn clutch plates or incorrect cable/hydraulic adjustment.
Carburetor Jetting Sensitivity:
These engines are sensitive to altitude and temperature changes, requiring proper jetting adjustments.
Suspension Seals:
Fork and shock seals can wear, leading to leaks, especially under aggressive riding conditions.
Ktm Heritage:
KTM is an Austrian manufacturer renowned for its off-road motorcycles, with a strong history in motocross, enduro, and rally racing.
Sx Evolution:
The SX line represents KTM's motocross competition models. These bikes were designed for aggressive track performance, featuring potent engines and performance-oriented suspension.
Mxc Evolution:
The MXC (often EXC versions in certain markets) denotes cross-country or enduro models, typically offering wider-ratio gearboxes, larger fuel tanks, lights, and sometimes softer suspension settings than SX models.
Exc Evolution:
The EXC series is KTM's dedicated enduro competition line, designed for challenging off-road terrain. These models often feature strong low-end torque, robust suspension, and lighting for street legality in some configurations.
Manufacturing Origin:
Austria
