KTM 250 - 380 SX/MXC/EXC Engine Repair Manual - Service Informations

Oct 28, 2026

Repair manual for the KTM 250 / 300 / 380 engine (SX, MXC, EXC) describing servicing procedures and the engine repair workflow. Includes service information with sections for general information, removing and refitting the engine, disassembling and servicing individual components, assembling the engine, electrical system work, troubleshooting, and technical specifications. Provides a periodic maintenance schedule and wiring diagrams, plus loose-leaf updating instructions with replacement page lists for model years 1999 through 2003.

LanguageEnglish

CategoryTechnology

FormatPDF

Pages153

Reading Time6 h 26 min

AccessFree to download

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 Troubleshooting

9 Technical Specifications

10 Periodic Maintenance Schedule

11 Wiring Diagrams

Important Information / Updating Instructions

250/300/380 SX,MXC,EXC REPAIR MANUAL ENGINE KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria [www.ktm.at](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 IMPORTANT INFORMATION /UPDATING 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: 14-20, 26, 28-36, 37, 41, 42, 50, 51, 67, 72-77, 83, 121-126, 127, 134-136, 137, 151-153 Repair manual KTM 250 / 300 / 380 Art No 3206004-E | Remove page (s) | Replace by page (s) | Insert page (s) | after page | | --- | --- | --- | --- | | 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 | | | | | | | 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. EXPLANATION - UPDATING Repair manual KTM 250 / 300 / 380 Art No 3206004-E 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 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“) 11/2002 Modification / Updating: Technical Specification, Periodic Maintenance Schedule, Wiring Diagrams

FAQs

What engine models and variants are covered in this repair manual?

It covers KTM 250 / 300 / 380 engines with SX, MXC, and EXC variants.

Which major repair topics are included?

The manual includes removing/refitting, disassembling, servicing components, assembling, electrical work, troubleshooting, technical specifications, periodic maintenance, and wiring diagrams.

How do the updating instructions work for the loose-leaf repair manual?

Print the specified replacement pages and insert them into the existing loose-leaf manual according to the provided remove/replace/insert-after page table and model-year update notes.

Oct 28, 2026

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