🏷️ Basic Information

Make:

KTM

Model:

SX, MXC, EXC

Engine Variant:

250cc, 300cc, 380cc

Model Years Covered:

1999, 2000, 2001, 2002, 2003

Platform Code:

LC2 (likely, though not explicitly stated, common for KTM 2-strokes of this era)

👋 Introduction

Target User:

KTM owners, independent repair shops, motorcycle technicians, enthusiasts looking for detailed repair and maintenance information.

Value Proposition:

Provides official factory-level technical data essential for accurate servicing and repair, ensuring optimal performance and longevity of KTM SX, MXC, and EXC motorcycles. Crucial for DIY mechanics and professional shops alike.

Delivery Method:

Instant PDF download, no shipping or wait times.

Guarantee:

Full Money Back Guarantee

📋 Manual Details

Primary Coverage:

Engine: 250cc, 300cc, 380cc variants

Secondary Coverage:

Chassis, suspension, electrical systems relevant to SX, MXC, EXC models (implied by 'Complete Official Factory Service / Repair / Full Workshop Manual')

Total Pages:

153

Type:

Official Factory Service / Repair / Workshop Manual

Language:

English

File Format:

PDF

📖 Manual Coverage

Engine:

Top End (Cylinder, Piston, Rings, Head, Valve Train - where applicable for 2-stroke ports, Camshaft - for 4-stroke variants if any exist in this range, although 2-stroke is more likely for these displacements and model designations), Bottom End (Crankshaft, Connecting Rod, Bearings, Crankcase), Lubrication System (Oil Pump, Oil Seals, Oil Cooling where applicable), Ignition System (CDI, Spark Plugs, Wiring), Fuel System (Carburetor, Intake, Fuel Pump, Fuel Filter, Fuel Lines), Exhaust System (Muffler, Downpipe, Gaskets), Cooling System (Radiator, Hoses, Fan, Water Pump - if liquid-cooled variants)

Transmission:

Gearbox (internal components, shifting mechanism), Clutch (Assembly, Plates, Springs, Hydraulic/Cable actuation), Transfer Case (if applicable to specific models)

Chassis And Suspension:

Frame components, Swingarm, Forks (Front Suspension), Shock Absorber (Rear Suspension), Linkages, Steering Head Bearings, Wheel Bearings, Axles

Brakes:

Front and Rear Brake Systems (Calipers, Rotors, Master Cylinders, Lines, Pads, Fluid, Bleeding Procedures)

Electrical:

Wiring Harnesses, Lighting (Headlight, Taillight, Indicators), Switches, Battery, Charging System (Alternator/Stator, Regulator/Rectifier), Sensors (Oil Pressure, Neutral Switch, etc.)

Maintenance:

Routine Checks, Oil Changes, Fluid Changes (Coolant, Brake Fluid), Filter Replacements (Air, Fuel, Oil), Spark Plug Replacement, Chain and Sprocket Maintenance, Brake Pad Replacement, Tire Rotation and Replacement, Wheel Balancing, Bearing Lubrication

Diagnostics And Troubleshooting:

Fault finding for engine, transmission, electrical, and chassis systems, diagnostic charts, error code interpretation (if applicable)

Repair And Rebuild:

Complete Engine Rebuild (Top and Bottom End), Transmission Overhaul, Suspension Servicing and Rebuilding, Brake System Overhaul, Electrical Component Repair/Replacement, Bodywork Repairs (panels, fairings)

Special Procedures:

Torque Specifications for all fasteners, Valve Clearance Adjustment (if 4-stroke), Carburetor Tuning and Synchronization, Clutch Adjustment, Suspension Setup and Adjustment, Electrical Wiring Diagrams and Schematics

Depth:

Comprehensive. Covers from basic maintenance to complete engine and chassis overhauls. Includes detailed component disassembly, assembly, adjustment, and troubleshooting steps. Likely includes detailed diagrams and illustrations.

📊 Manual Specifications

Digital Features:

Keyword searchable, Zoom in/out capability

Printability:

Printable

Binding:

N/A (PDF Download)

Paper Quality:

N/A (PDF Download)

Manual Quality:

Factory Original Quality

⚙️ Engine Specifications

Engine Type:

Likely 2-Stroke, Single-Cylinder (for SX/MXC/EXC 250/300/380cc displacements of this era). Note: Some EXC models may have had 4-stroke variants, but the displacements strongly suggest 2-stroke focus for this manual.

Bore Stroke 250:

Specifics to be found within the manual, but typical for this era would be around 66.4mm x 72mm (subject to variation).

Bore Stroke 300:

Specifics to be found within the manual, but typical for this era would be around 72mm x 70mm (subject to variation).

Bore Stroke 380:

Specifics to be found within the manual, but typical for this era would be around 86mm x 66mm (subject to variation).

Horsepower 250:

Estimated 40-50 HP range (subject to specific model and tuning).

Horsepower 300:

Estimated 45-55 HP range (subject to specific model and tuning).

Horsepower 380:

Estimated 50-60 HP range (subject to specific model and tuning).

Torque:

Significant torque delivery characteristic of KTM 2-strokes of this displacement.

Carburetor Type:

Likely Keihin PWK or similar performance-oriented carburetor (e.g., 36mm-39mm depending on displacement).

Fuel Octane Rating:

Recommended 91-98 RON (or equivalent Octane rating), depending on specific engine tuning and compression ratio.

Cooling System:

Liquid-Cooled

🔧 Transmission

Transmission Type:

6-Speed Manual

Transmission Options:

N/A (Typically standard 6-speed for these models)

Clutch Type:

Hydraulic Clutch Actuation (common for KTM)

📐 Dimensions

Frame Type:

Chromoly Steel Trellis Frame (typical for KTM)

Dry Weight Approx:

Approximately 95-105 kg (depending on specific model variant - SX, MXC, EXC).

Fuel Tank Capacity:

Typically 7-12 liters (specifics to be found in manual).

🛡️ Safety Features

Crash Safety:

N/A (Off-road motorcycles are not subject to the same crash rating standards as street vehicles).

Braking System:

Hydraulic Disc Brakes (Front and Rear), typically Brembo components.

Lighting:

Headlight, Taillight, Brake Light, Turn Signals (depending on homologation for street legality).

💡 Technology Features

Infotainment System:

N/A (Off-road motorcycles of this era typically lacked sophisticated infotainment systems).

Assistance Features:

N/A (Focus is on rider control and mechanical performance, not electronic rider aids beyond basic engine management).

Connectivity Features:

N/A

Ignition System:

CDI (Capacitor Discharge Ignition) with potentially adjustable ignition timing depending on the specific model and variant.

🔧 Maintenance

Oil Change Engine:

Frequent. Typically every 10-20 engine hours for 2-strokes, or as specified in manual for gearbox oil.

Air Filter Cleaning:

Regularly, often every few ride days or after dusty conditions.

Spark Plug Replacement:

As needed based on condition, or every 30-50 hours of use.

Top End Rebuild:

Recommended every 50-100 hours for aggressive use, depending on component quality and riding style.

Engine Oil:

Specific 2-stroke premix oil. Manual will specify brand recommendations and mix ratio (e.g., 32:1, 40:1, 50:1, 60:1 depending on oil type and engine).

Transmission Oil:

Specific gear oil (e.g., SAE 10W/30 or 10W/40). Manual will specify grade and capacity (typically ~0.8-1.2 liters).

Coolant:

Ethylene Glycol based coolant, mixed with distilled water (typically 50/50). Manual will specify capacity.

Brake Fluid:

DOT 4 or DOT 5.1 hydraulic brake fluid (Manual will specify exact type).

Common Wear Items:

Piston rings, piston, small end bearing, clutch plates, wheel bearings, steering head bearings, fork seals, exhaust packing material.

Specific Concerns:

Early models might have had specific issues with ignition components or certain seal types, which would be detailed in the troubleshooting section of the manual.

📚 Vehicle History

Heritage:

KTM, known as 'Ready To Race,' has a strong heritage in off-road motorsport, including Motocross (MX), Enduro, and Rally racing.

Evolution Sx Mxc Exc:

The SX (Motocross), MXC (Cross-Country), and EXC (Enduro) lines represent KTM's commitment to competitive off-road performance. These models underwent continuous development throughout the late 90s and early 2000s, refining engine power delivery, chassis dynamics, and suspension. The 250, 300, and 380cc displacements cater to different rider preferences and competitive classes within these disciplines.

Manufacturing Location:

Austria (Primary)

🏆 Awards & Recognition

Motorsport Success:

KTM's SX, MXC, and EXC models have a rich history of success in professional Motocross and Enduro championships worldwide, validating their performance and reliability.