2004 KTM 250 EXC Motorcycle
Totally new engine based on KTM's new generation
3.5 kg engine weight reduction.
Lighter and more compact engine.
Boyesen intake reed case.
EXC crankshaft has significantly more oscillating
mass when compared to the SX engine for perfectly
tuned enduro riding.
Dual-ring pistons for increased durability.
Cylinder head with special enduro combustion
Kokusan 2K3 digital ignition system and
ignition cover with more space for the heavier
Special digi-box with specifically enduro-tuned
EXC 5-speed transmission features extra-short
1st gear and a slightly longer 5th gear.
Keihin PWK 36 AG carburettor specially tuned
for the flat, rideable torque curve of an
Exhaust system is a total new design, offering
the perfect fit for the new enduro setup,
additionally they are equipped with a new
shorter silencer, in combination they are
responsible for broad usable powerband and
a flat enduro-style output curve.
Stronger clutch plates offer more reliability.
One-piece ignition rotor.
Single-tube racing exhaust with new tuned
Additional useful torque.
High specification chromoly frame features
reduced wall thickness at the frame loops
of the Racing models from 1.8 mm to 1.5 mm
contribute to lower overall weight (total
frame weight now less than 9 kg).
New forged parts work as linkage carrier
(in the swing arm and foot peg area) reducing
Reinforced steering head gusset plate for
New 10 mm longer swing arm, attached with
a 17 mm strengthened swing arm pivot.
Inner tubes of the new 48 mm White Power
USD fork are guided with the utmost precision
through three (previously 2) bushing guides
offering greater sensibility.
Newly tuned PDS.
New front brake pads.
New, even lighter, perforated, high-powered
front and rear brake disks.
Integrated reservoir foot brake-cylinder
New, extra-light brake system with 26 mm
rear brake callipers.
Pirelli MT 83 high specification competition
One-piece fender with integrated side-panels
sits on a new sub frame which lowers the rear
end by 9 mm.
New license plate holders long (series)
and short for competition.
New taillight for short license plate holder.
All seats have a new seat base for rear
fender, anchored by a single bolt located
underneath the seat.
New larger air-filter box.
New air filter carrier with triple mounting
pins for more reliability (2-stroke).
Dual Compound Renthal grips (grey/orange).
New decals for the spoiler and air box cover.
New frame guards.
Only differences between 250 and 300 EXC
are the digi box configuration, the exhaust
port timing and the piston/cylinder (bore
x stroke 250 EXC: 66.4/72 mm, 300 EXC: 72/72
Engine - single cylinder, 2-stroke
Displacement (cc) - 249
Bore x stroke (mm) - 72 x 72
Starter - kick-starter
Transmission - 5 gears
Carburetor - Keihin PWK 38 AG
Control - TVC
Lubrication - mixture oil lubrication
Transmission lubrication - 0,7 l Motorex
Top Speed 15W50
Primary drive - 26:72
Cooling - liquid cooled
Clutch - wet multi-disc clutch, operated
Ignition - Kokusan digital 2K-3
Frame - chromium molybdenum
Subframe - aluminium
Handlebar - tapered Renthal Ø 28 mm
Front suspension - WP-USD 48 MA
Rear suspension - WP-PDS-shock absorber
Suspension travel, front/rear - 300 / 335
Front / Rear brakes - disc brakes 260 /
Front / rear rims - 1.60 x 21"; 2.15 x
Front / rear tires - 90/90-21"; 140/80-18"
Transmission - 13:42
Chain - X-ring chain 5/8 x 1/4"
Main silencer - aluminum
Steering head angle - 63°
Wheel caster - 116 mm
Wheelbase - 1475±10 mm
Ground clearance (unloaded) - 385 mm
Seat height - 925 mm
Fuel capacity - approx. 9 litres
Weight (ready to race, no fuel) - approx.