Complete factory shop manual including electrical wiring diagrams for 1983-2010 KTM 250 EGS, 250 EXC, 250 EXC, 250 EXC-F (AUS/EU/USA), 250 EXC-F SIX DAYS, 250 EXC SIX DAYS, 250 EXC-USA, 250GS, 250 MX, 250 MXC, 250 SX, 250 SX-F, 250 SXS, 250 SXS-F, 250 XC, 250 XC-F, 250 XCF-W, 250 XC-W, 300 EGS, 300 EXC, 300 EXC SIX DAYS, 300 EXC-USA, 300 MXC, 300SX, 300 SXS, 300 XC, 300 XC-W, 380 EGS, 380 SX, 380 MXC, 380 EXC, 400 SX, 400 MXC, 400 XC, 400 EXC, 400 SMR, 400 SXS RACING, 400 SX, 400 MXC, 400 XC, 400 EXC, 400 SMR, 400 SXS RACING, 520 SX, 520 MXC, 520 XC, 520 EXC, 520 SMR RACING, 525 SX, 525 MXC, 525 XC, 525 EXC, 525 SMR RACING, 540 SXS, 560 SMR, 610 CRATE Motorcycle. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page to save your precious time.

This repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

MAKE: KTM
YEAR: 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
MODEL: 250 EGS, 250 EXC, 250 EXC, 250 EXC-F (AUS/EU/USA), 250 EXC-F SIX DAYS, 250 EXC SIX DAYS, 250 EXC-USA, 250GS, 250 MX, 250 MXC, 250 SX, 250 SX-F, 250 SXS, 250 SXS-F, 250 XC, 250 XC-F, 250 XCF-W, 250 XC-W, 300 EGS, 300 EXC, 300 EXC SIX DAYS, 300 EXC-USA, 300 MXC, 300SX, 300 SXS, 300 XC, 300 XC-W, 380 EGS, 380 SX, 380 MXC, 380 EXC, 400 SX, 400 MXC, 400 XC, 400 EXC, 400 SMR, 400 SXS RACING, 400 SX, 400 MXC, 400 XC, 400 EXC, 400 SMR, 400 SXS RACING, 520 SX, 520 MXC, 520 XC, 520 EXC, 520 SMR RACING, 525 SX, 525 MXC, 525 XC, 525 EXC, 525 SMR RACING, 540 SXS, 560 SMR, 610 CRATE

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"'04-'10 250-300.pdf"
229 pages; 2004-2007 Repair Manual for 250 EXC, 250 EXC, 250 EXC SIX DAYS, 250 EXC-USA, 250 MXC, 250 SX, 250 SXS, 250 XC, 250 XC-W, 300 EXC, 300 EXC SIX DAYS, 300 EXC-USA, 300 MXC, 300SX, 300 XC, 300 XC-W

"'05-'10 250"
55 MB, 700+ pages PDF; 2005-2010 Service Manual for 250 EXC-F (AUS/EU/USA), 250 EXC-F SIX DAYS, 250 SX-F, 250 SXS-F, 250 XC-F, 250 XCF-W

"'05-'08 250"
177 MB, 3,000+ pages PDF, EN/DE/FR/IT/ES; 2005-2008 Service Manual (Repair Manual. Owner's Manual...) for 250 SX-F, 250 EXC-F (USA/EU), 250 EXC-F SIX DAYS, 250 XCF-W, 250 XC-F, 250 SXS-F

"'00-'06 250-610"
35 MB, 600+ PDF, 2000-2006 Service Manual (Repair Manual. Owner's Manual...) for 250 EXC RACING
400 SX, 400 MXC, 400 XC, 400 EXC, 400 SMR, 400 SXS RACING, 450 SX, 400 MXC, 400 XC, 400 EXC, 400 SMR, 400 SXS RACING, 520 SX, 520 MXC, 520 XC, 520 EXC, 520 SMR RACING, 525 SX, 525 MXC, 525 XC, 525 EXC, 525 SMR RACING, 540 SXS, 560 SMR, 610 CRATE

"'04-'06 250-300.pdf"
159 pages; Repair Manual 2004-2006 for 250 SX, 250 SXS, 250 MXC, 250 EXC, 250 EXC SIX DAYS, 250 XC, 250 XC-W, 300 SX, 300 SXS, 300 MXC, 300 EXC, 300 EXC SIX DAYS, 300 XC, 300 XC-W

"'05-'06 250 SX-F.pdf"
125 pages; Repair Manual for 2005-2006 250 SX-F

"'99-'03 250-300-380 SX, MXC, EXC.pdf"
153 pages; Repair Manual 1999-2003 for 250 EGS, 250 SX, 250 MXC, 250 EXC, 300 EGS, 300 SX, 300 MXC, 300 EXC, 380 EGS, 380 SX, 380 MXC, 380 EXC

"'00-'03 250-525 SX_MXC_EXC Racing.pdf"
167 pages; Repair Manual Engine for 250-400-520-525 SX, MXC, EXC RACING

"250MX ('83-'91), 250MXC ('84-'03), 250GS ('83-'99) (EN-DE).pdf"
63 pages, EN/DE; 250MX ('83-'91), 250MXC ('84-'03), 250GS ('83-'99) Owners Repair Manual

EXCERPT:
1 SERVICE-INFORMATION
2 GENERAL INFORMATION
3 REMOVING AND REFITTING ENGINE
4 DISASSEMBLING THE ENGINE
5 SERVICING INDIVIDUAL COMPONENTS
6 ASSEMBLING THE ENGINE
7 ELECTRICAL
8 FUEL SYSTEM
9 TROUBLE SHOOTING
10 TECHNICAL SPECIFICATIONS
11 PERIODIC MAINTENANCE SCHEDULE
12 WIRING DIAGRAM
...
Servicing the right engine housing half
– Remove all shaft seal rings and use an oven to heat the casing half to approx. 150°C.
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° - 180° C. At this housing temperature, the new (cold) bearings can be inserted in the bearing seats without pressing.
Grooved ball bearing of crankshaft 1
Press the old grooved ball-bearing inwards. Press in the new grooved ball bearing from inside up to the stop.
Grooved ball bearing of main shaft 2
Press in the new ball bearing from inside up to the stop.
Grooved ball bearing of countershaft 3
Press in the new grooved ball bearing from downward to the stop.
Grooved ball bearing of the shift roller 4
Remove bolt A and press bearing towards the inside. Press in the new ball bearing from the inside to the stop and secure the retaining bolt with Loctite 243.
Needle bushing of the shift shaft 5
Press the old needle bushing inwards, press in the new needle bushing flush from the outside.
Grooved ball bearing of centrifugal timer 6
Use a self-made "supporting plate" to support the puller to avoid damage to the housing (see illustration).
Pull out the bearing using a Ø 5-8 mm inside puller 151.12.018.100.
Press in the new grooved ball bearing to the stop.
Bearing bolt kick-starter intermediate gear 7
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.
Kickstarter release plate 8
Secure the screws with Loctite 243 when changing the release plate.
Crankshaft seal ring 9
Press in the new shaft seal ring from the outside with the sealing lip facing inward, until flush.
– Finally check clear passage of the crankshaft ball bearing lubrication bore B.
...