🏷️ Basic Information Identification Make: KTM Model: 250/300 Series Product Name: KTM 250/300 Service & Repair Manual 2004-2010 Model Variant Coverage: SX, SXS, MXC, EXC, EXC-E, EXC SIX DAYS, EXC-E SIX DAYS, XC, XC-W Production Years Covered: 2004, 2005, 2006, 2007, 2008, 2009, 2010 👋 Introduction Market Position Target Audience: KTM 250/300 owners, amateur mechanics, professional technicians, and do-it-yourself enthusiasts. Competitive Analysis Value Proposition: Provides dealer-level repair and maintenance information at a fraction of the cost, empowering owners to maintain their high-performance KTM motorcycles. Key Features Content Quality: 100% complete and intact, no missing or corrupt pages. Detailed illustrations, step-by-step instructions, notes, cautions, and warnings. Accessibility: Instant download in PDF format, compatible with Windows, Mac, and Linux operating systems. Searchable text and printable pages. 📋 Manual Details Coverage Areas Primary Coverage: Service and Repair for KTM 250cc and 300cc motorcycles. Page Count Total Pages: Over 230 pages Manual Type Type: Workshop Service and Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine disassembly, assembly, inspection, and repair (including cylinder head, cylinder block, crankshaft, connecting rod, pistons, valves, valve timing). Cooling System: Radiator, water pump, coolant flow, thermostat, hoses, and fan system. Fuel System: Carburetor (specific models) tuning, cleaning, and overhaul; fuel tank, fuel lines, and fuel filter maintenance. Ignition System: Ignition coil, spark plug, CDI unit, stator, and associated wiring. Lubrication System: Oil pump, oil filter, oil lines, and lubrication points. Exhaust System: Exhaust pipe, muffler, and emissions control components (where applicable). Transmission And Drivetrain: Clutch unit, clutch system (master and slave cylinders, lines), manual transmission (gearbox), drive shaft, chain maintenance and adjustment. Suspension System: Front fork (upside-down telescopic, specific model types), rear shock absorber, linkage systems, adjustments, and seal replacement. Brake System: Front and rear brake calipers, master cylinders, brake fluid, brake lines, brake pads, brake discs, and bleeding procedures. Wheel And Tire System: Wheel bearings, spoke tension, tire replacement, and recommended tire pressures. Electrical System: Wiring diagrams, battery maintenance, charging system (alternator/stator, rectifier/regulator), lighting system, starter system, and combination meter. Chassis And Bodywork: Frame inspection and repair, body panel removal and installation, handlebars, footpegs, seat, and plastic components. Procedures Included Routine Maintenance: Oil changes, filter replacement, chain lubrication and adjustment, air filter cleaning, spark plug replacement, coolant checks and changes. Troubleshooting: Diagnostic guides for common starting, running, and performance issues, with specific attention to electrical faults and engine problems. Engine Repair: Top-end rebuilds (piston, rings, cylinder, head), bottom-end overhauls (crankshaft, bearings, seals), valve adjustments, and carburetor rebuilds. Transmission Repair: Clutch pack replacement, gearbox disassembly and reassembly, shift mechanism repair. Suspension Service: Fork seal replacement, fork oil changes, shock absorber servicing, linkage bearing replacement. Brake Service: Brake fluid flush and bleed, caliper seal replacement, pad and rotor replacement. Electrical Diagnostics: Wiring harness inspection, component testing (stator, CDI, regulators), troubleshooting electrical faults using wiring diagrams. Bodywork Repair: Panel removal/installation, fairing repair, seat replacement. Technical Depth Depth: Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds. Includes detailed specifications and diagnostic procedures. 📊 Manual Specifications File Format Digital Format: PDF Print Quality Printability: All pages are printable without restriction. Binding Type Binding: Digital Download (PDF) Paper Type Paper Type Equivalent: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: 2-Stroke Single Cylinder (typically Liquid-Cooled) Engine Variants Engine Displacement: Approximately 249cc for 250 models, and approximately 293cc for 300 models. Specific displacements may vary slightly by sub-model and year. Performance Horsepower Range: Estimated 40-55+ HP depending on model, tuning, and exhaust. (Specific figures require consulting individual model year data.) Torque Range: Estimated 25-35+ lb-ft depending on model and tuning. (Specific figures require consulting individual model year data.) Fuel System Carburetor Types: Likely Keihin PWK or similar high-performance carburetor models. Lubrication Oil Type: Pre-mix ratio specified in manual (typically 40:1 or 50:1 for 2-stroke oil). Engine Construction Bore X Stroke: Varies by specific 250/300 displacement. For example, 300cc models often around 72mm bore x 72mm stroke. 🔧 Transmission Standard Transmission Type: 6-Speed Manual Sequential Gearbox Features Clutch Type: Hydraulically operated Wet Multi-Plate Clutch Fluid Specs Transmission Oil: Specific gear oil type and viscosity will be detailed in the manual (e.g., SAE 80W/90). 📐 Dimensions Weights Dry Weight: Typically in the range of 210-230 lbs (95-105 kg), depending on the specific model variant (e.g., EXC vs. SX). 🛡️ Safety Features Ratings Safety Features Focus: Manual focuses on mechanical and electrical safety aspects of operation and repair, rather than crash ratings. Active Features Braking System: Hydraulic disc brakes front and rear. 💡 Technology Features Infotainment Infotainment Systems: N/A (Focus is on performance and off-road capability, not infotainment). Driver Assistance Assistance Features: N/A (Off-road motorcycles typically do not feature electronic driver assistance systems like ABS or traction control in this era). 🔧 Maintenance Service Intervals Oil Change Interval: Detailed within manual based on usage...