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KTM · Two-stroke single, premix, chain drive

EXC 250

Library entry covers 1992-2017, Carb premix

52 factory 38 guideline

Published source

KTM Owner's Manual 2013, 125/200/250/300 EXC and XC-W, 9.1 Service schedule and 9.2 Service work, printed pp.35-36 (ManualsLib pages 37-38)

Factory owner's handbook. Covers 2013 KTM 250 EXC (carbureted two-stroke) owner's manual; chart read from the rendered pages.

90 items for a 1999 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Two-stroke
Engine lubrication: Two-stroke premix (oil in fuel)
Oil filtration: None (no filter)
Valve gear: None (two-stroke porting)
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Single carburetor
Cooling: Liquid cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Separate gearbox oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, single shock / cantilever
Front brake: Disc, hydraulic
Rear brake: Disc, hydraulic
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

1999 KTM EXC 250

On the road: every 150 mi

1 item

Check two-stroke oil tank / carry premix oil

Pre-ride / on the road

Guideline

Running a two-stroke out of oil seizes it. Injection bikes: check the tank. Premix: carry oil and a measure.

On the road: every 300 mi

3 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Guideline

Lube warm, ideally at the end of the riding day so it soaks in overnight. Sooner after rain.

On the road: every 500 mi

1 item

Check coolant level

Pre-ride / on the road

Guideline

On the road: every 20 h

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Factory

Manual: Check the chain tension. Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.

Every 1,000 mi or 1 month

1 item

Check battery electrolyte, top up with distilled water

Ignition and electrics

Guideline

Wet-cell batteries on old machines need regular topping up, more in hot weather.

Every 2,000 mi or 12 months

1 item

Replace spark plugs (two-stroke)

Engine

Guideline

Every 3,000 mi or 12 months

6 items

Clean fuel tap filter / sediment bowl

Fuel and air

Guideline
Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check spoke tension and wheel true

Wheels and tires

Guideline

Every 3,000 mi or 2 years

1 item

Decarbonize exhaust ports, pipes and baffles

Engine

Guideline

Two-strokes coke up the exhaust port and muffler baffles; power falls off gradually.

Every 4,000 mi or 12 months

2 items

Inspect, clean and gap spark plugs

Engine

Guideline
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Guideline

Every 6,000 mi or 12 months

5 items

Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Lubricate control cables and lever pivots

Controls and cables

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 10,000 mi or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 12,000 mi or 2 years

2 items

Replace air filter element

Fuel and air

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 18,000 mi

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 20,000 mi or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 20 h

36 items

Change the glass fiber yarn filling of the main muffler

Engine

Factory

Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Check that the electrical equipment is functioning properly

Engine

Factory

Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Check the antifreeze and coolant level

Engine

Factory

Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Check the headlight setting

Engine

Factory

Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Check the idle

Engine

Factory

Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Check the intake diaphragm

Engine

Factory

Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Check the rim run-out

Engine

Factory

Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Check the screws and nuts for tightness

Engine

Factory

Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Final check: check the vehicle for safe operation and take a test ride

Engine

Factory

Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Inspect coolant hoses and clamps

Engine

Factory

Manual: Check all hoses (fuel, cooling, bleeding, drainage) and sleeves for cracking, leaks and incorrect routing. Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Make the service entry in KTM DEALER.NET and in the service record

Engine

Factory

Factory: 9.1 Service schedule: marked S20A and S40A, so every 20 operating hours.
Replace spark plugs

Engine

Factory

Manual: Change the spark plug and spark plug connector. Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Check throttle cable(s) free play and return

Fuel and air

Factory

Manual: Check that the throttle cables are undamaged, routed without sharp bends and set correctly. Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Clean / inspect air filter

Fuel and air

Factory

Manual: Clean the air filter and air filter box. Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Check and charge the battery (all 200/250/300 models)

Ignition and electrics

Factory

Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Change gearbox oil

Primary and gearbox

Factory

Manual: Change the gear oil. Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Check/correct the fluid level of the hydraulic clutch

Primary and gearbox

Factory

Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Grease all moving parts (e.g. side stand, hand lever, chain) and check for smooth operation

Final drive

Factory

Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Inspect chain and sprockets for wear (measure stretch)

Final drive

Factory

Manual: Check the chain, rear sprocket, engine sprocket, and chain guide. Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Check steering head bearing adjustment

Front end

Factory

Manual: Check the play of the steering head bearing. Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Check the frame and swingarm

Rear suspension and frame

Factory

Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Clean and grease rear suspension linkage

Rear suspension and frame

Factory

Manual: Check the heim joints at the top and bottom of the shock absorber. Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Check brake pads and discs

Brakes

Factory

Manual: Check the front brake linings. Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Check the brake discs

Brakes

Factory

Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Check the free travel of the foot brake lever

Brakes

Factory

Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Check the free travel of the hand brake lever

Brakes

Factory

Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Check the front brake fluid level

Brakes

Factory

Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Check the rear brake fluid level

Brakes

Factory

Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Check the rear brake linings

Brakes

Factory

Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Inspect brake hoses; replace old rubber

Brakes

Factory

Manual: Check the brake lines for damage and leakage. Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Check the spoke tension

Wheels and tires

Factory

Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Check the tire air pressure

Wheels and tires

Factory

Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Check the wheel hubs

Wheels and tires

Factory

Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Check wheel bearings for play

Wheels and tires

Factory

Manual: Check the wheel bearing for play. Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Check the tire condition. Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.
Check the cables for damage and routing without sharp bends

Controls and cables

Factory

Factory: 9.1 Service schedule: marked both S20A (every 20 operating hours) and S40A (every 40 operating hours/after every race), so every 20 operating hours.

Every 40 h

6 items

Check the starter drive (all 200/250/300 models)

Engine

Factory

Factory: 9.2: S40A and S80A, so every 40 operating hours.
Check the clutch

Primary and gearbox

Factory

Factory: 9.1 Service schedule: marked only in S40A (every 40 operating hours/after every race).
Change fork oil

Front end

Factory

Manual: Perform a fork service (EXC EU/AUS, XC-W). Factory: 9.2: S10N (once after 10 operating hours), S40A and S80A, so once after 10 hours, then every 40 operating hours.
Check the swingarm bearing

Rear suspension and frame

Factory

Factory: 9.1 Service schedule: marked only in S40A (every 40 operating hours/after every race).
Inspect rear shocks for leaks and damping

Rear suspension and frame

Factory

Manual: Service the shock absorber. Factory: 9.2: S40A and S80A, so every 40 operating hours.
Check the exhaust control for functioning and smooth operation

Controls and cables

Factory

Factory: 9.1 Service schedule: marked only in S40A (every 40 operating hours/after every race).

Every 80 h or 12 months

1 item

Check/set the carburetor components

Fuel and air

Factory

Factory: 9.2: S80A (every 80 operating hours, every 40 when used for motorsports) and J1A (annually).

Every 80 h

4 items

Change all engine bearings

Engine

Factory

Factory: 9.2: S80A, every 80 operating hours (every 40 when used for motorsports).
Change the connecting rod, conrod bearing and crank pin

Engine

Factory

Factory: 9.2: S80A, every 80 operating hours (every 40 when used for motorsports).
Change the piston and check the cylinder (all 200/250/300 models)

Engine

Factory

Factory: 9.2: S80A, every 80 operating hours (every 40 when used for motorsports).
Check the transmission and shift mechanism

Primary and gearbox

Factory

Factory: 9.2: S80A, every 80 operating hours (every 40 when used for motorsports).

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 12 months

5 items

Replace hydraulic clutch fluid

Primary and gearbox

Factory

Manual: Change the hydraulic clutch fluid. Factory: 9.2 Service work (as additional order): J1A, annually.
Grease the steering head bearing

Front end

Factory

Factory: 9.2 Service work (as additional order): J1A, annually.
Change the rear brake fluid

Brakes

Factory

Factory: 9.2 Service work (as additional order): J1A, annually.
Replace brake fluid

Brakes

Factory

Manual: Change the front brake fluid. Factory: 9.2 Service work (as additional order): J1A, annually.
Check speedometer / odometer against a known distance

Controls and cables

Guideline

Old speedos drift with tire size and drive wear. Use phone GPS over a measured 10 miles / km.

Every 2 years

3 items

Replace coolant

Engine

Guideline
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline

Every 4 years

2 items

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

2 items

Replace inner tubes and rim tape with tires

Wheels and tires

Guideline
Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.