Ktm Exc Repair Manual RA_250/380EXC_03_E

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250/300/380 SX,MXC,EXC

Repair manual KTM 250 / 300 / 380

Art No 3206004 -E

REPAIR MANUAL
ENGINE

KTM SPORTMOTORCYCLE AG
5230 Mattighofen
Austria
www.ktm.at

250 - 380
SX,MXC,EXC
REPAIR
MANUAL
ENGINE

1 SERVICE-INFORMATIONS
2 GENERAL INFORMATION
3 REMOVING AND REFITTING ENGINE
4 DISASSEMBLING THE ENGINE
5 SERVICING ON INDIVIDUAL COMPONENTS
6 ASSEMBLING THE ENGINE
7 ELECTRICAL
8 TROUBLE SHOOTING
9 TECHNICAL SPECIFICATIONS
10 PERIODIC MAINTENANCE SCHEDULE
11 WIRING DIAGRAMS
12
13
14
15
16

I M P O RTA N T I N F O R M AT I O N /U P D AT I N G

INSTRUCTIONS

To be able to continue using the existing loose-leaf repair instructions, simply print the following
pages and insert them in the existing repair instructions:

Art No 3206004 -E

14-20, 26, 28-36, 37, 41, 42, 50, 51, 67, 72-77, 83, 121-126, 127, 134-136,
137, 151-153

Remove page (s)

Replace by page (s)

Insert page (s)

2-1 to 2-4

2-1C to 2-6C

3-4

3-4C

4-1 to 4-9

4-1C to 4-8C

5-1

5-1C

5-4

5-4C / 5-5C

5-13 to 5-14

5-13C to 5-14C

7-1

7-1C

7-5C to 7-10C

9-1

9-1C

9-37C to 9-42C

10-1

10-1C

10-6C to 10-8C

11-1

11-1C

11-14C to 11-16C

after page

Repair manual KTM 250 / 300 / 380

KTM REPAIR MANUAL IN LOOSE-LEAF FORM
STORING THE REPAIR MANUAL IN THE BINDER
– Put the index into the binder.
– Put the front page of the repair manual (210x297 mm) into the transparent pocket provided for
this purpose on the outside of the binder.
– Put the spine label (170x45 mm) into the transparent pocket provided for this purpose on the
spine of the binder.
– Put the summary list of contents (150x297 mm) into the transparent pocket provided for this
purpose on the inside of the binder or insert this page on the beginning of the manual.
– Then insert the individual chapters of the manual between the sheets of the index according to
the page number printed in the right bottom corner of each page.
Example: page no. 3-5
3 = chapter 3
5 = page 5
All pages with a page number that begins with the digit 3, for example, must be put under the
index heading „Chapter 3“.
– Index sheets that have not been marked with a certain chapter are for your personal convenience.
The respective headings can be entered in the list of contents.

E X P L A N AT I O N - U P D AT I N G
3.205.63-E

Repair Manual 250 / 300 / 380 SX, MXC, EXC
Basicversion Modelyear 1999
(Engine number with first digit “9“)

11/1998
3.205.87-E

Updating of Rep.Manual 3.205.63-E
Modelyear 2000
(Engine number with first digit “0“)

2/2000

Art No 3206004 -E

3.210.02-E

Updating of Rep.Manual 3.205.63-E
Modelyear 2001/2002
(Engine number with first digit “1“)
(Engine number with first digit “2“)

3/2001
3.206.004-E Updating of Rep.Manual 3.205.63-E
Modelyear 2003
(Engine number with first digit “3“)

Repair manual KTM 250 / 300 / 380

11/2002
Modification / Updating:
Technical Specification,
Periodic Maintenance Schedule, Wiring Diagrams

Edition 11/2002

INTRODUCTION
This repair manual offers extensiv repair-instructions and is an up-to-date version that describes the
latest models of the series. However, the right to modifications in the interest of technical
improvement is reserved without updating the current issue of this manual.
A description of general working modes common in work shops has not been included. Safety rules
common in the work shop have also not been listed. We take it for granted that the repairs are made
by qualified profesionally trained mechanics.
Read through the repair manual before beginning with the repair work.



WARNING




STRICT COMPLIANCE WITH THESE INSTRUCTIONS
ESSENTIAL TO AVOID DANGER TO LIFE AND LIMB.
!

CAUTION

IS

!

NON-COMPLIANCE WITH THESE INSTRUCTIONS CAN LEAD TO
DAMAGE OF MOTORCYCLE COMPONENTS OR RENDER
MOTORCYCLES UNFIT FOR TRAFFIC !

„NOTE” POINTS OUT USEFUL TIPS.
Use only ORIGINAL KTM SPARE PARTS when replacing parts.
The KTM high performance engine is only able to meet user expectations if the maintenance work is
performed regularly and professionally.

KTM Austria’s certificate of achievement for its quality system ISO 9001 is the beginning of an on
going total reengineered quality plan for a brighter tomorrow.
KTM Sportmotorcycle AG
5230 Mattighofen, Austria
All design and assembly modification rights reserved.

C by KTM SPORTMOTORCYCLE AG, AUSTRIA

All rights reserved

REPLY FAX FOR REPAIR MANUALS
We have made every effort to make our repair manuals as accurate as possible but it is always possible for
a mistake or two to creep in.
To keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist us
as follows:
If you find any errors or inaccuracies in one of our repair manual – whether these are technical errors,
incorrect or unclear repair procedures, tool problems, missing technical data or torques, inaccurate or
incorrect translations or wording, etc. – please enter the error(s) in the table below and fax the completed
form to us at 0043/7742/6000/5349.
NOTE to table:
Enter the complete item no. for the repair manual in column 1 (e.g.: 3.210.66-E).
You will find the number on the cover page or in the left margin on each right page of the manual.

–

–

Enter the corresponding page number in the repair manual (e.g.: 5-7c) in column 2.

–

Enter the current text (inaccurate or incomplete) in column 3 by quoting or describing the respective
passage of the text. If your text deviates from the text contained in the repair manual, please write your
text in German or English if possible.

–

Enter the correct text in column 4.

Your corrections will be reviewed and incorporated in the next issue of our repair manual.
Item no. of repair manual

Page

Current text

Correct text

Additional suggestions, requests or comments on our Repair Manuals (in German or English):

Name mechanic/shop foreman

Company/work shop

2-1C

2

GENERAL INFORMATION
INDEX

Repair manual 250 / 300 / 380

Art Nr 3206004 -E

OPERATING RANGES OF THE CARBURETOR . . . . .
CARBURETOR ADJUSTMENT . . . . . . . . . . . . . . . .
CHECKING OF THE SETTING OF THE TVC SYSTEM
BLEEDING OF THE HYDRAULIC CLUTCH . . . . . . .
SPECIAL TOOLS - ENGINE . . . . . . . . . . . . . . . . . .
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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.2-2
.2-3
.2-4
.2-4
.2-5
.2-6
.2-6

2-2C

OPERATING RANGES OF THE CARBURETOR

main jet
jet needle

jet needle

idle jet
throttle valve
air control screw
idle adjusting screw

mixture too lean:

Art No 3206004 -E

not enough fuel in proportion to air

2

mixture too rich:
too much fuel in proportion to air

1

Idling range

A

Repair manual KTM 250 / 300 / 380

Operation with closed throttle valve. This range is influenced by the position of the air control screw 1 and the idle adjusting screw
2. Only make adjustments when the engine is hot.
To this end, slightly increase the idling speed of the engine by means of the idle adjusting screw. Turning it clockwise produces a
higher idling speed and turning the screw counterclockwise produces a lower idling speed. Create a round and stable engine speed
using the air control screw (basic position of the air control screw = open by 1.5 turns). Then adjust to the normal idling speed by
means of the idle adjusting screw.

Opening up

B

Engine behavior when the throttle opens. The idle jet and the shape of the throttle valve influences this range. If, despite good
idling-speed and part-throttle setting, the engine sputters and smokes when the throttle is fully opened and develops its full power
not smoothly but suddenly at high engine speeds, the mixture to the carburetor will be too rich, the fuel level too high or the float
needle is leaking.

Part-throttle range

C

Operation with partly open throttle valve. This range is only influenced by the jet needle (shape and position). The optimum
part-throttle setting is controlled by the idling setting in the lower range and by the main jet in the upper range. If the engine runs
on a four-stroke cycle or with reduced power when it is accelerated with the throttle partly open, the jet needle must be lowered by
one notch. If then the engine pings, especially when accelerating under full power at maximum engine revs, the jet needle should
be raised.
If these faults should occur at the lower end of the part throttle range at a four-stroke running, make the idling range leaner; if the
engine pings, adjust the idling range richer.

Full throttle range

D

Operation with the throttle fully open (flat out). This range is influenced by the main jet and the jet needle. If the porcelain of the
new spark plug is found to have a very bright or white coating or if the engine rings, after a short distance of riding flat out, a larger
main jet is required. If the porcelain is dark brown or black with soot the main jet must be replaced by a smaller one.

2-3C
Carburetor adjustment
Basic information on the original carburetor setting
The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient
temperature of approx. 20° C (68° F), mainly for off-road use and central European premium-grade fuel (ROZ 95 MOZ). Mixing
ratio 2-stroke motor oil : super fuel 1:40 – 1:60.
Basic information on a change of the carburetor setting
Always start out from the original carburetor setting. Essential requirements are a clean air filter system, air-tight exhaust system and
an intact carburetor. Experience has shown that adjusting the main jet, the idling jet and the jet needle is sufficient and that changes
of other parts of the carburetor will not greatly affect engine performance.
RULE OF THUMB:
high altitude or high temperatures
➞
choose leaner carburetor adjustment
low altitude or low temperatures
➞
choose richer carburetor adjustment






WARNING

– ONLY
–
–
–

USE PREMIUM-GRADE GASOLINE ROZ 95 MIXED WITH HIGH-GRADE TWO-STROKE ENGINE OIL. OTHER TYPES OF GASOLINE CAN CAUSE ENGINE
FAILURE, AND USE OF SAME WILL VOID YOUR WARRANTY.
ONLY USE HIGH-GRADE 2-STROKE ENGINE OIL OF KNOWN BRANDS.
NOT ENOUGH OIL OR LOW-GRADE OIL CAN CAUSE EROSION OF THE PISTON. USING TOO MUCH OIL, THE ENGINE CAN START SMOKING AND FOUL THE
SPARK PLUG.
IN THE CASE OF A LEANER ADJUSTMENT OF THE CARBURETOR PROCEED CAUTIOUSLY. ALWAYS REDUCE THE JET SIZE IN STEPS OF ONE NUMBER TO AVOID
OVERHEATING AND PISTON SEIZURE.

NOTE: If despite a changed adjustment the engine does not run properly, look for mechanical faults and check the ignition system.

Basic information on carburetor wear
As a result of engine vibrations, throttle valve, jet needle, and needle jet are subjected to increased wear. This wear may cause
carburetor malfunction (e.g., overly rich mixture). Therefore, these parts should be replaced after 10000 kilometers (6000 miles).

jet needle

N
N
N
N
N

85
85
85
85
85

A
B
C
D
E

throttle valve open

effect

0 – 1/4



–

0 – 1/4



–

–

0 – 1/4



–

–

–

1

0 – /4

Explanation - Example
Compared to the needle N 85 A, the jet needle N 85 C is two steps leaner
in the range from the closed position of the throttle to 1/4 throttle.
Otherwise, there are not differences.



–

–

–

–

N 85 C
NOZ
NOZ
NOZ
NOZ
NOZ
NOZ
NOZ
NOZ

C
D
E
F
G
H
I
J

N3CG
N3CH
N3CW

0 – 1/4
1

0 – /4
0 – 1/4
1

0 – /4



–

–


–

–

–


–

–

–

–


–

–

–

–

–

0 – 1/4



–

–

–

–

–

–

0 – 1/4



–

–

–

–

–

–

–

0 – 1/4



–

1

0 – /4



–

–



–

0 – /4

1

0 – 1/4



–

–

CAUTION
!
WHEN CHANGING THE JET NEEDLE, MAKE SURE THAT YOU USE THE
TYPE (N 85 ,NOZ OR N3). THE TECHNICAL DATASHEET TELLS
NEEDLE CAN BE USED FOR WHICH MODEL.

!
CORRECT NEEDLE
YOU WHICH JET

2-4C
Checking the setting of the TVC system
The function of the TVC system is checked with the engine running.
This test checks the start of advance and the end of advance.
– For this, remove the left control cover.
– Connect a rev counter (either to the ignition cable or to the blue/white
cable in the electronics box, depending on the rev counter design).
– Start engine, accelerate gently and observe when the TVC system
starts to advance (tooth segment creeps upwards).

start of advance

end of advance

250 Model 1999

5400 U/min

7550 U/min

250 from Modell 2000 on

5000 U/min

7000 U/min

300 up to Modell 2000

5300 U/min

7750 U/min

300 from Modell 2001 on

5900 U/min

7750 U/min

380

5200 U/min

7200 U/min

– If necessary, turn the adjusting screw 1.

Art No 3206004 -E

NOTE: Twisting the adjusting screw in delays the commencement of
adjustment by the TVC system, twisting the adjusting screw out means
that the TVC system will perform the adjustment earlier.

1

Bleeding of the hydraulic clutch

Repair manual KTM 250 / 300 / 380

3

– Take off cover together with rubber bellows.
– At the slave cylinder of the clutch, remove the bleeder nipple 2. It its
place, mount the bleeder syringe 3 which is filled with SAE 10
hydraulic oil.

2

– Refill oil, until oil is discharged from the bore 4 of the master cylinder
in a bubble-free state. Make sure that the oil does not overflow.

4

!
– HAVING
–
–

CAUTION

!

COMPLETED THE BLEEDING PROCEDURE, YOU HAVE TO VERIFY THAT THE
OIL LEVEL IN THE MASTER CYLINDER IS CORRECT.
KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH
CONTROL. NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS.
ALWAYS USE BIODEGRADABLE HYDRAULIC OIL SAE 10 TO FILL UP THE MASTER
CYLINDER. NEVER REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID.

2-5C

SPECIAL TOOLS – ENGINE

250 / 300 / 380
13

10

17

6
5

14
16

1
4

7

19

18

26
25

8

11

9

Fig.
1
3
4
5
6
7
8
9
9
10
11
13
14
16
17
18
18
18
19
25
26

Part no.
560.12.001.000
546.29.003.000
560.12.004.000
546.29.009.044
6 276 807
510.12.011.000
544.12.012.000
584.29.037.040
584.29.037.043
510.12.016.000
546.29.012.100
501.12.013.000
501.12.030.000
6 899 785
151.12.017.000
151.12.018.100
151.12.018.000
151.12.018.200
546.29.027.000
0276 179 000
503.29.050.000

Description
Universal engine work stand
Clutch holder
Gear wheel segment
Magneto extractor M 27x1 Kokusan
Magneto extractor M 26x1,5 SEM
Circlip plier
Holding spanner for flywheel SEM
Mounting tool inner ring NJ 207
Mounting tool inner ring NJ 207
Protection cap
Holding spanner for flywheel Kokusan
Dial gauge 0-10 mm
Dial gauge support
Loctite 243 blue 6 ccm
Bearing puller
Internal bearing puller 18-23 mm
Internal bearing puller 12-16 mm
Internal bearing puller 5-7 mm
Clutch rivetting tool
Extractor primary gear
Vent springe for hydraulic clutch

3

2-6C

CLEANING
Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces.
The best manner would be to use warm water that has been mixed with a normal brand-name washing detergent and a sponge.
The hard dirt can be removed before washing with the help of a soft water jet.
CAUTION

!

!

NEVER

CLEAN YOUR MOTORCYCLE WITH A HIGH-PRESSURED CLEANER OR A HIGH-PRESSURED WATER JET. THE WATER COULD OTHERWISE RUN INTO THE
ELECTRICAL COMPONENTS, CONNECTORS, SHEATHED CABLES, BEARINGS, CARBURETOR, ETC. AND CAUSE DISTURBANCES OR LEAD TO A PREMATURE
DESTRUCTION OF THESE PARTS.

– Before cleaning with water, plug the exhaust pipe to prevent water ingress.
– You should use normal brand-name detergents to clean the motorcycle. Especially dirty parts should also be cleaned with the help
of a paint brush.
– After the motorcycle has been rinsed with a soft water jet, it should be dried by air pressure and a cloth. Then take a short drive until
the engine has reached the working temperature and also use the brakes. By warming these components, the residual water can
evaporate from inaccessable parts of the engine and the brakes.
– Slide back the protective covers on the handlebar-mounted instruments so that any water that may have seeped into this part of the
motorcycle is allowed to evaporate.
– After the motorcycle has cooled down, oil and grease all the gliding bearing parts. Treat the chain with a chain spray.
– To prevent failures in the electric system, you should treat the ignition lock, the emergency OFF switch, the short circuit button, the
light switch and the socket connectors with contact spray.

CONSERVATION FOR WINTER OPERATION

Art No 3206004 -E

In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying, you will have to take
precautions against the aggressive road salt.
– clean the motorcycle thoroughly and let it dry after each ride
– treat the engine, carburetor, swing arm, and all other bare or galvanized parts (except for brake discs) with a wax-based anti-corrosion agent.
WARNING




KEEP THE ANTI-CORROSION AGENT FROM GETTING INTO CONTACT WITH THE BRAKE DISCS, OTHERWISE THIS WILL SIGNIFICANTLY REDUCE THE BRAKING POWER.
!
AFTER

CAUTION

!

RIDES ON SALTED ROADS, CLEAN MOTORCYCLE THOROUGHLY WITH COLD WATER AND LET IT DRY WELL.

STORAGE
Should you wish to make a pause over a longer space of time, please observe the following instructions:
–
–
–
–

Repair manual KTM 250 / 300 / 380

–
–
–
–
–
–

Clean motorcycle thoroughly (see chapter: CLEANING)
Change engine oil (old engine oil contains aggressive contaminants).
Check antifreeze and amount of cooling liquid.
Let the engine warm up again, close fuel cock and wait until the engine dies off by itself. In this way the carburetor jets are prevented
from becoming resin- clogged by the old fuel.
Remove spark plug and fill in approx. 5 ccm of engine oil into the cylinder through the opening. Actuate kick-starter 10 times in order
to distribute the oil onto the cylinder walls and mount the spark plug.
Let fuel flow out of tank into an appropriate container.
Correct tire pressure.
Lubricate bearing points of the control levers, footrests, etc. as well as the chain.
The storage place should be dry and not be subjected to too big temperature fluctuations.
Cover the motorcycle with an air permeated tarp or blanket. Do not use non airtight materials as a possible humidity might not be
able to escape and thereby cause corrosion.

CAUTION
!
!
IT WOULD BE VERY BAD TO LET THE ENGINE RUN FOR A SHORT TIME DURING THE STORAGE PERIOD. THE ENGINE WOULD NOT GET WARMED UP ENOUGH AND
THE THUS DEVELOPED STEAM WOULD CONDENSE DURING THE COMBUSTION PROCESS AND CAUSE THE VALVES AND EXHAUST TO RUST.

USE AFTER A PERIOD OF STORAGE
– Fill up the tank with fresh fuel.
– Check the motorcycle as before each start (see driving instructions)
– Take a short, careful test ride first.
NOTE: Before you put your motorcycle away for the winter, you should check all parts for their function and wear. Should any service
jobs, repairs, or any refitting be necessary, you should have them carried out during the off-season (lower workload at mechanics'
shops). This way, you can avoid the long waiting times at your shop at the beginning of the next biking season.

3-1C

REMOVING AND REFITTING ENGINE
INDEX

Repair manual 250 / 300 / 380

Art No 3206004 -E

REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
REFITTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3

3-2C
Dismounting the engine
– Clean motorcycle thoroughly.
– Prop up motorcycle on an appropriate stand.
– Remove seat, right side paneling, and tank with spoilers.

– Dismount exhaust system.

Art No 3206004 -E

– Drain coolant, and disconnect radiator hoses from engine.
– Dismount engine strut 1.
– Disconnect plug-and-socket connector of ignition system and sparkplug connector.

1

– Remove sprocket cover 2 and chain.

Repair manual KTM 250 / 300 / 380

2

– Remove footbrake cylinder cover 3.
– Disengage and remove spring 4.

3

4

3-3C
– Loosen the 3 screws, and remove intermediate flange chamber 1 of
KTC system together with O-ring.
– Remove engine fastening screw 2.
– Remove cable ties and loose the cable of ignition from frame.

1

2

– Loosen both hose clamps, and pull caburetor out of carburetor
connection boot and intake flange.

– Remove transmission-oil drain plug 3 together with sealing ring, and
drain the transmission oil.
– Remove the 2 screws 4, and dismount clutch slave cylinder.

4

!

4

!

NOT ACTUATE THE CLUTCH LEVER WITH THE CLUTCH SLAVE CYLINDER
DISMOUNTED.

5
6
3

CAUTION

DO

– Remove engine fastening screw 5.
– Remove hexagon nut of swingarm pivot 6.
– Remove swingarm pivot, and pull swing arm backward out of the
frame so as to make lifting the engine out of the frame easier.
– Lift engine out of frame.
NOTE: Cylinder head and cylinder can be dismounted even if the engine
remains mounted. Likewise, work on clutch, primary drive, gearshift
mechanism, and ignition system can be carried out.

3-4C
Refitting the engine
– To install the engine, reverse the steps for removing the engine.

Filling in of transmission oil:
– Remove the plug 1 and top up with engine oil 15W-50 (i. e.
MOTOREX TOP SPEED 4T).

1

Art No 3206004 -E

– In order to check the transmission oil level the control screw 2 on the
clutch cover is to be removed. Oil should just barely escape from the
inspection opening when the motorcycle is in an upright position.

2

CAUTION
!
!
TRANSMISSION AND CLUTCH WILL BE SUBJECT TO AXCESSIVE WEAR AND TEAR, IF YOU
USE TOO LITTLE OR LOW GRADE OIL. USE ONLY HIGH-GRADE OIL (I.E. MOTOREX
TOP SPEED 4T).

Filling in of cooling liquid:
– Make sure that the drain screw 3 is fastened.
– Pour approx. 0.50 litres (0.13 US gallons) coolant into the system.

Repair manual KTM 250 / 300 / 380

40% coolant : 60% water

3

4

– Remove the screw 4 on the right radiator and tilt the motorcycle to
the right approx. 30 degree angle.
– Now add cooling liquid until it emerges free of bubbles at the right
radiator. Then immediately mount the screw so that no more air can
enter the right radiator.
– Return the motorcycle to its original position and top up the left
radiator until the coolant can be seen approx. 10 mm (0.4 in) above
the radiator fins.

4-1C

DISASSEMBLING THE ENGINE

Repair manual 250 / 300 / 380

Art No 3206004 -E

INDEX

DRAINING GEAR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISMOUNTING OF SPROCKET AND SHIFT LEVER . . . . . . . . . . . . .
DISMOUNTING OF CYLINDER HEAD, CYLINDER AND PISTON . . .
DISMOUNTING OF CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . .
DISMOUNTING OF PRESSURE CAP AND CLUTCH DISCS . . . . . . . .
DISMOUNTING OF THE PRIMARY DRIVE . . . . . . . . . . . . . . . . . . .
DISMOUNTING OF KICKSTARTER . . . . . . . . . . . . . . . . . . . . . . . .
DISMOUNTING OF THE SHIFT LOCK . . . . . . . . . . . . . . . . . . . . . .
DISMOUNTING OF IGNITION COVER . . . . . . . . . . . . . . . . . . . . .
DISMOUNTING OF THE IGNITION (KOKUSAN) . . . . . . . . . . . . . . .
DISMOUNTING OF THE IGNITION (SEM) . . . . . . . . . . . . . . . . . . .
DISMOUNTING OF INTAKE FLANGE AND REED VALVE HOUSING .
PARTING OF ENGINE HOUSING HALVES . . . . . . . . . . . . . . . . . . . .
DISMOUNTING OF GEARSHIFT MECHANISM AND TRANSMISSION
DISMOUNTING OF THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . .

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.4-2
.4-2
.4-2
.4-3
.4-4
.4-4
.4-5
.4-5
.4-5
.4-6
.4-6
.4-7
.4-7
.4-7
.4-8

4

4-2C
– Cleaning the engine thoroughly.
– Clamp the engine into the workstand.
– Remove the kickstarter together with the distance bushing behind.

Draining gear oil
NOTE: The transmission oil should already be drained when the engine is
dismounted. Otherwise, the transmission oil will leak out of the drive
shaft following the removal of the slave cylinder of the clutch.
– Unscrew plug 1, allowing oil to drain.

1

Art No 3206004 -E

Dismounting of sprocket and shift lever
– Remove circlip 2 from countershaft using circlip pliers. Slide off engine
sprocket, distance bushing and O-ring.
– Undo the screw 3 and remove the shift lever.
– Pull out the clutch push rod 4 from drive shaft.

2
4
3
Dismounting of cylinder head, cylinder and piston

Repair manual KTM 250 / 300 / 380

– Unscrew the 6 collar screws 5 and remove cylinder head and the two
O-rings.

5

– Undo the screws 6 and remove the left control cover together with
the gasket.

6

4-3C
– Undo the screws 1 and remove the right control cover.

1

– Remove the securing clip of the ball socket 2 and unhook the ball
socket 3 from the adjusting lever.
– Remove gasket of the control cover.

3

2

– Remove the 4 collar nuts 4 on cylinder base and remove cylinder.

4

– Cover the crankcase.
– Place piston on wooden jig and remove both piston pin locking pins.
– Expel piston pin from piston without exerting undue force. Use a
suitable mandrel if necessary.
– Remove piston and piston pin needle-bearing from conrod eye.
– Remove the cylinder base gaskets.
CAUTION
!
!
THE PISTON PIN MUST NEVER BE FORCED OUT WITH A PUNCH. THIS WOULD DAMAGE
THE CONROD BEARING.

Dismounting of clutch cover

6

– Remove collar screws and clutch cover including gasket.
NOTE: The water pump cover 6, the outer cover 5 and the cover lid 7
do not need to be removed. The water pump and the centrifugal timer
remain in the clutch cover.

5

7

4-4C
Dismounting of pressure cap and clutch discs
– Loosen collar screws 1 in diagonally opposite sequence to prevent
wedging of discs as springs expand.
– Remove collar screws, springs and spring retainers.

1

– Take pressure cap and disc package out of outer clutch hub.
– Take thrust bearing 2 off the drive shaft.

2

Dismounting of the primary drive
Art No 3206004 -E

– Block the primary gear with the gear wheel segment 3 (see
illustration).
– Undo the hexagon nut (LH thread) and remove it together with the
detent edged ring.

3

– Release the lock washer of the inner clutch hub.
– Connect clutch holder 4 to inner clutch hub and loosen hexagon nut
(see illustration).
– Remove clutch holder.
– Remove inner clutch hub and outer clutch hub together with bearing
from main shaft.

Repair manual KTM 250 / 300 / 380

4

– Pulling the primary gear 5 and the distance bushing 6 off the
crankshaft.

5

6

NOTE: The primary gear and the outer clutch hub belong together.
Always replace both together!

4-5C
Dismounting of kickstarter
– Remove circlip 1 and kickstarter intermediate gear.
– Carefully release collar screw 2 kickstarter spring is tensioned, release
tension on kickstarter spring and unhook spring hanger.

2

!
CAREFULLY

CAUTION
DANGER

RELEASE THE KICKSTARTER SPRING!

!
OF INJURY!

– Take the complete kickstarter shaft out of the housing.
– Take care of the stop disc, which could stay in the housing.

1
Dismounting of the shift lock
– Press the sliding plate 3 back with a screw driver so it no longer
engages with the driver for the shaft roller, at the same time remove
shift shaft from the housing.

3

NOTE: Watch the stop disc which remains in the housing.

– Remove allan head screw 4 and take driver for roller 5 and locking
piece 6 from the shift roller.
NOTE: From model 2002 driver for roller 5 and locking piece 6 are
made of aluminium.

5

6

4

NOTE: Disassemble locating lever only if the engine case must be
replaced.

7

– Remove screw 7 and locking lever with spring and bush.

Dismounting of ignition cover
– Undo the 5 screws and remove the ignition cover together with the
gasket.

4-6C
Dismounting of the ignition (Kokusan)
– Hold the flywheel with the holding spanner 1 and undo the collar nut.

1

– Put the protection cover on the crankshaft thread, twist in the flywheel
extractor and remove the flywheel.

Art No 3206004 -E

– Undo the 3 screws 2 and remove the stator together with the base
plate.

2

Dismounting of the ignition (SEM)

Repair manual KTM 250 / 300 / 380

– Hold the flywheel with the special tool and undo the collar nut.
– Place protective cap on crankshaft thread.
– Twist in the flywheel extractor and remove the flywheel.

3

– Loosen the 3 collar screws 3, and take base plate with stator out of
the casing.

4-7C
Dismounting of intake flange and reed valve housing
– Remove the 5 collar screws 1.
– Remove intake flange and reed valve housing.

1

Parting of engine housing halves
– Top ignition-gear upwards and remove all 11 housing screws.
– Loosen the 2 engine fixtures on the engine work stand.

– Lift left-hand housing half with suitable tools by on the bosses
provided, or part with a few light plastic mallet blows against the
countershaft from the right-hand housing half.
!

CAUTION

!

APART WITH A SCREW DRIVER OR SIMILAR TOOL MUST BE AVOIDED, SINCE
THE SEAL FACES ARE EASILY DAMAGED.

LEVERING

NOTE: Watch gear shaft stop discs 2 to prevent them sticking to inside
of housing.

Dismounting of gearshift mechanism and transmission
– Take the two stop discs 2 off the transmission shafts.
– Pull the 2 pressure springs 3 out of the shift rails.

2
2
3

4-8C
– Pull out the shift rails and swing the shift forks aside.
– Pull the shift roller out of the bearing seat.
– Remove the shift forks.

1

NOTE: During disassembly, watch out for the shift rollers 1 on the
driving pins of the shift forks. They may remain in the shift roller.
Although the counter shaft shift forks are identical they should be refitted
in the same position as before if reused. Therefore mark accordingly upon
removal.

– Remove the 2 pressure springs 2 from the engine case.

2
2

Art No 3206004 -E

– Pull the drive shaft together with the countershaft out of the bearing
seats.

Repair manual KTM 250 / 300 / 380

– Remove 1st-gear idler gear 3 with needle cage and the two stop discs
from the engine case.

3
Dismounting the crankshaft
– Pull crankshaft from the bearing seat (if necessary, use a plastic
hammer and tap carefully on the crankshaft journal).
– Remove O-ring from crankshaft.
– Clean all parts and check for wear, replace if necessary.
NOTE: When an engine is completely overhauled it is recommended that
all gaskets, shaft seal rings and O-rings are renewed.

5-1C

SERVICING ON INDIVIDUAL COMPONENTS

5

Repair manual 250 / 300 / 380

Art No 3206004 -E

INDEX

WORKING ON THE RIGHT-HAND HOUSING HALF . .
WORKING ON THE LEFT-HAND HOUSING HALF . . . .
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT WEBS – MEASURE OUTER DIMENSION
PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PISTON RING END GAP . . . . . . . . . . . . . . . . . . . . . .
CHECKING CYLINDER FOR WEAR . . . . . . . . . . . . . .
RECOATED CYLINDER . . . . . . . . . . . . . . . . . . . . . . .
NIKASIL COATING OF CYLINDER . . . . . . . . . . . . . . .
CYLINDER EXHAUST CONTROL SYSTEM . . . . . . . . .
CYLINDER PREASSEMBLY . . . . . . . . . . . . . . . . . . . .
EXHAUST CONTROL, CLUTCH COVER . . . . . . . . . . .
PREASSEMBLY OF CLUTCH COVER . . . . . . . . . . . . .
REED VALVE HOUSING, INTAKE FLANGE . . . . . . . . .
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACE OUTER CLUTCH HUB . . . . . . . . . . . . . . . .
SHIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . .
PREASSEMBLY OF SHIFT SHAFT . . . . . . . . . . . . . . . .
IGNITION (KOKUSAN) . . . . . . . . . . . . . . . . . . . . . . .
SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECK STATOR AND PULSE GENERATOR (KOKUSAN)
IGNITION (SEM) . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECK STATOR (SEM) . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLY MAINSHAFT . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLY COUNTERSHAFT . . . . . . . . . . . . . . . . . . .
KICKSTARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLE OF KICKSTARTER SHAFT . . . . . . . . . . . . .

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. .5-2
. .5-3
. .5-4
. .5-4
. .5-4
. .5-4
. .5-5
. .5-5
. .5-5
. .5-6
. .5-6
. .5-8
. .5-8
. .5-9
.5-10
.5-11
.5-12
.5-12
.5-13
.5-13
.5-13
.5-14
.5-14
.5-15
.5-15
.5-16
.5-17
.5-17

Engine housing
NOTE: Read through the following section before commencing work. Then determine the assembly sequence so that the engine
housing halves only need to be heated up once before replacing the bearings.
Having first removed the dowels, in order to expel the bearings or remove them with light mallet blows, the housing halves must be
placed on a suitably large plane surface, supporting the whole of the sealing surface without damaging it. A wooden panel is best
used as a base.
Bearings or shaft seal rings should not be hammered into their seats. If no suitable press is available, use a suitable mandrel and
hammer them in with great care. Cold bearings will practically drop into their seats at an engine housing temperature of approx.
150° C.
After cooling, should the bearings fail to lock in the bore, they are bound to rotate after warming. In that event the housing must
be replaced.

5-2C
Working on the right-hand housing half

8

3
7

9

– Remove all shaft seal rings and use an oven to heat the casing half to
approx. 150°C.
Grooved ball bearing of crankshaft 1
Press old grooved ball-bearing inwards. Press in new ball bearing to the
stop. The open side of the ball cage must be towards the bottom
(outside) of the case.

10
6

!

5

CAUTION

!

DO

NOT USE FORCE WHEN PRESSING THE GROOVED BALL BEARING AGAINST THE
RETAINING BRACKET 3 TO AVOID A BENDING OF THE BRACKET, WHICH WOULD RESULT
IN EXCESSIVE AXIAL PLAY OF THE MAINSHAFT.

11

2

Grooved ball bearing of main shaft 2
Press in new ball bearing from inside up to the stop.

Grooved ball bearing of countershaft 4
Press in new grooved ball bearing from downward to the stop. The open
side of the ball cage must be face inwards.
Grooved ball bearing of the shift roller 5
Remove retaining screws A and press bearing inwards. Press in new ball
bearing from inside to the stop and secure retaining screws with Loctite
243.

1

4

Needle bushing of the shift shaft 6
Press old needle bushing inwards, press in new needle bushing flush from
the outside.
Grooved ball bearing of centrifugal timer 7
The bearings usually fall out of their seat of their own accord by knocking
the housinq half on a plane piece of wood when the housing has a
temperature of 150° C. If necessary use a 6 mm internal bearing extractor
and guide hammer (see illustration). Press in new grooved ball bearing to
the stop.

Art No 3206004 -E

A

Bearing bolt kickstarter intermediate gear 8
Experience has shown that it is never necessary to replace the bearing
bolt. It is not recommended to mount a used bearing bolt in a new
housing half, as it is practically impossible to remove it without causing
damage.

A

Kickstarter release plate 9
When replacing the release plate, secure the flat-head screws with Loctite
243.
Crankshaft seal ring bk
Press in new shaft seal ring from the outside, with sealing lip facing
inward, until flush.

Repair manual KTM 250 / 300 / 380

Stop screw kickstarter bl
When mounting the stop screw, it must be secured with Loctite 243. Do
not forget new copper seal ring.

7

Retaining bracket 3
When replacing the retaining bracket, the two collar screws are to be
secured with Loctite 243.

– Finally check clear passage of the crankshaft ball bearing lubrication
bore S.

S

5-3C
Working on the left-hand housing half
– Remove all shaft seal rings and use an oven to heat the casing half to
approx. 150°C.

7

Crankshaft roller bearing 1
Press old roller bearing inwards, press in new ball bearing to the stop with
the open side of ball cage downwards (outside). The inner ring on the
crankshaft must also be renewed (see paragraph about crankshaft).

6

Needle bearing of drive shaft 2
Press old grooved ball bearing inward, press new grooved ball bearing
from the inside up to the stop.

8

Grooved ball bearing of countershaft 3
Press old ball bearing inwards, press in new ball bearing to the stop from
inside.

2
3

4

Grooved ball bearing of shift roller 4
Ball bearing falls out of its seat of its own accord when housing half has
been heated to approx. 150° C.
If necessary, knock housing half on a plane piece of wood. Press in new
grooved ball bearing to the stop.

1

5

D

5

Needle bushing of shift shaft 5
Remove shaft seal ring and press old needle bushing inwards. Press in
new needle bushing from the outside to the collar D.
Crankshaft seal ring 6
Press in new crankshaft seal ring from the outside, with sealing lip facing
inwards. The seal ring is 1 mm (0.04 in) lower than the upper edge ot the
collar (see sketch).
Counter shaft seal ring 7
Press in the new shaft seal ring, until it is flush with machined surface.
Shift shaft seal ring 8
Press in the new shaft seal ring, until it is flush with machined surface.
When housing half has cooled off, check to see that the bearings are
tight.

1 mm (0.04 in.)

6

– Finally check clear passage of the crankshaft roller bearing lubrication
bore S.

S

5-4C
Crankshaft
– When replacing the roller bearing, the inner crankshaft ring must also
be renewed.
– Heat special tool 584.29.037.040 on a heating pad up to approx.
150°C and slip it on the inner ring immediately. Press the special tool
together tightly so as to obtain a good heat transfer and pull the inner
ring off the crankshaft.
– To mount the new inner ring, heat the special tool again to approx.
150°C, engage the inner ring and slip it on the crankshaft journal
immediately.
!

CAUTION

!

CLAMP THE CRANKSHAFT WITH A STUD OR WEB IN THE VICE, AND NEVER TRY
TO KNOCK THE BEARING INNER RING FREE. THE CRANKSHAFT WEBS MAY BE
COMPRESSED AND THE CONROD PLUG AND BEARING MAY BE DAMAGES, THEREBY
MAKING THE CRANKSHAFT UNUSABLE.

NEVER

NOTE: Distance adjustment of the main bearings is not requested.

Crankshaft webs – measure outer dimension
Art No 3206004 -E

Crankshaft webs – measure outer dimension with a sliding caliper as
illustrated.
Crankshaft webs – outer dimension = 60 mm ± 0.05 mm

Piston

Repair manual KTM 250 / 300 / 380

If a used piston is to remain in service then the following should be
checked:
1. Piston running surface: Check for pressure marks (seizing marks) minor
friction marks can be removed with a fine abrasive stick.
2. Piston ring grooves: The piston rings must not get jammed in the
grooves. For cleaning the grooves, use an old piston ring or abrasive
paper (grain size 400).
3. The piston ring locating pins must be firmly seated in the piston and
must not be worn out.
4. Check piston rings for wear and check end gap.

Piston ring end gap
– Insert piston ring into the cylinder and adjust. Piston ring must be
approx. 10 mm (1/2 inch) from top of cylinder.
– The end gap B can now be checked with a feeler gauge.
Piston ring end gap: max. 0.40 mm (0.015 in)
NOTE: If the end gap is greater check piston and cylinder for wear. If
piston and cylinder wear are within the permitted tolerance limits, replace
the piston ring.

5-5C
Checking cylinder for wear
Measure diameter of cylinder approx. 10 mm (0.4 in.) below top of
cylinder edge. Check diameter in several corresponding places to see if
cylinder in worn oval.

10mm
x
y

Engine

Cylinder Ø

Piston size

250

67,500 - 67,512
67,513 - 67,525

1
2

300

72,000 - 72,012
72,013 - 72,025

1
2

380

78,000 - 78,012
78,013 - 78,025

1
2

66,340
66,351
71,940
71,951

1
2
1
2

250
starting with the 2000 mod

300
starting with the 2000 mod

-

66,350
66,360
71,950
71,960

Recoated cylinder

1

NOTE: If the cylinder diameter is larger than e.g. 66.360 mm the cylinder
must be regenerated or replaced.
For reconditioning of the old cylinder all exhaust control components
must be removed. The intermediate flange 1 remains with the cylinder.
The piston size is stamped into the bottom of the piston.

Nikasil coating of cylinder
Nikasil is the brand name for a cylinder coating process, developed by the
piston manufacturer Mahle. The name is derived from the two materials
used in this process - a nickel layer into which the particularly hard silicon
carbide is inbedded.
The main advantages of the Nikasil coating are:
● excellent heat dissipation and thus better power output
● low wear
● low weight of the cylinder.
NOTE: The worn coating can be regenerated at low cost provided that
the cylinders running surface is flawless.

5-6C
7

6

5
1

14
13
12

only 250

11
7

10
2

4

3

6

1

9

5
8

9
3

17

2
Art No 3206004 -E

8
18

16

19

Cylinder exhaust control system
Dismantle and clean all exhaust control components, check for signs of wear and damage.
Control rollers 1 – Check clearance of bearings. Remove oil-derived deposits.
Check toothing of control rollers for signs of wear.

Repair manual KTM 250 / 300 / 380

Gear segments 2 – Check toothing of gear segments and control rollers for signs of wear.
Bearing sleeves 3 – Check bearing sleeves of the control flap for play and easy operation.
Control flap 4 – Clean the control flap. The control flap must not graze inside the exhaust port.
Silicon O-rings 5, 8 + 9 – Check silicon O-rings of control flap and control rollers for signs of wear. Renew if necessary.

7

6

Cylinder preassembly

7

– Mount silicon O-rings (16x2 mm) 5 on control rollers and grease.
– Place control rollers 1 in cylinder and mount retaining brackets 6;
secure flat-head screws 7 with Loctite 243.

6

5-7C

14

13

12

11

10

2
3

9
4
9

3

2

8

17
16

– Mount and grease silicon O-rings (15x1,50 mm) 9 on control flap and grease.
– Slightly grease the bearing sleeves 3 and plug them on the control flap.
– Mount toothed segments 2 (the toothed segment with the cylindrical pin has to be mounted on the right side).
– On the right-hand side, mount bearing bushing bk with collar outside, adjusting lever bl with ball head on outside, overload
spring bm with short leg on outside and spring sleeve bn to control flap.
– Coat allan head screw bo with Loctite 243 and screw up about 5 revolutions, hook the short leg of the overload spring on to the
cylinder pin (see illustration) and tighten the allan head screw.
– On the left side, mount the stop plate 8. Apply Loctite 243 to the threads of the two screws bq + br, and mount them.
– Turn control rollers 1 in cylinder in such a way that ports are completely open and no edges protrude.

– Place preassembled control flap in cylinder, engage gear segments in
control rollers in such a manner that, when the control flap is ,open
(pivoted right to the top), the markings of the gear segments and the
gear rollers coincide. Please check that the two control rollers do not
block the cross-section of the port when the control flap is open.
– Coat sealing surface thinly with silicon and mount intermediate flange
bs with 4 O-rings (11,3x2,4 mm).
– Mount exhaust flange bt and spring hangers. If you are dealing with
a throttled version, do not forget the exhaust throttle.
– Finally check smooth running of exhaust control system.
NOTE: It must be possible to push adjusting lever bl further upwards
against the spring force.

11

16

17

5-8C
6

7

LOCTITE 243

8
13
14
A

12
11
4
3

10
2

9

LOCTITE 243

LOCTITE 243

1

Exhaust control, clutch cover

1
Art No 3206004 -E

– Remove screws 1 and take off the bearing support.
– Take cup tappet 2, adjusting spring 3 and auxiliary spring 4 out of
clutch cover.
– Take off water pump cover, remove allen head screw 6 and take off
water pump wheel 7.
– The centrifugal timer 8 can be pulled out of the bearing.
– Clean all parts and check for signs of wear.
Check play and easy operatability of the adjusting lever in the bearing 9.
Check pin A of adjusting lever for wear.

1

Check linkage ball heads bk for clearance.
Remove circlip bl and check axial bearings bm and washers for signs of
wear.
If the water pump shaft seal ring bn is replaced, it should be coated with
Loctite 243 on the outside.

Repair manual KTM 250 / 300 / 380

Check grooved ball bearing bo for clearance.

Preassembly of clutch cover
– Grease water pump shaft seal ring bn and mount centrifugal timer 8.
– Fit adjusting spring 3, auxiliary spring 4 and cup tappet 2 in the
clutch cover.
– Fit bearing support with control lever and linkage. Secure both screws
1 with Loctite 243.
– Mount water pump wheel 7, coat screw 6 with Loctite 243 and
mount with washer.
– Mount dowels of the water pump cover.
– Position gasket and fix water pump cover with 5 collar screws. The
two screws mounted at the dowels must each be provided with one
copper gasket.

6

7

5-9C
Reed valve housing, intake flange
NOTE: Reed paddles 1 gradually lose tension through operation,
resulting in power loss. Damaged or worn reed paddles must be replaced.
If the reed sealing surfaces 2 of the reed valve housing are also
damaged, replace the complete reed valve housing.
!
SECURE

CAUTION

ALL SCREWS OF THE REED VALVE HOUSING WITH

!
LOCTITE 243.

Velocity insert 3
Check for firm mounting and for signs of damage.
LOCTITE 243

Intake flange 4
Check for cracks and other signs of damage.

3
1

4

2
1
LOCTITE 243

5-10C

4
3

13,5 mm

7

A
6
11

5

LOCTITE 242

13

14
12

B

8

Art No 3206004 -E

1
2

10
9

Clutch

Repair manual KTM 250 / 300 / 380

Thrust bearing 1 check for wear
Push rod 2 Check for wear. Minimum length: 199 mm (new: 199.80 mm)
Clutch springs 3
New spring length 42,5 mm / 1.7 in (new 43 mm / 1.73 in). Replace all 6 springs if applicable.
9 Lining discs 4
Minimum thickness 2.60 mm (0.102 in) / new disc 2.70 mm (0.106 in). Discs must be plane; there must be minimum spacing of
13.50 mm (0.531 in) between starting surfaces.
8 Steel discs 5
Must be plane, check for mechanical damage.
Inner clutch hub 6
Check contact surfaces of steel discs on the inner clutch hub, maximum 0.50 mm (0.02 in) indentations.
Pressure cap 7
Check contact surfaces A between lining disc and pressure cap for signs of mechanical damage and score marks.
Outer clutch hub 8
Check start surfaces of clutch discs on for wear. If indentations exceed 0.50 mm (0.02 in), replace outer clutch hub (see below).
Check inner ring 9 and needle cage bk for wear.

5-11C
Replace outer clutch hub
– Drill open the clutch rivets bl in area of retaining bracket bm and
remove parts.
– Check 8 absorbing elements bn for signs of mechanical damage,
replace all 8 where applicable.
CAUTION
!
!
THE ABSORBING ELEMENTS ARE WIDER THAN THE PRIMARY GEAR CROWN. TO ENSURE

11

12

THAT THE OUTER CLUTCH HUB 8 AND RETAINING BRACKET ARE POSITIONED DIRECTLY
ON THE PRIMARY GEAR CROWN bo, THE PARTS MUST BE HELD IN POSITION UNDER
TENSION WITH THE CLUTCH RIVETTING TOOL C WHILE RIVETING.

C

11

8

14
13

C

12

5-12C

5
E

6

D
LOCTITE 243

4

C

7

8

10
LOCTITE 243

LOCTITE 243

1
A
LOCTITE 243

3

1
2

3

B

Art No 3206004 -E

1
Shift mechanism
Shift forks 1
Check shift fork blades A and shift roller driving pin B for signs of wear.

0,40 0,80 mm

Shift roller 2
Check shift grooves for wear.
Check position of shift roller in grooved ball bearings 3.
Slide plate 4
Check slide plate at meshing points C for wear.
Check return surface D for wear (renew, if strongly notched).
Check that guide pin E is securely fixed and check for wear.

Repair manual KTM 250 / 300 / 380

Sliding guides
Check sliding guides (excess between guide pin and shift quadrant not to
be more than 0.7 mm / 0.03 in).

9

Grooved ball bearings 3
Check grooved ball bearings for easy movement.
Shift mechanism
Assemble shift mechanism (see below) and check free play between slide
plate 4 and shift quadrant 5. Free play should be 0.40 - 0.80 mm (0.016
- 0.032 in).

Preassembly of shift shaft
– Fix shift shaft in vice at shorter end (use covered clamps).
– Mount slide plate 4 with guide pins downwards, hook guide pins into
shift quadrant 5.
– Mount pressure spring 6.
– Slide on spring guide 7, slide on return spring 8 with offset end
upwards over the spring guide and lift offset end over bolt 9 (see
illustration).
– Mount the stop disc bk (14x30x1 mm).

5-13C
Ignition (Kokusan)

2K-1

General information
The measurements described below will only reveal severe problems. Coil
short circuits leading to weak ignition sparks or low generator output,
respectively, can only be detected with the help of an ignition test bench.
In the case of malfunction always check the cables and the plug and
socket connections of the ignition system first.
Make sure to select the correct measuring range when performing
measurements.

Spark plug
– Set the electrode distance.
2K-2

Electrode distance: 0.60 mm (0.024 in)
Insulator
Check for cracks and fissures.
CAUTION
OTHERWISE

!
2K-3

ALWAYS USE A
THE CDI UNIT.

SPARK PLUG WITH RESISTOR.

!
PROBLEMS CAN OCCUR IN

2K-4

Check stator and pulse generator (Kokusan)
Use an ohmmeter to perform the following measurements:

Kokusan 2K-1/2K-4

Kokusan 2K-2

Kokusan 2K-3

Ignition

Measure

Cable colours

Resistance

2K-1

Pulser coil
Exciter

red – green
black/red – red/white

100 Ω 15%
24 Ω 15%

2K-2

Pulser coil
Exciter
Charge coil

red – green
black/red – red/white
ground – yellow

100 Ω 15%
24 Ω 15%
0,74 Ω 15%

2K-3

Pulser coil
Exciter
Charge coil

red – green
black/red – red/white
ground – yellow
white – yellow

100 Ω 15%
12.7 Ω 15%
0.65 Ω 15%
0.16 Ω 15%

2K-4

Pulser coil
Exciter
Charge coil

red – green
black/red – red/white
yellow – yellow

100 Ω 15%
24 Ω 15%
0.65 Ω 15%

NOTE: The measuring must be performed at a temperature of 20° C.
Otherwise significant deviations must be expected.
Replace the stator if the measured values deviate significantly from the
setpoint values.

5-14C
Ignition (SEM)
General information
The measurements described below will only reveal severe problems. Coil
short circuits leading to weak ignition sparks or low generator output,
respectively, can only be detected with the help of an ignition test bench.
In the case of malfunction always check the cables and the plug and
socket connections of the ignition system first.
Make sure to select the correct measuring range when performing
measurements.

Spark plug
110 mm

– Set the electrode distance.
Electrode distance: 0.60 mm (0.024 in)

LOCTITE 243

Insulator
Check for cracks and fissures.
!
ALWAYS USE A
THE CDI UNIT.

CAUTION
OTHERWISE

SPARK PLUG WITH RESISTOR.

!
PROBLEMS CAN OCCUR IN

Check stator (SEM)
Art No 3206004 -E

Perform the following measurements with an ohmmeter.
+ Pole
black

– Pole
red

Resistance
1,7 kΩ

black

green

165 Ω  20 Ω

green

red

1,7 kΩ

yellow

yellow

1,0 Ω

Repair manual KTM 250 / 300 / 380

NOTE: The measuring must be performed at a temperature of 20° C.
Otherwise significant deviations must be expected.
Replace the stator if the measured values deviate significantly from the
setpoint values.

SEM K11

5-15C
Transmission

11

10

Secure mainshaft or countershaft in the vice (using soft jaw-covers).
Remove gears and check the following for wear:
– Needle bearing
– Mainshaft and countershaft pivot points including idler gears
– Shift dogs and gear wheels
– Tooth faces of all gears
– Tooth profile of mainshaft and countershaft and correspondending
gears
– Easy operation of gear-change
Carefully clean components and replace damaged components.

9

NOTE: Always place circlips with sharp edge facing the components
secured, ensuring that they are not overexpanded (use special pliers).
Check that after any repair of the transmission, circlips should axially not
move more than 0.20 mm (0.006 in) and must not seize between stop
discs.

8
7
6
Assembly mainshaft
– Fix mainshaft in vice with toothed end upwards (use covered clamps).
– Oil all parts before assembly.
– Mount the split needle cage 1 on mainshaft, push 5th idler gear 2
over it with collar downwards.
– Place internally toothed stop disc 3 (22.4x25.7x32.0x1.5 mm) in
position and mount circlip 4 (25x1.64 mm) with sharp edge upwards.
– Place 3rd sliding gear 5 in position with shift groove downwards,
mount circlip 6 (25x1.64 mm) with sharp edge downwards and
internally toothed stop disc 7 (22.4x25.7x32.0x1.5 mm)
– Mount the split needle cage 8, 4th idler gear 9 with shift dogs
downwards 2nd gear bk with collar downwards and stop disc bl
(20.2x33x1.5 mm).
– Finally check all gears for easy running.

5

4
3

2

1

5-16C
Transmission

13

12

Secure mainshaft or countershaft in the vice (using soft jaw-covers).
Remove gears and check the following for wear:
– Needle bearing
– Mainshaft and countershaft pivot points including idler gears
– Shift dogs and gear wheels
– Tooth faces of all gears
– Tooth profile of mainshaft and countershaft and correspondending
gears
– Easy operation of gear-change
Carefully clean components and replace damaged components.
NOTE: Always place circlips with sharp edge facing the components
secured, ensuring that they are not overexpanded (use special pliers).
Check that after any repair of the transmission, circlips should axially not
move more than 0.20 mm (0.006 in) and must not seize between stop
discs.

11
10

9

Assembly countershaft

Art No 3206004 -E

–
–
–
–
–

–
–

1

–

2

Repair manual KTM 250 / 300 / 380

3

4

5
6

7

8

Fix countershaft in vice with toothed end (use covered clamps).
Oil all parts before assembly.
Push stop disc 1 (26x40x1,5 mm) onto countershaft.
Mount 3rd idler gear 2 with shift dog recesses upwards and circlip 3
(25x2 mm) with sharp edge upwards.
Mount 5th sliding gear 4 with shift groove downwards, stop disc 5
(22,2x33x1,5 mm), needle cage 6, 1st free gear 7 with shift dog
recesses downwards and stop disc 8 (17,2x34x1,5 mm) with collar
upwards on the countershaft.
Remove countershaft from vice and fix again with toothed end
upwards.
Mount 4th sliding gear 9 with shift dog upwards, stop disc bk
(28,2x40x1,5 mm), needle cage bl, 2nd idler gear bm with shift dog
recesses downwards and stop disc bn (25,7x40x1,5 mm).
Finally check all gears for easy running.

5-17C

LOCTITE 243

7
8
1
LOCTITE 243

9
6

3
5

4

10

2
LOCTITE 648

Kickstarter

A

Starter gear 1
Check clearance of starter gear.
Starter intermediate gear 2
Check clearance of starter intermediate gear.
Locking pawl 3
Check for signs of wear and damage.

3

Kickstarter shaft 4
Check for signs of wear and damage.

5

For changing the locking pawl, press bearing needle 9 out of the
kickstarter shaft.

Assemble of kickstarter shaft
– Fix the kickstarter shaft 4 in a vice with the toothed end upwards (use
covered vice clamps).
– Mount ratchet spring 5 on kickstarter shaft as shown in the
illustration.
– Place needle cage 6 in position, push starter gear 1 over it, pressing
locking pawl 3 inwards so that starter gear passes smoothly over it.
– Hook legs of the starter spring 7 into driving hub 8, push both
together on the starter shaft, hook starter spring leg into kickstarter
shaft bore A.
– Release kickstarter shaft, and fix stop disc bk with a small amount of
grease on the kickstarter shaft.

6-1C

6

ASSEMBLING THE ENGINE

Repair manual 250 / 300 / 380

Art No 3206004 -E

INDEX

CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE ENGINE HOUSING . . . . . . . . . . . . . . .
MOUNTING SHIFT MECHANISM . . . . . . . . . . . . . . . . . .
MOUNTING KICKSTARTER . . . . . . . . . . . . . . . . . . . . . . .
MOUNT PRIMARY DRIVE AND CLUTCH . . . . . . . . . . . . .
MOUNTING CLUTCH DISCS AND PRESSURE CAP . . . . . .
MOUNTING CLUTCH COVER . . . . . . . . . . . . . . . . . . . . .
MOUNTING PISTON AND CYLINDER . . . . . . . . . . . . . . .
ADJUSTING DIMENSION „X“ . . . . . . . . . . . . . . . . . . . . .
ADJUSTING CONTROL FLAP (DIMENSION „Z“) . . . . . . .
MOUNTING STEERING COVERS . . . . . . . . . . . . . . . . . . .
MOUNTING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . .
MOUNTING REED VALVE HOUSING AND INTAKE FLANGE
MOUNTING ENGINE SPROCKET . . . . . . . . . . . . . . . . . . .
MOUNTING THE IGNITION (KOKUSAN) . . . . . . . . . . . . .
MOUNTING THE IGNITION (SEM) . . . . . . . . . . . . . . . . .
ADJUSTING IGNITION POINT (SEM) . . . . . . . . . . . . . . . .
MOUNTING IGNITION COVER . . . . . . . . . . . . . . . . . . . .
MOUNTING STARTING LEVER AND SHIFT LEVER . . . . . .

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. .6-2
. .6-2
. .6-3
. .6-4
. .6-4
. .6-5
. .6-6
. .6-6
. .6-7
. .6-7
. .6-8
. .6-9
. .6-9
. .6-9
.6-10
.6-10
.6-11
.6-11
.6-11
.6-11

6-2C
– Secure the right-hand housing half in the engine work stand.

Crankshaft
– Insert crankshaft from above through grooved ball bearing and push
carefully as far as stop.
!
WHEN

CAUTION

!

PUSHING IN CRANKSHAFT, MAKE SURE CONROD IS FACING CYLINDER.

Transmission
– Grease the driving pins of the shift forks and mount the shift rollers 1.
– Fix the lower stop disc on the countershaft with a small amount of
grease.
– Mount drive shaft together with countershaft, and insert them into the
bearings as far as they will go.

1

– Shift fork 2 with driving pin A in the middle belongs to the mainshaft.
– Mount the two other shift forks 3 at the countershaft, using the
marks applied before disassembly for better orientation.

2
Art No 3206004 -E

CAUTION
!
USED SHIFT FORKS SHOULD BE MOUNTED IN THE SAME
WATCH AT THE MARKINGS FROM DISMANTLING.

A

!
SLIDING GEAR AS BEFORE.

3
– Attach the shift forks to the sliding gears, and insert shift roller into the
grooved ball bearing.
– Attach the shift forks to the shift roller.
!

CAUTION

!

ATTACHING THE SHIFT FORKS, MAKE SURE THAT THE SHIFT DRUMS DO NOT
SLIDE OFF THE SHIFT FORKS.

Repair manual KTM 250 / 300 / 380

WHEN

6-3C
– Fix the 4 pressure springs 1 with ample amounts of grease in the
gearshift rails.

1

– Oil gearshift rails and insert them into the gearshift forks (short
gearshift rail toward drive shaft). Insert gearshift rails into the casing
bores as far as they will go.
NOTE: It must now be possible to gently turn gear shafts.

2

– Slide stop disc 2 (20.2x 33x1.5 mm) on the drive shaft, and stop disc
3 (25.7x40 x1.5 mm) on the countershaft.

3

Assembling the engine housing
– Remove engine fastener from engine work stand.
– Check that both dowels are in proper place in right-hand housing and
that transmission shaft stop discs have been mounted.
– Apply light coat of grease to sealing surfaces of the housing and
position new gasket.
– Grease shaft seal rings in left-hand half and place left-hand half in
position.
– Position screws and tighten with 8 Nm (6 ft.lb).
– Gently knock crankshaft with plastic hammer and check easy running
of shafts.
– Fix engine in work stand.

45

60

60
60

45

45
M6 x ...

45

60

45
45

45

6-4C
Mounting shift mechanism

1

–
–
–
–

Place locating spring with bent leg upwards into engine housing.
Insert collar sleeve into spring with collar upwards.
Coat collar screw 1 with Loctite 243.
Insert locating lever 2 with roll upwards and fix all parts with collar
screw.
– Hook locking spring 3 to lever. The other end of the retaining spring
must abut the casing nose B.

2
B
3

LOCTITE 243

4
6

– Mount roller locking device 4 (plastic part) to shift roller. Ensure that
the flat parts are not in the middle. Pull locking lever from shift roller.
– Mount driver for shift roller 5.
– Coat allan head screw 6 with Loctite 243 and mount.
NOTE: From model 2002 on driver for roller 5 and locking piece 4 are
made of aluminium.

5

– Grease assembled shift shaft and push into bearings together with
stop disc until slide plate contacts driver for shaft roller.
– Now squeeze, and push shift shaft in to the stop.
– Check that legs of return spring surround both left and right side of
housing nose A.
– Mount the foot shift lever and shift through all gears. When shifting
through the gears, turn the countershaft. Then remove the foot shift
lever.

Art No 3206004 -E

A

Mounting kickstarter
– Place spacing washer on the stop face an place preassembled
kickstarter shaft in bearing bore in such a way that the locking pawl is
outside the release plate.

Repair manual KTM 250 / 300 / 380

NOTE: If the kickstarter shaft is mounted correctly, the visible end of the
starter spring must point forward (see photo).

8
7

9

– Hook spring hanger 7 to starter spring, coat screw 9 with
Loctite 243, tighten starter spring approx. 90° clock-wise and fix
spring pawl with allan head screw.
– Adjust starter spring so that the distance to the kickstarter shaft is the
same all around.
– Place starter intermediate gear 8 with the high collar (see sketch)
showing towards the engine casing on to the bearing.
– Slip on stop disc (17.2x25x1 mm) and mount circlip with the sharp
edge showing upwards.

6-5C
Mount primary drive and clutch

1

– Grease crankshaft seal ring.
– Put the oiled O-ring (25x1.50 mm) onto the crankshaft and mount the
distance bushing with the chamfer facing the crank web.
– Insert woodruff key into crankshaft.
– Place primary gear 1 onto crankshaft with collar downwards.
– Put the inner ring onto the main shaft with the collar facing
downwards, then mount the oiled needle cage 2.

2

– Mount outer clutch hub and stop disc 3.

3

– Apply Loctite 243 to the thread of the main shaft.
– Mount inner clutch hub, new lock washer and hexagon nut to main
shaft.
– Position clutch holder 4 and tighten hexagon nut with 100 Nm
(74 ft.lb.).
– Remove the clutch holder and secure the hexagon nut by bending
both brackets of the lock washer upwards.

4

5

– Apply Loctite 243 to thread of the crankshaft.
– Fit locking washer and hexagon nut (left hand thread) by hand.
– Block primary drive with gear segment 5 and tighten primary gear
hexagon nut with 150 Nm (110 ft.lb.).
– Remove gear segment and check easy running of primary drive by
turning crankshaft.

6-6C
Mounting clutch discs and pressure cap
– Oil the thrust bearing 1, and slide it over the drive shaft.

1

– Oil lining discs before mounting.
– Beginning with one lining disc, mount alternately 9 lining discs (≠ 2.70
mm / 0.10 in) and 8 intermediate discs (≠ 1.20 mm / 0.047 in), with
a lining disc forming the final layer upwards.
– Place pressure cap into position; fit clutch springs, spring retainer and
collar screws.
– Tighten the collar screws crosswise. Do not apply more than 6 Nm (4.5
ft.lb.) to prevent damaging of the threads in the inner clutch hub.

Mounting clutch cover
Art No 3206004 -E

– Check whether both dowels are mounted in clutch cover or engine
housing.
– Grease kickstarter shaft seal ring and position clutch cover gasket.
Secure gasket with a little grease.
– Carefully position preassembled clutch cover and press into place,
turning crankshaft so that centrifugal timer can engage in the primary
gear.
– Fit collar screws (see sketch for screw lengths) and tighten with 8 Nm
(6 ft.lb.).
– Then check easy running of all shafts.
NOTE: If the clutch cover cannot be mounted, verify whether or not the
kickstarter spring has been positioned correctly.

70

Repair manual KTM 250 / 300 / 380

30

70
70
45
M6x ...

30
70

30
30

30
30
30

6-7C
Mounting piston and cylinder
– Before assembly, oil all parts thoroughly at the sliding points.
– Insert needle bearing in conrod eye, mount piston (arrow on piston
head shows direction for exhaust duct).
– Mount piston pin and wire circlips with open side showing downwards
(see sketch).
– Mount cylinder base gaskets.
– Place piston on selfmade wooden stand and position piston ring.

– Place on preassembled cylinder, remove wooden stand and tighten
cylinder down crosswise, using two nuts.

X

Adjusting dimension „X“
Dimension „X“ is the dimension from upper edge of piston to upper edge
of cylinder with cylinder under low tension and piston in TDC position.
The dimension „X“ should be adjusted extremely carefully by inserting
cylinder base gaskets of suitable thicknesses.
!

CAUTION

!

THE DIMENSION „X“ IS TOO LARGE, THE COMPRESSION RATIO WILL BE REDUCED
AND THE ENGINE LOOSES POWER. ON THE OTHER HAND, IF THE DIMENSION „X“ IS
TOO SMALL, THE ENGINE WILL PING AND OVERHEAT.

IF

– Set the piston to TDC, and apply a sliding gage or straight-edge to the
cylinder. Now, check the distance between the piston's upper edge
and the sliding gage. This distance should be from 0 mm to 0.10 mm
at the most. It can be corrected, if necessary, by adding or removing
of cylinder-base gaskets.
!
THE

CAUTION

!

PISTON MUST NOT PROTRUDE BEYOND THE CYLINDER'S UPPER EDGE.

Dimension „X“ = 0 mm

+ 0,1 mm

– Mount the 2 remaining collar nuts at the cylinder base, and tighten
each of the 4 collar nuts to 35 Nm (27 ft.lb.).

6-8C
Adjusting control flap (dimension “Z“)

control
flap

Note: Dimension “Z“ is the distance from the lower edge of the control
flap to the upper edge of the cylinder, as measured in the centre of the
exhaust port.

250
250
250
300
380

Model 1999 : 48,0 mm + 0,2 / - 0,6 mm
Model 2000 : 50,5 mm + 0,2 / - 0,6 mm
ab Model 2001 : 49,5 mm + 0,2 / - 0,6 mm
: 46,0 mm + 0,2 / - 0,6 mm
: 50,5 mm + 0,2 / - 0,6 mm

– Undo the screws of the stop plate (left side of the cylinder) 1 and 2
and apply Loctite 243 to the threads. Then mount both screws but do
not tighten them yet.
– Set preselected value on depth gauge and fix.
– Swifel control flap upwards and hold depth gauge into cylinder as
shown in the illustration.
– Control flap must rest against depth gauge.

–
–
–
–

Art No 3206004 -E

3

2

Allow bump plate 3 to rest against retaining bracket 4.
Secure bump plate fastening screws 1 and 2.
Remove depth gauge.
Having tightened the screws 1 + 2, you have to check the dimension
"Z" again and correct it, if necessary.

4

1
– Press linkage of control flap 5 down-wards as far as stop and press
ball socket 6 onto ball of adjusting lever.
When pressing ball socket do not:
● pull the linkage too far up (max. 1 mm / 0.04 in).
● swivel control flap upwards.

Repair manual KTM 250 / 300 / 380

6

– Adjust linkage length if necessary.
– To do so, loosen counter nut 7 and turn ball socket accordingly.
– Retighten counter nut.

7
5

– Once adjustments are completed, remove ball socket once again and
fit gasket for control cover.
– Refit ball socket and fit safety device 8.

8

6-9C
Mounting steering covers
– Mount the right-hand control cover 1, and fix it with 3 screws.

1

– Place gasket in position and fix left-hand steering cover 2 on cylinder.

2

Mounting cylinder head
– Clean cylinder and cylinder head sealing surface, place O-rings in
grooves.
– Mount cylinder head with water nozzle on the exhaust side.

– Oil the collar nuts at threads and contact faces.
– Mount the collar screws with new copper gaskets and tighten them
crosswise, taking three turns to achieve the total tightening torque of
35 Nm (25 ft.lb.).
– In first stage, only tighten until slight resistance is felt.

Mounting reed valve housing and intake flange
– Place reed valve housing with velocity insert in inlet duct and fix intake
flange with the 5 collar screws.

6-10C
Mounting engine sprocket
– Lubricate O-ring 1 with oil and slide over counter shaft.
– Slide distance bushing 2 in position so that O-ring is in correct
position.

1

2

– Slide sprocket onto the countershaft with the collar facing inward, and
fix it with the circlip 3 (sharp edge facing outward).

3

Mounting the ignition (Kokusan)
Art No 3206004 -E

– Insert the woodruff key into the crankshaft.
– Apply Loctite 243 to 3 screws 4 and fix the stator (do not yet tighten
the 3 screws all the way).

4

C

– At engines with ignition type 2K-4 the marking C must coincide with
the marking on the stator.
– At engines with all other ignitions (not SEM) the marking B must
coincide with the marking on the stator.

B
Repair manual KTM 250 / 300 / 380

– Turn stator such that the mark A on the stator coincides with the mark
in the casing, and tighten the 3 screws of the stator.

A

– Mount the rotor.
– Mount the detent edged ring and the nut.
– Hold the rotor with the holding spanner and tighten the nut with 60
Nm (45 ft.lb.).

6-11C
Mounting the ignition (SEM)

1

2

3

–
–
–
–
–
–
–

4

Insert woodruff key into crankshaft.
Apply Loctite 243 to the threads of the 3 screws 2.
Mount base plate 1 together with stator, and tighten the 3 screws.
Mount the cable guide 3 into the cutaway portion of the casing.
Mount the rotor.
Mount the detent edged ring and the nut.
Hold the rotor with the holding spanner and tighten the nut with 60
Nm (45 ft.lb.).

Adjusting ignition point (SEM)

5

– Make sure that the stator can be turned on the intermediate plate.
Otherwise, loosen the 3 screws 4.
– Mount flywheel.
– Screw dial gauge into spark plug thread.
– Place adjusting pin 5 in flywheel bore (“91“) 2 mm (0.08 in) and turn
flywheel until pin slots into recess 6 in stator.
– Turn flywheel and stator jointly to TDC.
– Turn dial gauge scale to 0 and turn flywheel with stator clockwise
accordingly to preignition.
Ignition point:

6

–
–
–
–
–

Carefully remove flywheel to prevent further turning of stator.
Tighten the three stator cylinder screws.
Mount flywheel and tighten collar nut with 60 Nm (45 ft.lb).
Check ignition point once more.
Remove dial gauge and fit spark plug with OR.

Mounting ignition cover
– Put on a new gasket, and fix the ignition cover by means of the 5
screws.

Mounting starting lever and shift lever
– Push distance bushing onto kickstarter shaft and mount kickstarter.
– Mount shift lever.
– Operate the kickstarter a few times and check if the engine turns
freely.
– Oil the push rod, and insert it into the drive shaft.
NOTE: The transmission oil should be filled in only after the engine has
been mounted. Otherwise, a part of the transmission oil would leak out
through the drive shaft.

7-1C

7

ELECTRICAL
INDEX

Repair manual 250 / 300 / 380

Art No 3206004 -E

CHECKING THE VOLTAGE REGULATOR-RECTIFIER (SHINDENGEN)
CHECKING THE VOLTAGE REGULATOR (KOKUSAN) . . . . . . . . . .
CHECKING THE VOLTAGE REGULATOR (TYMPANIUM) . . . . . . . .
CHECKING THE CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . .
IGNITION COIL (SEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IGNITION COIL (KOKUSAN) . . . . . . . . . . . . . . . . . . . . . . . . . . .
CDI UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE VOLTAGE REGULATOR (MOD. 2000) . . . . . . . . .
CHECKING THE CAPACITOR (MOD. 2000) . . . . . . . . . . . . . . . . .

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.7-2
.7-2
.7-2
.7-3
.7-3
.7-3
.7-3
.7-4
.7-4

STATIC IGNITION VALUES 250 - 380 SX, EXC . . . . . . . . . . . . . . . . . .7-5
STATIC GENERATOR VALUES 250 - 380 EXC . . . . . . . . . . . . . . . . . . .7-7
STATIC IGNITION AND GENERATOR VALUES 250 MXC, EXC (USA) . .7-9

7-2C
Checking the voltage regulator-rectifier (Shindengen)
– Start the engine and switch on the low beam.
– Connect a voltmeter to the two terminals of the capacitor (red/white
cable = positive, brown cable = negative).
– Accelerate the engine to a speed of 5000 r.p.m. and read off the
voltage.
Nominal value: 14.0 – 15.0 V
In the case of a significant deviation from the nominal value:
– Check the capacitor
– Check the connector between the stator and the voltage regulatorrectifier and the connector between the voltage regulator-rectifier and
the cable tree.
– Check the stator.
– Replace the voltage regulator-rectifier.

Checking the voltage regulator (Kokusan)
A defect voltage regulator can cause different kinds of trouble:
● No voltage in the circuit
In this case, the voltage regulator must be disconnected at idle speed.
The voltage regulator is defect if the power consumers now work
properly.
If the power consumers are still not supplied with power, the switch,
the wiring harness or the ignition system must be checked for defects.
● Excessive voltage in the circuit
The bulbs burn out. In this case the voltage regulator must be
replaced.

Repair manual KTM 250 / 300 / 380

Art No 3206004 -E

Checking the voltage regulator (Tympanium)
NOTE: The voltage regulators are connected downstream of the
switches. One of the voltage regulators regulates only the brake light
circuit, the other regulates the circuit for the head light, the tail light, the
speedometer illumination and the horn.
A defect voltage regulator can cause different kinds of trouble:
● No voltage in the circuit
In this case, the voltage regulator must be disconnected at idle speed.
The voltage regulator is defect if the power consumers now work
properly.
If the power consumers are still not supplied with power, the switch,
the wiring harness or the ignition system must be checked for defects.
● Excessive voltage in the circuit
The bulbs burn out.
Connect a voltmeter (yellow cable = positive, brown cable = negative)
to check the voltage. Start the engine and switch on the power
consumers.
At an engine speed of 3000 r.p.m, the voltage regulator must supply a
voltage of 12.0 - 14.0 V A.C. At higher engine speeds, the limit of 14.0
V should not be exceeded either.
If the reading significantly deviates from the nominal value, replace the
voltage regulator.

7-3C
Checking the capacitor
– Discharge the capacitor by bridging the two terminals with a
screwdriver and remove.
– Connect the negative pole of a 12V battery with the negative terminal
of the capacitor. The connection between the positive pole of the
battery and the positive terminal of the capacitor (marked +) is made
with a test lamp 1.
– When the power circuit is closed, the test lamp must begin to light up.
As capacitor charging increases, the brightness of the test lamp must
decrease.
– The test lamp must go out after 0,5-2 seconds (depending on the lamp
capacity).
– If the test lamp does not go out or does not light up at all, the
capacitor is faulty.

1

CAUTION
!
!
DISCHARGE THE CAPACITOR BEFORE AND AFTER EACH TEST.
WHEN INSTALLING THE CAPACITOR, MAKE SURE THAT THE TERMINALS ARE CONNECTED
IN ACCORDANCE WITH THEIR MARKINGS (CONNECT RED/WHITE CABLE TO +
TERMINAL).

Ignition coil (SEM)
As this ignition coil uses electronic components, you are advised not to
use conventional measuring instruments. An accurate function test can
only be carried out on an ignition test bench.

Ignition coil (Kokusan)
– Disconnect all cables and remove the spark plug connector.
– Use an ohmmeter to measure the following values.
NOTE: The indicated setpoint values correspond to a temperature
of 20° C.
Replace the ignition coil if the measured values deviate significantly from
the setpoint values.
Measurement
Primary coil

Cable colours
blue/white – ground

Resistance
0,425 - 0,575 Ω

Secondary coil

blue/white – ignition wire

10,8 - 16,2 kΩ

CDI unit
Check the cables and plug and socket connections of the CDI unit 2.
The CDI unit function can only be checked on an ignition test bench.
CAUTION
!
NEVER USE A COMMERCIAL MEASURING DEVICE
COMMERCIAL MEASURING DEVICES CAN DESTROY
COMPONENTS.

2

!
TO CHECK THE CDI UNIT.
HIGHLY SENSITIVE ELECTRONIC

7-4C
Checking the voltage regulator
– Start the engine and switch on the low beam.
– Connect a voltmeter to the two terminals of the capacitor.
– Accelerate the engine to a speed of 5000 r.p.m. and read off the
voltage.
Nominal value: 14.0 - 15.0 V
In the case of a significant deviation from the nominal value:
– Check the capacitor
– Check the connector between the stator and the voltage regulatorrectifier and between the voltage regulator and the cable tree.
– Check the stator.
– Replace the voltage regulator-rectifier.

Checking the voltage regulator
– Start the engine.
– Connect a voltmeter to the two terminals of the capacitor.
– Accelerate the engine to a speed of 5000 r.p.m. and read off the
voltage.
Nominal value: 14.0 - 15.0 V
In the case of a significant deviation from the nominal value:
– Check the capacitor
– Check the connector between the stator and the voltage regulatorrectifier and between the voltage regulator and the cable tree.
– Check the stator.
– Replace the voltage regulator-rectifier.

Checking the capacitor
Art No 3206004 -E

– Discharge the capacitor by bridging the two connections with a cable
bridge and dismount it.
– Connect the negative pole of a 12V battery with the negative terminal
of the capacitor. The connection between the positive pole of the
battery and the positive terminal of the capacitor is made with a test
lamp 1.
– When the power circuit is closed, the test lamp must light up briefly
and return to its dark state after 1 second at the latest.
– If the test lamp does not go out or does not light up at all, the
capacitor is faulty.

Repair manual KTM 250 / 300 / 380

1

+

–

7-5C
STATIC IGNITION VALUES 250-380 SX, EXC (KOKUSAN 2K-1, 2K-3, 2K-4)
Measuring conditions:
– cold engine
– seat and tank removed
– all connectors and the ground connection in a non-corroding condition, connectors tightly connected
– spark plug screwed out and spark plug connector attached to ground
– light switch turned off
– the gap between the rotor and pulse generator must be set to 0.75 mm
– kick the kick starter forcefully at least 5 times for each measurement

Static ignition values 250-380 SX, EXC (except 250 USA)

1

Check the pulse generator for an output signal – two-pin connector 1
with green and red cable colors (also see circuit diagram on opposite
page):
– Apply the red measuring lead of the peak voltage adapter to the green
cable and the black measuring lead to the red cable, disconnect both
connectors 1 to disconnect the CDI unit 2

1

Multimeter display: 6 volts +/- 1 volt
(250 SX model 2000/2001: 5 volts +/- 1 volt)

3

– Same measurement with CDI unit connected
Multimeter display: 3 volts +/- 1 volt
(250 SX model 2000/2001: 9 volts +/- 1 volt)
Check the generator charging coil for ignition capacitor charge for output voltage – two-pin connector 3 with black/red and red/white cable
colors (also see circuit diagram on opposite page):
– Apply the red measuring lead of the peak voltage adapter to the
black/red cable and the black measuring lead to the red/white cable,
disconnect connector 3 to disconnect the CDI unit 2
Multimeter display: 35 volts +/- 5 volts
– Same measurement with connectors CDI unit connected
Multimeter display: 200 volts +/- 10 volts

S

4

Check the primary voltage output 4 for ignition coil control (also see circuit diagram on opposite page) for output voltage (blue/white cable
color):
– Apply the red measuring lead R of the peak voltage adapter to the
black/white cable (ground) and the black measuring lead S to the
blue/white cable, CDI unit 2 and ignition coil 5 connected

R

Multimeter display: 200 volts +/- 10 volts
NOTE: the ignition coil does not need to be removed to measure.

5

Repair manual KTM 250 / 300 / 380

Art No 3206004 -E

7-6C

SPORTMOTORCYCLES

5

2

250-380 EXC 2000

4
1

3

7-7C
STATIC GENERATOR VALUES 250-380 EXC (KOKUSAN 2K-3)
Measuring conditions:
– cold engine
– seat and tank removed
– all connectors and the ground connection in a non-corroding condition, connectors tightly connected
– light switch turned off
– kick the kick starter forcefully at least 5 times for each measurement

Static generator values 250-380 EXC (except 250 USA)
Check the generator output 6 (also see circuit diagram on opposite
page) for voltage between the following cable colors:
– between yellow and brown (ground), connector 7 disconnected
Multimeter display (250): 19 volts +/- 2 volts
(300-380): 15 volts +/- 1 volt

7

– between white and brown (ground), connector 8 disconnected
Multimeter display (250): 24 volts +/- 2 volts
(300-380): 19 volts +/- 1 volt

8

– Repeat both measurements with connector 7 and 8 connected. The
measured values should be the same.
NOTE: the black measuring lead of the peak voltage adapter must be
applied to the ground.
Check regulator rectifier output voltage 9 (also see circuit diagram on
opposite page) cable colors yellow/red, regulator rectifier bk connected,
capacitor bl disconnected:
– between yellow/red and brown (ground)
Multimeter display: 14 volts +/- 1 volt

10

S

NOTE:
– the black measuring lead S of the peak voltage adapter must be
applied to the ground.
– 300/380 USA corresponds to 300/380 EXC Europe but with less
accessories (blinkers, horn, no capacitor installed). Features no rectification, only an over-voltage regulation.

Repair manual KTM 250 / 300 / 380

Art No 3206004 -E

7-8C

SPORTMOTORCYCLES

10

250-380 EXC 2000

6

9

11

7-9C
STATIC IGNITION AND GENERATOR VALUES 250 MXC, EXC USA (KOKUSAN 2K-2)
Measuring conditions:
– cold engine
– seat and tank removed
– all connectors and the ground connection in a non-corroding condition, connectors tightly connected
– spark plug screwed out and spark plug connector attached to ground
– light switch turned off
– the gap between the rotor and pulse generator must be set to 0.75 mm
– kick the kick starter forcefully at least 5 times for each measurement

Static ignition values 250 MXC, EXC USA

1

Check the pulse generator for an output signal – two one-pin connectors
1 with green and red cable colors (also see circuit diagram on opposite
page):
– Apply the red measuring lead of the peak voltage adapter to the green
cable and the black measuring lead to the red cable, disconnect both
connectors 1 to disconnect the CDI unit 2

1

Multimeter display: 3.5 volts +/- 1 volt

3

– Same measurement with CDI unit connected
Multimeter display: 2 volts +/- 0.5 volt
Check the generator charging coil for ignition capacitor charge for output voltage – two-pin connector 3 with black/red and red/white cable
colors (also see circuit diagram on opposite page)
– apply the red measuring lead of the peak voltage adapter to the
black/red cable and the black measuring lead to the red/white cable,
disconnect connector 3 to disconnect the CDI unit 2
Multimeter display: 45 volts +/- 5 volts
– Same measurement with connectors CDI unit connected
Multimeter display: 220 volts +/- 10 volts

S

4

Check the primary voltage output 4 for ignition coil control (also see circuit diagram on opposite page) for output voltage (blue/white cable
color):
– apply the red measuring lead R of the peak voltage adapter to the
black/white cable (ground) and the black measuring lead S to the
blue/white cable, CDI unit 2 and ignition coil 5 connected

R

Multimeter display: 210 volts +/- 10 volts
NOTE: the ignition coil does not need to be removed to measure.

5

Static generator values 250 MXC, EXC USA
Check the generator output 6 for the lighting system (also see circuit
diagram on opposite page) for voltage:
– between yellow and brown (ground), connector disconnected
Multimeter display: 10.5 volts +/- 1 volt

Repair manual KTM 250 / 300 / 380

Art No 3206004 -E

7-10C

250 EXC 2001

5

4
3

2
1
6

8-1C

TROUBLE SHOOTING
INDEX

Repair manual 250 / 300 / 380

Art No 3206004 -E

TROUBLE SHOOTING 250 - 380 . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2

8

8-2C

TROUBLE SHOOTING
If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected.
Should an error occur nevertheless, we advise you to use the trouble shooting chart in order to find the cause of error.

TROUBLE

CAUSE

Art No 3206004 -E

Engine fails to start

Engine
running

without

idle

Repair manual KTM 250 / 300 / 380

Engine has not enough
power

REMEDY

Operating error

Open fuel tap, switch o ignition, replenish fuel, do not use choke

Fuel supply interrupted

Close fuel tap, loosen fuel hose at carburettor, lead into a
basin and open fuel tap,
– if fuel leaks out, clean carburettor
– if no fuel leaks out, check tank ventilation, i.e. clean fuel tap

Electrode distance too great

Reduce electrode distance (0.60 mm)

Plug fouled by oil, wet or bridged

Clean spark plug or renew

Ignition wire or spark plug connector
damaged

Dismount spark plug, connect ignition cable, hold to ground
(blank place on engine) and actuate kickstarter, a strong spark
must be produced at the spark plug
– If no spark is produced, loosen spark plug cap from ignition
cable, hold about 5 mm from ground and actuate kickstarter
– If a spark now occurs, replace spark plug cap
– If no spark is produced, check ignition system

Kill button wire or
short-circuit switch faulty

Disconnect yellow-black coloured cable from CDI and check
ignition spark. If the spark is O.K. repair defective part of
cable, ignition lock or ignition switch

Loose ignition cable connectors

Inspect cable connectors

Spark too weak

Examine ignition system

Water in the carburetor and jets
blocked

Dismantle and clean carburetor

Idle adjusting
adjustment

Readjust idle running or replace idle adjusting screw

screw

out

of

Ignition system damaged

Examine ignition system

Wear

Overhaul engine

Charred glass fiber yarn in silencer

Renew filling

Air filter obstructed

Clean or renew airfilter

Control flap does not work

Check control flap, joint rod and centrifugal timer

Fuel supply partly interrupted or
blocked

Blow through fuel pipe and clean carburetor

Loss of compression through loose
spark plug

Tighten spark plug

Exhaust system damaged

Check exhaust system for damage

Engine has not enough preignition

Check and adjust ignition

8-3C
TROUBLE

CAUSE

Engine has not enough
power

Reed paddles tensionless or damaged, surface of reed valve housing
damaged

Replace reed paddles or reed valve housing

Wear

Overhaul engine

Electronical ignition timing faulty

Check ignition system

Carburetor overflows if level adjust
too high, float needle seating is
dirty or enlarged

Clean carburetor, if necessary replace float needle and adjust
level

Loose carburetor jets

Tighten jets

Incorrect heat range spark plug or
low quality spark plug

Refer to technical data section

Incorrect or faulty spark plug connector

Test and/or replace spark plug connectors correct type

Loose, corroded or non conductive
ignition socket connector

Check and seal with silicon

Lack of fuel

Clean fuel pipes, examine tank aeration and clean

Spark plug with incorrect heat value
(Ignition by incandescence)

Fit correct spark plug

Engine takes air out of control

Check intake flange and carburettor if firmly setted

Insufficient liquid in cooling system

Top up coolant and bleed cooling system check cooling system
for leaks

Cooling system not or insufficiently
bleeded

Bleed cooling system (see operating instructions)

Radiator fins clogged

Clean radiator fins with water jet

Frothing in cooling system

Renew coolant using branded anti-freeze/anti-corrosive

Pinched or kinked water hoses

Replace with correct routed hoses

Incorrect ignition timing because of
loose stator bolts

Readjust to correct ignition timing specifications, secure
screws properly with Loctite 243

Incorrect dimension ,,X“

Measure and adjust to correct specification

Emission of white smoke
(steam)

Cylinder head or O-ring of cylinder
head gasket leaks

Check cylinder head, replace O-ring

Excessive oil escapes from
transmission breather tube

Excessive oil quantity in transmission

Correct transmission oil level

Water pump shaft seal ring or righthand crankshaft seal ring defect

Replace shaft seal ring and change gear oil, check coolant

Engine revs not high and
running with four stroke
cycle

High rpm misfiring

Engine spluters into the
carburetor

Engine overheating

Silicon O-rings of control roller or of
control flap leaks
All switched on lamps
blown out

Voltage regulator faulty

REMEDY

Replace O-rings
Control connections of voltage regulator. Check voltage
regulator

9-1C

9

TECHNICAL SPECIFICATIONS

Repair manual 250 / 300 / 380

Art No 3206004 -E

INDEX

MODEL 1999
ENGINE 250 - 380 USA .
ENGINE 250 - 380 . . . . .
CHASSIS 250 - 380 . . . .
CARBURETOR SETTINGS

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MODEL 2000
ENGINE 250 - 380 USA .
ENGINE 250 - 380 . . . . .
CHASSIS 250 - 380 . . . .
CARBURETOR SETTINGS

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.9-10
.9-12
.9-14
.9-15

MODEL 2001
ENGINE 250 - 380 USA .
ENGINE 250 - 380 . . . . .
CHASSIS 250 - 380 . . . .
CARBURETOR SETTINGS

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.9-19
.9-21
.9-23
.9-24

MODEL 2002
ENGINE 250 - 380 USA .
ENGINE 250 - 380 . . . . .
CHASSIS 250 - 380 . . . .
CARBURETOR SETTINGS

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.9-28
.9-30
.9-32
.9-33

.9-2
.9-4
.9-6
.9-7

MODEL 2003
ENGINE 250 - 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-37
CHASSIS 250 - 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-39
CARBURETOR SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-41

Gear ratio
1st Gear
2nd Gear
3rd Gear
4th Gear
5th Gear
Gear lubrication
Available chain sprockets
Coolant
Ignition system
Generator output
Carburetor
Air-filter

TVC start open
TVC fully open
Primary drive
Clutch
Transmission

Design
Piston displacement
Bore / stroke
Fuel
Oil / gasolin ratio
Crankshaft bearing
Connecting rod bearing
Piston pin bearing
Piston
Piston ring
(upper edge piston Dimension "X" upper edge cylinder)
Ignition timing
Spark plug
Electrode gap
of the
Dimension "Z" (height
control flap)

Engine

250 EXC, MXC

300 EXC, MXC

380 SX

250/300/380 SX/MXC/EXC ‘99

Art No 3206004 -E

KOKUSAN 2K-1
no generator

15:29
17:27
19.25
21:23
23:21

15:29
18:26
19:22
21:20
23:18

EXC
M-XC
15:29
15:29
15:29
18:26
18:26
18:26
19:22
19:24
19:24
21:20
21:23
21:23
23:18
23:21
23:21
0.8 l engine oil 20W-40 (Shell Advance VSX4)
13t / 14t / 15t for chain 5/8 x 1/4"
1.3 litres, 40% anti freeze, 60% water, at least -25 °C (-13 °F)
KOKUSAN 2K-2
KOKUSAN 2K-1
12V 40W
no generator
flat-slide carburetor, carburetor setting see table 3
wet foam type air filter insert

KOKUSAN 2K-2
12V 40W

EXC
15:29
18:26
19:22
21:20
23:18

5400/min
5300/min
5200/min
7550/min
7750/min
7200/min
straight cut spur gears, primary ratio 25:72
straight cut spur gears, primary ratio 26:72
multiple disc clutch in oil bath, hydraulic operated (Shell HF-E15)
5 speed, claw actuated
MXC
15:29
18:26
19:24
21:23
23:21

380 EXC, MXC

(only for USA)

Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber
249 ccm
297 ccm
368 ccm
67.5 / 69.5 mm (2.66 / 2.74 in)
72 / 73 mm (2.84 / 2.88 in)
78 / 77 mm (3 / 2.98 in)
SUPER fuel, research octane no 95, mixed with high-grade two stroke oil (Shell Advance Racing X)
1:50 - 1:60 when using high grade two stroke oil. When in doupt, please contact your importer or use 1:40 mix ratio to be on the safe side
1 deep-groove ball bearing / 1 cylinder roller bearing
needle bearing
needle bearing
cast piston
forged piston
cast piston
two plain compression rings
0 mm +0.1 mm (0 in + 0.004 in)
1.8 mm (0.07 in) (17 °) BTDC
2.0 mm (0.08 in) (17°) BTDC
2.2 mm (0.09 in) (17 °) BTDC
NGK BR 8 ECM
0.6 mm (0.024 in)
48 mm (1.9 in)
46 mm (1.7 in)
50.5 mm (1.99 in)

250 SX

TECHNICAL SPECIFICATIONS - ENGINE

Repair manual KTM 250 / 300 / 380

9-2C

9-3C
TIGHTENING TORQUES
Flange bolts - cylinder-head

M8

35 Nm (25 ft.lb)

Nuts-cylinder base

M 10

35 Nm (25 ft.lb)

Flywheel collar nut

M 12x1

Nut for primary sprocket (LH thread)

M 18x1.5

Loctite 243 150 Nm (110 ft.lb)

Nut for inner clutch hub

M 18x1.5

Loctite 243 100 Nm (74 ft.lb)

Crankcase and cover bolts

M6

60 Nm (44 ft.lb)

8 Nm

Swingarm pivot

M 14

Flat head bolt release plate kickstarter

M 6x16

Other bolts

M6
M8
M 10

(6 ft.lb)

100 Nm (74 ft.lb)
Loctite 648 19 Nm (14 ft.lb)
10 Nm (7 ft.lb)
25 Nm (19 ft.lb)
45 Nm (33 ft.lb)

TOLERANCES AND FITTING CLEARANCES
Piston fitting clearance

0.05 mm (250)

Piston ring end gap

0.3 – 0.4 mm

Connecting rod bearing - radial clearance

0.021 – 0.032 mm

Transmission shafts end float

0.1 – 0.2 mm

Clutch springs - length

Ø 2.5

0.06 mm (300)

0.08 mm (380)

new = 43 mm, minimum length = 42 mm

GASKET THICKNESSES
Crankcase

0.5 mm

Clutch cover

0.5 mm

Cylinder bottom gasket

as required

Available cylinder bottom gaskets

0.2/0.4/ 0.5 / 0.7 mm

Cylinder-head gasket

O-rings

BASIC CARBURETOR SETTING

TABLE 3

250 SX

Carburetor
Keihin PWK 38
Carburetor setting number
090598
Main jet
172(168,170,175)
Idling jet
45(48,50)
Starting jet
85
Jet needle
NOZ G(NOZ H,NOZ I)
Needle position from top
II
Throttle valve
6
Air adjustment screw open
1,5

250 MXC, EXC
300 MXC, EXC

380 SX, MXC, EXC

Keihin PWK 38
100598
175(170,172,178)
45(42,48)
85
N85 C(N85 D)
III
6
1,5 Umdr.

Keihin PWK 38
070598
170(168,172,175)
48(45,50)
85
NOZ H(NOZ G,NOZ I)
II
6
1,5 Umdr.

300 EXC, EGS

380 SX

249 ccm

297 ccm

368 ccm
78 / 77 mm (3 / 2.98 in)

15:29
17:27
19.25
21:23
23:21

no generator

Generator output

Carburetor
Air-filter

KOKUSAN 2K-1

Ignition system

Coolant

ailable chain sprockets

Gear lubrication

Gear ratio
1st Gear
2nd Gear
3rd Gear
4th Gear
5th Gear

Transmission

Clutch

NGK BR 8 ECM

5300/min
7750/min

46 mm (1.7 in)

0.6 mm (0.024 in)

for chain 5/8 x 1/4"
SEM K11
flat-slide carburetor, carburetor setting see table 4
wet foam type air filter insert

12V 130W

5200/min
7200/min

no generator

KOKUSAN 2K-1

15:29
18:26
19:24
21:23
23:21

12V 130W

SEM K11

15:29
18:26
19:22
21:20
23:18

straight cut spur gears, primary ratio 26:72

1.3 litres, 40% anti freeze, 60% water, at least -25 °C (-13 °F)

13t / 14t / 15t

0,8 l engine oil 20W-40 (Shell Advance VSX4)

15:29
18:26
19:22
21:20
23:18

5 speed, claw actuated

1.4 mm (0.06 in) (14,5°) BTDC

50.5 mm (1.99 in)

2.1 mm (0.08 in) (17 °) BTDC

multiple disc clutch in oil bath, hydraulic operated (Shell HF-E15)

straight cut spur gears, primary ratio 25:72

Primary drive

48 mm (1.9 in)
5400/min
7550/min

(height of the
control flap)

TVC start open
TVC fully open

Dimension "Z"

Electrode gap

Spark plug

1.2 mm (0.05 in) (13.5 °) BTDC

0 + 0.1 mm (0 + 0.004 in)

Dimension "X" upper edge cylinder)

Ignition timing

two plain compression rings

Piston ring
1.2 mm (0.05 in) (13.5 °) BTDC

forged piston

Piston

1,9 mm (0.07 in) (17 °) BTDC

needle bearing

Piston pin bearing

(upper edge piston -

needle bearing

Connecting rod bearing

cast piston

1 deep-groove ball bearing / 1 cylinder roller bearing

cast piston

1:50 - 1.60 when using high grade two stroke oil. When in doupt, please contact your importer or use 1:40 mix ratio to be on the safe side

Crankshaft bearing

SUPER fuel, research octane no 95, mixed with high-grade two stroke oil (Shell Advance Racing X)

72 / 73 mm (2.84 / 2.88 in)

380 EXC, EGS

(all models out of USA)

Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber

250 EXC, EGS

67.5 / 69.5 mm (2.66 / 2.74 in)

250 SX

250/300/380 SX/EXC/EGS ‘99

Art No 3206004 -E

Oil / gasoline ratio

Fuel

Bore / stroke

Piston displacement

Design

Engine

TECHNICAL SPECIFICATIONS - ENGINE

Repair manual KTM 250 / 300 / 380

9-4C

9-5C
TIGHTENING TORQUES
Flange bolts - cylinder-head
Nuts-cylinder base
Flywheel collar nut
Nut for primary sprocket (LH thread)
Nut for inner clutch hub
Crankcase and cover bolts
Swingarm pivot
Flat head bolt release plate kickstarter
Other bolts

M
M
M
M
M
M
M
M
M
M
M

8
10
12x1
18x1.5
18x1.5
6
14
6x16
6
8
10

35
35
60
Loctite 243 150
Loctite 243 100
8
100
Loctite 648 19
10
25
45

Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm

(25
(25
(44
(110
(74
(6
(74
(14
(7
(19
(33

ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)

TOLERANCES AND FITTING CLEARANCES
Piston fitting clearance
Piston ring end gap
Connecting rod bearing - radial clearance
Transmission shafts end float
Clutch springs - length

0.05 mm (250) 0.06 mm (300) 0.08 mm (380)
0.3 – 0.4 mm
0.021 – 0.032 mm
0.1 – 0.2 mm
Ø 2.5 new = 43 mm, minimum length = 42 mm

GASKET THICKNESSES
Crankcase
Clutch cover
Cylinder bottom gasket
Available cylinder bottom gaskets
Cylinder-head gasket

0.5 mm
0.5 mm
as required
0.2/0.4/ 0.5 / 0.7 mm
O-rings

BASIC CARBURETOR SETTING
250 SX

TABLE 4

Carburetor

Keihin PWK 38
090598
Carburetor setting number
172(168,170,175)
Main jet
45(48,50)
Idling jet
85
Starting jet
NOZ G(NOZ H,NOZ I)
Jet needle
II
Needle position from top
6
Throttle valve
1,5
Air adjustment screw open
–
Performance restrictor

250 MXC, EXC
300 MXC, EXC

250/300 EGS
AUSTRALIA

Keihin PWK 38
100598
175(170,172,178)
45(42,48)
85
N85 C(N85 D)
III
6
1,5 Umdr.
–

Keihin PWK 38
100598
175(170,172,178)
45(42,48)
85
N85 C(N85 D)
III
6
1,5 Umdr.
slide stop 31mm

380 SX, MXC, EXC

380 EGS
AUSTRALIA

Keihin PWK 38
Keihin PWK 38
060598
070598
175(168,170,172)
170(168,172,175)
45(48,50)
48(45,50)
85
85
NOZ H(NOZ G,NOZ I) NOZ G(NOZ H,NOZ I)
II
II
6
6
1,5 Umdr.
1,5 Umdr.
slide stop 36mm
–

9-6C
TECHNICAL SPECIFICATIONS CHASSIS
250/380SX

250 / 300 / 380 SX / MXC / EXC / EGS

250/300/380 MXC

Frame

WP Extreme Ø 50 mm

Wheel travel front/rear

280 / 320 mm (11.0 / 12.6 in)

Rear suspension

WP Progressive Damping System shock absorber, aluminium swingarm

Front brake

Disc brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated

Rear brake

Disc brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated

Front tires
Air pressure offroad
Air press. road driver only
Rear tires
Air pressure offroad
Air press. road driver only

80/100 - 21“ 51M
–
1.0 bar (14 psi)
–

80/100 - 21“ 51M
–
1.0 bar (14 psi)
–

90/90 - 21“ 54R
80/100 - 21“ 51M
1.0 bar (14 psi)
1.5 bar (21 psi)

90/90 - 21“ 54R
–
1.0 bar (14 psi)
1.5 bar (21 psi)

110/90 - 19“ 62M
–
1.0 bar (14 psi)
–

110/100 - 18“ 64M
–
1.0 bar (14 psi)
–

140/80 - 18“ 70R
110/100 - 18“ 64M
1.0 bar (14 psi)
2.0 bar (28 psi)

140/80 - 18“ 70R
–
1.0 bar (14 psi)
2.0 bar (28 psi)

7.5 liter
(2 US gallons)

12 liter
(3.2 US gallons)

9.5 or 12 liter
(2.5 or 3.2 US gallons)

9.5 or 12 liter
(2.5 or 3.2 US gallons)

14:50

14:52

14:50 / 14:52

14:50 / 15:48

Fuel tank capacity
Final drive ratio
Chain

5/8 x 1/4"

Available final sprockets

38, 40, 42, 45, 48, 50, 52

Steering head angle

63.5°

Wheel base

1481 ± 10 mm (58.3 ± 0.4 in)

Seat height, unloaded

925 mm (36.4 in)

Ground clearance, unloaded

385 mm (15 in)

Dead-weight without fuel
Art No 3206004 -E

250/300/380 EGS

Central chrome-moly-steel frame

Fork

101 kg (223 lbs)

102.5 kg (226.3 lbs)

STANDARD ADJUSTMENT - FORK

103.7 kg (229 lbs)

109 kg (240.6 Ibs)

STANDARD-ADJUSTMENT - SHOCK ABSORBER

WP 918T768

WP 918T769

Compression adjuster

12

12

Compression adjuster

5

6

Rebound adjuster

12

12

Rebound adjuster

14

12

4.2 N/mm

4.0 N/mm

5 mm (0.2 in)

5 mm (0.2 in)

Spring
Spring preload
Air chamber length

150 mm (5.9 in)

155 mm (6.1 in)

Capacity per fork leg

approx. 750 ccm

approx. 750 ccm

SAE 5

SAE 5

Fork oil

Repair manual KTM 250 / 300 / 380

250/300/380 EXC

‘99

WP 1218T712

Spring
Spring preload

WP 1218T714

PDS3–250

PDS2–250

5 mm (0.20 in)

6 mm (0.23 in)

NOTE:
The damping units in the left and the right fork leg are of
different design. Make sure not to mix them up in case of
repair or service jobs.

TORQUES
Collar bolt front wheel spindle

M 10

40 Nm (30 ft.lb)

Brake caliper front

M8

25 Nm (19 ft.lb)

Clamping bolts upper fork bridge

M8

15 Nm (11 ft.lb)

+ Loctite 243
Clamping bolts lower fork bridge

M8

20 Nm (15 ft.lb)

Clamping bolts fork stubs

M8

15 Nm (11 ft.lb)

Collar nut rear wheel spindle

M 20x1,5

80 Nm (59 ft.lb)

Hexagon nut swing arm bolt

M 14x1,5

100 Nm (74 ft.lb)

Shock absorber top

M 12

60 Nm (44 ft.lb)

Shock absorber bottom

M 12

40 Nm (30 ft.lb)

Other bolts on chassis

M6
M8
M 10

10 Nm (7 ft.lb)
25 Nm (19 ft.lb)
45 Nm (33 ft.lb)

The clamping bolts of the fork plates must be
tightened in several (3) steps. Otherwise, the bolts
might come loose.

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

2300 m
7500 ft

1500 m
5000 ft

750 m
2500 ft

300 m
1000 ft

LSCHR
LD
POS
HD

=
=
=
=

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

Luftregulierschraube offen
Leerlaufdüse
Clip Position von oben
Hauptdüse

Meeresniveau
Sea level

301 m
1001 ft

751 m
2501 ft

1501 m
5001 ft

2301 m
7501 ft

LSCHR
LD
NADEL
POS
HD

5.

3.

1.

1/2
50
N85A
4
185

3/4
50
N85B
3
182

7
48
N85B
3
180

1 1/4
48
N85B
3
178

1 1/2
45
N85C
3
175

4.

2.

-2°F to 20°F

-20°C bis -7°C

AS
IJ
POS
MJ

=
=
=
=

1
45
N85B
3
180

1 1/4
45
N85C
2
178

1 1/2
45
N85C
3
175

1 3/4
42
N85C
2
172

2
40
N85C
1
170

42°F to 60°F

6°C bis 15°C

1 1/2
42
N85C
1
175

1 3/4
45
N85C
2
172

2
45
N85C
2
170

2 1/4
42
N85D
1
168

2 1/2
40
N85D
1
165

79°F to 98°F

25°C bis 38°C

1 3/4
42
N85D
1
172

2
42
N85D
2
170

2 1/4
42
N85D
1
168

2 1/2
40
N85D
1
165

2 3/4
38
N85D
1
165

99°F to 120°F

37°C bis 49°C

NICHT FÜR STRASSENBETRIEB
Kraftstoff: Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Super unleaded ROZ 95

1 1/4
45
N85C
2
178

1 1/2
45
N85C
2
175

1 3/4
45
N85C
2
172

2
42
N85C
2
170

2 1/4
40
N85D
1
168

61°F to 78°F

16°C bis 24°C

Air screw open from fully-seated
Idling jet
Clip position from top
Main jet

3/4
48
N85B
3
182

1
48
N85B
2
180

1 1/4
45
N85B
3
178

1 1/2
45
N85C
2
175

1 3/4
42
N85C
2
172

19°F to 41°F

-6°C bis 5°C

KTM 250/300 MXC/EXC EU, USA‘99 KEIHIN PWK 38

TEMPERATUR

3000 m
10000 ft

ALTITUDE

MEERESHÖHE

VERGASERREGULIERUNG
CARBURETOR SETTING

9-7C

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

2300 m
7500 ft

1500 m
5000 ft

750 m
2500 ft

300 m
1000 ft

LSCHR
LD
POS
HD

=
=
=
=

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

Luftregulierschraube offen
Leerlaufdüse
Clip Position von oben
Hauptdüse

Meeresniveau
Sea level

301 m
1001 ft

751 m
2501 ft

1501 m
5001 ft

2301 m
7501 ft

LSCHR
LD
NADEL
POS
HD

Art No 3206004 -E

5.

3.

1.

1/2
50
NOZF
4
180

3/4
50
NOZG
3
178

1
48
NOZG
3
175

1 1/4
48
NOZG
3
172

1 1/2
45
NOZH
3
170

4.

2.

-2°F to 20°F

-20°C bis -7°C

AS
IJ
POS
MJ

=
=
=
=

1
45
NOZG
3
180

1 1/4
45
NOZH
2
172

1 1/2
45
NOZH
2
170

1 3/4
42
NOZH
1
168

2
40
NOZH
1
165

42°F to 60°F

6°C bis 15°C

1 1/2
42
NOZH
1
170

1 3/4
45
NOZI
2
168

2
45
NOZH
2
165

2 1/4
42
NOZI
1
162

2 1/2
40
NOZI
1
160

79°F to 98°F

25°C bis 38°C

1 3/4
42
NOZI
1
168

2
42
NOZI
2
165

2 1/4
42
NOZI
2
162

2 1/2
40
NOZI
1
160

2 3/4
38
NOZI
1
160

99°F to 120°F

37°C bis 49°C

NICHT FÜR STRASSENBETRIEB
Kraftstoff: Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Super unleaded ROZ 95

1 1/4
45
NOZH
2
172

1 1/2
45
NOZH
2
170

1 3/4
45
NOZH
2
168

2
42
NOZI
1
165

2 1/4
40
NOZI
1
162

61°F to 78°F

16°C bis 24°C

Air screw open from fully-seated
Idling jet
Clip position from top
Main jet

3/4
48
NOZG
3
178

1
48
NOZG
2
175

1 1/4
45
NOZG
3
172

1 1/2
45
NOZH
2
170

1 3/4
42
NOZH
2
168

19°F to 41°F

-6°C bis 5°C

KTM 250 SX EUROPA, USA ‘99 KEIHIN PWK 38

TEMPERATUR

3000 m
10000 ft

ALTITUDE

MEERESHÖHE

VERGASERREGULIERUNG
CARBURETOR SETTING

Repair manual KTM 250 / 300 / 380

9-8C

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

2300 m
7500 ft

1500 m
5000 ft

750 m
2500 ft

300 m
1000 ft

LSCHR
LD
POS
HD

=
=
=
=

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

Luftregulierschraube offen
Leerlaufdüse
Clip Position von oben
Hauptdüse

Meeresniveau
Sea level

301 m
1001 ft

751 m
2501 ft

1501 m
5001 ft

2301 m
7501 ft

LSCHR
LD
NADEL
POS
HD

5.

3.

1.

1/2
52
F
4
182

3/4
52
G
3
180

1
50
G
3
178

1 1/4
50
G
3
175

1 1/2
48
H
3
172

4.

2.

-2°F to 20°F

-20°C bis -7°C

AS
IJ
POS
MJ

=
=
=
=

1
48
G
3
178

1 1/4
48
H
2
175

1 1/2
48
H
2
172

1 3/4
45
H
1
170

2
45
H
1
168

42°F to 60°F

6°C bis 15°C

1 1/2
48
H
1
172

1 3/4
48
NOZI
2
170

2
48
H
2
168

2 1/4
45
I
1
165

2 1/2
42
I
1
162

79°F to 98°F

25°C bis 38°C

1 3/4
45
I
1
170

2
45
NOZI
2
168

2 1/4
45
I
2
165

2 1/2
42
I
1
162

2 3/4
40
I
1
162

99°F to 120°F

37°C bis 49°C

NICHT FÜR STRASSENBETRIEB
Kraftstoff: Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Super unleaded ROZ 95

1 1/4
48
H
2
175

1 1/2
48
N0ZH
2
172

1 3/4
48
H
2
170

2
45
I
1
168

2 1/4
42
I
1
165

61°F to 78°F

16°C bis 24°C

Air screw open from fully-seated
Idling jet
Clip position from top
Main jet

3/4
50
G
3
180

1
50
G
2
178

1 1/4
48
G
3
175

1 1/2
48
H
2
172

1 3/4
45
H
2
170

19°F to 41°F

-6°C bis 5°C

KTM 380 SX/MXC/EXC EU, USA ‘99 KEIHIN PWK 38

TEMPERATUR

3000 m
10000 ft

ALTITUDE

MEERESHÖHE

VERGASERREGULIERUNG
CARBURETOR SETTING

9-9C

Gear ratio
1st Gear
2nd Gear
3rd Gear
4th Gear
5th Gear
Gear lubrication
Available chain sprockets
Coolant
Ignition system
Generator output
Carburetor
Air-filter

TVC start open
TVC fully open
Primary drive
Clutch
Transmission

Engine
Design
Piston displacement
Bore / stroke
Fuel
Oil / gasolin ratio
Crankshaft bearing
Connecting rod bearing
Piston pin bearing
Piston
Piston ring
edge piston Dimension "X" (upper
upper edge cylinder)
Ignition timing
Spark plug
Electrode gap
of the
Dimension "Z" (height
control flap)

Art No 3206004 -E

KOKUSAN 2K-4
no generator

15:29
17:27
19:25
21:23
23:21

EXC
15:29
18:26
19:22
21:20
23:18

EXC
MXC
15:29
15:29
15:29
18:26
18:26
18:26
19:22
19:24
19:24
21:20
21:23
21:23
23:18
23:21
23:21
0.8 l engine oil 20W-40 (Shell Advance VSX4)
13t / 14t / 15t for chain 5/8 x 1/4"
1.3 litres, 40% anti freeze, 60% water, at least -25 °C (-13 °F)
KOKUSAN 2K-2
KOKUSAN 2K-1
12V 40W
no generator
flat-slide carburetor, carburetor setting see table
wet foam type air filter insert

MXC
15:29
17:27
19:25
21:23
23:21

MXC
15:29
18:26
19:24
21:23
23:21

KOKUSAN 2K-3
12V 110W

EXC
15:29
18:26
19:22
21:20
23:18

5000/min
5300/min
5200/min
7500/min
7750/min
7200/min
straight cut spur gears, primary ratio 25:72
straight cut spur gears, primary ratio 26:72
multiple disc clutch in oil bath, hydraulic operated (Shell HF-E15)
5 speed, claw actuated

250 EXC, MXC
300 EXC, MXC
380 SX
380 EXC, MXC
Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber
249 ccm
297 ccm
368 ccm
66.4 / 72 mm (2.62 / 2.84 in)
72 / 73 mm (2.84 / 2.88 in)
78 / 77 mm (3 / 2.98 in)
unleaded SUPER fuel, research octane no 95, mixed with high-grade two stroke oil (Shell Advance Racing X)
1:40 – 1:60 when using high grade two stroke oil. When in doupt, please contact your importer or use 1:40 mix ratio to be on the safe side
1 deep-groove ball bearing / 1 cylinder roller bearing
needle bearing
needle bearing
cast piston
forged piston
cast piston
one plain compression rings
two plain compression rings
0 +0.1 mm (0 + 0.004 in)
2.0 mm (0.07 in) (17 °) BTDC
2.2 mm (0.09 in) (17 °) BTDC
NGK BR 8 ECM
0.6 mm (0.024 in)
50,5 mm (1.99 in)
46 mm (1.7 in)
50.5 mm (1.99 in)

250 SX

TECHNICAL DATA - ENGINE 250/300/380 SX / MXC / EXC 2000 (only USA)

Repair manual KTM 250 / 300 / 380

9-10C

9-11C
TIGHTENING TORQUES - ENGINE
Flange bolts - cylinder-head

M8

35 Nm (25 ft.lb)

Nuts-cylinder base

M 10

35 Nm (25 ft.lb)

Flywheel collar nut

M 12x1

Nut for primary sprocket (LH thread)

M 18x1.5

Loctite 243 150 Nm (110 ft.lb)

Nut for inner clutch hub

M 18x1.5

Loctite 243 100 Nm (74 ft.lb)

Crankcase and cover bolts

M6

Swingarm pivot

M 14

Flat head bolt release plate kickstarter

M 6x16

Other bolts

M6
M8
M 10

60 Nm (44 ft.lb)

8 Nm

(6 ft.lb)

100 Nm (74 ft.lb)
Loctite 648 19 Nm (14 ft.lb)
10 Nm (7 ft.lb)
25 Nm (19 ft.lb)
45 Nm (33 ft.lb)

TOLERANCES AND FITTING CLEARANCES
Piston fitting clearance

0.05 mm (250)

Piston ring end gap

0.3 – 0.4 mm

Connecting rod bearing - radial clearance

0.021 – 0.032 mm

Transmission shafts end float

0.1 – 0.2 mm

Clutch springs - length

Ø 2.5

0.06 mm (300)

0.08 mm (380)

new = 43 mm, minimum length = 42 mm

GASKET THICKNESSES
Crankcase

0.5 mm

Clutch cover

0.5 mm

Cylinder bottom gasket

as required

Available cylinder bottom gaskets

0.2/0.4/ 0.5 / 0.75 mm

Cylinder-head gasket

O-rings

BASIC CARBURETOR SETTING

Carburetor
Carburetor setting number
Main jet
Idling jet
Starting jet
Jet needle
Needle position from top
Slide
Air adjustment screw open
Performance restrictor
Power jet jet

250 SX

250 MXC, EXC

300 MXC, EXC

380 SX, MXC, EXC

Keihin PWK 38 AG PJ
110499
172 (170,175)
48 (45,50)
85
NOZ E (NOZ F)
III
7
1,5
–
55

Keihin PWK 38 AG
130499
180 (178,182)
45 (48)
85
NOZ G (NOZ H)
III
6
1,5
–
–

Keihin PWK 38 AG
140499
175 (172,178)
45 (48)
85
NOZ H (NOZ I)
III
6
1,5
–
–

Keihin PWK 38 AG
150499
170 (168,172)
45 (48)
85
NOZ H (NOZ I)
III
6
1,5
–
–

Gear ratio
1st Gear
2nd Gear
3rd Gear
4th Gear
5th Gear
Gear lubrication
ailable chain sprockets
Coolant
Ignition system
Generator output
Carburetor
Air-filter

TVC start open
TVC fully open
Primary drive
Clutch
Transmission

Engine
Design
Piston displacement
Bore / stroke
Fuel
Oil / gasoline ratio
Crankshaft bearing
Connecting rod bearing
Piston pin bearing
Piston
Piston ring
edge piston Dimension "X" (upper
upper edge cylinder)
Ignition timing
Spark plug
Electrode gap
of the
Dimension "Z" (height
control flap)

Art No 3206004 -E

KOKUSAN 2K-4
no generator

15:29
17:27
19.25
21:23
23:21

15:29
15:29
18:26
18:26
19:22
19:24
21:20
21:23
23:18
23:21
0,8 l engine oil 20W-40 (Shell Advance VSX4)
13t / 14t / 15t for chain 5/8 x 1/4"
1.3 litres, 40% anti freeze, 60% water, at least -25 °C (-13 °F)
KOKUSAN 2K-3
KOKUSAN 2K-1
12V 110W
no generator
flat-slide carburetor, carburetor setting see table
wet foam type air filter insert

KOKUSAN 2K-3
12V 110W

15:29
18:26
19:22
21:20
23:18

5000/min
5300/min
5200/min
7500/min
7750/min
7200/min
straight cut spur gears, primary ratio 25:72
straight cut spur gears, primary ratio 26:72
multiple disc clutch in oil bath, hydraulic operated (Shell HF-E15)
5 speed, claw actuated

250 EXC
300 EXC
380 SX
380 EXC
Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber
249 ccm
297 ccm
368 ccm
66.4 / 72 mm (2.62 / 2.84 in)
72 / 73 mm (2.84 / 2.88 in)
78 / 77 mm (3 / 2.98 in)
unleaded SUPER fuel, research octane no 95, mixed with high-grade two stroke oil (Shell Advance Racing X)
1:40 – 1:60 when using high grade two stroke oil. When in doupt, please contact your importer or use 1:40 mix ratio to be on the safe side
1 deep-groove ball bearing / 1 cylinder roller bearing
needle bearing
needle bearing
cast piston
forged piston
cast piston
one plain compression ring
two plain compression rings
0 + 0.1 mm (0 + 0.004 in)
2.0 mm (0.07 in) (17 °) BTDC
2.2 mm (0.08 in) (17 °) BTDC
NGK BR 8 ECM
0.6 mm (0.024 in)
50,5 mm (1.99 in)
46 mm (1.7 in)
50.5 mm (1.99 in)

250 SX

TECHNICAL DATA - ENGINE 250/300/380 SX / EXC 2000 (all models out of USA)

Repair manual KTM 250 / 300 / 380

9-12C

9-13C
TIGHTENING TORQUES
Flange bolts - cylinder-head

M8

35 Nm (25 ft.lb)

Nuts-cylinder base

M 10

35 Nm (25 ft.lb)

Flywheel collar nut

M 12x1

Nut for primary sprocket (LH thread)

M 18x1.5

Loctite 243 150 Nm (110 ft.lb)

Nut for inner clutch hub

M 18x1.5

Loctite 243 100 Nm (74 ft.lb)

Crankcase and cover bolts

M6

Swingarm pivot

M 14

Flat head bolt release plate kickstarter

M 6x16

Other bolts

M6
M8
M 10

60 Nm (44 ft.lb)

8 Nm

(6 ft.lb)

100 Nm (74 ft.lb)
Loctite 648 19 Nm (14 ft.lb)
10 Nm (7 ft.lb)
25 Nm (19 ft.lb)
45 Nm (33 ft.lb)

TOLERANCES AND FITTING CLEARANCES
Piston fitting clearance

0.05 mm (250)

Piston ring end gap

0.3 – 0.4 mm

Connecting rod bearing - radial clearance

0.021 – 0.032 mm

Transmission shafts end float

0.1 – 0.2 mm

Clutch springs - length

Ø 2.5

0.06 mm (300)

0.08 mm (380)

new = 43 mm, minimum length = 42 mm

GASKET THICKNESSES
Crankcase

0.5 mm

Clutch cover

0.5 mm

Cylinder bottom gasket

as required

Available cylinder bottom gaskets

0.2/0.4/ 0.5 / 0.75 mm

Cylinder-head gasket

O-rings

BASIC CARBURETOR SETTING

Carburetor
Carburetor setting number
Main jet
Idling jet
Starting jet
Jet needle
Needle position from top
Throttle valve
Air adjustment screw open
Performance restrictor
Power jet jet

250 SX

250 MXC, EXC

300 MXC, EXC

380 SX, MXC, EXC

250/300 EXC
throttled

Keihin PWK 38 AG PJ
110499
172 (170,175)
48 (45,50)
85
NOZ E (NOZ F)
III
7
1,5
–
55

Keihin PWK 38 AG
130499
180 (178,182)
45 (48)
85
NOZ G (NOZ H)
III
6
1,5
–
–

Keihin PWK 38 AG
140499
175 (172,178)
45 (48)
85
NOZ H (NOZ I)
III
6
1,5
–
–

Keihin PWK 38 AG
150499
170 (168,172)
45 (48)
85
NOZ H (NOZ I)
III
6
1,5
–
–

Keihin PWK 38 AG
050799
175
35
85
R 1475 J
III
6
1,5
slide stop 34mm
–

9-14C
TECHNICAL SPECIFICATIONS CHASSIS
250/380 SX

250/300/380 MXC

Frame

White Power – Up Side Down 43 MA

Wheel travel front/rear

295/320 mm (11,3/12,6 in)

Rear suspension

WP Progressive Damping System shock absorber, aluminium swingarm

Front brake

Disc brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated

Rear brake

Disc brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated

Brake discs
Front tires
Front tires USA
Air pressure offroad
Air pressure road driver only
Rear tires
Rear tires USA
Air pressure offroad
Air pressure road driver only
Fuel tank capacity

7,5 liter (2 US Gallons)

Wear limit max. 0,4 mm (0,016 in)
–
80/100 - 21“51M
1,0 bar (14psi)
1,5 bar (21psi)
–
100/100 - 18“ 64M
1,0 bar (14psi)
2,0 bar (28psi)
12 liter (3,2 US Gallons)

90/90 - 21“ 54R
80/100 - 21“51M
1,0 bar (14psi)
1,5 bar (21psi)
140/80 - 18“ 70R
100/100 - 18“ 64M
1,0 bar (14psi)
2,0 bar (28psi)
9,5/12 liter (2,5/3,2 US Gallons)

14:50t
14:50t

–
14:52t

15:48t / 14:50t
14:52t

80/100 - 21“51M
80/100 - 21“51M
1,0 bar (14psi)
–
100/90 - 19“ 62M
100/90 - 19“ 62M
1,0 bar (14psi)
–

Final drive ratio
Final drive ratio USA
Chain

5/8 x 1/4 "

Available final sprockets

38t, 40t, 42t, 45t, 48t, 50t, 52t

Steering head angle

63,5°

Wheel base

Art No 3206004 -E

250/300/380 EXC

Central chrome-moly-steel frame

Fork

1481 ± 10 mm (58,3 ± 0,4 in)

Seat height, unloaded

925 mm (36,5 in)

Ground clearance, unloaded

385 mm (15,2 in)

Dead-weight *
Dead-weight USA *

101 kg (223 lbs)
101 kg (223 lbs)

–
102,5 kg (226,3 lbs)

109 kg (240,6 lbs)
103,7 kg (229 lbs)

* Dead-weight without fuel

TIGHENING

STANDARD ADJUSTMENT-FORK
Compression adjuster
Rebound adjuster

WP 0518U785

WP 0518U787

14

14

TORQUES

-

Collar nut front wheel spindle

CHASSIS
M 16x1,5

40 Nm (30 ft.lb)

Brake caliper front

M8

25 Nm (19 ft.lb)

12

12

4,0 N/mm

4,0 N/mm

Clamping bolts upper fork bridge

M8

20 Nm (15 ft.lb)

Spring preload

6 mm (0.24in)

6,5 mm (0.26in)

Clamping bolts lower fork bridge

M8

15 Nm (11 ft.lb)

Air chamber length

140 mm (5.5in)

150 mm (5.9in)

Clamping bolts fork stubs

M8

10 Nm

Capacity per fork leg

approx. 840 ccm

approx. 830 ccm

Collar nut rear wheel spindle

M 20x1.5

80 Nm (59 ft.lb)

SAE 5

SAE 5

Hexagon nut swing arm bolt

M 14x1.5

100 Nm (74 ft.lb)

Spring

Fork oil
Repair manual KTM 250 / 300 / 380

250/300/380 SX, MXC, EXC 2000

STANDARD ADJUSTMENT - SHOCK ABSORBER
Compression adjuster
Rebound adjuster
Spring
Spring preload

WP 1218U718

WP 1218U720

4

5

18

20

PDS3–250

PDS2-250

5 mm (0.2 in)

5 mm (0.2 in)

+ Loctite 243

(7 ft.lb)

Collar bolt handlebar clamp

M8

20 Nm (15 ft.lb)

Allen head bolt handlebar support

M 10

40 Nm (30 ft.lb)

Shock absorber top

M 12

60 Nm (44 ft.lb)

Shock absorber bottom

M 12

60 Nm (44 ft.lb)

Screw adjusting ring spring preload

M6

Other bolts on chassis

M6
M8
M 10

8 Nm

(6 ft.lb)

10 Nm (7 ft.lb)
25 Nm (19 ft.lb)
45 Nm (33 ft.lb)

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

2300 m
7500 ft

1500 m
5000 ft

750 m
2500 ft

300 m
1000 ft

LSCHR
LD
POS
HD

=
=
=
=

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

Luftregulierschraube offen
Leerlaufdüse
Clip Position von oben
Hauptdüse

Meeresniveau
Sea level

301 m
1001 ft

751 m
2501 ft

1501 m
5001 ft

2301 m
7501 ft

LSCHR
LD
NADEL
POS
HD

5.

3.

1.

1/2
52
NOZC
4
180

3/4
52
NOZC
4
178

1
50
NOZD
4
175

1 1/4
50
NOZD
3
172

1 1/2
48
NOZD
3
170

4.

2.

-2°F to 20°F

-20°C bis -7°C

AS
IJ
POS
MJ

=
=
=
=

1
48
NOZD
3
180

1 1/4
48
NOZE
3
172

1 1/2
48
NOZE
3
170

1 3/4
45
NOZE
2
168

2
45
NOZE
2
165

42°F to 60°F

6°C bis 15°C

1 1/2
48
NOZE
3
170

1 3/4
48
NOZE
3
168

2
48
NOZF
2
165

2 1/4
45
NOZF
2
162

2 1/2
42
NOZG
1
160

79°F to 98°F

25°C bis 38°C

1 3/4
45
NOZE
2
168

2
45
NOZF
2
165

2 1/4
45
NOZF
2
162

2 1/2
42
NOZG
2
160

2 3/4
40
NOZH
1
160

99°F to 120°F

37°C bis 49°C

NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 95

1 1/4
48
NOZD
3
172

1 1/2
48
NOZE
3
170

1 3/4
48
NOZE
2
168

2
45
NOZE
2
165

2 1/4
42
NOZF
2
161628

61°F to 78°F

16°C bis 24°C

Air screw open from fully-seated
Idling jet
Clip position from top
Main jet

3/4
50
NOZC
4
178

1
50
NOZD
4
175

1 1/4
48
NOZD
3
172

1 1/2
48
NOZD
3
170

1 3/4
45
NOZE
3
168

19°F to 41°F

-6°C bis 5°C

KTM 250 SX EUR/USA 2000 KEIHIN PWK 38AG PJ

TEMPERATUR

3000 m
10000 ft

ALTIDUDE

MEERESHÖHE

VERGASERREGULIERUNG
CARBURETOR SETTING

9-15C
21.06.99

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

2300 m
7500 ft

1500 m
5000 ft

750 m
2500 ft

300 m
1000 ft

LSCHR
LD
POS
HD

=
=
=
=

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

Luftregulierschraube offen
Leerlaufdüse
Clip Position von oben
Hauptdüse

Meeresniveau
Sea level

301 m
1001 ft

751 m
2501 ft

1501 m
5001 ft

2301 m
7501 ft

LSCHR
LD
NADEL
POS
HD

Art No 3206004 -E

5.

3.

1.

1
50
NOZE
5
188

1 1/4
45
NOZF
4
185

1 1/4
45
NOZG
4
182

1 1/4
42
NOZG
3
180

1 3/4
40
NOZH
3
178

4.

2.

-2°F to 20°F

-20°C bis -7°C

AS
IJ
POS
MJ

=
=
=
=

1 1/2
45
NOZG
3
182

1 1/4
45
NOZG
3
180

1 1/2
42
NOZG
3
178

1 3/4
40
NOZH
2
175

1 3/4
40
NOZH
2
172

42°F to 60°F

6°C bis 15°C

1 1/2
42
NOZH
3
178

1 3/4
42
NOZH
3
175

1 3/4
42
NOZI
2
172

2
40
NOZI
2
170

2 1/2
38
NOZI
2
170

79°F to 98°F

25°C bis 38°C

1 3/4
42
NOZH
2
175

1 3/4
42
NOZH
2
172

2
40
NOZI
2
170

2
40
NOZI
2
168

1 3/4
38
NOZI
2
168

99°F to 120°F

37°C bis 49°C

NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 95

1 1/4
45
NOZG
3
180

1 1/2
42
NOZG
3
178

1 3/4
42
NOZH
2
175

1 3/4
40
NOZH
2
172

2
38
NOZI
2
170

61°F to 78°F

16°C bis 24°C

Air screw open from fully-seated
Idling jet
Clip position from top
Main jet

1 1/4
48
NOZF
4
185

1 1/4
45
NOZG
4
182

1 1/2
45
NOZG
3
180

1 1/2
42
NOZG
3
178

1 3/4
40
NOZH
3
175

19°F to 41°F

-6°C bis 5°C

KTM 250 MXC/EXC EUR/USA 2000 KEIHIN PWK 38 AG

TEMPERATUR

3000 m
10000 ft

ALTIDUDE

MEERESHÖHE

VERGASERREGULIERUNG
CARBURETOR SETTING

Repair manual KTM 250 / 300 / 380

9-16C

21.06.99

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

2300 m
7500 ft

1500 m
5000 ft

750 m
2500 ft

300 m
1000 ft

LSCHR
LD
POS
HD

=
=
=
=

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

Luftregulierschraube offen
Leerlaufdüse
Clip Position von oben
Hauptdüse

Meeresniveau
Sea level

301 m
1001 ft

751 m
2501 ft

1501 m
5001 ft

2301 m
7501 ft

LSCHR
LD
NADEL
POS
HD

5.

3.

1.

1/2
50
NOZF
4
182

3/4
50
NOZG
3
180

1
48
NOZG
3
178

1 1/4
48
NOZG
3
175

1 1/2
45
NOZH
3
172

4.

2.

-2°F to 20°F

-20°C bis -7°C

AS
IJ
POS
MJ

=
=
=
=

1
45
NOZG
3
178

1 1/4
45
NOZH
2
175

1 1/2
45
NOZH
2
172

1 3/4
42
NOZH
1
170

2
40
NOZH
1
168

42°F to 60°F

6°C bis 15°C

1 1/2
42
NOZH
1
172

1 3/4
45
NOZI
2
170

2
45
NOZH
2
168

2 1/4
42
NOZI
1
165

2 1/2
40
NOZI
1
162

79°F to 98°F

25°C bis 38°C

1 3/4
42
NOZI
1
170

2
42
NOZI
2
168

2 1/4
42
NOZI
2
165

2 1/2
40
NOZI
1
162

2 3/4
38
NOZI
1
162

99°F to 120°F

37°C bis 49°C

NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 95

1 1/4
45
NOZH
2
175

1 1/2
45
NOZH
2
172

1 3/4
45
NOZH
22
170

2
42
NOZI
1
168

2 1/4
40
NOZI
1
165

61°F to 78°F

16°C bis 24°C

Air screw open from fully-seated
Idling jet
Clip position from top
Main jet

3/4
48
NOZG
3
180

1
48
NOZG
2
178

1 1/4
45
NOZG
3
175

1 1/2
45
NOZH
2
172

1 3/4
42
NOZH
2
170

19°F to 41°F

-6°C bis 5°C

KTM 300 MXC/EXC EUR/USA 2000 KEIHIN PWK 38 AG

TEMPERATUR

3000 m
10000 ft

ALTIDUDE

MEERESHÖHE

VERGASERREGULIERUNG
CARBURETOR SETTING

9-17C
21.06.99

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

2300 m
7500 ft

1500 m
5000 ft

750 m
2500 ft

300 m
1000 ft

LSCHR
LD
POS
HD

=
=
=
=

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

Luftregulierschraube offen
Leerlaufdüse
Clip Position von oben
Hauptdüse

Meeresniveau
Sea level

301 m
1001 ft

751 m
2501 ft

1501 m
5001 ft

2301 m
7501 ft

LSCHR
LD
NADEL
POS
HD

Art No 3206004 -E

5.

3.

1.

1/2
50
NOZF
4
182

3/4
50
NOZG
3
180

1
48
NOZG
3
178

1 1/4
48
NOZG
3
175

1 1/2
45
NOZH
3
172

4.

2.

-2°F to 20°F

-20°C bis -7°C

AS
IJ
POS
MJ

=
=
=
=

1
45
NOZG
3
178

1 1/4
45
NOZH
2
175

1 1/2
45
NOZH
2
172

1 3/4
42
NOZH
1
170

2
40
NOZH
1
168

42°F to 60°F

6°C bis 15°C

1 1/2
42
NOZH
1
172

1 3/4
45
NOZI
2
170

2
45
NOZH
2
168

2 1/4
42
NOZI
1
165

2 1/2
40
NOZI
1
162

79°F to 98°F

25°C bis 38°C

1 3/4
42
NOZI
1
170

2
42
NOZI
2
168

2 1/4
42
NOZI
2
165

2 1/2
40
NOZI
1
162

2 3/4
38
NOZI
1
162

99°F to 120°F

37°C bis 49°C

NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 95

1 1/4
45
NOZH
2
175

1 1/2
45
NOZH
2
172

1 3/4
45
NOZH
22
170

2
42
NOZI
1
168

2 1/4
40
NOZI
1
165

61°F to 78°F

16°C bis 24°C

Air screw open from fully-seated
Idling jet
Clip position from top
Main jet

3/4
48
NOZG
3
180

1
48
NOZG
2
178

1 1/4
45
NOZG
3
175

1 1/2
45
NOZH
2
172

1 3/4
45
NOZH
2
170

19°F to 41°F

-6°C bis 5°C

KTM 380 SX / MXC / EXC EUR / USA 2000 KEIHIN PWK 38 AG

TEMPERATUR

3000 m
10000 ft

ALTIDUDE

MEERESHÖHE

VERGASERREGULIERUNG
CARBURETOR SETTING

Repair manual KTM 250 / 300 / 380

9-18C

21.06.99

Available chain sprockets
Coolant
Ignition system
Generator output
Carburetor
Air-filter

Gear ratio
1st Gear
2nd Gear
3rd Gear
4th Gear
5th Gear
Gear lubrication

TVC start open
TVC fully open
Primary drive
Clutch
Transmission

Engine
Design
Piston displacement
Bore / stroke
Fuel
Oil / gasolin ratio
Crankshaft bearing
Connecting rod bearing
Piston pin bearing
Piston
Piston ring
edge piston Dimension "X" (upper
upper edge cylinder)
Ignition timing
Spark plug
Electrode gap
of the
Dimension "Z" (height
control flap)

Art No 3206004 -E

KOKUSAN 2K-4
no generator

15:29
17:27
19:25
21:23
23:21

EXC
15:29
18:26
19:22
21:20
23:18

MXC
EXC
MXC
15:29
15:29
15:29
15:29
17:27
18:26
18:26
18:26
19:25
19:22
19:24
19:24
21:23
21:20
21:23
21:23
23:21
23:18
23:21
23:21
SX 0.8 l engine oil 20W-40 (Shell Advance VSX4)
MXC/EXC 0,8 l gear oil 80W (Shell Gear EP 80)
13t / 14t / 15t for chain 5/8 x 1/4"
1.3 litres, 40% anti freeze, 60% water, at least -25 °C (-13 °F)
KOKUSAN 2K-2
KOKUSAN 2K-3
12V 40W
no generator
flat-slide carburetor, carburetor setting see table
wet foam type air filter insert

MXC
15:29
18:26
19:24
21:23
23:21

KOKUSAN 2K-3
12V 110W

EXC
15:29
18:26
19:22
21:20
23:18

5000/min
5900/min
5200/min
7000/min
7750/min
7200/min
straight cut spur gears, primary ratio 25:72
straight cut spur gears, primary ratio 26:72
multiple disc clutch in oil bath, hydraulic operated (Shell HF-E15)
5 speed, claw actuated

250 EXC, MXC
300 EXC, MXC
380 SX
380 EXC, MXC
Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber
249 ccm
297 ccm
368 ccm
66.4 / 72 mm (2.62 / 2.84 in)
72 / 73 mm (2.84 / 2.88 in)
78 / 77 mm (3 / 2.98 in)
unleaded SUPER fuel, research octane no 95, mixed with high-grade two stroke oil (Shell Advance Racing X)
1:40 – 1:60 when using high grade two stroke oil. When in doupt, please contact your importer or use 1:40 mix ratio to be on the safe side
1 deep-groove ball bearing / 1 cylinder roller bearing
needle bearing
needle bearing
cast piston
forged piston
cast piston
one plain compression rings
two plain compression rings
0 +0.1 mm (0 + 0.004 in)
1,9 mm (0,07 in) BTDC
2.4 mm (0.095 in) BTDC
2.43 mm (0.096 in) BTDC
2.6 mm (0.1 in) BTDC
NGK BR 8 ECM
0.6 mm (0.024 in)
49,5 mm (1.95 in)
46 mm (1.7 in)
50.5 mm (1.99 in)

250 SX

TECHNICAL DATA - ENGINE 250/300/380 SX / MXC / EXC 2001 (only USA)

Repair manual KTM 250 / 300 / 380

9-19C

9-20C
TIGHTENING TORQUES - ENGINE
Flange bolts - cylinder-head
Nuts-cylinder base
Flywheel collar nut
Nut for primary sprocket (LH thread)
Nut for inner clutch hub
Crankcase and cover bolts
Swingarm pivot
Flat head bolt release plate kickstarter
Other bolts

M8
M 10
M 12x1
M 18x1.5
M 18x1.5
M6
M 14
M 6x16
M6
M8
M 10

35
35
60
Loctite 243 150
Loctite 243 100
8
100
Loctite 648 19
10
25
45

Nm (25 ft.lb)
Nm (25 ft.lb)
Nm (44 ft.lb)
Nm (110 ft.lb)
Nm (74 ft.lb)
Nm
(6 ft.lb)
Nm (74 ft.lb)
Nm (14 ft.lb)
Nm
(7 ft.lb)
Nm (19 ft.lb)
Nm (33 ft.lb)

TOLERANCES AND FITTING CLEARANCES
Piston fitting clearance
Piston ring end gap
Connecting rod bearing - radial clearance
Transmission shafts end float
Clutch springs - length

0.06 mm (250) 0.06 mm (300) 0.08 mm (380)
0.3 – 0.4 mm
0.021 – 0.032 mm
0.1 – 0.2 mm
Ø 2.5 new = 43 mm, minimum length = 42 mm

GASKET THICKNESSES
Crankcase

0.5 mm

Clutch cover

0.5 mm

Cylinder bottom gasket

as required

Available cylinder bottom gaskets

0.2/0.4/ 0.5 / 0.75 mm

Cylinder-head gasket

O-rings

BASIC CARBURETOR SETTING

Carburetor
Carburetor setting number
Main jet
Idling jet
Starting jet
Jet needle
Needle position from top
Slide
Air adjustment screw open
Performance restrictor
Power jet jet

250 SX

250 MXC, EXC

300 MXC, EXC

380 SX, MXC, EXC

Keihin PWK 38 AG PJ
010300
172 (170,175)
48 (45,50)
85
NOZ E (NOZ F)
III
7
1,5
–
55

Keihin PWK 38 AG
030300
178 (175,180)
45 (48)
85
NOZ G (NOZ H)
IV
6,5
1,5
–
–

Keihin PWK 38 AG
050300
175 (172,178)
45 (48)
85
NOZ H (NOZ I)
III
6,5
1,5
–
–

Keihin PWK 38 AG
070300
170 (168,172)
45 (48)
85
NOZ G (NOZ I/NOZ H)
III
6,5
1,5
–
–

Gear ratio
1st Gear
2nd Gear
3rd Gear
4th Gear
5th Gear
Gear lubrication
ailable chain sprockets
Coolant
Ignition system
Generator output
Carburetor
Air-filter

TVC start open
TVC fully open
Primary drive
Clutch
Transmission

Engine
Design
Piston displacement
Bore / stroke
Fuel
Oil / gasoline ratio
Crankshaft bearing
Connecting rod bearing
Piston pin bearing
Piston
Piston ring
edge piston Dimension "X" (upper
upper edge cylinder)
Ignition timing
Spark plug
Electrode gap
of the
Dimension "Z" (height
control flap)

Art No 3206004 -E

KOKUSAN 2K-4
no generator

15:29
17:27
19.25
21:23
23:21
0,8 l engine oil 20W-40 (Shell Advance VSX4)

15:29
15:29
18:26
18:26
19:22
19:24
21:20
21:23
23:18
23:21
0,8 l gear oil 80W (Shell Gear EP 80)
0,8 l engine oil 20W-40 (Shell Advance VSX4)
13t / 14t / 15t for chain 5/8 x 1/4"
1.3 litres, 40% anti freeze, 60% water, at least -25 °C (-13 °F)
KOKUSAN 2K-3
KOKUSAN 2K-3
12V 110W
no generator
flat-slide carburetor, carburetor setting see table
wet foam type air filter insert

KOKUSAN 2K-3
12V 110W

15:29
18:26
19:22
21:20
23:18
0,8 l gear oil 80W (Shell Gear EP 80)

5000/min
5900/min
5200/min
7000/min
7750/min
7200/min
straight cut spur gears, primary ratio 25:72
straight cut spur gears, primary ratio 26:72
multiple disc clutch in oil bath, hydraulic operated (Shell HF-E15)
5 speed, claw actuated

250 EXC
300 EXC
380 SX
380 EXC
Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber
249 ccm
297 ccm
368 ccm
66.4 / 72 mm (2.62 / 2.84 in)
72 / 73 mm (2.84 / 2.88 in)
78 / 77 mm (3 / 2.98 in)
unleaded SUPER fuel, research octane no 95, mixed with high-grade two stroke oil (Shell Advance Racing X)
1:40 – 1:60 when using high grade two stroke oil. When in doupt, please contact your importer or use 1:40 mix ratio to be on the safe side
1 deep-groove ball bearing / 1 cylinder roller bearing
needle bearing
needle bearing
cast piston
forged piston
cast piston
one plain compression ring
two plain compression rings
0 + 0.1 mm (0 + 0.004 in)
1,9 mm (0,07 in) BTDC
2.4 mm (0.095 in) BTDC
2.43 mm (0.096 in) BTDC
2.6 mm (0.1 in) 17 °) BTDC
NGK BR 8 ECM
0.6 mm (0.024 in)
49,5 mm (1.94 in)
46 mm (1.7 in)
50.5 mm (1.99 in)

250 SX

TECHNICAL DATA - ENGINE 250/300/380 SX / EXC 2001 (all models out of USA)

Repair manual KTM 250 / 300 / 380

9-21C

9-22C
TIGHTENING TORQUES
Flange bolts - cylinder-head
Nuts-cylinder base
Flywheel collar nut
Nut for primary sprocket (LH thread)
Nut for inner clutch hub
Crankcase and cover bolts
Swingarm pivot
Flat head bolt release plate kickstarter
Other bolts

M8
M 10
M 12x1
M 18x1.5
M 18x1.5
M6
M 14
M 6x16
M6
M8
M 10

35
35
60
Loctite 243 150
Loctite 243 100
8
100
Loctite 648 19
10
25
45

Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm

(25
(25
(44
(110
(74
(6
(74
(14
(7
(19
(33

ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)

TOLERANCES AND FITTING CLEARANCES
Piston fitting clearance

0.06 mm (250)

Piston ring end gap

0.3 – 0.4 mm

Connecting rod bearing - radial clearance

0.021 – 0.032 mm

Transmission shafts end float

0.1 – 0.2 mm

Clutch springs - length

Ø 2.5

0.06 mm (300)

0.08 mm (380)

new = 43 mm, minimum length = 42 mm

GASKET THICKNESSES
Crankcase

0.5 mm

Clutch cover

0.5 mm

Cylinder bottom gasket

as required

Available cylinder bottom gaskets

0.2/0.4/ 0.5 / 0.75 mm

Cylinder-head gasket

O-rings

BASIC CARBURETOR SETTING

Carburetor
Carburetor setting number
Main jet
Idling jet
Starting jet
Jet needle
Needle position from top
Slide
Air adjustment screw open
Performance restrictor
Power jet jet

250 EXC AUS
throttled

300 EXC AUS
throttled

380 EXC
throttled

Keihin PWK 38 AG
040300
178 (175,180)
45 (48)
85
NOZ G (NOZ H)
IV
6,5
1,5
slide stop 34mm
–

Keihin PWK 38 AG
060300
175 (172,178)
45 (48)
85
NOZ H (NOZ I)
III
6,5
1,5
slide stop 34mm
–

Keihin PWK 38 AG
080300
170 (168,172)
45 (48)
85
NOZ G (NOZ I/NOZ H)
III
6,5
1,5
slide stop 36mm
–

380 SX

250/300 EXC
throttled

BASIC CARBURETOR SETTING
250 SX

Carburetor
Carburetor setting number
Main jet
Idling jet
Starting jet
Jet needle
Needle position from top
Throttle valve
Air adjustment screw open
Performance restrictor
Power jet jet

Keihin PWK 38 AG PJ
Keihin PWK 38 AG
010300
070300
172 (170,175)
170 (168,172)
48 (45,50)
45 (48)
85
85
NOZ E (NOZ F)
NOZ G (NOZ I/NOZ H)
III
III
7
6,5
1,5
1,5
–
–
55
–

Keihin PWK 38 AG
020300
175 (172,178,180)
35
85
R 1475 J
III
6,5
1,5
slide stop 34mm
–

9-23C

TECHNICAL SPECIFICATIONS CHASSIS
250/380 SX

250/300/380 MXC

Frame
Fork

White Power – Up Side Down 43 MA
295/320 mm (11,3/12,6 in)

Rear suspension

WP Progressive Damping System shock absorber, aluminium swingarm

Front brake

Disc brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated

Rear brake

Disc brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated

Brake discs
Front tires
Front tires USA
Air pressure offroad
Air pressure road driver only
Rear tires
Rear tires USA
Air pressure offroad
Air pressure road driver only
Fuel tank capacity

7,5 liter (2 US Gallons)

Wear limit max. 0,4 mm (0,016 in)
–
80/100 - 21“51M
1,0 bar (14psi)
1,5 bar (21psi)
–
100/100 - 18“ 64M
1,0 bar (14psi)
2,0 bar (28psi)
11 liter (2,9 US Gallons)

90/90 - 21“ 54R
80/100 - 21“51M
1,0 bar (14psi)
1,5 bar (21psi)
140/80 - 18“ 70R
100/100 - 18“ 64M
1,0 bar (14psi)
2,0 bar (28psi)
8,5/11 liter (2,2/2,9 US Gallons)

14:50t
14:50t

–
14:52t

15:48t / 14:50t
14:52t

80/100 - 21“51M
80/100 - 21“51M
1,0 bar (14psi)
–
100/90 - 19“ 62M
100/90 - 19“ 62M
1,0 bar (14psi)
–

Final drive ratio
Final drive ratio USA
Chain

5/8 x 1/4 "

Available final sprockets

38t, 40t, 42t, 45t, 48t, 50t, 52t

Steering head angle

63,5°

Wheel base

Art No 3206004 -E

250/300/380 EXC

Central chrome-moly-steel frame

Wheel travel front/rear

1481 ± 10 mm (58,3 ± 0,4 in)

Seat height, unloaded

925 mm (36,5 in)

Ground clearance, unloaded

385 mm (15,2 in)

Dead-weight *
Dead-weight USA *

101 kg (223 lbs)
101 kg (223 lbs)

–
102,5 kg (226,3 lbs)

109 kg (240,6 lbs)
103,7 kg (229 lbs)

* Dead-weight without fuel

TIGHENING

STANDARD ADJUSTMENT-FORK
Compression adjuster
Rebound adjuster
Spring

WP 0518V703

WP 0518V704

14

14

12

12

4,0 N/mm

4,0 N/mm

TORQUES

Collar nut front wheel spindle

-

CHASSIS

M 16x1,5

40 Nm (30 ft.lb)

Brake caliper front

M8

25 Nm (19 ft.lb)

Clamping screws upper fork bridge

M8

20 Nm (15 ft.lb)

+ Loctite 243

Spring preload

5 mm (0.20in)

5 mm (0.20in)

Clamping bolts lower fork bridge

M8

15 Nm (11 ft.lb)

Air chamber length

130 mm (5.1in)

150 mm (5.9in)

Clamping bolts fork stubs

M8

10 Nm

SAE 5

SAE 5

Fork oil
Repair manual KTM 250 / 300 / 380

250/300/380 SX, MXC, EXC 2001

STANDARD ADJUSTMENT - SHOCK ABSORBER
WP 1218V730

WP 1218V731

Compression adjuster

5

5

Rebound adjuster

25

25

PDS7–265

PDS2-250

5 mm (0.2 in)

6 mm (0.24 in)

Spring
Spring preload

(7 ft.lb)

Collar nut rear wheel spindle

M 20x1.5

80 Nm (59 ft.lb)

Hexagon nut swing arm bolt

M 14x1.5

100 Nm (74 ft.lb)

Collar bolt handlebar clamp

M8

20 Nm (15 ft.lb)

Allen head bolt handlebar support

M 10

40 Nm (30 ft.lb)

Shock absorber top

M 12

60 Nm (44 ft.lb)

Shock absorber bottom

M 12

60 Nm (44 ft.lb)

Screw adjusting ring spring preload

M6

Other bolts on chassis

M6
M8
M 10

+ Loctite 243

8 Nm

(6 ft.lb)

10 Nm (7 ft.lb)
25 Nm (19 ft.lb)
45 Nm (33 ft.lb)

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

2300 m
7500 ft

1500 m
5000 ft

750 m
2500 ft

300 m
1000 ft

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

LSCHR = Luftregulierschraube offen
LD
= Leerlaufdüse
POS
= Clip Position von oben
HD
= Hauptdüse
Schieber= 7
Zerstäuber= 6 mm

Meeresniveau
Sea level

301 m
1001 ft

751 m
2501 ft

1501 m
5001 ft

2301 m
7501 ft

LSCHR
LD
NADEL
POS
HD

5.

3.

1.

1/2
52
NOZC
5
180

3/4
52
NOZC
4
178

1
50
NOZD
4
175

1 1/4
50
NOZD
3
172

1 1/2
48
NOZD
3
170

4.

2.

-2°F to 20°F

-20°C bis -7°C

1
48
NOZD
3
175

1 1/4
48
NOZE
3
172

1 1/2
48
NOZE
3
170

1 3/4
45
NOZE
2
168

2
45
NOZE
2
165

42°F to 60°F

6°C bis 15°C

1 1/2
48
NOZE
3
170

1 3/4
48
NOZE
3
168

2
48
NOZF
2
165

2 1/4
45
NOZF
2
162

2 1/2
42
NOZG
1
160

79°F to 98°F

25°C bis 38°C

1 3/4
45
NOZE
2
168

2
45
NOZF
2
165

2 1/4
45
NOZF
2
162

2 1/2
42
NOZG
2
160

2 3/4
40
NOZH
1
160

99°F to 120°F

37°C bis 49°C

NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 95

1 1/4
48
NOZD
3
172

1 1/2
48
NOZE
3
170

1 3/4
48
NOZE
2
168

2
45
NOZE
2
165

2 1/4
42
NOZF
2
162

61°F to 78°F

16°C bis 24°C

AS = Air screw open from fully-seated
IJ
= Idling jet
POS = Clip position from top
MJ = Main jet
Slide = 7
Atomizer= 6 mm

3/4
50
NOZC
4
178

1
50
NOZD
4
175

1 1/4
48
NOZD
3
172

1 1/2
48
NOZD
3
170

1 3/4
45
NOZE
3
168

19°F to 41°F

-6°C bis 5°C

KTM 250 SX EUR/USA 2001 KEIHIN PWK 38AG PJ

TEMPERATUR

3000 m
10000 ft

ALTIDUDE

MEERESHÖHE

VERGASERREGULIERUNG
CARBURETOR SETTING

9-24C

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

2300 m
7500 ft

1500 m
5000 ft

750 m
2500 ft

300 m
1000 ft

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

LSCHR = Luftregulierschraube offen
LD
= Leerlaufdüse
POS
= Clip Position von oben
HD
= Hauptdüse
Schieber= 6,5
Zerstäuber= 6 mm

Meeresniveau
Sea level

301 m
1001 ft

751 m
2501 ft

1501 m
5001 ft

2301 m
7501 ft

LSCHR
LD
NADEL
POS
HD

Art No 3206004 -E

5.

3.

1.

1
52
NOZE
5
188

1 1/4
48
NOZF
5
185

1 1/4
48
NOZG
4
182

1 1/4
45
NOZG
3
180

1 3/4
42
NOZH
3
178

4.

2.

-2°F to 20°F

-20°C bis -7°C

1 1/2
48
NOZG
4
182

1 1/4
48
NOZG
4
180

1 1/2
45
NOZG
3
178

1 3/4
42
NOZH
2
175

1 3/4
42
NOZH
2
172

42°F to 60°F

6°C bis 15°C

1 1/2
45
NOZH
3
178

1 3/4
45
NOZH
3
175

1 3/4
45
NOZI
2
172

2
42
NOZI
2
170

2 1/2
40
NOZI
2
170

79°F to 98°F

25°C bis 38°C

1 3/4
45
NOZH
2
175

1 3/4
45
NOZH
2
172

2
42
NOZI
2
170

2
42
NOZI
2
168

1 3/4
40
NOZI
1
168

99°F to 120°F

37°C bis 49°C

NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 95

1 1/4
48
NOZG
3
180

1 1/2
45
NOZG
3
178

1 3/4
45
NOZH
3
175

1 3/4
42
NOZH
2
172

2
40
NOZI
2
170

61°F to 78°F

16°C bis 24°C

AS = Air screw open from fully-seated
IJ
= Idling jet
POS = Clip position from top
MJ = Main jet
Slide = 6,5
Atomizer= 6 mm

1 1/4
50
NOZF
5
185

1 1/4
48
NOZF
4
182

1 1/2
48
NOZG
3
180

1 1/2
45
NOZG
3
178

1 3/4
42
NOZH
3
175

19°F to 41°F

-6°C bis 5°C

KTM 250 MXC/EXC EUR/USA 2001 KEIHIN PWK 38 AG

TEMPERATUR

3000 m
10000 ft

ALTIDUDE

MEERESHÖHE

VERGASERREGULIERUNG
CARBURETOR SETTING

Repair manual KTM 250 / 300 / 380

9-25C

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

2300 m
7500 ft

1500 m
5000 ft

750 m
2500 ft

300 m
1000 ft

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

LSCHR = Luftregulierschraube offen
LD
= Leerlaufdüse
POS
= Clip Position von oben
HD
= Hauptdüse
Schieber= 6,5
Zerstäuber= 6 mm

Meeresniveau
Sea level

301 m
1001 ft

751 m
2501 ft

1501 m
5001 ft

2301 m
7501 ft

LSCHR
LD
NADEL
POS
HD

5.

3.

1.

1/2
50
NOZF
5
185

3/4
50
NOZG
5
182

1
48
NOZG
4
180

1 1/4
48
NOZG
3
178

1 1/2
45
NOZH
3
175

4.

2.

-2°F to 20°F

-20°C bis -7°C

1
45
NOZG
4
180

1 1/4
45
NOZH
4
178

1 1/2
45
NOZH
3
175

1 3/4
42
NOZH
2
172

2
40
NOZH
2
170

42°F to 60°F

6°C bis 15°C

1 1/2
42
NOZH
3
170

1 3/4
45
NOZI
3
172

2
45
NOZH
2
170

2 1/4
42
NOZI
2
168

2 1/2
40
NOZI
2
165

79°F to 98°F

25°C bis 38°C

1 3/4
42
NOZI
2
168

2
42
NOZI
2
170

2 1/4
42
NOZI
2
168

2 1/2
40
NOZI
2
165

2 3/4
38
NOZI
1
162

99°F to 120°F

37°C bis 49°C

NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 95

1 1/4
45
NOZH
3
172

1 1/2
45
NOZH
3
175

1 3/4
45
NOZH
3
172

2
42
NOZI
2
170

2 1/4
40
NOZI
2
168

61°F to 78°F

16°C bis 24°C

AS = Air screw open from fully-seated
IJ
= Idling jet
POS = Clip position from top
MJ = Main jet
Slide = 6,5
Atomizer= 6 mm

3/4
48
NOZG
5
182

1
48
NOZG
4
180

1 1/4
45
NOZG
3
178

1 1/2
45
NOZH
3
175

1 3/4
42
NOZH
3
172

19°F to 41°F

-6°C bis 5°C

KTM 300 MXC/EXC EUR/USA 2001 KEIHIN PWK 38 AG

TEMPERATUR

3000 m
10000 ft

ALTIDUDE

MEERESHÖHE

VERGASERREGULIERUNG
CARBURETOR SETTING

9-26C

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

2300 m
7500 ft

1500 m
5000 ft

750 m
2500 ft

300 m
1000 ft

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

LSCHR = Luftregulierschraube offen
LD
= Leerlaufdüse
POS
= Clip Position von oben
HD
= Hauptdüse
Schieber= 6,5
Zerstäuber= 6 mm

Meeresniveau
Sea level

301 m
1001 ft

751 m
2501 ft

1501 m
5001 ft

2301 m
7501 ft

LSCHR
LD
NADEL
POS
HD

Art No 3206004 -E

5.

3.

1.

1/2
50
NOZE
5
180

3/4
50
NOZF
5
178

1
48
NOZG
4
175

1 1/4
48
NOZG
3
172

1 1/2
45
NOZH
3
170

4.

2.

-2°F to 20°F

-20°C bis -7°C

1
45
NOZG
4
175

1 1/4
45
NOZG
4
172

1 1/2
45
NOZG
3
170

1 3/4
42
NOZH
2
168

2
40
NOZH
2
165

42°F to 60°F

6°C bis 15°C

1 1/2
42
NOZH
3
170

1 3/4
45
NOZH
2
168

2
45
NOZI
2
165

2 1/4
42
NOZI
2
162

2 1/2
40
NOZI
2
160

79°F to 98°F

25°C bis 38°C

1 3/4
42
NOZH
2
168

2
42
NOZH
2
165

2 1/4
42
NOZI
2
162

2 1/2
40
NOZI
2
160

2 3/4
38
NOZI
1
158

99°F to 120°F

37°C bis 49°C

NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 95

1 1/4
45
NOZG
3
172

1 1/2
45
NOZG
3
170

1 3/4
45
NOZH
3
168

2
42
NOZH
2
165

2 1/4
40
NOZI
2
162

61°F to 78°F

16°C bis 24°C

AS = Air screw open from fully-seated
IJ
= Idling jet
POS = Clip position from top
MJ = Main jet
Slide = 6,5
Atomizer= 6 mm

3/4
48
NOZF
5
178

1
48
NOZF
4
175

1 1/4
45
NOZG
3
172

1 1/2
45
NOZG
3
170

1 3/4
45
NOZH
3
168

19°F to 41°F

-6°C bis 5°C

KTM 380 SX / MXC / EXC EUR / USA 2001 KEIHIN PWK 38 AG

TEMPERATUR

3000 m
10000 ft

ALTIDUDE

MEERESHÖHE

VERGASERREGULIERUNG
CARBURETOR SETTING

Repair manual KTM 250 / 300 / 380

9-27C

Available chain sprockets
Coolant
Ignition system
Generator output
Carburetor
Air-filter

Gear ratio
1st Gear
2nd Gear
3rd Gear
4th Gear
5th Gear
Gear lubrication

TVC start open
TVC fully open
Primary drive
Clutch
Transmission

Engine
Design
Piston displacement
Bore / stroke
Fuel
Oil / gasolin ratio
Crankshaft bearing
Connecting rod bearing
Piston pin bearing
Piston
Piston ring
edge piston Dimension "X" (upper
upper edge cylinder)
Ignition timing
Spark plug
Electrode gap
of the
Dimension "Z" (height
control flap)

KOKUSAN 2K-1
no generator

15:29
17:27
19:25
21:23
23:21

EXC
15:29
18:26
19:22
21:20
23:18

MXC
EXC
MXC
15:29
15:29
15:29
15:29
17:27
18:26
18:26
18:26
19:25
19:22
19:24
19:24
21:23
21:20
21:23
21:23
23:21
23:18
23:21
23:21
SX 0.8 l engine oil 20W-40 (Shell Advance VSX4)
MXC/EXC 0,8 l engine oil 10W-40 (Shell Advance Ultra 4)
13t / 14t / 15t for chain 5/8 x 1/4"
1.3 litres, 40% anti freeze, 60% water, at least -25 °C (-13 °F)
KOKUSAN 2K-2
KOKUSAN 2K-3
12V 40W
no generator
flat-slide carburetor, carburetor setting see table
wet foam type air filter insert

MXC
15:29
18:26
19:24
21:23
23:21

KOKUSAN 2K-3
12V 110W

EXC
15:29
18:26
19:22
21:20
23:18

5000/min
5900/min
5200/min
7000/min
7750/min
7200/min
straight cut spur gears, primary ratio 25:72
straight cut spur gears, primary ratio 26:72
multiple disc clutch in oil bath, hydraulic operated (Shell HF-E15)
5 speed, claw actuated

250 MXC/EXC
300 MXC/EXC
380 SX
380 MXC/EXC
Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber
249 ccm
297 ccm
368 ccm
66.4 / 72 mm (2.62 / 2.84 in)
72 / 73 mm (2.84 / 2.88 in)
78 / 77 mm (3 / 2.98 in)
unleaded SUPER fuel, research octane no 95, mixed with high-grade two stroke oil (Shell Advance Racing X)
1:40 – 1:60 when using high grade two stroke oil. When in doupt, please contact your importer or use 1:40 mix ratio to be on the safe side
1 deep-groove ball bearing / 1 cylinder roller bearing
needle bearing
needle bearing
cast piston
forged piston
cast piston
one plain compression rings
two plain compression rings
0 +0.1 mm (0 + 0.004 in)
1,9 mm (0,07 in) BTDC
1,94 mm (0,08 in) BTDC
2.1 mm (0,09 in) BTDC
NGK BR 8 ECM
0.6 mm (0.024 in)
49,5 mm (1.95 in)
46 mm (1.7 in)
50.5 mm (1.99 in)

250 SX

TECHNICAL DATA - ENGINE 250/300/380 SX / MXC / EXC 2002 (only USA)

9-28C

9-29C
TIGHTENING TORQUES - ENGINE
Flange bolts - cylinder-head

M8

35 Nm (25 ft.lb)

Nuts-cylinder base

M 10

35 Nm (25 ft.lb)

Flywheel collar nut

M 12x1

Nut for primary sprocket (LH thread)

M 18x1.5

Loctite 243 150 Nm (110 ft.lb)

Nut for inner clutch hub

M 18x1.5

Loctite 243 100 Nm (74 ft.lb)

Crankcase and cover bolts

M6

Swingarm pivot

M 14

Flat head bolt release plate kickstarter

M 6x16

Other bolts

M6
M8
M 10

60 Nm (44 ft.lb)

8 Nm

(6 ft.lb)

100 Nm (74 ft.lb)
Loctite 648 19 Nm (14 ft.lb)
10 Nm (7 ft.lb)
25 Nm (19 ft.lb)
45 Nm (33 ft.lb)

Repair manual KTM 250 / 300 / 380

Art No 3206004 -E

TOLERANCES AND FITTING CLEARANCES
Piston fitting clearance

0.06 mm (250)

Piston ring end gap

0.3 – 0.4 mm

Connecting rod bearing - radial clearance

0.021 – 0.032 mm

Transmission shafts end float

0.1 – 0.2 mm

Clutch springs - length

Ø 2.5

0.06 mm (300)

0.08 mm (380)

new = 43 mm, minimum length = 42 mm

GASKET THICKNESSES
Crankcase

0.5 mm

Clutch cover

0.5 mm

Cylinder bottom gasket

as required

Available cylinder bottom gaskets

0.2/0.4/ 0.5 / 0.75 mm

Cylinder-head gasket

O-rings

BASIC CARBURETOR SETTING

Carburetor
Carburetor setting number
Main jet
Idling jet
Starting jet
Jet needle
Needle position from top
Slide
Air adjustment screw open
Performance restrictor
Power jet jet

250 SX

250 MXC, EXC

300 MXC, EXC

380 SX, MXC, EXC

Keihin PWK 38 AG
061200
170 (168,172)
48 (45,50)
85
NOZ E (NOZ F/D)
III
6,5
1,5
–
–

Keihin PWK 38 AG
030201
178 (175,180)
45 (48)
85
NOZ E (NOZ F)
IV
6,5
1,5
–
–

Keihin PWK 38 AG
040201
175 (172,178)
45 (48)
85
NOZ H (NOZ I)
III
6,5
1,5
–
–

Keihin PWK 38 AG
050201
170 (168,172)
45 (48)
85
NOZ G (NOZ H)
III
6,5
1,5
–
–

KOKUSAN 2K-1
no generator

15:29
17:27
19.25
21:23
23:21
0,8 l engine oil 20W-40 (Shell Advance VSX4)

15:29
18:26
19:24
21:23
23:21
0,8 l engine oil 20W-40 (Shell Advance VSX4)

13t / 14t / 15t for chain 5/8 x 1/4"
1.3 litres, 40% anti freeze, 60% water, at least -25 °C (-13 °F)
KOKUSAN 2K-3
KOKUSAN 2K-3
12V 110W
no generator
flat-slide carburetor, carburetor setting see table
wet foam type air filter insert

15:29
18:26
19:22
21:20
23:18
0,8 l engine oil 10W-40 (Shell Advance Ultra 4)

KOKUSAN 2K-3
12V 110W

15:29
18:26
19:22
21:20
23:18
0,8 l engine oil 10W-40 (Advance Ultra

5000/min
5900/min
5200/min
7000/min
7750/min
7200/min
straight cut spur gears, primary ratio 25:72
straight cut spur gears, primary ratio 26:72
multiple disc clutch in oil bath, hydraulic operated (Shell HF-E15)
5 speed, claw actuated

TVC start open (height of the
TVC fully open control flap)
Primary drive
Clutch
Transmission

Gear ratio
1st Gear
2nd Gear
3rd Gear
4th Gear
5th Gear
Gear lubrication
4)
ailable chain sprockets
Coolant
Ignition system
Generator output
Carburetor
Air-filter

250 EXC
300 EXC
380 SX
380 EXC
Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber
249 ccm
297 ccm
368 ccm
66.4 / 72 mm (2.62 / 2.84 in)
72 / 73 mm (2.84 / 2.88 in)
78 / 77 mm (3 / 2.98 in)
unleaded SUPER fuel, research octane no 95, mixed with high-grade two stroke oil (Shell Advance Racing X)
1:40 – 1:60 when using high grade two stroke oil. When in doupt, please contact your importer or use 1:40 mix ratio to be on the safe side
1 deep-groove ball bearing / 1 cylinder roller bearing
needle bearing
needle bearing
cast piston
forged piston
cast piston
one plain compression ring
two plain compression rings
0 + 0.1 mm (0 + 0.004 in)
1,9 mm (0,07 in) BTDC
1,94 mm (0.075 in) BTDC
2.1 mm (0.08 in) BTDC
NGK BR 8 ECM
0.6 mm (0.024 in)
49,5 mm (1.94 in)
46 mm (1.7 in)
50.5 mm (1.99 in)

250 SX

Engine
Design
Piston displacement
Bore / stroke
Fuel
Oil / gasoline ratio
Crankshaft bearing
Connecting rod bearing
Piston pin bearing
Piston
Piston ring
edge piston Dimension "X" (upper
upper edge cylinder)
Ignition timing
Spark plug
Electrode gap
Dimension "Z"

TECHNICAL DATA - ENGINE 250/300/380 SX / EXC 2002 (all models out of USA)

9-30C

9-31C
TIGHTENING TORQUES
Flange bolts - cylinder-head
Nuts-cylinder base
Flywheel collar nut
Nut for primary sprocket (LH thread)
Nut for inner clutch hub
Crankcase and cover bolts
Swingarm pivot
Flat head bolt release plate kickstarter
Other bolts

M8
M 10
M 12x1
M 18x1.5
M 18x1.5
M6
M 14
M 6x16
M6
M8
M 10

35
35
60
Loctite 243 150
Loctite 243 100
8
100
Loctite 648 19
10
25
45

Nm (25
Nm (25
Nm (44
Nm (110
Nm (74
Nm (6
Nm (74
Nm (14
Nm (7
Nm (19
Nm (33

ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)

TOLERANCES AND FITTING CLEARANCES
Piston fitting clearance
Piston ring end gap
Connecting rod bearing - radial clearance
Transmission shafts end float
Clutch springs - length

0.06 mm (250) 0.06 mm (300) 0.08 mm (380)
0.3 – 0.4 mm
0.021 – 0.032 mm
0.1 – 0.2 mm
Ø 2.5 new = 43 mm, minimum length = 42 mm

Repair manual KTM 250 / 300 / 380

Art No 3206004 -E

GASKET THICKNESSES
Crankcase
Clutch cover
Cylinder bottom gasket
Available cylinder bottom gaskets
Cylinder-head gasket

0.5 mm
0.5 mm
as required
0.2/0.4/ 0.5 / 0.75 mm
O-rings

BASIC CARBURETOR SETTING

Carburetor
Carburetor setting number
Main jet
Idling jet
Starting jet
Jet needle
Needle position from top
Slide
Air adjustment screw open
Performance restrictor
Power jet jet

250 SX

380 SX
380 SX USA

250/300 EXC
throttled

Keihin PWK 38 AG
061200
170 (168,172)
48 (45,50)
85
NOZ E (NOZ F/D)
III
6,5
1,5
–
–

Keihin PWK 38 AG
050201
170 (168,172)
45 (48)
85
NOZ G (NOZ H)
II
6,5
1,5
–
–

Keihin PWK 38 AG
061200
175 (172,178,180)
35 (45/48)
85
R 1475 J (NOZ E/H)
III
6,5
1,5
slide stop 34mm
–

250 EXC USA

300 EXC AUS
throttled

300 MXC/EXC
USA

Keihin PWK 38 AG
030201
178 (175,180)
45 (48)
85
NOZ E (NOZ F)
IV
6,5
1,5
–
–

Keihin PWK 38 AG
070201
170 (172,168)
45 (48)
85
NOZ G (NOZ H)
II
6,5
1,5
slide stop 36mm
–

Keihin PWK 38 AG
040201
175 (178,172)
45 (48)
85
NOZ H (NOZ I)
III
6,5
1,5
–
–

BASIC CARBURETOR SETTING

Carburetor
Carburetor setting number
Main jet
Idling jet
Starting jet
Jet needle
Needle position from top
Slide
Air adjustment screw open
Performance restrictor
Power jet jet

9-32C
TECHNICAL SPECIFICATIONS CHASSIS
250/380 SX

250/300/380 SX, MXC, EXC 2002
250/300/380 MXC

Frame

250/300/380 EXC

Central chrome-moly-steel frame

Fork

White Power – Up Side Down 48 MA

Wheel travel front/rear

White Power – Up Side Down 43 MA
295/320 mm (11,3/12,6 in)

Rear suspension

WP Progressive Damping System shock absorber, aluminium swingarm

Front brake

Disc brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated

Rear brake

Disc brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated

Brake discs
Front tires
Front tires USA
Air pressure offroad
Air pressure road driver only
Rear tires
Rear tires USA
Air pressure offroad
Air pressure road driver only
Fuel tank capacity

7,5 liter (2 US Gallons)

Wear limit max. 0,4 mm (0,016 in)
–
80/100 - 21“51M
1,0 bar (14psi)
1,5 bar (21psi)
–
100/100 - 18“ 64M
1,0 bar (14psi)
2,0 bar (28psi)
11 liter (2,9 US Gallons)

90/90 - 21“ 54R
80/100 - 21“51M
1,0 bar (14psi)
1,5 bar (21psi)
140/80 - 18“ 70R
100/100 - 18“ 64M
1,0 bar (14psi)
2,0 bar (28psi)
8,5/11 liter (2,2/2,9 US Gallons)

14:50t
14:50t

–
14:52t

15:48t / 14:50t
14:52t

80/100 - 21“51M
80/100 - 21“51M
1,0 bar (14psi)
–
100/90 - 19“ 62M
100/90 - 19“ 62M
1,0 bar (14psi)
–

Final drive ratio
Final drive ratio USA
Chain

5/8 x 1/4 "

Available final sprockets

38t, 40t, 42t, 45t, 48t, 50t, 52t

Steering head angle

63,5°

Wheel base

1481 ± 10 mm (58,3 ± 0,4 in)

Seat height, unloaded

925 mm (36,5 in)

Ground clearance, unloaded

385 mm (15,2 in)

Dead-weight *
Dead-weight USA *

101 kg (223 lbs)
101 kg (223 lbs)

–
102,5 kg (226,3 lbs)

109 kg (240,6 lbs)
103,7 kg (229 lbs)

* Dead-weight without fuel

TIGHENING

STANDARD ADJUSTMENT-FORK
Compression adjuster
Rebound adjuster
Spring
Spring preload
Air chamber length
Fork oil

WP 1418W709

WP 0518W711

20

20

Spring
Spring preload

CHASSIS
40 Nm (30 ft.lb)

Brake caliper front

M8

25 Nm (19 ft.lb)
+ Loctite 243

16

12
4,0 N/mm

Clamping bolts upper fork bridge

M8

20 Nm (15 ft.lb)

5 mm (0.20in)

5 mm (0.20in)

Clamping bolts lower fork bridge

M8

15 Nm (11 ft.lb)

100 mm (4,0 in)

140 mm (5.9in)

Clamping bolts fork stubs

M8

10 Nm

SAE 5

SAE 5

WP 1218V736

WP 1218V737

15 LS (low speed)

15

2 HS (high speed)
Rebound adjuster

-

M 16/20x1,5

4,2 N/mm

STANDARD ADJUSTMENT - SHOCK ABSORBER
Compression adjuster

TORQUES

Collar nut front wheel spindle

25

25

PDS7–260

PDS6–260

4 mm (0.16 in)

5 mm (0.19 in)

(7 ft.lb)

Collar nut rear wheel spindle

M 20x1.5

80 Nm (59 ft.lb)

Hexagon nut swing arm bolt

M 14x1.5

100 Nm (74 ft.lb)

Collar bolt handlebar clamp

M8

20 Nm (15 ft.lb)

Allen head bolt handlebar support

M 10

40 Nm (30 ft.lb)

Shock absorber top

M 12

60 Nm (44 ft.lb)

Shock absorber bottom

M 12

60 Nm (44 ft.lb)

Screw adjusting ring spring preload

M6

Other bolts on chassis

M6
M8
M 10

+ Loctite 243

8 Nm

(6 ft.lb)

10 Nm (7 ft.lb)
25 Nm (19 ft.lb)
45 Nm (33 ft.lb)

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

2300 m
7500 ft

1500 m
5000 ft

750 m
2500 ft

300 m
1000 ft

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

LSCHR = Luftregulierschraube offen
LD
= Leerlaufdüse
POS
= Clip Position von oben
HD
= Hauptdüse
Schieber= 6,5
Zerstäuber= 5 mm

Meeresniveau
Sea level

301 m
1001 ft

751 m
2501 ft

1501 m
5001 ft

2301 m
7501 ft

LSCHR
LD
NADEL
POS
HD

Art No 3206004 -E

5.

3.

1.

1/2
52
NOZC
5
180

3/4
50
NOZC
4
178

1
50
NOZD
4
175

1 1/4
48
NOZD
3
172

1 1/2
48
NOZE
3
170

4.

2.

-2°F to 20°F

-20°C bis -7°C

1
50
NOZD
3
175

1 1/4
48
NOZD
3
172

1 1/2
48
NOZE
3
170

1 3/4
45
NOZE
2
168

2
45
NOZF
2
165

42°F to 60°F

6°C bis 15°C

1 1/2
48
NOZE
3
170

1 3/4
45
NOZE
3
168

2
45
NOZF
2
165

2 1/4
42
NOZG
2
162

2 1/2
42
NOZH
1
160

79°F to 98°F

1 3/4
45
NOZE
2
168

2
45
NOZF
2
165

2 1/4
42
NOZG
2
162

2 1/2
42
NOZH
1
160

2 3/4
40
NOZI
1
158

99°F to 120°F

37°C bis 49°C

NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 95

1 1/4
48
NOZD
3
172

1 1/2
48
NOZE
3
170

1 3/4
45
NOZE
2
168

2
45
NOZF
2
165

2 1/4
42
NOZG
2
162

61°F to 78°F

25°C bis 38°C

KEIHIN PWK 38AG
16°C bis 24°C

AS = Air screw open from fully-seated
IJ
= Idling jet
POS = Clip position from top
MJ = Main jet
Slide = 6,5
Atomizer= 5 mm

3/4
50
NOZC
4
178

1
50
NOZD
4
175

1 1/4
48
NOZD
3
172

1 1/2
48
NOZE
3
170

1 3/4
45
NOZE
3
168

19°F to 41°F

-6°C bis 5°C

KTM 250 SX EUR/USA 2002

TEMPERATUR

3000 m
10000 ft

ALTIDUDE

MEERESHÖHE

VERGASERREGULIERUNG
CARBURETOR SETTING

Repair manual KTM 250 / 300 / 380

9-33C

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

2300 m
7500 ft

1500 m
5000 ft

750 m
2500 ft

300 m
1000 ft

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

LSCHR = Luftregulierschraube offen
LD
= Leerlaufdüse
POS
= Clip Position von oben
HD
= Hauptdüse
Schieber= 6,5
Zerstäuber= 5 mm

Meeresniveau
Sea level

301 m
1001 ft

751 m
2501 ft

1501 m
5001 ft

2301 m
7501 ft

LSCHR
LD
NADEL
POS
HD

5.

3.

1.

1
50
NOZC
5
188

1 1/4
48
NOZC
5
185

1 1/4
48
NOZD
4
182

1 1/4
45
NOZD
3
180

1 3/4
45
NOZE
3
178

4.

2.

-2°F to 20°F

-20°C bis -7°C

1 1/2
48
NOZD
4
182

1 1/4
45
NOZD
4
180

1 1/2
45
NOZE
3
178

1 3/4
45
NOZF
2
175

1 3/4
42
NOZG
2
172

42°F to 60°F

6°C bis 15°C

1 1/2
45
NOZE
3
178

1 3/4
45
NOZF
3
175

1 3/4
42
NOZG
2
172

2
42
NOZH
2
170

2 1/2
40
NOZI
2
168

79°F to 98°F

25°C bis 38°C

1 3/4
45
NOZF
2
175

1 3/4
42
NOZG
2
172

2
42
NOZH
2
170

2
40
NOZI
2
168

1 3/4
40
NOZI
1
165

99°F to 120°F

37°C bis 49°C

NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 95

1 1/4
45
NOZD
3
180

1 1/2
45
NOZE
3
178

1 3/4
45
NOZF
3
175

1 3/4
42
NOZG
2
172

2
42
NOZH
2
170

61°F to 78°F

16°C bis 24°C

AS = Air screw open from fully-seated
IJ
= Idling jet
POS = Clip position from top
MJ = Main jet
Slide = 6,5
Atomizer= 5 mm

1 1/4
48
NOZC
5
185

1 1/4
48
NOZD
4
182

1 1/2
45
NOZD
3
180

1 1/2
45
NOZE
3
178

1 3/4
45
NOZF
3
175

19°F to 41°F

-6°C bis 5°C

KTM 250 MXC/EXC EUR/USA 2002 KEIHIN PWK 38 AG

TEMPERATUR

3000 m
10000 ft

ALTIDUDE

MEERESHÖHE

VERGASERREGULIERUNG
CARBURETOR SETTING

9-34C

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

2300 m
7500 ft

1500 m
5000 ft

750 m
2500 ft

300 m
1000 ft

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

LSCHR = Luftregulierschraube offen
LD
= Leerlaufdüse
POS
= Clip Position von oben
HD
= Hauptdüse
Schieber= 6,5
Zerstäuber= 5 mm

Meeresniveau
Sea level

301 m
1001 ft

751 m
2501 ft

1501 m
5001 ft

2301 m
7501 ft

LSCHR
LD
NADEL
POS
HD

Art No 3206004 -E

5.

3.

1.

1/2
50
NOZF
5
185

3/4
48
NOZG
5
182

1
48
NOZG
4
180

1 1/4
45
NOZH
3
178

1 1/2
45
NOZH
3
175

4.

2.

-2°F to 20°F

-20°C bis -7°C

1
48
NOZG
4
180

1 1/4
45
NOZH
4
178

1 1/2
45
NOZH
3
175

1 3/4
45
NOZH
2
172

2
42
NOZI
2
170

42°F to 60°F

6°C bis 15°C

1 1/2
45
NOZH
3
175

1 3/4
45
NOZH
3
172

2
42
NOZI
2
170

2 1/4
42
NOZI
2
168

2 1/2
40
NOZJ
2
165

79°F to 98°F

25°C bis 38°C

1 3/4
45
NOZH
2
172

2
42
NOZI
2
170

2 1/4
42
NOZI
2
168

2 1/2
40
NOZJ
1
165

2 3/4
40
NOZJ
1
162

99°F to 120°F

37°C bis 49°C

NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 95

1 1/4
45
NOZH
3
178

1 1/2
45
NOZH
3
175

1 3/4
45
NOZH
3
172

2
42
NOZI
2
170

2 1/4
42
NOZI
2
168

61°F to 78°F

16°C bis 24°C

AS = Air screw open from fully-seated
IJ
= Idling jet
POS = Clip position from top
MJ = Main jet
Slide = 6,5
Atomizer= 5 mm

3/4
48
NOZG
5
182

1
48
NOZG
4
180

1 1/4
45
NOZH
3
178

1 1/2
45
NOZH
3
175

1 3/4
45
NOZH
3
172

19°F to 41°F

-6°C bis 5°C

KTM 300 MXC/EXC EUR/USA 2002 KEIHIN PWK 38 AG

TEMPERATUR

3000 m
10000 ft

ALTIDUDE

MEERESHÖHE

VERGASERREGULIERUNG
CARBURETOR SETTING

Repair manual KTM 250 / 300 / 380

9-35C

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

2300 m
7500 ft

1500 m
5000 ft

750 m
2500 ft

300 m
1000 ft

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

LSCHR = Luftregulierschraube offen
LD
= Leerlaufdüse
POS
= Clip Position von oben
HD
= Hauptdüse
Schieber= 6,5
Zerstäuber =5 mm

Meeresniveau
Sea level

301 m
1001 ft

751 m
2501 ft

1501 m
5001 ft

2301 m
7501 ft

LSCHR
LD
NADEL
POS
HD

5.

3.

1.

1/2
50
NOZE
5
180

3/4
48
NOZF
5
178

1
48
NOZF
4
175

1 1/4
45
NOZG
3
172

1 1/2
45
NOZG
3
170

4.

2.

-2°F to 20°F

-20°C bis -7°C

1
48
NOZF
4
175

1 1/4
45
NOZG
4
172

1 1/2
45
NOZG
3
170

1 3/4
45
NOZH
2
168

2
42
NOZH
2
165

42°F to 60°F

6°C bis 15°C

1 1/2
45
NOGH
3
170

1 3/4
45
NOZH
2
168

2
42
NOZH
2
165

2 1/4
42
NOZI
2
162

2 1/2
40
NOZI
2
160

79°F to 98°F

25°C bis 38°C

1 3/4
45
NOZH
2
168

2
42
NOZH
2
165

2 1/4
42
NOZI
2
162

2 1/2
40
NOZI
2
160

2 3/4
40
NOZI
1
158

99°F to 120°F

37°C bis 49°C

NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 95

1 1/4
45
NOZG
3
172

1 1/2
45
NOZG
3
170

1 3/4
45
NOZH
3
168

2
42
NOZH
2
165

2 1/4
42
NOZI
2
162

61°F to 78°F

16°C bis 24°C

AS = Air screw open from fully-seated
IJ
= Idling jet
POS = Clip position from top
MJ = Main jet
Slide = 6,5
Atomizer= 5 mm

3/4
48
NOZF
5
178

1
48
NOZF
4
175

1 1/4
45
NOZG
3
172

1 1/2
45
NOZG
3
170

1 3/4
45
NOZH
3
168

19°F to 41°F

-6°C bis 5°C

KTM 380 SX / MXC / EXC EUR / USA 2002 KEIHIN PWK 38 AG

TEMPERATUR

3000 m
10000 ft

ALTIDUDE

MEERESHÖHE

VERGASERREGULIERUNG
CARBURETOR SETTING

9-36C

Gear ratio
1st gear
2nd gear
3rd gear
4th gear
5th gear
Gear lubrication
ailable chain sprockets
Coolant
Ignition system
Generator output
Ignition system USA (MXC)
Generator output
Carburetor
Air- filter

TVC start open
TVC fully open
Primary drive
Clutch
Transmission

Engine
Desgin
Piston displacement
Bore / stroke
Fuel
Oil / gasolino ratio
Crankshaft bearing
Connecting rod bearing
Piston pin bearing
Piston
Piston ring
(upper edge piston Dimension “X“ upper edge cylinder)
Ingition timing
Spark plug
Electrode gap
(height of the
Dimension “Z“ control flap)

EXC
15:29
18:26
19:22
21:20
23:18

5000/min
7000/min

EXC
15:29
18:26
19:22
21:20
23:18

0,8 l engine oil 10W-40
13Z / 14Z / 15Z for chain 5/8 x 1/4"
1.3 liters, 40% antifreeze, 60% water, at least -25 °C (-13 °F)
KOKUSAN 2K-3
12V 110W
KOKUSAN 2K-2
12V 40W
flat-slide carburetor, carburetor setting see table
wet foam type air filter insert

MXC
15:29
17:27
19:25
21:23
23:21

straight cut spur gears, primary ratio 25:72
multiple disc clutch in oil bath, hydraulically operated (Shell HF-E15
5 speed, claw actuated

5900/min
7750/min

MXC
15:29
18:26
19:24
21:23
23:21

250 MXC/EXC
300 MXC/EXC
Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber
249 ccm
297 ccm
66,4 / 72 mm (2.62 / 2.84 in)
72 / 73 mm (2.84 / 2.88 in)
unleaded SUPER fuel, research octane no 95, mixed with high-grade, two- stroke oil
1:40 – 1:60 when using high grade, two- stroke oil. When in dout, please contact your importer or use 1:40 mix ratio to be on the safe side
1 deep-groove ball bearing / 1 cylinder roller bearing
needle bearing
needle bearing
cast piston
forged piston
two plain compression rings
0 + 0,1 mm (0 + 0.004 in)
1,9 mm vor OT
1,94 mm vor OT
NGK BR 7 ES
0,60 mm
49,5 mm (0.024 in)
46 mm (1.7 in)

250/300 MXC / EXC 2003

Art No 3206004 -E

TECHNICAL DATA - ENGINE

Repair manual KTM 250 / 300 / 380

9-37C

9-38C
TIGHTENING TORQUES
Flange bolts - cylinder-head
Nuts-cylinder base
Flywheel collar nut
Flat head screw release plate kickstarter
Nut for primary sprocket (LH thread)
Nut for inner clutch hub
Crankcase and cover bolts
Swingarm pivot
Other screws

M8
M 10
M 12x1
M 6x16
M 18x1.5
M 18x1.5
M6
M 14
M6
M8
M 10

35
35
60
Loctite 648 19
Loctite 243 150
Loctite 243 100
8
100
10
25
45

Nm (25
Nm (25
Nm (44
Nm (14
Nm (110
Nm (74
Nm (6
Nm (74
Nm (7
Nm (19
Nm (33

ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)
ft.lb)

TOLERANCES AND FITTING CLEARANCES
Piston fitting clearance
Piston ring end gap
Connecting rod bearing - radial clearance
Transmission shafts end float
Clutch springs - length
Crankshaft webs – outer dimension
Runout Crankshaft journal Crankshaft

0.06 mm (250 / 300)
0.3 – 0.4 mm
0.021 – 0.032 mm
0.1 – 0.2 mm
Ø 2.5 minimum length = 42 mm, new = 43 mm
60 mm ± 0,05 mm
max 0,06 (neu 0,03)

GASKET THICKNESSES
Crankcase
Clutch cover
Cylinder bottom gasket
Available cylinder bottom gaskets
Cylinder-head gasket

0.5 mm
0.5 mm
as required
0.2/0.4/ 0.5 / 0.75 mm
O-rings

BASIC CARBURETOR SETTING

Carburetor
Carburetor setting number
Main jet
Idling jet
Starting jet
Jet needle
Needle position from top
Slide
Air adjustment screw open
Performance restrictor
Power jet nozzle

250/300 EXC
throttled

250 EXC USA

300 EXC AUS
throttled

300 MXC / EXC
USA

Keihin PWK 38 AG
120202
175 (182,185)
35 (48)
85
R 1475 J
(N3CH/N3CW)
III
6.5
1.5
slide stop 34mm

Keihin PWK 38 AG
140202
182 (185)
48
85
N3CH (N3CW)
IV
6.5
1.5
–
–

Keihin PWK 38 AG
130202
175 (172,178)
35 (45,48)
85
R1475J (NOZ H/NOZ
I)
II
6.5
1.5
slide stop 34mm

Keihin PWK 38 AG
150202
175 (172,178)
45 (48)
85
NOZ H (NOZ I)
III
6.5
1.5
–
–

9-39C

TECHNICAL SPECIFICATIONS CHASSIS

250/300 MXC, EXC 2003

250/300 MXC
Frame
Fork

White Power – Up Side Down 48 MA

Wheel travel front/rear

300/335 mm (11.8/13.2 in)

Rear suspension

WP PDS 5018 (Progressive Damping System) shock absorber, aluminium swingarm

Front brake

Disc brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated

Rear brake

Disc brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated

Brake discs
Front tires
Front tires USA
Air pressure offroad
Air pressure road driver only
Rear tires
Rear tires USA
Air pressure offroad
Air pressure road driver only
Fuel tank capacity

Wear limit max. 0,4 mm (0,016 in)
–
80/100 - 21“51M
1,0 bar (14psi)
1,5 bar (21psi)
–
100/100 - 18“ 64M
1,0 bar (14psi)
2,0 bar (28psi)
11 liter (2,9 US Gallons)

90/90 - 21“ 54R
80/100 - 21“51M
1,0 bar (14psi)
1,5 bar (21psi)
140/80 - 18“ 70R
100/100 - 18“ 64M
1,0 bar (14psi)
2,0 bar (28psi)
9/11 liter (2,3/2,9 US Gallons)

–
14:52t

15:48t / 14:50t
14:52t

Final drive ratio
Final drive ratio USA
Chain

5/8 x 1/4 "

Available final sprockets

38t, 40t, 42t, 45t, 48t, 50t, 52t

Art No 3206004 -E

Bulbs

headlight

HS1 12V 35/35W

parking light

12V 5W (base W2, 1x9,5d)

instrument light

12V 1,2W (base W2, 1x4,6d)

brake- rear light

12V 21/5W (base BaY15d)

flasher light

12V 10W (basel Ba15s)

license plate illumination

12V 1,2W (base 1x4,6d)

Steering head angle

63,5°

Wheel base

1481 ± 10 mm (58,3 ± 0,4 in)

Seat height, unloaded

925 mm (36,5 in)

Ground clearance, unloaded

385 mm (15,2 in)

STANDARD ADJUSTMENT-FORK
Repair manual KTM 250 / 300 / 380

250/300 EXC
Central chrome-moly-steel frame

STANDARD ADJUSTMENT - SHOCK ABSORBER

WP 4860 MXMA

WP 5018-MCC

1418X736

1218X759

Compression adjuster

20

Compression adjuster

17

Rebound adjuster

20

Rebound adjuster

26

Spring
Spring preload
Air chamber length
Fork oil

4,0 N/mm
5 mm (0.20in)
110 mm (4,3 in)
SAE 5

Spring
Spring preload

71-90/260
7 mm (0.27 in)

9-40C
TIGHTENING TORQUES Collar screw, front wheel spindle
Brake caliper, front

CHASSIS

M 24x1,5
M8

40 Nm
Loctite 243 + 25 Nm

Brake disk, front

M 6 10.9

Loctite 243 + 15 Nm

Brake disk, rear

M6

Loctite 243 + 15 Nm

Clamping screws, upper fork bridge

M8

20 Nm

Clamping screws, lower fork bridge

M8

15 Nm

Clamping screws, fork stubs

M8

10 Nm

Collar nut, rear wheel spindle

M 20x1,5

80 Nm

Hexagon nut, swing arm bolt

M 14x1,5

100 Nm

Hexagon collar screw, handlebar clamp

M8

20 Nm

Allan head screw, handlebar support

M 10

Loctite 243 + 40 Nm

Shock absorber, top

M 12

60 Nm

Shock absorber, bottom

M 12

60 Nm

Sprocket screws

M8

Loctite 243 + 35 Nm

Ball joint for push rod

M6

Loctite 243 + 10 Nm

Engine mounting bolt

M 10

45 Nm

Engine brace

M8

33 Nm

Screw adjusting ring spring preload shock abs.

M6

8 Nm

Spoke nipple

M4,5 /M5

5 Nm

Other screws on chassis

M6
M8
M 10

10 Nm
25 Nm
45 Nm

Other collar nuts on chassis

M6
M8
M 10

15 Nm
30 Nm
50 Nm

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

2300 m
7500 ft

1500 m
5000 ft

750 m
2500 ft

300 m
1000 ft

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

LSCHR = Luftregulierschraube offen
LD
= Leerlaufdüse
POS
= Clip Position von oben
HD
= Hauptdüse
Schieber= 6,5
Zerstäuber= 5 mm

Meeresniveau
Sea level

301 m
1001 ft

751 m
2501 ft

1501 m
5001 ft

2301 m
7501 ft

LSCHR
LD
NADEL
POS
HD

Art No 3206004 -E

5.

3.

1.

3/4
52
N3CG
5
190

1
50
N3CG
5
188

1
48
N3CG
4
188

1
48
N2CH
4
185

1
48
N3CH
4
182

4.

2.

-2°F to 20°F

-20°C bis -7°C

1
48
N3CG
4
188

1
48
N3CH
4
185

1
48
N3CH
4
182

1
48
N3CH
3
182

1,5
48
N3CH
3
180

42°F to 60°F

6°C bis 15°C

1
48
N3CH
4
182

1
48
N3CH
3
182

1,5
48
N3CH
3
180

1,5
45
N3CW
3
178

1,5
45
N3CW
3
175

79°F to 98°F

25°C bis 38°C

1
48
N3CH
3
182

1,5
48
N3CH
3
180

1,5
45
N3CW
3
178

1,5
45
N3CW
3
175

2
45
N3CW
2
172

99°F to 120°F

37°C bis 49°C

NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 95

1
48
N3CH
4
185

1
48
N3CH
4
182

1
48
N3CH
3
182

1,5
48
N3CH
3
180

1,5
45
N3CW
3
178

61°F to 78°F

16°C bis 24°C

AS = Air screw open from fully-seated
IJ
= Idling jet
POS = Clip position from top
MJ = Main jet
Slide = 6,5
Atomizer= 5 mm

1
50
N3CG
5
188

1
48
N3CG
4
188

1
48
N3CH
4
185

1
48
N3CH
4
182

1
48
N3CH
3
182

19°F to 41°F

-6°C bis 5°C

KTM 250 MXC/EXC EUR/USA 2003 KEIHIN PWK 38 AG

TEMPERATUR

3000 m
10000 ft

ALTIDUDE

MEERESHÖHE

VERGASERREGULIERUNG
CARBURETOR SETTING

Repair manual KTM 250 / 300 / 380

9-41C

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

LSCHR
LD
NADEL
POS
HD

2300 m
7500 ft

1500 m
5000 ft

750 m
2500 ft

300 m
1000 ft

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

AS
IJ
NEEDLE
POS
MJ

LSCHR = Luftregulierschraube offen
LD
= Leerlaufdüse
POS
= Clip Position von oben
HD
= Hauptdüse
Schieber= 6,5
Zerstäuber= 5 mm

Meeresniveau
Sea level

301 m
1001 ft

751 m
2501 ft

1501 m
5001 ft

2301 m
7501 ft

LSCHR
LD
NADEL
POS
HD

5.

3.

1.

1/2
50
NOZF
5
185

3/4
48
NOZG
5
182

1
48
NOZG
4
180

1 1/4
45
NOZH
3
178

1 1/2
45
NOZH
3
175

4.

2.

-2°F to 20°F

-20°C bis -7°C

1
48
NOZG
4
180

1 1/4
45
NOZH
4
178

1 1/2
45
NOZH
3
175

1 3/4
45
NOZH
2
172

2
42
NOZI
2
170

42°F to 60°F

6°C bis 15°C

1 1/2
45
NOZH
3
175

1 3/4
45
NOZH
3
172

2
42
NOZI
2
170

2 1/4
42
NOZI
2
168

2 1/2
40
NOZJ
2
165

79°F to 98°F

25°C bis 38°C

1 3/4
45
NOZH
2
172

2
42
NOZI
2
170

2 1/4
42
NOZI
2
168

2 1/2
40
NOZJ
1
165

2 3/4
40
NOZJ
1
162

99°F to 120°F

37°C bis 49°C

NICHT FÜR STRASSENBETRIEB
Kraftstoff: Euro-Super bleifrei ROZ 95
NOT FOR HIGHWAY USE
Fuel: Euro-Super unleaded ROZ 95

1 1/4
45
NOZH
3
178

1 1/2
45
NOZH
3
175

1 3/4
45
NOZH
3
172

2
42
NOZI
2
170

2 1/4
42
NOZI
2
168

61°F to 78°F

16°C bis 24°C

AS = Air screw open from fully-seated
IJ
= Idling jet
POS = Clip position from top
MJ = Main jet
Slide = 6,5
Atomizer= 5 mm

3/4
48
NOZG
5
182

1
48
NOZG
4
180

1 1/4
45
NOZH
3
178

1 1/2
45
NOZH
3
175

1 3/4
45
NOZH
3
172

19°F to 41°F

-6°C bis 5°C

KTM 300 MXC/EXC EUR/USA 2003 KEIHIN PWK 38 AG

TEMPERATUR

3000 m
10000 ft

ALTIDUDE

MEERESHÖHE

VERGASERREGULIERUNG
CARBURETOR SETTING

9-42C

10-1C

LUBRICATION AND MAINTENANCE SCHEDULE
INDEX

MODEL 1999
LUBRICATION AND MAINTENANCE SCHEDULE 250 - 380 . . . . . . .10-2
MODEL 2000
LUBRICATION AND MAINTENANCE SCHEDULE 250 - 380 . . . . . . .10-3
MODEL 2001/2002
LUBRICATION AND MAINTENANCE SCHEDULE 250 - 380 . . . . . . .10-4

Repair manual 250 / 300 / 380

Art No 3206004 -E

MODEL 2003
LUBRICATION AND MAINTENANCE SCHEDULE 250 - 300 . . . . . . .10-6

10

10-2C

Repair manual KTM 250 / 300 / 380

Art No 3206004 -E

●

●
●
●

at least
once a year

after 4000 km
(2500 miles) or once a year

Check transmission oil level
Change transmission oil
Check spark plug and electrode gap
Change spark plug
Functional testing of the exhaust control system
Check intake manifold for leaks and cracks
Drain and clean carburetor float chamber
Adjust idling
Check breather hoses of engine case and gas tank for correct position without buckles
Clean and check airfilter element, box and carburetor connection boot
Check chain, sprockets, guides and chain wear
Clean and oil chain
Check chain tension
Check coolant level
Check quality of antifreeze
Check cooling system for leaks - visual inspection
Check exhaust system for cracks and leaks
Replace glass fiber yarn of silencer
Check of the exhaust suspension system
Check brake fluid level front and rear
Change brake fluid
Check thickness of disc brake pads
Check brake discs
Inspect condition and installation of front and rear brake hoses
Check free travel and free movability of hand brake lever and foot brake lever
Check the oil level in the master cylinder of the hydraulic clutch
Change the oil of the hydraulic clutch
Check telescopic fork action
Check telescopic fork for leaks
Push up the protective bellows and remove the dirt; the drain holes must be free of obstructions
Clean the dust scrabbers of the telescopic force
Undo the bleeder screws at the fork legs
Change oil of telescopic fork
Service telescopic fork completely
Check steering head bearing free play
Clean and regrease steering head bearing
Check setting and damping of shock absorber
Service shock absorber completely
Grease swingarm needle bearings (don’t grease the pivot bearing for the shock absorber)
Check for even spoke tension and rim alignment
Check wheel bearings
Check tires for cuts and air pressure
Check cables for damage and free movement
Adjust and oil control cables
Check electrical system
Check battery holder and connections (CH, Singapore)
Check adjustment of headlight
Apply contact spray to light switches, flasher switches and ignition lock
Check all bolts, nuts, screws and clamps for proper tightness
Clean and lubricate control lever pivot points

after washing

AT A REGULAR COMPETITION USE OF THE BIKE, THE 4000 KM (2500 MILES)
SERVICE IS TO BE DONE AFTER EVERY RACE

before each start

125-380 6.98

after 2000 km
(1250 miles) or 20 hours

KTM
dealer
1st service after 1000 km
(600 miles) or 10 hours

KTM
rider

PERIODIC LUBRICATION AND MAINTENANCE SCHEDULE

●
●

●
●
●

●

●
●
●

●
●
●
●
●
●
●
●

●

●

●

●

●

●
●
●
●
●

●
●

●

●
●
●
●
●
●
●
●
●
●

●
●
●

●
●
●
●
●
●

●
●
●

●

●
●

●
●
●
●
●
●
●

●

●
●
●

●

●
●
●

●
●
●
●

●

●
●

●
●

●
●
●

●
●

●

●
●
●
●
●
●
●
●
●
●
●

10-3C

after 4000 km
(2500 miles) or once a year

at least
once a year

Check transmission oil level

after washing

AT A REGULAR COMPETITION USE OF THE BIKE, THE 4000 KM (2500 MILES)
SERVICE IS TO BE DONE AFTER EVERY RACE

before each start

125-380 6.99

after 2000 km
(1250 miles) or 20 hours

KTM
dealer
1st service after 1000 km
(600 miles) or 10 hours

KTM
rider

PERIODIC LUBRICATION AND MAINTENANCE SCHEDULE

●

●

●

●

●
●

Change transmission oil

●

Check spark plug and electrode gap

●

Change spark plug

●

Functional testing of the exhaust control system
Check intake manifold for leaks and cracks

●

●
●

Drain and clean carburetor float chamber

●

Adjust idling

●

Check breather hoses of engine case and gas tank for correct position without buckles

●

●

●

Clean and check airfilter element, box and carburetor connection boot

●

Check chain, sprockets, guides and chain wear

●

Clean and oil chain

●

●

Check chain tension

●

●

●

Check coolant level

●

●

●

●

●

●

●

●

●

Check quality of antifreeze
Check cooling system for leaks - visual inspection

●

Art No 3206004 -E

Check exhaust system for cracks and leaks

●

Replace glass fiber yarn of silencer
Check of the exhaust suspension system

●

Check brake fluid level front and rear

●

●

●
●

●

●
●

Check brake disks for wear and wobbling
Inspect condition and installation of front and rear brake hoses

●

●

Check free travel and free movability of hand brake lever and foot brake lever

●

●

●
●
●

Check the oil level in the master cylinder of the hydraulic clutch

●
●

Change the oil of the hydraulic clutch
Check telescopic fork action

●

●
●

Check telescopic fork for leaks
●

Clean the dust scrabbers of the telescopic force

●

●
●

Undo the bleeder screws at the fork legs
Repair manual KTM 250 / 300 / 380

●

●

Change brake fluid
Check thickness of disc brake pads

●

Change oil of telescopic fork

●

Service telescopic fork completely

●
●

Check steering head bearing free play

●
●

Clean and regrease steering head bearing
Check setting and damping of shock absorber

●

●

●

Service shock absorber completely

●

Grease swingarm needle bearings (dont grease the pivot bearing for the shock absorber)

●

Check for even spoke tension and rim alignment

●

Check wheel bearings

●

●

Check tires for cuts and air pressure

●

●

Check cables for damage and free movement

●

●

●
●

Adjust and oil control cables
Check electrical system

●

●

●

●

●

●
●

Check adjustment of headlight
●

Apply contact spray to light switches, flasher switches and emergency off switch
Check all bolts, nuts, screws and clamps for proper tightness
Clean and lubricate control lever pivot points

●

●
●

●

●

●
●

●

10-4C

PERIODIC MAINTENANCE SCHEDULE 2001/02

WHEELS

CHASSIS

BRAKES

ADD-ON-PARTS

CARBURETOR

ENGINE

A washed motorcycle can be checked more quickly which saves money!
Check gear box oil level
Change gear box oil
Check spark plugs, adjust distance between electrodes
Renew spark plugs
Check the carburettor connection boot for cracks and leaks
Check idle speed setting
Check that vent hoses are not damaged or bent
Check cooling system for leaks, check quantity of anti freeze
Check exhaust system for leaks and fitment
Check cables for damage, smooth operation, bends; adjust and lubricate
Check oil level of the clutch master cylinder
Clean air filter and filter box
Check electric wires for damage and bends
Check headlamp setting
Check function of electric systems (low-, high beam, break light, indicator,
indicator lamps, speedometer illumination, horn, emergency OFF switch or button
Check brake fluid level, lining thickness, break lining
Check brake lines for damage and leaks
Check/adjust smooth operation and free travel of handbrake/foot brake lever
Check tightness of brake system screws
Check shock absorber and fork for leaks and function
Clean fork dust bellows
Bleed fork legs
Check swing arm bearings
Check/adjust steering head bearings
Check tightness of all chassis screws (triple clamps, fork leg axle passage
axle nuts and screws, swing arm bearings, shock absorber)
Check spoke tension and rim joint
Check tyres and air pressure
Check chain, rear sprockets and chain guides for wear, fitment and tension
Lubricate chain
Check clearance of wheel bearings

IMPORTANT RECOMMENDED MAINTENANCE WORK
Check function of exhaust control
Complete maintenance of shock absorber
Complete maintenance of fork
Clean and grease steering head bearings and gasket elements
Clean and adjust carburetor
Replace glass fibre yarn filling of the exhaust main silencer
Treat electric contacts and switches with contact grease
Change hydraulic clutch fluid
Change break fluid

250/300/380 SX/MXC/EXC

1. service after
after
after
10 hours
4000 kilometer
20 hours
or
or
or
1000 kilometer 2000 kilometer once a year
●
●
●

●
●

●
●
●
●
●

●

●
●
●
●
●
●

●
●
●
●
●
●
●
●
●
●
●
●

●
●

●
●
●
●
●
●
●
●
●
●

●
●
●
●

●
●
●
●
●

THAT CAN BE CARRIED OUT BY EXTRA ORDER
at least
once a year
●
●

every 2 years
or 20000 km

●
●
●
●
●
●
●

IF MOTORCYCLE IS USED FOR COMPETITION 4000KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MORE THAN 5 HOURS OR 500 KM!
MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!

10-5C
CARRIED

OUT BY THE

Repair manual KTM 250 / 300 / 380

Art No 3206004 -E

Check gear box oil level
Check brake fluid level
Check brake pads for wear
Check lights for function
Check horn for function
Lubricate and adjust cables and nipples
Bleed fork legs regulary
Remove and clean fork dust bellows regulary
Clean and lubricate chain, check tension and adjust if necessary
Clean air filter and filter box
Check tires for pressure and wear
Check cooling liquid level
Check fuel lines for leaks
Drain and clean float chamber
Check all control elements for smooth operation
Check brake performance
Treat blank metal parts (with the exception of brake and exhaust systems)
with wax-based anti corrosion agent
Treat ignition and steering locks and light switches with contact spray
Check tightness of screws, nuts and hose clamps regular

RIDER
Once a year

TO BE

For crosscountry use

MAINTENANCE

After every
cleaning

AND

Before each
start

IMPORTANT CHECKS

●
●
●
●
●
●

●

●
●
●
●

●
●
●
●
●
●

●
●
●
●

10-6C

PERIODIC MAINTENANCE SCHEDULE 2003

WHEELS

CHASSIS

BRAKES

ADD-ON-PARTS

CARBURETOR

ENGINE

A clean motorcycle can be checked more quickly which saves money!
Check gear box oil level
Change gear box oil
Check spark plugs, adjust distance between electrodes
Renew spark plugs
Check the carburetor connection boot for cracks and leaks
Check idle speed setting
Check that vent hoses are not damaged or bent
Check cooling system for leaks, check quantity of antifreeze
Check exhaust system for leaks and fitment
Check cables for damage, smooth operation, bends; adjust and lubricate
Check oil level of the clutch master cylinder
Clean air filter and filter box
Check electric wires for damage and bends
Check headlamp setting
Check function of electric systems (low beam, high beam, break light, indicator,
indicator lamps, speedometer illumination, horn, emergency OFF switch or button
Check brake fluid level, lining thickness, brake lining
Check brake lines for damage and leaks
Check/adjust smooth operation and free travel of handbrake/foot brake lever
Check tightness of brake system screws
Check shock absorber and fork for leaks and function
Clean dust bellows
Bleed fork legs
Check swing arm bearings
Check/adjust steering head bearings
Check tightness of all chassis screws (triple clamps, fork leg axle passage
axle nuts and screws, swing arm bearings, shock absorber)
Check spoke tension and rim joint
Check tires and air pressure
Check chain, rear sprockets and chain guides for wear, fitment and tension
Lubricate chain
Check clearance of wheel bearings

IMPORTANT RECOMMENDED MAINTENANCE WORK
Check function of exhaust control
Complete maintenance of shock absorber
Complete maintenance of fork
Clean and grease steering head bearings and gasket elements
Clean and adjust carburetor
Replace glass fibre- yarn filling of the exhaust main silencer
Treat electric contacts and switches with contact grease
Change hydraulic clutch fluid
Change break fluid

250/300 MXC/EXC

1st service
after
after
after 10 hours
4000 kilometer
20 hours
or
or
or
1000 kilometers 2000 kilometers once a year
●
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●
●
●
●
●

●
●
●
●

●
●
●
●
●

THAT CAN BE CARRIED OUT BY EXTRA ORDER
at least
once a year
●
●

every 2 years
or 20000 km

●
●
●
●
●
●
●

IF MOTORCYCLE IS USED FOR COMPETITION 4000KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!
SERVICE INTERVALS SHOULD NEVER BE EXCEEDED BY MORE THAN 5 HOURS OR 500 KM!
MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE FOR CARE AND CHECKS DONE BY THE RIDER!

10-7C
CARRIED

OUT BY THE

Repair manual KTM 250 / 300 / 380

Art No 3206004 -E

Check gear box oil level
Check brake fluid level
Check brake pads for wear
Check lights for function
Check horn for function
Lubricate and adjust cables and nipples
Bleed fork legs regulary
Remove and clean dust bellows regularly
Clean and lubricate chain, check tension and adjust if necessary
Clean air filter and filter box
Check tires for pressure and wear
Check cooling liquid level
Check fuel lines for leaks
Empty and clean float chamber
Check all control elements for smooth operation
Check brake performance
Treat blank metal parts (with the exception of brake and exhaust systems)
with wax-based anti corrosion agent
Treat ignition and steering locks and light switches with contact spray
Check tightness of screws, nuts and hose clamps regularly

RIDER
Once a year

TO BE

For crosscountry use

MAINTENANCE

After every
cleaning

AND

Before each
start

IMPORTANT CHECKS

●
●
●
●
●
●

●

●
●
●
●

●
●
●
●
●
●

●
●
●
●

10-8C
RECOMMENDED
USED

250/300 EXC AND MXC ENGINE
FOR ENDURO COMPETITIONS BY YOUR KTM WORKSHOP
(ADDITIONAL ORDER FOR THE KTM WORKSHOP)
INSPECTION OF THE

Check the reed-type intake valve for wear
Check the clutch shoes for wear
Check the length of the clutch springs
Check the cylinder and piston for wear
Check the exhaust control for proper functioning and smooth running
Check the eccentricity of the crankshaft journal
Check the radial clearance of the conrod bearings
Check the radial clearance of the piston pin main bearing
Check the crankshaft main bearing for wear
Replace the crankshaft bearings and conrod bearings
Check the entire transmission including roller and bearings for wear

30
hours
●
●
●
●
●
●
●
●
●

45
hours
●
●
●
●
●
●

60
hours
●
●
●
●
●
●
●
●
●

●
●

90
hours
●
●
●
●
●
●

120
hours
●
●
●
●
●
●
●
●
●

●
●

135
hours
●
●
●
●
●
●

●
●

RECOMMENDED

INSPECTION OF THE 250/300 EXC AND MXC ENGINE
USED FOR HOBBY- ENDURO BY YOUR KTM WORKSHOP
(ADDITIONAL ORDER FOR THE KTM WORKSHOP)

Check the reed-type intake valve for wear
Check the clutch shoes for wear
Check the length of the clutch springs
Check the cylinder and piston for wear
Check the exhaust control for proper functioning and smooth running
Check the eccentricity of the crankshaft journal
Check the radial clearance of the conrod bearings
Check the radial clearance of the piston pin main bearing
Check the crankshaft main bearing for wear
Replace the crankshaft bearings and conrod bearings
Check the entire transmission including roller and bearings for wear

60
hours

90
hours

120
hours

180
hours

240
hours

270
hours

●
●
●
●
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●

●
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NOTE: IF THE INSPECTION ESTABLISHES THAT PERMISSIBLE TOLERANCES ARE EXCEEDED, THE RESPECTIVE COMPONENTS MUST
BE REPLACED.

11-1C

WIRING DIAGRAMS
INDEX

MODEL 1999
WIRING DIAGRAM 250 - 380 EXC . . . . . . . . . . . . . . . . . . . . . . . . .11-2
WIRING DIAGRAM 250 - 380 EGS . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
WIRING DIAGRAM 250 - 380 EXC (USA) . . . . . . . . . . . . . . . . . . . .11-5

Repair manual 250 / 300 / 380

Art No 3206004 -E

MODEL 2000
WIRING DIAGRAM 250 - 300 EXC USA . . . . . . . . . . . . . . . . . . . . .11-6
WIRING DIAGRAM 250 - 380 EXC . . . . . . . . . . . . . . . . . . . . . . . . .11-7
WIRING DIAGRAM 380 EXC USA . . . . . . . . . . . . . . . . . . . . . . . . . .11-9
MODEL 2001/2002
WIRING DIAGRAM 250 EXC (USA) . . . . . . . . . . . . . . . . . . . . . . . .11-10
WIRING DIAGRAM 250 - 380 EXC . . . . . . . . . . . . . . . . . . . . . . . .11-11
WIRING DIAGRAM 300 - 380 EXC (USA) . . . . . . . . . . . . . . . . . . .11-13
MODEL 2003
WIRING DIAGRAM 250 - 300 EXC (EU/AUS) . . . . . . . . . . . . . . . . .11-14
WIRING DIAGRAM 250 - 300 EXC (USA) . . . . . . . . . . . . . . . . . . .11-16

11

Repair manual KTM 250 / 300 / 380

Art No 3206004 -E

11-2C

11-3C

Repair manual KTM 250 / 300 / 380

Art No 3206004 -E

11-4C

11-5C

SPORTMOTORCYCLES

Repair manual KTM 250 / 300 / 380

Art No 3206004 -E

11-6C

11-7C
SPORTMOTORCYCLES

Repair manual KTM 250 / 300 / 380

Art No 3206004 -E

11-8C

SPORTMOTORCYCLES

11-9C

Repair manual KTM 250 / 300 / 380

Art No 3206004 -E

11-10C

11-11C

Repair manual KTM 250 / 300 / 380

Art No 3206004 -E

11-12C

Repair manual KTM 250 / 300 / 380

Art No 3206004 -E

11-13C

11-14C
250-300 EXC 2003

Repair manual KTM 250 / 300 / 380

Art No 3206004 -E

11-15C

KTM 250-300 EXC 2003

250/300 EXC 2003

11-16C



---

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