Enduro · Two stroke
The 250 two stroke enduro bike. Lighter and snappier than the 300, registrable, electric start, and fuel injected since 2018. Sold in Australia from 1990 to 2023, 34 model years.
The 250 EXC is the 300 EXC's smaller brother, and for a lot of riders it is the better bike. It is snappier and more playful, it is a touch lighter, and it rewards a rider who likes to rev a two stroke. It has all the same kit: electric start, hydraulic clutch, registration, and TPI then TBI fuel injection from 2018.
It suits a lighter or more aggressive rider, an enduro racer in the E1 class, or a trail rider who finds the 300 too lazy. Against the 300 EXC it gives away torque in the steep, technical stuff and gains a livelier feel everywhere else. Against a Husqvarna TE 250 or GasGas EC 250 it is the same bike with different suspension and bodywork.
Gearbox oil every 10 to 15 hours (about 800 ml of a light gear oil or JASO MA 10W 40), air filter every ride in dust, and keep the oil injection tank full on the TPI and TBI bikes. A 250 revs harder than a 300, so top ends come a little sooner: rings around 50 to 70 hours and a piston around 100 for a trail bike, sooner if raced.
Clean the power valve at every top end. Grease the linkage and swingarm after wet rides and keep the coolant fresh.
Engine hours between jobs: the schedule the Digital Garage tracks for this bike, based on the manual. Racers and hard riders go sooner, as above. Ride in sand or mud and halve the engine ones.
| Job | Every |
|---|---|
| Air filter clean and re-oil | 3h |
| Chain clean, lube and adjust | 5h |
| Spoke tension check | 10h |
| Fastener torque check | 10h |
| Transmission oil change | 15h |
| Cables and throttle lube | 15h |
| Air boot and intake seal check | 25h |
| Spark plug replace | 25h |
| Rings only replace | 30h |
| Silencer repack | 30h |
| Linkage bearings grease | 30h |
| Rear brake pads | 30h |
| Power valve clean | 40h |
| Tyres inspect / replace | 40h |
| Tubes and rim locks | 40h |
| Clutch plates inspect | 50h |
| Chain slider, guide and roller | 50h |
| Front brake pads | 50h |
| Grips inspect / replace | 50h |
| Top end rebuild (piston and rings) | 60h |
| Reed valve inspect | 60h |
| Fork service (oil and seals) | 60h |
| Swingarm bearings grease | 60h |
| Steering head bearings grease | 60h |
| Wheel bearings inspect | 60h |
| Radiator, hoses and clamps | 60h |
| Carburettor / throttle body clean | 80h |
| Chain and sprockets replace | 80h |
| Shock service | 80h |
| Wiring and connectors | 80h |
| Bottom end inspect / rebuild | 100h |
| Water pump seal and impeller | 100h |
| Brake discs inspect | 100h |

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On a carburetted bike ask about the jetting and the last top end. On a TPI bike make sure the oil injection has never run dry and it idles cleanly hot. Look for a dented pipe, bent radiators, a cracked sump guard and a worn clutch. Check the rego status and whether it has been de restricted.
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Can fail or clog. Heavy smoke or stalling at idle wants a look. Keep the oil tank full.
Carbon builds up and it sticks. A clean, not a rebuild.
Rocks find the pipe. Small dents are fine.