KTM 300 EXC, Repair Manual

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TABLE OF CONTENTS
3
9.21 Assembling the rebound adjuster...................... 70
9.22 Assembling the seal ring retainer...................... 70
9.23 Assembling the piston rod................................ 71
9.24 Assembling the damper ................................... 72
9.25 Bleeding and filling the damper ....................... 75
9.26 Filling the damper with nitrogen ....................... 77
9.27 Installing the spring ........................................ 78
9.28 Changing the heim joint................................... 79
10 EXHAUST.................................................................. 81
10.1 Removing the main silencer ............................. 81
10.2 Installing the main silencer.............................. 81
10.3 Changing the glass fiber yarn filling of the
main silencer.................................................. 81
11 AIR FILTER ............................................................... 83
11.1 Removing the air filter box lid .......................... 83
11.2 Installing the air filter box lid ........................... 83
11.3 Removing the air filter..................................... 83
11.4 Installing the air filter...................................... 83
11.5 Cleaning the air filter and air filter box .............. 84
11.6 Sealing the air filter box .................................. 84
12 FUEL TANK, SEAT, TRIM ........................................... 85
12.1 Opening the filler cap...................................... 85
12.2 Closing the filler cap ....................................... 85
12.3 Removing the seat .......................................... 85
12.4 Mounting the seat ........................................... 86
12.5 Removing the fuel tank.................................... 86
12.6 Installing the fuel tank .................................... 87
12.7 Fuel tap ......................................................... 88
13 MASK, FENDER......................................................... 89
13.1 Removing the front fender ............................... 89
13.2 Installing the front fender ................................ 89
13.3 Removing the headlight mask with the
headlight........................................................ 89
13.4 Refitting the headlight mask with the
headlight........................................................ 90
14 WHEELS ................................................................... 91
14.1 Checking the tire air pressure........................... 91
14.2 Checking the tire condition .............................. 91
14.3 Checking the brake discs ................................. 92
14.4 Checking the spoke tension.............................. 92
14.5 Front wheel .................................................... 93
14.5.1 Removing the front wheel ............................ 93
14.5.2 Installing the front wheel ............................. 93
14.5.3 Removing the brake disc of the front brake.... 94
14.5.4 Installing the brake disc of the front brake .... 94
14.6 Rear wheel ..................................................... 94
14.6.1 Removing the rear wheel ............................. 94
14.6.2 Installing the rear wheel .............................. 95
14.6.3 Removing the brake disc of the rear brake..... 96
14.6.4 Installing the brake disc of the rear brake...... 96
14.6.5 Checking the chain for dirt .......................... 96
14.6.6 Cleaning the chain ...................................... 97
14.6.7 Checking the chain tension.......................... 97
14.6.8 Checking the chain, rear sprocket, engine
sprocket and chain guide............................. 98
14.6.9 Adjusting the chain tension ......................... 99
15 WIRING HARNESS, BATTERY................................... 101
15.1 Plug-in connection, ignition timing map .......... 101
15.2 Removing the main fuse ................................ 101
15.3 Installing the main fuse................................. 101
15.4 Recharging the battery .................................. 101
15.5 Disconnecting the negative cable of the
battery ......................................................... 102
15.6 Connecting the negative cable of the battery.... 103
15.7 Removing the battery .................................... 103
15.8 Installing the battery ..................................... 104
15.9 Checking the charging voltage ........................ 104
15.10 Checking the closed current........................... 104
15.11 Checking the starter relay .............................. 105
16 BRAKE SYSTEM ...................................................... 106
16.1 Checking the front brake linings ..................... 106
16.2 Changing the front brake linings ..................... 106
16.3 Checking the free travel of the hand brake
lever ............................................................ 108
16.4 Adjusting free travel of hand brake lever (All
250/300 EXC models)................................... 108
16.5 Adjusting the basic position of the hand
brake lever (all 250/300 XC
‑
W) ...................... 108
16.6 Checking the front brake fluid level ................ 109
16.7 Adding front brake fluid................................. 109
16.8 Changing the front brake fluid........................ 110
16.9 Checking the rear brake linings ...................... 111
16.10 Changing the brake linings of the rear brake .... 112
16.11 Checking the free travel of foot brake lever ...... 113
16.12 Adjusting the basic position of the foot brake
lever ............................................................ 113
16.13 Checking the rear brake fluid level.................. 114
16.14 Adding brake fluid for the rear brake............... 114
16.15 Changing the rear brake fluid ......................... 115
17 LIGHTING SYSTEM, INSTRUMENTS ......................... 117
17.1 Checking the headlight setting ....................... 117
17.2 Adjusting the headlight range......................... 117
17.3 EXC EU/AUS, XC
‑
W....................................... 117
17.3.1 Speedometer overview ............................... 117
17.3.2 Activation and test .................................... 118
17.3.3 Setting kilometers or miles ........................ 118
17.3.4 Adjusting the speedometer functions .......... 118
17.3.5 Setting the clock ...................................... 119
17.3.6 Activating the additional functions ............. 119
17.3.7 Setting the wheel circumference ................ 120
17.3.8 Querying lap time ..................................... 120
17.4 250/300 SIX DAYS ....................................... 121
17.4.1 Speedometer overview ............................... 121
17.4.2 Activation and test .................................... 121
17.4.3 Setting kilometers or miles ........................ 121
17.4.4 Setting the speedometer functions ............. 122
17.4.5 Setting the clock ...................................... 122
17.4.6 Setting the wheel circumference ................ 123
17.4.7 Viewing the lap time ................................. 123
18 ENGINE .................................................................. 124
18.1 Removing the engine..................................... 124
18.2 Installing the engine...................................... 128
18.3 Engine disassembly....................................... 133
18.3.1 Clamping the engine into the engine work
stand....................................................... 133
18.3.2 Draining the gear oil.................................. 133
18.3.3 Removing the clutch push rod.................... 133
18.3.4 Removing the shift lever ............................ 133
18.3.5 Removing the engine sprocket.................... 133
18.3.6 Removing the spacer................................. 134
18.3.7 Removing the starter motor........................ 134
18.3.8 Removing the kick starter .......................... 135
18.3.9 Removing the cylinder head....................... 136