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KTM 300 EXC Repair Manual (289 pages)

Table of Contents

Brand: KTM
|
Category: Motorcycle
|
Size: 3.99 MB

• Table of Contents

  4

• 1 Means of Representation

  7

  • Symbols Used

    7

  • Formats Used

    7

• 2 Safety Advice

  8

  • Use Definition — Intended Use

    8

  • Degrees of Risk and Symbols

    8

  • Tampering Warning

    8

  • Safe Operation

    9

  • Protective Clothing

    9

  • Work Rules

    9

  • Environment

    9

  • Owner’s Manual

    9

• 3 Important Notes

  10

  • Guarantee, Warranty

    10

  • Operating and Auxiliary Substances

    10

  • Spare Parts, Accessories

    10

  • Service

    10

  • Figures

    10

  • Customer Service

    10

• 4 View of Vehicle

  11

  • View of Vehicle, Front Left (Example)

    11

  • View of Vehicle, Rear Right (Example)

    12

• 5 Serial Numbers

  13

  • Chassis Number

    13

  • Type Label

    13

  • Key Number (All EXC Models)

    13

  • Engine Number

    13

  • Fork Part Number

    13

  • Shock Absorber Part Number

    14

• 6 Controls

  15

  • Clutch Lever

    15

  • Hand Brake Lever

    15

  • Throttle Grip

    15

  • Kill Switch (All EXC Models)

    15

  • Kill Switch (All XC-W Models)

    16

  • Horn Button (All EXC Models)

    16

  • Light Switch (All EXC Models)

    16

  • Light Switch (All XC-W Models)

    16

  • Turn Signal Switch (All EXC Models)

    16

  • Emergency off Switch (EXC AUS)

    17

  • Electric Starter Button (200/250/300 EXC EU, 250/300 SIX DAYS, XC-W)

    17

  • Electric Starter Button (EXC AUS)

    17

  • Overview of Indicator Lamps (EXC EU/AUS)

    17

  • Overview of Indicator Lamps (SIX DAYS EU)

    17

  • Overview of Indicator Lamps (300 XC-W SIX DAYS USA)

    18

  • Opening the Filler Cap

    18

  • Closing the Filler Cap

    18

  • Fuel Tap

    19

  • Choke

    19

  • Shift Lever

    19

  • Kick Starter

    20

  • Foot Brake Lever

    20

  • Side Stand

    20

  • Steering Lock (All EXC Models)

    20

  • Locking the Steering (All EXC Models)

    21

  • Unlocking the Steering (All EXC Models)

    21

• 7 Speedometer

  22

  • Exc, XC-W

    22

  • Speedometer Overview

    22

  • Activation and Test

    22

  • Setting Kilometers or Miles

    22

  • Adjusting the Speedometer Functions

    23

  • Setting the Clock

    23

  • Querying Lap Time

    23

  • Display Mode SPEED (Speed)

    24

  • Display Mode SPEED/H (Service Hours)

    24

  • Setup Menu

    24

  • Unit of Measurement Menu

    25

  • Display Mode SPEED/CLK (Time)

    25

  • Setting the Clock

    25

  • Display Mode SPEED/LAP (Lap Time)

    26

  • Viewing the Lap Time

    26

  • Display Mode SPEED/ODO (Odometer)

    26

  • Display Mode SPEED/TR1 (Trip Master 1)

    26

  • Display Mode SPEED/TR2 (Trip Master 2)

    27

  • Setting TR2 (Trip Master 2)

    27

  • Display Mode SPEED/A1 (Average Speed 1)

    27

  • Display Mode SPEED/A2 (Average Speed 2)

    28

  • Display Mode SPEED/S1 (Stop Watch 1)

    28

  • Display Mode SPEED/S2 (Stop Watch 2)

    28

  • Table of Functions

    28

  • Table of Conditions and Menu Activation

    29

  • Six Days

    29

  • Speedometer Overview

    29

  • Activation and Test

    30

  • Setting Kilometers or Miles

    30

  • Setting the Speedometer Functions

    30

  • Setting the Clock

    31

  • Viewing the Lap Time

    31

  • Display Mode SPEED (Speed)

    32

  • Display Mode SPEED/H (Service Hours)

    32

  • Setup Menu

    32

  • Setting the Unit of Measurement

    33

  • Display Mode SPEED/CLK (Time)

    33

  • Setting the Clock

    33

  • Display Mode SPEED/LAP (Lap Time)

    34

  • Viewing the Lap Time

    34

  • Display Mode SPEED/ODO (Odometer)

    34

  • Display Mode SPEED/TR1 (Trip Master 1)

    34

  • Display Mode SPEED/TR2 (Trip Master 2)

    35

  • Setting TR2 (Trip Master 2)

    35

  • Display Mode SPEED/A1 (Average Speed 1)

    35

  • Display Mode SPEED/A2 (Average Speed 2)

    36

  • Display Mode SPEED/S1 (Stop Watch 1)

    36

  • Display Mode SPEED/S2 (Stop Watch 2)

    36

  • Table of Functions

    37

  • Table of Conditions and Menu Activation

    38

KTM 300 EXC Owner’s Manual (154 pages)

Table of Contents

Brand: KTM
|
Category: Motorcycle
|
Size: 7.05 MB

• Table of Contents

  4

• Table of Contents 2

  4

• 1 Means of Representation

  7

  • Symbols Used

    7

  • Formats Used

    7

• 2 Safety Advice

  8

  • Use Definition — Intended Use

    8

  • Degrees of Risk and Symbols

    8

  • Tampering Warning

    8

  • Safe Operation

    9

  • Protective Clothing

    9

  • Work Rules

    9

  • Environment

    9

  • Owner’s Manual

    9

• 3 Important Notes

  10

  • Guarantee, Warranty

    10

  • Operating and Auxiliary Substances

    10

  • Spare Parts, Accessories

    10

  • Service

    10

  • Figures

    10

  • Customer Service

    10

• 4 View of Vehicle

  11

  • View of Vehicle, Front Left (Example)

    11

  • View of Vehicle, Rear Right (Example)

    12

• 5 Serial Numbers

  13

  • Chassis Number

    13

  • Type Label

    13

  • Key Number (All EXC Models)

    13

  • Engine Number

    13

  • Fork Part Number

    13

  • Shock Absorber Part Number

    14

• 6 Controls

  15

  • Clutch Lever

    15

  • Hand Brake Lever

    15

  • Throttle Grip

    15

  • Kill Switch (EXC EU/AU, EXC Factory Edition, 300 EXC BR)

    15

  • Kill Switch (Six Days EU)

    16

  • Kill Switch (All XC-W Models)

    16

  • Horn Button (EXC EU/AU, EXC Factory Edition, 300 EXC BR)

    16

  • Horn Button (Six Days EU)

    16

  • Light Switch (EXC EU/AU, EXC Factory Edition, 300 EXC BR)

    16

  • Light Switch (Six Days EU)

    17

  • Light Switch (All XC-W Models)

    17

  • Turn Signal Switch (EXC EU/AU, EXC Factory Edition, 300 EXC BR)

    17

  • Turn Signal Switch (Six Days EU)

    17

  • Emergency off Switch (EXC AU)

    17

  • Electric Starter Button (All 200/250/300 EU/US Models, 300 EXC BR)

    18

  • Electric Starter Button (EXC AU)

    18

  • Overview of Indicator Lamps (All EXC Models)

    18

  • Overview of Indicator Lamps (All XC-W Models)

    18

  • Opening the Filler Cap

    18

  • Closing the Filler Cap

    19

  • Fuel Tap

    19

  • Choke

    20

  • Shift Lever

    20

  • Kick Starter

    20

  • Foot Brake Lever

    20

  • Side Stand

    21

  • Steering Lock (All EXC Models)

    21

  • Locking the Steering (All EXC Models)

    21

  • Unlocking the Steering (All EXC Models)

    22

• 7 Speedometer

  23

  • Speedometer Overview

    23

  • Activation and Test

    23

  • Setting Kilometers or Miles

    23

  • Setting the Speedometer Functions

    24

  • Setting the Clock

    24

  • Viewing the Lap Time

    24

  • Display Mode SPEED (Speed)

    25

  • Display Mode SPEED/H (Service Hours)

    25

  • Setup Menu

    25

  • Setting the Unit of Measurement

    26

  • Display Mode SPEED/CLK (Time)

    26

  • Setting the Clock

    27

  • Display Mode SPEED/LAP (Lap Time)

    27

  • Viewing the Lap Time

    27

  • Display Mode SPEED/ODO (Odometer)

    28

  • Display Mode SPEED/TR1 (Trip Master 1)

    28

  • Display Mode SPEED/TR2 (Trip Master 2)

    28

  • Setting TR2 (Trip Master 2)

    28

  • Display Mode SPEED/A1 (Average Speed 1)

    29

  • Display Mode SPEED/A2 (Average Speed 2)

    29

  • Display Mode SPEED/S1 (Stop Watch 1)

    30

  • Display Mode SPEED/S2 (Stop Watch 2)

    30

  • Table of Functions

    30

  • Table of Conditions and Menu Activation

    31

• 8 Preparing for Use

  32

  • Advice on First Use

    32

  • Running in the Engine

    33

  • Preparing the Vehicle for Difficult Riding Conditions

    33

  • Preparations for Riding on Dry Sand

    34

  • Preparations for Riding on Wet Sand

    34

  • Preparations for Riding on Wet and Muddy Surfaces

    35

  • Preparations for Riding at High Temperatures and Low Speeds

    35

  • Preparing for Riding at Low Temperatures or in Snow

    36

Brand: KTM
|
Category: Motorcycle
|
Size: 4.41 MB

• Table of Contents

  4

• 1 Means of Representation

  7

  • Symbols Used

    7

  • Formats Used

    7

• 2 Safety Advice

  8

  • Use Definition — Intended Use

    8

  • Degrees of Risk and Symbols

    8

  • Tampering Warning

    8

  • Safe Operation

    9

  • Protective Clothing

    9

  • Work Rules

    9

  • Environment

    9

  • Owner’s Manual

    9

• 3 Important Notes

  10

  • Guarantee, Warranty

    10

  • Operating and Auxiliary Substances

    10

  • Spare Parts, Accessories

    10

  • Service

    10

  • Figures

    10

  • Customer Service

    10

• 4 View of Vehicle

  11

  • View of Vehicle, Front Left (Example)

    11

  • View of Vehicle, Rear Right (Example)

    12

• 5 Serial Numbers

  13

  • Chassis Number

    13

  • Type Label

    13

  • Key Number (All EXC Models)

    13

  • Engine Number

    13

  • Fork Part Number

    13

  • Shock Absorber Part Number

    14

• 6 Controls

  15

  • Clutch Lever

    15

  • Hand Brake Lever

    15

  • Throttle Grip

    15

  • Kill Switch (All EXC Models)

    15

  • Kill Switch (XC-W)

    16

  • Horn Button (All EXC Models)

    16

  • Light Switch (All EXC Models)

    16

  • Light Switch (XC-W)

    16

  • Turn Signal Switch (All EXC Models)

    16

  • Emergency off Switch (EXC AUS)

    17

  • Electric Starter Button (200/250/300 EXC EU, 250/300 EXC SIX DAYS EU, XC-W)

    17

  • Electric Starter Button (EXC AUS)

    17

  • Overview of Indicator Lamps (All EXC Models)

    17

  • Speedometer

    17

  • Overview

    17

  • Activation and Test

    18

  • Tripmaster Switch

    18

  • Setting Kilometers or Miles

    18

  • Adjusting the Speedometer Functions

    18

  • Setting the Clock

    19

  • Querying Lap Time

    19

  • Display Mode SPEED (Speed)

    20

  • Display Mode SPEED/H (Operating Hours)

    20

  • Display Mode SPEED/CLK (Clock)

    20

  • Display Mode SPEED/LAP (Lap Time)

    21

  • Display Mode SPEED/ODO (Odometer)

    21

  • Display Mode SPEED/TR1 (Trip Master 1)

    21

  • Display Mode SPEED/TR2 (Trip Master 2)

    21

  • Display Mode SPEED/A1 (Average Speed 1)

    22

  • Display Mode SPEED/A2 (Average Speed 2)

    22

  • Display Mode SPEED/S1 (Stop Watch 1)

    22

  • Display Mode SPEED/S2 (Stop Watch 2)

    23

  • 6.14.19 Table of Functions

    23

  • 6.14.20 Table of Conditions and Menu Activation

    23

  • Opening the Filler Cap

    24

  • Closing the Filler Cap

    24

  • Fuel Tap

    25

  • Choke

    25

  • Shift Lever

    25

  • Kick Starter

    26

  • Foot Brake Lever

    26

  • Side Stand

    26

  • Steering Lock (All EXC Models)

    26

  • Locking the Steering (All EXC Models)

    27

  • Unlocking the Steering (All EXC Models)

    27

Brand: KTM
|
Category: Motorcycle
|
Size: 7.6 MB

• Table of Contents

  4

• Means of Representation

  8

• Symbols Used

  8

• Formats Used

  8

• Safety Advice 2

  9

• Use Definition — Intended Use

  9

• Misuse

  9

• Degrees of Risk and Symbols

  9

• Tampering Warning

  10

• Safe Operation

  10

• Protective Clothing

  11

• Work Rules

  11

• Environment

  11

• Owner’s Manual

  11

• Important Notes

  12

• Manufacturer Warranty, Implied Warranty

  12

• Fuel, Auxiliary Substances

  12

• Spare Parts, Accessories

  12

• Service

  12

• Figures

  12

• Customer Service

  12

• View of Vehicle 4

  13

• View of Vehicle, Front Left (Example)

  13

• View of Vehicle, Rear Right (Example)

  14

• Serial Numbers 5

  15

• Vehicle Identification Number

  15

• Type Label

  15

• Key Number

  15

• Engine Number

  15

• Fork Part Number

  16

• Shock Absorber Article Number

  16

• Controls 6

  17

• Clutch Lever

  17

• Hand Brake Lever

  17

• Throttle Grip

  17

• Switch-Off Button

  17

• Horn Button

  18

• Light Switch

  18

• Turn Signal Switch

  18

• Emergency off Switch

  18

• Start Button

  19

• Overview of Indicator Lamps

  19

• Opening the Fuel Tank Filler Cap

  19

• Closing the Fuel Tank Filler Cap

  20

• Fuel Tap

  20

• Choke

  21

• Shift Lever

  21

• Foot Brake Lever

  21

• Side Stand

  22

• Steering Lock

  22

• Locking the Steering

  22

• Unlocking the Steering

  23

• Combination Instrument

  24

• Combination Instrument Overview

  24

• Activation and Test

  24

• Setting the Kilometers or Miles

  24

• Adjusting Combination Instrument Function

  25

• Setting the Clock

  26

• Viewing the Lap Time

  26

• Display Mode SPEED (Speed)

  27

• Display Mode SPEED/H (Operating Hours)

  27

• Setup Menu

  27

• Adjusting the Unit of Measurement

  28

• Display Mode SPEED/CLK (Time)

  29

• Setting the Clock

  29

• Display Mode SPEED/LAP (Lap Time)

  29

• Viewing the Lap Time

  30

• Display Mode SPEED/ODO (Odometer)

  30

• Display Mode SPEED/TR1 (Trip Master 1)

  31

• Display Mode SPEED/TR2 (Trip Master 2)

  31

• Adjusting TR2 (Trip Master 2)

  31

Brand: KTM
|
Category: Motorcycle
|
Size: 4.26 MB

• Table of Contents

  4

• Means of Representation

  7

• Important Information

  8

• View of Vehicle

  10

  • View of Vehicle, Front Left (Example)

    10

  • View of Vehicle, Rear Right (Example)

    11

• Serial Numbers

  12

  • Chassis Number

    12

  • Type Label

    12

  • Key Number (All EXC Models)

    12

  • Engine Number

    13

  • Fork Part Number

    13

  • Shock Absorber Part Number

    13

• Controls

  14

  • Clutch Lever

    14

  • Hand Brake Lever

    14

  • Throttle Grip

    14

  • Kill Switch (All EXC Models)

    14

  • Short Circuit Button (XC-W)

    15

  • Light Switch (All EXC Models)

    15

  • Turn Signal Switch (All EXC Models)

    15

  • Horn Button (All EXC Models)

    15

  • Emergency off Switch (200 EXC AUS)

    15

  • Emergency off Switch (250/300 EXC AUS)

    16

  • Electric Starter Button (250/300 EXC EU, EXC SIX DAYS, 250/300 XC-W)

    16

  • Electric Starter Button (250/300 EXC AUS)

    16

  • Light Switch (XC-W)

    16

  • Overview of Indicator Lamps (All EXC Models)

    16

  • Speedometer

    17

  • Speedometer Activation and Test

    17

  • Tripmaster Switch

    17

  • Setting Kilometers or Miles

    17

  • Setting the Clock

    18

  • Adjusting the Speedometer Functions

    18

  • Querying Lap Time

    19

  • Display Mode SPEED (Speed)

    19

  • Display Mode SPEED/H (Operating Hours)

    19

  • Display Mode SPEED/CLK (Clock)

    20

  • Display Mode SPEED/LAP (Lap Time)

    20

  • Display Mode SPEED/ODO (Odometer)

    20

  • Display Mode SPEED/TR1 (Trip Master 1)

    20

  • Display Mode SPEED/TR2 (Trip Master 2)

    21

  • Display Mode SPEED/A1 (Average Speed 1)

    21

  • Display Mode SPEED/A2 (Average Speed 2)

    21

  • Display Mode SPEED/S1 (Stop Watch 1)

    22

  • Display Mode SPEED/S2 (Stop Watch 2)

    22

  • Fuel Tap

    23

  • Opening the Filler Cap

    23

  • Closing the Filler Cap

    24

  • Shift Lever

    24

  • Kickstarter

    24

  • Foot Brake Lever

    25

  • Side Stand

    25

  • Steering Lock (All EXC Models)

    25

  • Locking the Steering (All EXC Models)

    25

  • Unlocking the Steering (All EXC Models)

    26

• Preparing for Use

  27

  • Advice on First Use

    27

  • Running in the Engine

    28

  • Preparing the Vehicle for Difficult Operating Conditions

    28

  • Preparations for Riding on Dry Sand

    29

  • Preparations for Riding on Wet Sand

    29

  • Preparations for Riding on Wet and Muddy Surfaces

    30

  • Preparations for Riding at High Temperatures and Low Speeds

    30

  • Preparing for Rides at Low Temperatures or in Snow

    31

• Riding Instructions

  32

  • Checks and Maintenance Work When Preparing for Use

    32

  • Starting

    32

  • Start off

    33

  • Shifting, Riding

    33

  • Braking

    33

  • Stopping, Parking

    34

  • Refueling

    34

• Service Schedule

  36

  • Maintenance Work (as an Additional Order)

    37

• Table of Contents

  5

• Updating Instructions

  7

• Explanation — Updating

  9

• General Information

  14

• Operating Ranges of the Carburetor

  16

  • Basic Information on a Change of the Carburetor Setting

    17

  • Basic Information on the Original Carburetor Setting

    17

• Carburetor Adjustment

  17

  • Bleeding of the Hydraulic Clutch

    18

    • Checking the Setting of the TVC System

      18

    • Special Tools — Engine 250/300/380

      19

  • Cleaning

    20

  • Conservartion for Winter Operation

    20

  • Storage

    20

  • Removing and Refitting Engine

    22

    • Dismounting the Engine

      24

    • Filling in of Cooling Liquid

      26

    • Filling in of Transmission Oil

      26

    • Refitting the Engine

      26

  • Disassembling the Engine

    28

    • Dismounting of Cylinder Head, Cylinder and Piston

      30

    • Dismounting of Sprocket and Shift Lever

      30

    • Draining Gear Oil

      30

    • Dismounting of Clutch Cover

      31

    • Dismounting of Pressure Cap and Clutch Discs

      32

    • Dismounting of the Primary Drive

      32

    • Dismounting of Ignition Cover

      33

    • Dismounting of Kickstarter

      33

    • Dismounting of the Shift Lock

      33

    • Dismounting of the Ignition (Kokusan)

      34

    • Dismounting of the Ignition (SEM)

      34

    • Dismounting of Gearshift Mechanism and Transmission

      35

    • Dismounting of Intake Flange and Reed Valve Housing

      35

    • Parting of Engine Housing Halves

      35

    • Dismounting the Crankshaft

      36

    • Servicing of Individual Components

      37

    • Working on the Right-Hand Housing Half

      39

    • Working on the Left-Hand Housing Half

      40

  • Crankshaft

    41

  • Crankshaft Webs – Measure Outer Dimension

    41

  • Piston

    41

  • Piston Ring End Gap

    41

  • Checking Cylinder for Wear

    42

  • Nikasil Coating of Cylinder

    42

  • Recoated Cylinder

    42

  • Cylinder Exhaust Control System

    43

  • Cylinder Preassembly

    43

  • Exhaust Control, Clutch Cover

    45

  • Preassembly of Clutch Cover

    45

  • Reed Valve Housing, Intake Flange

    46

  • Clutch

    47

  • Replace Outer Clutch Hub

    48

  • Preassembly of Shift Shaft

    49

  • Shift Mechanism

    49

  • Check Stator and Pulse Generator (Kokusan)

    50

  • Ignition (Kokusan)

    50

  • Kokusan Ignition & Spark Plug

    50

  • Check Stator (SEM)

    51

  • Ignition (SEM)

    51

  • SEM Ignition & Spark Plug

    51

  • Assembly Mainshaft

    52

  • Transmission

    52

  • Assembly Countershaft

    53

  • Assemble of Kickstarter Shaft

    54

  • Assembling the Engine

    55

  • Assembling the Engine Housing

    58

  • Mounting Kickstarter

    59

  • Mounting Shift Mechanism

    59

  • Mount Primary Drive and Clutch

    60

  • Mounting Clutch Discs and Pressure Cap

    61

  • Adjusting Dimension „X“

    62

  • Mounting Piston and Cylinder

    62

  • Adjusting Control Flap (Dimension “Z“)

    63

  • Mounting Cylinder Head

    64

  • Mounting Reed Valve Housing and Intake Flange

    64

  • Mounting Steering Covers

    64

  • Mounting Engine Sprocket

    65

  • Mounting the Ignition (Kokusan)

    65

  • Adjusting Ignition Point (SEM)

    66

  • Mounting Starting Lever and Shift Lever

    66

  • Mounting the Ignition (SEM)

    66

    • Electrical

      67

    • Checking the Voltage Regulator (Kokusan)

      69

    • Checking the Voltage Regulator (Tympanium)

      69

    • Checking the Voltage Regulator-Rectifier (Shindengen)

      69

    • CDI Unit

      70

    • Checking the Capacitor

      70

    • Ignition Coil (Kokusan)

      70

    • Ignition Coil (SEM)

      70

    • Checking the Voltage Regulator

      71

    • Static Ignition Values 250-380 SX, EXC (Kokusan 2K-1, 2K-3, 2K-4)

      72

    • Static Generator Values 250-380 EXC (Kokusan 2K-3) (Except 250 USA)

      74

    • Static Ignition Values 250 MXC, EXC USA (Kokusan 2K-2)

      76

    • Troubleshooting

      79

  • Trouble Shooting

    81

  • Technical Specifications

    83

    • Technical Specifications — Engine 250/300/380 SX/MXC/EXC ‘99 (Only for USA)

      85

    • Basic Carburetor Setting

      86

    • Gasket Thicknesses

      86

    • Tightening Torques

      86

    • Tolerances and Fitting Clearances

      86

    • Technical Specifications — Engine 250/300/380 SX/EXC/EGS ‘99 (All Models out of USA)

      87

    • Standard Adjustment — Fork

      89

    • Standard Adjustment — Shock Absorber

      89

    • Technical Specifications Chassis 250/300/380 SX/MXC/EXC/EGS ‘99

      89

    • Carburetor Setting KTM 250/300 MXC/EXC EU, USA‘99 KEIHIN PWK 38

      90

    • Carburetor Setting KTM 250 SX Europe, USA ‘99 KEIHIN PWK 38

      91

    • Carburetor Setting KTM 380 SX/MXC/EXC EU, USA ‘99 KEIHIN PWK 38

      92

    • Technical Data — Engine 250/300/380 SX/MXC/EXC 2000 (Only USA)

      93

    • Technical Data — Engine 250/300/380 SX/EXC 2000 (All Models out of USA)

      95

    • Technical Specifications Chassis 250/300/380 SX, MXC, EXC 2000

      97

    • Carburetor Setting G KTM 250 SX EUR/USA 2000 KEIHIN PWK 38AG PJ

      98

    • Carburetor Setting KTM 250 MXC/EXC EUR/USA 2000 KEIHIN PWK 38 AG

      99

    • Carburetor Setting KTM 300 MXC/EXC EUR/USA 2000 KEIHIN PWK 38 AG

      100

    • Carburetor Setting KTM 380 SX/MXC/ EXC/EUR/USA 2000 KEIHIN PWK 38 AG

      101

    • Technical Data — Engine 250/300/380 SX/MXC EXC 2001 (Only USA)

      103

    • Technical Data — Engine 250/300/380 SX / EXC 2001 (All Models out of USA)

      105

    • Technical Specifications Chassis 250/300/380 SX, MXC, EXC 2001

      107

    • Carburetor Setting KTM 250 SX EUR/USA 2001 KEIHIN PWK 38AG PJ

      108

    • Carburetor Setting KTM 250 MXC/EXC EUR/USA 2001 KEIHIN PWK 38 AG

      109

    • Carburetor Setting KTM 300 MXC/EXC EUR/USA 2001 KEIHIN PWK 38 AG

      110

    • Carburetor Setting KTM 380 SX / MXC / EXC EUR / USA 2001 KEIHIN PWK 38 AG

      111

    • Technical Data — Engine 250/300/380 SX / MXC / EXC 2002 (Only USA)

      112

    • Technical Data — Engine 250/300/380 SX / EXC 2002 (All Models out of USA)

      114

    • Technical Specifications Chassis 250/300/380 SX, MXC, EXC 2002

      116

    • Carburetor Setting KTM 250 SX EUR/USA 2002 KEIHIN PWK 38AG

      117

    • Carburetor Setting KTM 250 MXC/EXC EUR/USA 2002 KEIHIN PWK 38 AG

      118

    • Carburetor Setting KTM 300 MXC/EXC EUR/USA 2002 KEIHIN PWK 38 AG

      119

    • Carburetor Setting KTM 380 SX / MXC / EXC EUR / USA 2002 KEIHIN PWK 38 AG

      120

    • Technical Data — Engine 250/300 MXC/EXC 2003

      121

    • Periodic Lubrication and Maintenance Schedule

      131

    • Periodic Maintenance Schedule 2001/02

      132

    • Important Chacks and Maintenance to be Carried by the Rider

      133

    • Periodic Maintenance Schedule 2003

      134

    • Recommended Inspection of the 250/300 EXC and MXC Engine Used for Enduro Competitions by Your KTM Workshop

      136

    • Recommended Inspection of the 250/300 EXC and MXC Engine Used for Hobby Enduro by Your KTM Workshop

      136

Brand: KTM
|
Category: Motorcycle
|
Size: 9.08 MB

• Table of Contents

  5

• Serial Number Locations

  6

  • Chassis Number

    6

  • Engine Number, Engine Type

    6

• Operation Instruments

  6

  • Clutch Lever

    6

  • Hand Brake Lever

    6

  • Electronic Speedometer

    7

  • Indicator Lamps (EXC)

    11

  • Short Circuit Button

    11

  • Combination Switch (EXC)

    12

  • Headlamp Switch (XC-W)

    12

  • Flasher Switch

    12

  • Starter Button

    12

  • Emergency off Switch (Australia)

    12

  • Filler Cap

    13

  • Fuel Tap

    13

  • Choke Knob

    13

  • Shift Lever

    14

  • Kickstarter

    14

  • Foot Brake Pedal

    14

  • Side Stand

    14

  • Steering Lock

    14

  • Compression Damping of Fork

    15

  • Rebound Damping of Fork

    15

  • Spring Preload of the Fork

    15

  • Shock Absorber Compression Damping

    16

  • Shock Absorber Rebound Damping

    16

• General Tips and Warnings for Starting the Motorcycle

  17

  • Instructions for Your First Ride

    17

  • Running in

    17

• Driving Instructions

  18

  • What You Should Check before each Start

    18

  • Starting When the Engine Is Cold

    19

  • Starting When the Engine Is Warm

    19

  • What to Do When the Engine Is „Flooded

    19

  • Starting off

    19

  • Shifting/Riding

    20

  • Braking

    20

  • Stopping and Parking

    20

  • Refueling, Fuel

    20

• Periodic Maintenance Schedule

  21

• Maintenance Work on Chassis and Engine

  25

  • Changing the Spring Preloading of the Shock Absorber

    25

  • Pivot Bearing

    25

  • Basic Suspension Setup for the Weight of the Driver

    26

  • Checking the Shock Absorber and Spring

    26

  • Determining the Static Sag of the Shock Absorber

    26

  • Determining the Riding Sag of the Shock Absorber

    26

  • Changing the Spring Preload on the Telescopic Fork

    27

  • Checking the Basic Setup of the Telescopic Fork

    27

  • Breather Plug Front Fork

    27

  • Cleaning the Dust Sleeves of the Telescopic Fork

    28

  • Checking and Adjusting the Steering Head Bearing

    28

  • Changing the Fork Offset (Caster) XC/EXC Six Days

    29

  • How to Change the Handlebar Position

    30

  • Adapting Chain Guide to the Rear Sprocket

    31

  • Check Chain Tension

    32

  • Correct Chain Tension

    32

  • Chain Maintenance

    32

  • Chain Wear

    32

  • General Information about KTM Disc Brakes

    33

  • Changing Basic Position of the Hand Brake Lever

    34

  • Checking the Brake Fluid Level — Front Brake

    34

  • Refilling the Front Brake Fluid Reservoir

    34

  • Checking the Front Brake Pads

    34

  • Replacing the Front Brake Pads

    35

  • Checking the Rear Brake Fluid Level

    35

  • Refilling the Rear Brake Fluid Reservoir

    35

  • Changing the Basic Position of the Foot Brake Pedal

    36

  • Checking the Rear Brake Pads

    36

  • Replacing the Rear Brake Pads

    36

  • Dismounting and Mounting the Front Wheel

    37

  • Dismounting and Mounting the Rear Wheel

    38

  • Tires, Air Pressure

    38

  • Checking Spoke Tension

    39

  • Replacing the Battery of the Digital Speedometer

    39

  • Replacing the Headlight Lamp/Parking Light Lamp

    39

  • Battery

    40

  • Charging the Battery

    40

  • Fuse

    41

  • Cooling System

    41

  • Checking the Coolant Level

    42

  • Refilling/Bleeding the Cooling System

    42

  • Cleaning the Air Filter

    42

  • Checking the Oil Level of the Hydraulic Clutch

    43

  • Exhaust System

    43

  • Changing the Original Position of the Clutch Lever

    43

  • Bleeding the Hydraulic Clutch

    44

  • Carburetor Adjustment

    44

  • Draining the Float Chamber of the Carburetor

    46

  • Checking the Float Level

    46

  • Adjusting the Engine Characteristic Via the Ignition Curve

    46

  • Adjusting the Engine Characteristic Via the Auxiliary Spring

    47

  • Check Transmission Oil Level

    48

  • Changing the Transmission Oil

    48

Brand: KTM
|
Category: Motorcycle
|
Size: 5.14 MB

• Table of Contents

  5

• Serial Number Locations

  6

  • Chassis Number

    6

  • Engine Number, Engine Type

    6

• Operation Instruments

  6

  • Clutch Lever

    6

  • Hand Brake Lever

    6

  • Electronic Speedometer

    7

  • Indicator Lamps (EXC)

    11

  • Combination Switch (EXC)

    12

  • Headlamp Switch (XC-W)

    12

  • Flasher Switch

    12

  • Emergency off Switch (Australia)

    12

  • Filler Cap

    13

  • Filler Cap (XC, XC-W)

    13

  • Fuel Tap

    13

  • Choke Knob

    13

  • Shift Lever

    13

  • Kickstarter

    14

  • Foot Brake Pedal

    14

  • Side Stand

    14

  • Steering Lock

    14

  • Compression Damping of Fork

    15

  • Rebound Damping of Fork

    15

  • Spring Preload of the Fork(XC/EXC Six Days)

    15

  • Compression Damping of Shock Absorber (XC-W, EXC)

    16

  • Shock Absorber Compression Damping (XC-W/EXC)

    16

  • Shock Absorber Rebound Damping XC-W, EXC)

    16

• General Tips and Warnings for Starting the Motorcycle

  17

  • Instructions for Your First Ride

    17

  • Running in

    17

• Driving Instructions

  18

  • What You Should Check before each Start

    18

  • Starting When the Engine Is Cold

    19

  • Starting When the Engine Is Warm

    19

  • What to Do When the Engine Is „Flooded

    19

  • Starting off

    19

  • Shifting/Riding

    20

  • Braking

    20

  • Stopping and Parking

    20

  • Refueling, Fuel

    20

• Periodic Maintenance Schedule

  21

• Maintenance Work on Chassis and Engine

  25

  • Changing the Spring Preloading of the Shock Absorber

    25

  • Pivot Bearing

    25

  • Basic Suspension Setup for the Weight of the Driver

    26

  • Checking the Shock Absorber and Spring

    26

  • Determining the Static Sag of the Shock Absorber

    26

  • Determining the Riding Sag of the Shock Absorber

    26

  • Changing the Spring Preload on the Telescopic Fork

    27

  • Checking the Basic Setup of the Telescopic Fork

    27

  • Replacing Fork Springs

    28

  • Breather Plug Front Fork

    28

  • Cleaning the Dust Sleeves of the Telescopic Fork

    28

  • Changing the Fork Offset (Caster) (XC)

    29

  • Checking and Adjusting the Steering Head Bearing

    30

  • How to Change the Handlebar Position

    31

  • Check Chain Tension

    31

  • Correct Chain Tension

    32

  • Chain Maintenance

    32

  • Chain Wear

    32

  • General Information about KTM Disc Brakes

    33

  • Adjusting the Free Travel at the Hand Brake Lever

    34

  • Checking the Brake Fluid Level — Front Brake

    34

  • Refilling the Front Brake Fluid Reservoir

    34

  • Checking the Front Brake Pads

    34

  • Replacing the Front Brake Pads

    35

  • Changing the Basic Position of the Foot Brake Pedal

    35

  • Checking the Rear Brake Fluid Level

    35

  • Refilling the Rear Brake Fluid Reservoir

    35

  • Checking the Rear Brake Pads

    36

  • Replacing the Rear Brake Pads

    36

  • Dismounting and Mounting the Front Wheel

    36

  • Dismounting and Mounting the Rear Wheel

    37

  • Tires, Air Pressure

    38

  • Checking Spoke Tension

    38

  • Replacing the Battery of the Digital Speedometer

    39

  • Check/Set Distance of the Magnetic Sensor

    39

  • Replacing the Headlight Lamp/Parking Light Lamp

    39

  • Cooling System

    40

  • Checking the Coolant Level

    40

  • Refilling/Bleeding the Cooling System

    41

  • Cleaning the Air Filter

    41

  • Checking the Oil Level of the Hydraulic Clutch

    42

  • Exhaust System

    42

  • Changing the Original Position of the Clutch Lever

    42

  • Bleeding the Hydraulic Clutch

    43

  • Carburetor Adjustment

    43

  • Draining the Float Chamber of the Carburetor

    45

  • Checking the Float Level

    45

  • Adjusting the Engine Characteristic Via the Ignition Curve

    45

  • Adjusting the Engine Characteristic Via the Auxiliary Spring

    46

  • Check Transmission Oil Level (125/200)

    47

  • Changing the Transmission Oil (125/200)

    47

  • Check Transmission Oil Level (250/300)

    47

  • Changing the Transmission Oil (250/300)

    47

Brand: KTM
|
Category: Motorcycle
|
Size: 5.12 MB

• Table of Contents

  5

• Serial Number Locations

  6

  • Chassis Number

    6

  • Engine Number, Engine Type

    6

• Operation Instruments

  6

  • Clutch Lever

    6

  • Hand Brake Lever

    6

  • Electronic Speedometer

    7

  • Indicator Lamps (EXC)

    11

  • Short Circuit Button (SX)

    12

  • Combination Switch (EXC)

    12

  • Headlamp Switch (EXC USA)

    12

  • Flasher Switch

    12

  • Emergency off Switch (Australia)

    12

  • Filler Cap

    13

  • Fuel Tap

    13

  • Choke Knob

    13

  • Shift Lever

    13

  • Kickstarter

    14

  • Foot Brake Pedal

    14

  • Side Stand

    14

  • Steering Lock

    14

  • Compression Damping of Fork

    15

  • Rebound Damping of Fork

    15

  • Damping Action During Compression of Shock Absorber (SX)

    15

  • Compression Damping of Shock Absorber (MXC, EXC)

    16

  • Rebound Damping of Shock Absorber (SX, MXC, EXC)

    16

• General Tips and Warnings for Starting the Motorcycle

  17

  • Instructions for Your First Ride

    17

  • Running in

    17

• Driving Instructions

  18

  • What You Should Check before each Start

    18

  • Starting When the Engine Is Cold

    19

  • Starting When the Engine Is Warm

    19

  • What to Do When the Engine Is „Flooded

    19

  • Starting off

    19

  • Shifting/Riding

    19

  • Braking

    20

  • Stopping and Parking

    20

  • Refueling, Fuel

    20

• Periodic Maintenance Schedule

  21

• Maintenance Work on Chassis and Engine

  24

  • Changing the Spring Preload of the Shock Absorber

    24

  • Pivot Bearing

    24

  • Basic Suspension Setup for the Weight of the Driver

    25

  • Checking the Shock Absorber and Spring

    25

  • Determining the Static Sag of the Shock Absorber

    25

  • Determining the Riding Sag of the Shock Absorber

    25

  • Checking the Basic Setup of the Telescopic Fork

    26

  • Changing the Spring Preload on the Telescopic Fork

    26

  • Replacing Fork Springs

    27

  • Breather Plug Front Fork

    27

  • Cleaning the Dust Sleeves of the Telescopic Fork

    27

  • Changing the Fork Offset (SX)

    28

  • Checking and Adjusting the Steering Head Bearing

    29

  • How to Change the Handlebar Position

    30

  • Check Chain Tension

    30

  • Correct Chain Tension

    31

  • Chain Maintenance

    31

  • Chain Wear

    31

  • General Information about KTM Disc Brakes

    32

  • Adjusting the Free Travel at the Hand Brake Lever

    33

  • Checking the Brake Fluid Level — Front Brake

    33

  • Refilling the Front Brake Fluid Reservoir

    33

  • Checking the Front Brake Pads

    33

  • Replacing the Front Brake Pads

    34

  • Changing the Basic Position of the Foot Brake Pedal

    34

  • Checking the Rear Brake Fluid Level

    34

  • Refilling the Rear Brake Fluid Reservoir

    34

  • Checking the Rear Brake Pads

    35

  • Replacing the Rear Brake Pads

    35

  • Dismounting and Mounting the Front Wheel

    35

  • Dismounting and Mounting the Rear Wheel

    36

  • Tires, Air Pressure

    37

  • Checking Spoke Tension

    37

  • Replacing the Battery of the Digital Speedometer

    37

  • Check/Set Distance of the Magnetic Sensor

    38

  • Replacing the Headlight Lamp/Parking Light Lamp

    38

  • Cooling System

    39

  • Radiator Cover for the Cold Season

    39

  • Checking the Coolant Level

    39

  • Refilling/Bleeding the Cooling System

    40

  • Cleaning the Air Filter

    40

  • Changing the Original Position of the Clutch Lever

    41

  • Checking the Oil Level of the Hydraulic Clutch

    41

  • Bleeding of the Hydraulic Clutch

    41

  • Exhaust System

    41

  • Cleaning the Spark Arrestor (EXC USA)

    42

  • Carburetor Adjustment

    42

  • Draining the Float Chamber of the Carburetor

    43

  • Checking the Float Level

    43

  • Engine Characteristic 250/300 SX/MXC/EXC

    44

  • Check Transmission Oil Level (125/200)

    45

  • Changing the Transmission Oil (125/200)

    45

  • Check Transmission Oil Level (250/300)

    45

  • Changing the Transmission Oil (250/300)

    45

Brand: KTM
|
Category: Motorcycle
|
Size: 3.46 MB

• Chassis Number

  3

• Engine Number

  3

• Table of Contents

  5

• Serial Number Locations

  6

  • Chassis Number

    6

  • Engine Number, Engine Type (125/200)

    6

  • Engine Number, Engine Type (250/300/380)

    6

• Operation Instruments

  6

  • Clutch Lever

    6

  • Hand Brake Lever

    6

  • Digital Speedometer, Indicator Lamp (EXC)

    7

  • Digital Speedometer

    7

  • Odometer (EXC USA)

    7

  • Speedometer, Indicator Lamps (EXC — Australia)

    7

  • Short Circuit Button (SX)

    7

  • Combination Switch (EXC)

    8

  • Headlamp Switch (EXC USA)

    8

  • Flasher Switch

    8

  • Emergency off Switch (Australia)

    8

  • Filler Cap

    8

  • Refueling, Fuel

    9

  • Fuel Tap

    9

  • Choke Knob

    9

  • Shift Lever

    10

  • Kickstarter

    10

  • Foot Brake Pedal

    10

  • Compression Damping of Fork

    10

  • Rebound Damping of Fork

    10

  • Compression Damping of Shock Absorber

    11

  • Rebound Damping of Shock Absorber

    11

  • Steering Lock

    11

  • Side Stand

    11

• Driving Instructions

  12

  • Starting off

    13

  • Periodic Maintenance Schedule

    14

• Maintenance Work on Chassis and Engine

  16

  • Changing the Original Position of the Clutch Lever

    16

  • Checking and Adjusting the Steering Head Bearing

    16

  • Breather Plug Front Fork

    17

  • Cleaning the Dust Sleeves of the Telescopic Fork

    17

  • How to Change the Handlebar Position

    17

  • Changing the Spring Preloading of the Shock Absorber

    18

  • Pivot Bearing

    18

  • Check Chain Tension

    18

  • Correct Chain Tension

    19

  • Chain Maintenance

    19

  • Chain Wear

    19

  • General Informations about KTM Disc Brakes

    20

  • Adjusting of Free Travel at the Hand Brake Lever

    20

  • WIRING DIAGRAMME, CARBURETOR SETTING . . .Appendix

    21

  • Checking of Brake Fluid Level — Front Brake

    21

  • Refilling the Front Brake Fluid Reservoir

    21

  • Checking the Front Brake Pads

    21

  • Replacing the Front Brake Pads

    21

  • Changing the Basic Position of the Foot Brake Pedal

    22

  • Checking Rear Brake Fluid Level

    22

  • Refilling the Rear Brake Fluid Reservoir

    22

  • Checking the Rear Brake Pads

    23

  • Replacing the Rear Brake Pads

    23

  • Dismounting and Mounting the Front Wheel

    23

  • Dismounting and Mounting the Rear Wheel

    24

  • Tires-Air Pressure

    25

  • Checking Spoke Tension

    25

  • Replacing the Battery of the Digital Speedometer

    25

  • Adjustin Digital Speedometer

    27

  • Check/Set Distance of Magnetic Sensor

    27

  • Replacing Headlight Lamp (H4)

    28

  • Cooling System

    28

  • Radiator Cover for the Cold Season

    29

  • Checking the Coolant Level

    29

  • Refilling/Bleeding the Cooling System

    29

  • Cleaning the Air Filter

    30

  • Exhaust System

    30

  • Cleaning the Spark Arrestor (EXC USA)

    30

  • Draining of Float Chamber of the Carburetor

    30

  • Carburetor Adjustment

    31

  • Checking the Float Level

    32

  • Checking the Oil Level of the Hydraulic Clutch

    32

  • Bleeding of the Hydraulic Clutch

    32

  • Check Transmission Oil Level (125/200)

    33

  • Changing the Transmission Oil (125/200)

    33

  • Check Transmission Oil Level (250/300/380)

    33

  • Changing the Transmission Oil (250/300/380)

    33

Brand: KTM
|
Category: Motorcycle
|
Size: 4.82 MB

• Table of Contents

  5

• Serial Number Locations

  6

• Frame Number

  6

• Engine Number, Engine Type (125/200)

  6

• Engine Number, Engine Type (250/300/380)

  6

• Operation Instruments

  6

• Clutch Control Lever (125/200)

  6

• Clutch Control Lever (250/300/380)

  6

• Hand Brake Lever

  7

• Speedometer, Indicator Lamps (EXC)

  7

• Odometer (EXC USA)

  7

• Speedometer, Indicator Lamps (EGS)

  7

• Ignition Lock

  7

• Short Circuit Button (SX)

  8

• Combination Switch (EXC)

  8

• Headlamp Switch (EXC USA)

  8

• Flasher Switch

  8

• Emergency off Switch (Australia)

  8

• Filler Cap

  9

• Refueling, Fuel

  9

• Fuel Tap

  9

• Choke Knob

  10

• Shift Lever

  10

• Kickstarter

  10

• Foot Brake Pedal

  10

• Compression Damping of Fork

  10

• Rebound Damping of Fork

  11

• Compression Damping of Shock Absorber

  11

• Rebound Damping of Shock Absorber

  11

• Steering Lock

  11

• Side Stand

  11

• Driving Instructions

  12

• Starting When the Engine Is Cold

  13

• Starting When the Engine Is Warm

  13

• Starting off

  13

• Stopping and Parking

  13

• Periodic Lubrication and Maintenance Schedule

  14

• Maintenance Work on Chassis and Engine

  15

• Changing the Original Position of the Clutch Lever (125/200)

  15

• Checking and Adjusting the Steering Head Bearing

  15

• Check Chain Tension

  16

• Correct Chain Tension

  16

• Chain Maintenance

  16

• Chain Wear

  17

• General Informations about KTM Disc Brakes

  17

• Adjusting of Free Travel at the Hand Brake Lever

  17

• Checking of Brake Fluid Level — Front Brake

  18

• Refilling the Front Brake Fluid Reservoir

  18

• Checking the Front Brake Pads

  18

• Replacing the Front Brake Pads

  18

Brand: KTM
|
Category: Motorcycle
|
Size: 5.75 MB

• Table of Contents

  5

• Serial Number Locations

  6

• Chassis Number

  6

• Engine Number, Engine Type (125/200)

  6

• Engine Number, Engine Type (250/300/380)

  6

• Operation Instruments

  6

• Clutch Lever

  6

• Hand Brake Lever

  6

• Speedometer, Indicator Lamp (EXC)

  7

• Odometer (EXC USA)

  7

• Speedometer, Indicator Lamps (EGS)

  7

• Ignition Lock

  7

• Short Circuit Button (SX)

  8

• Combination Switch (EXC)

  8

• Headlamp Switch (EXC USA)

  8

• Flasher Switch

  8

• Emergency off Switch (Australia)

  8

• Filler Cap

  9

• Refueling, Fuel

  9

• Fuel Tap

  9

• Choke Knob

  10

• Shift Lever

  10

• Kickstarter

  10

• Foot Brake Pedal

  10

• Compression Damping of Fork

  10

• Rebound Damping of Fork

  11

• Compression Damping of Shock Absorber

  11

• Rebound Damping of Shock Absorber

  11

• Steering Lock

  11

• Center Stand

  11

• Driving Instructions

  12

• Starting off

  13

• Periodic Lubrication and Maintenance Schedule

  14

• Maintenance Work on Chassis and Engine

  15

• Changing the Original Position of the Clutch Lever

  15

• Checking and Adjusting the Steering Head Bearing

  15

• Pivot Bearing

  16

• Check Chain Tension

  16

• Correct Chain Tension

  16

• Chain Maintenance

  16

• Chain Wear

  17

• General Informations about KTM Disc Brakes

  17

• Adjusting of Free Travel at the Hand Brake Lever

  17

• Checking of Brake Fluid Level — Front Brake

  18

• Refilling the Front Brake Fluid Reservoir

  18

• Checking the Front Brake Pads

  18

• Replacing the Front Brake Pads

  18

• Changing the Basic Position of the Brake Pedal

  19

• Checking Rear Brake Fluid Level

  19

• Refilling the Rear Brake Fluid Reservoir

  19

• Technical Data

  1

• Gear Ratios

  2

• Basic Carburetor Setting

  2

• Tolerances and Fitting Clearances

  2

• Gasket Thicknesses

  2

• Crank Case

  3

• Clutch Cover

  4

• Crankshaft, Piston

  4

• Cylinder

  5

• Twin Valve Control

  5

• Carburettor

  6

• Clutch

  7

• Kickstarter

  7

• Ignition System

  8

• Transmission

  9

• Shifting Mechanism

  10

• Cooling System

  10

• Special Tools

  11