🏷️ Basic Information

Make:

KTM

Model:

250 SX, 300 SX, 250 EXC, 300 EXC, 380 EXC, 250 EXC Six Days, 300 EXC Six Days, 250 EXC Racing, 300 EXC Racing, 250 MXC, 300 MXC, 250 MXC Six Days, 300 MXC Six Days

Generation:

First Generation (PDS Suspension Era)

Chassis Codes:

Likely GS/XC/SX series prefixes for the respective models

👋 Introduction

Category:

Performance Off-Road Motorcycles (Enduro, Motocross, XC)

Competitors:

Yamaha YZ, Honda CR, Suzuki RM, Kawasaki KX (2-stroke variants of the era)

Brand Philosophy:

KTM's 'Ready to Race' heritage, focusing on performance and rider engagement

Model Focus:

Powerful 2-stroke engines, advanced WP suspension (including PDS rear), lightweight chassis

Manual Value Proposition:

Comprehensive, digital, instantly accessible service information for DIY mechanics and professionals

📋 Manual Details

Model Years Covered:

1999, 2000, 2001, 2002, 2003

Page Count:

153 pages

Manual Type:

Workshop Service Repair Manual

Language:

English

File Format:

PDF

📖 Manual Coverage

Engine:

2-stroke engine overhaul, top-end and bottom-end procedures, cooling system, lubrication, exhaust system

Transmission:

Gearbox disassembly, assembly, inspection, gear shift mechanism

Chassis:

Frame inspection and repair, subframe, steering head bearings, swingarm, linkage system (PDS)

Suspension:

Front fork (WP) service and overhaul, rear shock absorber (WP PDS) service and overhaul, adjustments, tuning

Brakes:

Hydraulic brake system inspection, maintenance, bleeding, caliper and master cylinder overhaul (front and rear)

Fuel System:

Carburetor (likely Keihin or Mikuni) disassembly, cleaning, adjustment, fuel tank, fuel lines

Electrical System:

Ignition system, lighting, wiring diagrams, battery maintenance, charging system

Cooling System:

Radiator, coolant hoses, thermostat, coolant specifications

Bodywork:

Fairings, seat, fenders, handlebars, controls

Maintenance:

Routine maintenance, oil changes, filter replacements, chain adjustment, spark plug replacement

Troubleshooting:

Diagnosis of common problems, fault finding, electrical issue resolution

Repair:

Step-by-step repair instructions for all major components and systems

Disassembly Assembly:

Detailed instructions for removing and installing parts, including engine and suspension components

Adjustments:

Carburetor jetting, suspension settings, clutch adjustment, brake lever adjustments

Depth:

Comprehensive (from basic maintenance to complete engine and suspension rebuilds)

Diagrams Illustrations:

Detailed pictorial diagrams, exploded views, and photographs

Special Tools:

Identification and usage of required special service tools

Specifications:

Factory specifications, tolerances, and torque values

📊 Manual Specifications

PDF Quality:

High quality, printable pages, zoomable content

Printability:

Yes, all pages are printable

Binding:

Not applicable (digital PDF download)

Paper Type:

Not applicable (digital PDF download)

Operating Systems:

Windows, Mac, Linux OS

Software Requirement:

Adobe Reader

⚙️ Engine Specifications

Engine Type:

2-stroke, liquid-cooled, single-cylinder

Engine Displacement 250:

Approx. 249cc

Engine Displacement 300:

Approx. 293cc

Engine Displacement 380:

Approx. 373cc

Horsepower 250:

Estimated 40-45 HP (varies by model and tuning)

Horsepower 300:

Estimated 45-50 HP (varies by model and tuning)

Horsepower 380:

Estimated 50-55 HP (varies by model and tuning)

Carburetor Type:

Keihin PWK (typically 36mm or 38mm) or Mikuni TMX (varies by specific model/year)

Fuel Type:

Unleaded gasoline with 2-stroke oil pre-mix (specified ratio in manual)

🔧 Transmission

Transmission Type:

6-speed manual

Clutch Type:

Hydraulic, multi-plate wet clutch

📐 Dimensions

Dry Weight 250/300:

Approx. 220-235 lbs (100-107 kg) depending on model

Dry Weight 380:

Slightly heavier than 250/300 models

💡 Technology Features

Infotainment System:

Not applicable (performance off-road motorcycle)

Driver Assistance Features:

Not applicable (performance off-road motorcycle)

Connectivity Features:

Not applicable (performance off-road motorcycle)

🔧 Maintenance

Oil Change Interval:

Refer to manual for specific gearbox oil change intervals; typically every 15-20 hours of riding.

Air Filter Cleaning:

Frequent cleaning required, especially in dusty conditions (refer to manual for hours).

Top End Rebuild:

Recommended every 40-80 hours of hard use, depending on riding style and maintenance.

Gearbox Oil:

Refer to manual for specific KTM recommended gearbox oil viscosity and type (e.g., SAE 10W/40 or 15W/50 motorcycle specific).

Coolant:

Ethylene glycol based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water.

Clutch Drag:

Can sometimes occur due to clutch plate wear or improper adjustment.

Suspension Seals:

Leaking fork or shock seals can be a common maintenance item requiring seal replacement.

Power Valve Sticking:

Carbon buildup can cause the power valve to stick, affecting engine performance.

Piston Wear:

Regular top-end inspections are crucial to monitor piston and cylinder wear.

📚 Vehicle History

Brand Focus:

KTM has a long history in off-road racing, especially motocross and enduro.

Chassis Development:

This era featured KTM's innovative PDS (Progressive Damping System) rear suspension, which eliminated a linkage system.

Engine Development:

Continued refinement of their potent 2-stroke engine platforms for competitive performance.