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Introducing the KTM 380 EXC, an offroad powerhouse that combines exceptional power with unmatched agility. Built from 1999 to 2003, the 380 EXC was a dominant force in enduro competitions, captivating riders with its adrenaline-pumping performance and uncompromising off-road capabilities.

At the heart of the KTM 380 EXC lies a potent 375.7cc single-cylinder engine, a masterpiece of engineering that delivers explosive power and responsive acceleration. The liquid-cooled design ensures consistent performance even in the most demanding conditions, while the advanced fuel injection system optimizes power delivery and reduces emissions.

The KTM 380 EXC boasts a lightweight and robust chassis that provides exceptional stability and handling. The precision-crafted aluminum frame is designed to withstand the rigors of offroad terrain, while the high-quality WP suspension components deliver unmatched rider comfort and control. The front suspension features a 43mm inverted cartridge fork with adjustable compression and rebound damping, ensuring precise handling and a smooth ride over rough terrain. The rear suspension utilizes a WP monoshock with adjustable preload, compression, and rebound damping, allowing riders to tailor the bike's handling characteristics to suit their riding style.

The KTM 380 EXC is renowned for its agile handling, thanks to its compact dimensions and low weight. The ergonomic design places the rider in an optimal riding position, providing maximum control and comfort during extended periods of riding. The wide handlebars offer precise steering input, while the off-road-specific seat provides ample support and reduces rider fatigue.

In addition to its exceptional performance, the KTM 380 EXC comes equipped with an array of features that enhance both functionality and safety. The hydraulically operated Brembo brakes provide superior stopping power, while the large-diameter disc rotors ensure effective heat dissipation. The signature KTM orange livery and distinctive graphics add a touch of style to the 380 EXC's aggressive appearance.

The KTM 380 EXC is the ultimate choice for riders seeking an offroad motorcycle that combines raw power, precision handling, and unmatched versatility. Whether you're conquering challenging trails, competing in enduro races, or simply exploring the great outdoors, the 380 EXC delivers an unforgettable riding experience that will leave you exhilarated and craving more.

KTM 380 EXC 1999 2000 2001 2002 2003 Workshop Service Manual for Repair.

This PDF service manual contains 153 pages.

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This KTM 380 EXC 1999 2000 2001 2002 2003 service manual provides data, characteristics, instructions and methodology to perform repair interventions on the vehicle and its components.

This manual includes special notes, important points, service data, precautions, etc. that are needed for the maintenance, adjustments, service, removal and installation of vehicle components for KTM 380 EXC 1999 2000 2001 2002 2003.
The most detailed, comprehensive step by step procedures, explanations, and pictorial diagrams from bumper to bumper you will ever see for KTM 380 EXC 1999 2000 2001 2002 2003.

KTM 380 EXC 1999 2000 2001 2002 2003 Service Repair Manual meets all your information needs to repair or make some adjustments to your KTM 380 EXC 1999 2000 2001 2002 2003 Service Repair Manual. This manual is intended as a handy, easy to read reference book for the mechanics and DIY persons. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order.

Detailed illustrations, exploded diagrams, drawings and photos guide you through every service repair procedure for KTM 380 EXC 1999 2000 2001 2002 2003 Service Repair Manual.

Adjustment and repair operations include reference to Service tool numbers and the associated illustration depicts the tool for KTM 380 EXC 1999 2000 2001 2002 2003. Where usage is not obvious the tool is shown in use.

This KTM 380 EXC 1999 2000 2001 2002 2003 service manual can be viewed on any computer, as well as zoomed and printed.
This service manual has been specially prepared so that the explanation is very simple. It has been prepared so that if this manual is thoroughly read, even comparatively new personel can give satisfactory after services to the customers as well as disassemble and maintain the vehicle.

All service and repair instructions included for KTM 380 EXC 1999 2000 2001 2002 2003.
Always use the correct special service tools or equipment specified. Under no circumstances use makeshift tools or equipment since the use of substitutes may adversely affect safe operation.
Where accurate measurements are required, they can only be made using calibrated, precision instruments.
Providing that the service schedules are respected, the customers can be sure of obtaining the maximum satisfaction and best result from his car. This manual provides general descriptions for accomplishing service and repair work with tested, efective tehniques. Following them will help assure reliability.
Information on the construction and function are included. This part should be understood before proceeding with troubleshooting, disassembling and servicing. Information on the troubleshooting, servicing specification lists, tightening torque, checking and adjusting, disassembling and assembling and servicing which cover procedures, precautions, factory specifications and allowable limits.
Information in this manual for KTM 380 EXC 1999 2000 2001 2002 2003 is divided into groups. These groups contain general information, diagnosis, testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and components. Appropiate service methods and correct repair procedures are esential for the safe, reliabe operation of all motor vehicles as well as the personal safety of the individual carrying out the work.

The illustrations in this manual are used to highlight the fundamental principles and procedures of basic interventions. They may not show exactly the KTM 380 EXC 1999 2000 2001 2002 2003 in your possession.

Adjustment and repair operations also include reference to wear limits for KTM 380 EXC 1999 2000 2001 2002 2003. Relevant data, useful assembly details all in this SERVICE MANUAL for KTM 380 EXC 1999 2000 2001 2002 2003.
In order to perform the work efficiently and to avoid costly mistakes, read the text and thoroughly familiarise yourself with procedures before starting work.
All work should be performed with great care and in a clean working area with adequate lighting.

Please peruse and utilize this manual for KTM 380 EXC 1999 2000 2001 2002 2003 fully to ensurea complete repair work for satisfying you or your customers by keeping their vehicle in optimum condition.
All information, illustration and specifications contained in this manual are based on the latest product information avaiable at the time of publication approval. The specification, maintenance and other information for the components are included, and diagnostic information has also been added where necessary. These torque values are intended for use in service assembly and installation procedures using the correct OEM fasteners. When replacing fasteners, always use the same type (part number) fastener as removed.
This KTM 380 EXC 1999 2000 2001 2002 2003 book outlines procedures for servicing and repairing vehicles using safe, effective methods. The procedures contain many NOTES, CAUTIONS and WARNINGS which should be followed along with standard safety procedures to eliminate the possibility of personal injury or improper service which could damage the vehicle or compromise its safety.

To maximise the life of your KTM 380 EXC 1999 2000 2001 2002 2003:
Accurately follow the maintenance requirements of the periodic maintenance chart in the service manual.
Do not allow problems to develop. Investigate unusual noises and changes in the riding characteristics of the KTM 380 EXC 1999 2000 2001 2002 2003. Rectify all problems as soon as possible (immediately if safety related).
Use only genuine KTM 380 EXC 1999 2000 2001 2002 2003 parts as listed in the parts catalogue.
Follow the procedures in this manual carefully and completely. Do not take short cuts.
Keep complete records of all maintenance and repairs with dates and any new parts installed.
Use only approved lubricants, as specified, in the manual of the KTM 380 EXC 1999 2000 2001 2002 2003.

This manual for KTM 380 EXC 1999 2000 2001 2002 2003 has been issued to provide you with technical information regarding the design, function, disassembly, adjusting work and troubleshooting on the components and model of the KTM 380 EXC 1999 2000 2001 2002 2003.
The descriptions are brief but precise and are supported by photographs, notes, drawings and schematics, as well as exploded and sectional drawings. All this information is intended to simplify any necessary repair work which can be performed on KTM 380 EXC 1999 2000 2001 2002 2003.
This manual also contains information about adjusting work and valuable reference data for such adjustment values.
For all maintenance and repair work on KTM 380 EXC 1999 2000 2001 2002 2003, all accident prevention guidelines must be strictly observed. To perform all repairs listed in this manual, a complete set of standard tools, as well as the special tools and fixtures shown and listed are necessary.
No special emphasis is put on replacing sealing components as we assume that these items are replaced during any repair. Unless specific values are given, all threaded connections should be tightened according to the required tightening torques listed on torque charts.
When describing work, which can be dangerous, we have described the required safety measures in this manual and indicated them by special remarks DANGER, CAUTION or NOTE.

This KTM 380 EXC 1999 2000 2001 2002 2003 Service Service Repair Manual QUALITY manual is 100 percents COMPLETE and INTACT, no MISSING/CORRUPT pages/sections to freak you out!

This KTM 380 EXC 1999 2000 2001 2002 2003 Service manual is known in many names:
KTM 380 EXC 1999 2000 2001 2002 2003 Service service manual.
KTM 380 EXC 1999 2000 2001 2002 2003 Service repair manual.
KTM 380 EXC 1999 2000 2001 2002 2003 Service workshop manual.
KTM 380 EXC 1999 2000 2001 2002 2003 Service shop manual.

This manual for KTM 380 EXC 1999 2000 2001 2002 2003 is designed primarily for use by trained technicians in a properly equipped workshop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. The work can only be carried out if the owner has the necessary hand and special service tools to complete the job.
A basic knowledge of mechanics, including the proper use of tools and workshop procedures is necessary in order to carry out maintenance and repair work, satisfactorily.


GENERAL TAGS FOR MOTORCYCLES:

SPECIFICATIONS for KTM 380 EXC 1999 2000 2001 2002 2003.
VEHICLE IDENTIFICATION NUMBER (V.I.N.) for KTM 380 EXC 1999 2000 2001 2002 2003.
WHEELS for KTM 380 EXC 1999 2000 2001 2002 2003.
FRONT WHEEL for KTM 380 EXC 1999 2000 2001 2002 2003.
REAR WHEEL for KTM 380 EXC 1999 2000 2001 2002 2003.
TIRES for KTM 380 EXC 1999 2000 2001 2002 2003.
FRONT BRAKE MASTER CYLINDER AND HAND LEVER for KTM 380 EXC 1999 2000 2001 2002 2003.
FRONT BRAKE LINE for KTM 380 EXC 1999 2000 2001 2002 2003.
FRONT BRAKE CALIPER for KTM 380 EXC 1999 2000 2001 2002 2003.
BRAKE PEDAL for KTM 380 EXC 1999 2000 2001 2002 2003.
REAR BRAKE MASTER CYLINDER for KTM 380 EXC 1999 2000 2001 2002 2003.
REAR BRAKE LINE for KTM 380 EXC 1999 2000 2001 2002 2003.
REAR BRAKE CALIPER for KTM 380 EXC 1999 2000 2001 2002 2003.
FENDERS for KTM 380 EXC 1999 2000 2001 2002 2003.
FRONT FORK for KTM 380 EXC 1999 2000 2001 2002 2003.
FORK CLAMPS: UPPER AND LOWER for KTM 380 EXC 1999 2000 2001 2002 2003.
STEERING HEAD BEARINGS for KTM 380 EXC 1999 2000 2001 2002 2003.
SWINGARM AND BRACE for KTM 380 EXC 1999 2000 2001 2002 2003.
FRAME for KTM 380 EXC 1999 2000 2001 2002 2003.
REAR SHOCK ABSORBER for KTM 380 EXC 1999 2000 2001 2002 2003.
THROTTLE CONTROL for KTM 380 EXC 1999 2000 2001 2002 2003.
CLUTCH CONTROL for KTM 380 EXC 1999 2000 2001 2002 2003.
HEADLAMP ASSEMBLY AND SUPPORT BRACKET for KTM 380 EXC 1999 2000 2001 2002 2003.
FOOTPEG, HEEL GUARD AND MOUNT for KTM 380 EXC 1999 2000 2001 2002 2003.
SPROCKET COVER for KTM 380 EXC 1999 2000 2001 2002 2003.
BELT GUARDS. for KTM 380 EXC 1999 2000 2001 2002 2003.
INTAKE COVER for KTM 380 EXC 1999 2000 2001 2002 2003.
SIDESTAND for KTM 380 EXC 1999 2000 2001 2002 2003.
SEAT LOCKS for KTM 380 EXC 1999 2000 2001 2002 2003.
ENGINE for KTM 380 EXC 1999 2000 2001 2002 2003.
ENGINE REMOVAL for KTM 380 EXC 1999 2000 2001 2002 2003.
ENGINE INSTALLATION for KTM 380 EXC 1999 2000 2001 2002 2003.
CYLINDER HEAD for KTM 380 EXC 1999 2000 2001 2002 2003.
CYLINDER AND PISTON for KTM 380 EXC 1999 2000 2001 2002 2003.
LUBRICATION SYSTEM for KTM 380 EXC 1999 2000 2001 2002 2003.
OIL RESERVOIR AND OIL HOSE ROUTING for KTM 380 EXC 1999 2000 2001 2002 2003.
OIL COOLER for KTM 380 EXC 1999 2000 2001 2002 2003.
OIL PRESSURE INDICATOR SWITCH for KTM 380 EXC 1999 2000 2001 2002 2003.
CRANKCASE BREATHING SYSTEM for KTM 380 EXC 1999 2000 2001 2002 2003.
OILING SYSTEM for KTM 380 EXC 1999 2000 2001 2002 2003.
OIL PUMP for KTM 380 EXC 1999 2000 2001 2002 2003.
HYDRAULIC LIFTERS for KTM 380 EXC 1999 2000 2001 2002 2003.
GEARCASE AND CAM GEARS for KTM 380 EXC 1999 2000 2001 2002 2003.
CRANKCASE for KTM 380 EXC 1999 2000 2001 2002 2003.
AIR CLEANER ASSEMBLY for KTM 380 EXC 1999 2000 2001 2002 2003.
ELECTRONIC CONTROL MODULE (ECM) for KTM 380 EXC 1999 2000 2001 2002 2003.
THROTTLE POSITION SENSOR (TPS) for KTM 380 EXC 1999 2000 2001 2002 2003.
IGNITION COIL for KTM 380 EXC 1999 2000 2001 2002 2003.
FUEL TANK for KTM 380 EXC 1999 2000 2001 2002 2003.
FUEL PUMP for KTM 380 EXC 1999 2000 2001 2002 2003.
THROTTLE BODY for KTM 380 EXC 1999 2000 2001 2002 2003.
EXHAUST SYSTEM for KTM 380 EXC 1999 2000 2001 2002 2003.
STARTER for KTM 380 EXC 1999 2000 2001 2002 2003.
IGNITION SYSTEM for KTM 380 EXC 1999 2000 2001 2002 2003.
IGNITION/HEADLAMP KEY SWITCH for KTM 380 EXC 1999 2000 2001 2002 2003.
SPARK PLUG CABLES for KTM 380 EXC 1999 2000 2001 2002 2003.
CHARGING SYSTEM for KTM 380 EXC 1999 2000 2001 2002 2003.
BATTERY CABLES for KTM 380 EXC 1999 2000 2001 2002 2003.
VOLTAGE REGULATOR for KTM 380 EXC 1999 2000 2001 2002 2003.
ALTERNATOR for KTM 380 EXC 1999 2000 2001 2002 2003.
TURN SIGNAL FLASHER, FRONT TURN SIGNALS, REAR TURN SIGNALS for KTM 380 EXC 1999 2000 2001 2002 2003.
HEADLIGHT, TAIL LAMP for KTM 380 EXC 1999 2000 2001 2002 2003.
MAIN FUSE AND FUSES for KTM 380 EXC 1999 2000 2001 2002 2003.
WIRING DIAGRAMS for KTM 380 EXC 1999 2000 2001 2002 2003.

AND MORE...

KTM 380 EXC 1999 2000 2001 2002 2003 Workshop Service Manual for Repair.