KTM 250sx 300sx engine Repair Manual. 2004-2006

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🏷️ Basic Information Identification Make: KTM Model: 250 SX / 300 SX Model Variant: SX, SXS, MXC, EXC Production Years Covered: 2004, 2005, 2006 Codes Engine Code Suffix: KTM engines...

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Taper: Motorcycle

Distributeur:

UGS: 433081

Mots clés: 2004 2005 2006 250sx 300 300sx KTM Motorcycle Motorcycles

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Model:

250 SX / 300 SX

Model Variant:

SX, SXS, MXC, EXC

Production Years Covered:

2004, 2005, 2006

Codes

Engine Code Suffix:

KTM engines of this era typically do not have distinct engine codes easily discernible without VIN breakdown, but refer to displacements.

👋 Introduction

Market Position

Market Segment:

High-performance off-road motorcycles (Motocross and Enduro).

Competitive Analysis

Competitor Models:

Yamaha YZ250, Honda CR250R, Suzuki RM250, Kawasaki KX250.

Key Features

Manual Benefit 1:

Enables correct and efficient repairs, saving time and preventing errors ('cockups').

Manual Benefit 2:

Provides essential technical data including all specifications and tolerances.

Manual Benefit 3:

Clarifies component functions for better understanding and diagnosis.

📋 Manual Details

Coverage Areas

Manual Scope:

Engine Repair Manual Only

Page Count

Page Count:

Manual Type

Manual Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Likely Print (based on description of 'easy-to-read text sections with top quality diagrams')

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine disassembly, assembly, overhaul, internal component inspection and replacement.

Engine Tuning:

Carburetor adjustment, ignition timing (if applicable to engine tuning aspects covered).

Fuel System Engine:

Carburetor (likely Keihin or similar) identification, removal, disassembly, cleaning, and reassembly.

Lubrication System:

Oil pump operation (if applicable), oil specifications, and inspection of lubrication passages.

Cooling System:

Radiator and coolant system maintenance related to engine operation (though primarily a dirt bike, some coolant management might be present).

Exhaust System:

Exhaust system component identification and maintenance as it relates to engine performance.

Procedures Included

Troubleshooting:

Fault finding for common engine issues, diagnostic procedures.

Repair Overhaul:

Step-by-step instructions for engine repair and complete overhaul.

Maintenance:

Regular engine maintenance procedures relevant to longevity and performance.

Component Replacement:

Detailed instructions for replacing specific engine internal parts (pistons, rings, valves, seals, bearings, etc.).

Technical Depth

Depth Of Coverage:

Comprehensive engine rebuild and repair, including detailed specifications and tolerances.

Diagnostic Information:

Information on diagnosing engine performance issues and component failures.

Specifications Data:

All necessary specifications and tolerances for engine components.

Component Function:

Explanation of the functions of various engine components.

📊 Manual Specifications

File Format

File Type:

Print (assumed)

Print Quality

Print Quality:

High quality, with easy-to-read text, top quality diagrams, pictures, and illustrations.

Binding Type

Binding:

Likely professional binding suitable for workshop use (e.g., stapled, saddle-stitched, or perfect bound).

Paper Type

Paper Quality:

Durable paper suitable for workshop environments.

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-Stroke

Displacement 250:

249 cc

Displacement 300:

293 cc

Bore Stroke 250 Approx:

Refer to manual for exact specifications (typically around 66.4 x 72 mm).

Bore Stroke 300 Approx:

Refer to manual for exact specifications (typically around 72 x 72 mm).

Cooling Method:

Liquid-Cooled

Induction:

Reed Valve Induction

Ignition:

Digital CDI (Capacitor Discharge Ignition)

Performance

Horsepower 250 Approx:

Refer to manual for specific output. Typically in the 45-50 hp range.

Horsepower 300 Approx:

Refer to manual for specific output. Typically in the 50-55 hp range.

Torque Approx:

Refer to manual for specific output. Higher torque in the 300cc variant.

Fuel System

Carburetor Type:

Likely Keihin PWK or similar, specific size to be confirmed in manual (e.g., 38mm).

Fuel Type:

Unleaded gasoline, octane rating to be specified in manual (recommendation for higher octane for performance).

Premix Ratio:

Refer to manual for exact oil-to-fuel ratio (commonly 40:1 or 50:1 for 2-stroke synthetics).

🔧 Transmission

Standard

Transmission Type:

6-Speed Manual Gearbox

Optional

Optional Transmissions:

None typically offered for these off-road models.

Features

Clutch Type:

Hydraulic Clutch Actuation

Gear Ratios:

Specific gear ratios will be detailed in the manual.

Transmission Oil Type:

Refer to manual for specific transmission fluid type and capacity (typically a dedicated gear oil).

📐 Dimensions

Exterior

Chassis Type:

Steel Frame (Chromoly)

Weights

Dry Weight Approx 250Sx:

Refer to manual. Typically around 96-100 kg.

Dry Weight Approx 300Sx:

Refer to manual. Slightly heavier than 250, around 98-102 kg.

Fuel Tank Capacity:

Refer to manual. Typically around 7-8.5 Liters.

🛡️ Safety Features

Ratings

Safety Ratings:

Not applicable for off-road competition motorcycles in the same way as street vehicles. Focus is on rider safety through design and component integrity.

Active Features

Braking System Front:

Hydraulic Disc Brakes (Brembo calipers common)

Braking System Rear:

Hydraulic Disc Brakes (Brembo calipers common)

Passive Features

Frame Construction:

High-strength steel frame designed for rigidity and rider feedback.

💡 Technology Features

Infotainment

Infotainment Features:

None. This is a pure competition motocross bike.

Driver Assistance

Rider Assistance:

None. Designed for direct rider control and feedback.

Connectivity

Connectivity Features:

None.

🔧 Maintenance

Service Intervals

Top End Rebuild Interval:

Refer to manual. Heavily dependent on usage and riding conditions, but can range from 40-100 hours for competitive use.

Piston Ring Replacement:

Refer to manual. Typically checked during top-end rebuilds.

Clutch Inspection:

Refer to manual. Regular inspection for wear is critical.

Fluid Specifications

Coolant Type:

Refer to manual. Typically a water-based coolant with anti-corrosion additives.

Brake Fluid Type:

Refer to manual. Typically DOT 4 or DOT 5.1.

2-Stroke Oil Type:

Refer to manual for recommended 2-stroke engine oil (high quality synthetic recommended).

Known Issues

Common Issues Engine:

Refer to manual for specific known issues. Common for 2-strokes of this era include piston/ring wear, clutch wear, and carburetor jetting sensitivity.

Maintenance Focus:

Regular cleaning of air filter, checking spark plug, maintaining correct chain tension, and adhering to lubrication schedules are critical.

📚 Vehicle History

Brand Heritage

Ktm Heritage:

KTM is renowned for its off-road racing heritage, particularly in Motocross, Enduro, and Rally Raid.

Model Evolution

Sx Model Line:

The SX line represents KTM's premier motocross competition models, known for their potent engines and race-ready chassis.

Production

Manufacturing Origin:

Austria

🏆 Awards & Recognition

Recognitions

Model Reputation:

KTM SX models of this era were highly regarded for their performance and competitive edge in their respective classes.