🏷️ Basic Information

Make:

KTM

Model:

250/300/380 (Two-Stroke Off-Road)

Model Designation Notes:

Covers multiple displacements within the two-stroke off-road platform. Specific models may include EXC, SX, or similar designations depending on the year and market.

Engine Codes Covered:

Various two-stroke engines typically designated by displacement (e.g., 250cc, 300cc, 380cc). Specific engine codes would vary by model year and sub-model.

👋 Introduction

Category:

Performance Off-Road Motorcycles (Enduro/Motocross)

Target User:

Owners and mechanics of KTM 250, 300, and 380cc two-stroke off-road motorcycles seeking detailed repair, maintenance, and troubleshooting information.

Competitors:

Yamaha YZ/WR series, Honda CR/XR series, Suzuki RM/DR series, Kawasaki KX/KDX series.

Value Proposition:

Provides in-depth, manufacturer-level technical guidance specifically tailored to KTM's robust two-stroke off-road platform, essential for maintaining peak performance and longevity.

📋 Manual Details

Technical Procedures:

Engine overhaul, transmission repair, chassis maintenance, electrical system diagnostics, suspension tuning, fuel system servicing, cooling system maintenance, braking system overhaul, exhaust system replacement, bodywork repair, and troubleshooting.

Model Year Coverage:

Likely covers a range of years for the 250, 300, and 380cc two-stroke models. Specific year range needs to be confirmed from the manual's content, but typically these manuals cover several consecutive model years (e.g., 1990s to early 2000s for older models, or specific recent generations).

Regional Coverage:

While the language is German, the technical content is likely applicable globally for these specific KTM off-road models.

Estimated Page Count:

Estimated 400-600 pages (typical for comprehensive service manuals covering multiple displacements and years).

Type:

Service Repair Manual

Language:

German

Format:

Likely a digital format (e.g., PDF) given the product description, enabling easy searching and printing. Could also be a printed manual.

📖 Manual Coverage

Engine Mechanical:

Complete engine disassembly, inspection, repair, and reassembly. Includes cylinder head, piston, connecting rod, crankshaft, bearings, seals, gaskets, and valve (if applicable to specific two-stroke designs like reed valves).

Engine Fuel System:

Carburetor overhaul (Mikuni, Keihin typically), jetting specifications, fuel lines, fuel tank, petcock, and fuel filters.

Engine Ignition System:

CDI unit, stator, ignition coil, spark plug, wiring diagrams, timing specifications, and troubleshooting ignition faults.

Engine Cooling System:

Radiator, hoses, coolant, water pump (if liquid-cooled), thermostat (if applicable), and bleeding procedures.

Transmission Gearbox:

Gearbox disassembly, inspection, repair, and reassembly. Includes gear sets, shift forks, shift drum, clutch assembly (wet multi-plate), clutch master and slave cylinders, and gearbox oil specifications.

Electrical System:

Complete wiring diagrams, lighting systems, battery maintenance, charging system, starter system (if electric start equipped), switches, fuses, relays, and diagnostic procedures for electrical faults.

Chassis Suspension:

Front fork (e.g., WP USD) and rear shock absorber servicing, seal replacement, oil levels, damping adjustments, and spring rates. Includes linkage systems.

Chassis Brakes:

Front and rear brake systems (hydraulic disc brakes typically). Includes brake caliper overhaul, master cylinder servicing, brake line replacement, pad replacement, fluid bleeding, and specifications for brake fluid (e.g., DOT 4).

Chassis Frame And Bodywork:

Frame inspection, body panel removal and installation, seat, fuel tank, fenders, handlebars, and footpegs.

Wheels And Tires:

Wheel bearing maintenance, spoke tensioning, tire pressure specifications, tire replacement, and rim maintenance.

Routine Maintenance:

Oil changes (gearbox), air filter cleaning/replacement, chain lubrication and adjustment, spark plug replacement, brake inspection, and general bolt checks.

Troubleshooting Guides:

Systematic diagnostic procedures for common and uncommon problems, categorized by symptom (e.g., starting issues, power loss, braking problems, electrical faults).

Overhaul Procedures:

Detailed step-by-step instructions for complete engine rebuilds, gearbox overhauls, and suspension component rebuilds.

Special Tool Requirements:

Lists and descriptions of specialized tools required for specific maintenance and repair tasks.

Technical Data Tables:

Torque specifications for all fasteners, engine clearances, fluid capacities, and electrical component data.

Depth:

Comprehensive, covering everything from basic user maintenance to complete engine and gearbox rebuilds, including electrical diagnostics and suspension tuning. Suitable for professional mechanics and experienced DIY enthusiasts.

📊 Manual Specifications

Format Details:

Likely PDF. Searchable text functionality is highly probable. Compatibility with most operating systems and devices.

Quality:

High-resolution diagrams and images, ensuring clarity for component identification and procedural steps.

Binding:

If printed: Spiral-bound or perfect bound for durability and lay-flat usability in a workshop environment. If digital: PDF.

Paper Quality:

If printed: Durable, matte-finish paper suitable for workshop conditions, resistant to oil and dirt.

⚙️ Engine Specifications

Engine Type:

Two-Stroke, Liquid-Cooled (typically)

Displacement Options:

250cc, 300cc, 380cc

Bore X Stroke:

Varies by displacement. Example for 250cc: approx. 66.4 x 72 mm. Example for 300cc: approx. 72 x 73.6 mm. Example for 380cc: approx. 82 x 72 mm. (Specific values detailed in manual).

Compression Ratio:

Typically around 8.5:1 to 9.5:1, depending on model and year. (Specific values detailed in manual).

Fuel Delivery:

Carburetor (e.g., Keihin PWK or Mikuni TM/VM series).

Ignition:

Digital CDI

Horsepower Range:

Approx. 40-55 HP (depending on displacement and specific tuning).

Torque Range:

Approx. 35-45 Nm (depending on displacement and specific tuning).

Recommended Fuel:

Unleaded gasoline with appropriate octane rating (e.g., RON 91-98). Manual will specify exact requirements and 2-stroke oil mixing ratios (pre-mix or oil injection systems).

Carburetor Size:

Typically 36mm or 38mm (e.g., Keihin PWK 36/38).

🔧 Transmission

Type:

6-Speed Constant Mesh

Clutch Type:

Wet Multi-Plate Clutch

Gear Ratios:

Specific ratios vary by model year and displacement, detailed in the manual. Typically designed for strong low-end and mid-range power delivery.

Gearbox Oil Type:

Manual transmission oil (e.g., SAE 10W/50 or 80W, API SG/SH/SJ). Specific type and viscosity detailed in the manual.

📐 Dimensions

Wheelbase:

Varies by model, typically 1450-1500 mm (approx. 57-59 inches).

Seat Height:

Varies by model, typically 950-980 mm (approx. 37.4-38.6 inches).

Dry Weight:

Typically 100-115 kg (approx. 220-254 lbs) depending on model and equipment.

🛡️ Safety Features

Safety Standards:

Designed for off-road use, adhering to relevant motorsport and off-road vehicle safety guidelines. Not street-legal in many configurations without additional equipment.

Braking System:

Hydraulic disc brakes front and rear. Brembo or Grimeca calipers are common.

Suspension Damping:

Adjustable compression and rebound damping on front forks and rear shock absorbers for optimal control and stability.

Frame Construction:

Chromium-molybdenum (CrMo) steel trellis frame for strength and rigidity.

💡 Technology Features

Features:

Minimal to none. These are performance-focused off-road motorcycles. Features typically include basic instrument clusters (speedometer, odometer, hour meter) and indicator lights.

Features:

None. Focus is on rider control and mechanical feedback.

Features:

None.

🔧 Maintenance

Engine Oil Change:

Gearbox oil: Every 15-20 hours of riding or annually. Manual will specify exact interval based on usage.

Air Filter Cleaning:

After every few rides or as needed depending on conditions. Regular cleaning and re-oiling are critical.

Spark Plug Replacement:

Every 40-60 hours of riding, or as indicated by performance issues. Specific plug types and gap specifications are crucial.

Piston Ring Replacement:

Recommended every 80-120 hours for optimal performance and compression, or based on wear measurements.

Engine Rebuild Interval:

Major engine rebuild (piston, rings, bearings, seals) typically recommended every 150-250 hours of hard use, depending on maintenance and riding style.

Gearbox Oil Capacity:

Approx. 0.7 - 0.9 liters (depending on model). Manual will provide exact capacity.

Brake Fluid Type:

DOT 4 (typically).

Coolant Type:

Ethylene glycol-based antifreeze/coolant, typically a 50/50 mix with distilled water. Manual specifies exact type and ratio.

Common Wear Items:

Piston rings, exhaust power valve components, clutch plates, wheel bearings, and suspension seals are common wear items that require regular inspection and replacement.

Power Valve Maintenance:

Power valve system requires regular cleaning and inspection for carbon buildup and proper function, as it significantly impacts performance delivery.

Carburetor Tuning:

Sensitivity to altitude, temperature, and humidity changes requires periodic carburetor jetting adjustments for optimal performance.

📚 Vehicle History

Origin:

KTM is an Austrian manufacturer renowned for its off-road racing heritage and performance-oriented motorcycles.

Two Stroke Legacy:

KTM has a long and successful history with two-stroke engines in motocross and enduro racing, continuously refining their designs for power, reliability, and handling.

Manufacturing Location:

Primarily Austria, though some components or assembly may occur elsewhere depending on the model year.

🏆 Awards & Recognition

Performance Acclaim:

KTM's two-stroke off-road bikes have a strong reputation and numerous accolades in professional racing and enthusiast reviews for their potent engines, sharp handling, and off-road prowess.

Durability Reputation:

Generally considered robust and durable when properly maintained, a testament to KTM's engineering focus on off-road performance.