KTM 300 EXC, Repair Manual

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TABLE OF CONTENTS
4
18.3.10 Removing the cylinder............................... 136
18.3.11 Removing the piston ................................. 137
18.3.12 Removing the water pump cover................. 138
18.3.13 Removing the clutch cover......................... 138
18.3.14 Removing the clutch discs ......................... 138
18.3.15 Removing the clutch basket ....................... 139
18.3.16 Removing the kick starter shaft .................. 140
18.3.17 Removing the intermediate kick starter
gear......................................................... 140
18.3.18 Removing the shift shaft............................ 141
18.3.19 Removing the shift drum locating unit ........ 141
18.3.20 Removing the locking lever ........................ 141
18.3.21 Removing the rotor.................................... 141
18.3.22 Removing the reed valve housing................ 142
18.3.23 Removing the left engine case section ........ 142
18.3.24 Removing the shift rails............................. 142
18.3.25 Removing the shift drum ........................... 143
18.3.26 Removing the shift forks............................ 143
18.3.27 Removing the transmission shafts............... 143
18.3.28 Removing the crankshaft ........................... 143
18.4
Work on individual parts ................................ 144
18.4.1 Work on the right section of the engine
case ........................................................ 144
18.4.2 Work on the left section of the engine
case ........................................................ 145
18.4.3 Removing the crankshaft bearing inner
race......................................................... 145
18.4.4 Installing the crankshaft bearing inner
race......................................................... 146
18.4.5 Changing the connecting rod, conrod
bearing, and crank pin .............................. 146
18.4.6 Checking the crankshaft run-out at the
bearing pin............................................... 147
18.4.7 Checking/measuring the cylinder ................ 147
18.4.8 Removing the exhaust control .................... 148
18.4.9 Checking the exhaust control ..................... 150
18.4.10 Installing the exhaust control ..................... 150
18.4.11 Cylinder - Nikasil
®
coating ......................... 152
18.4.12 Checking/measuring the piston................... 153
18.4.13 Checking the piston ring end gap ............... 154
18.4.14 Piston/cylinder - measuring the mounting
clearance ................................................. 154
18.4.15 Checking the reed valve housing, reed
valve, and intake flange............................. 155
18.4.16 Work on the clutch cover ........................... 155
18.4.17 Checking the clutch .................................. 159
18.4.18 Preassembling the shift shaft ..................... 160
18.4.19 Checking the shift mechanism ................... 161
18.4.20 Disassembling the main shaft .................... 162
18.4.21 Disassembling the countershaft.................. 163
18.4.22 Checking the transmission ......................... 163
18.4.23 Assembling the main shaft......................... 164
18.4.24 Assembling the countershaft ...................... 165
18.4.25 Checking the kick starter ........................... 167
18.4.26 Preassembling the kick starter shaft ........... 167
18.4.27 Checking the electric starter drive .............. 169
18.5
Engine assembly........................................... 170
18.5.1 Installing the crankshaft ............................ 170
18.5.2 Installing the transmission shafts ............... 170
18.5.3 Installing the shift forks............................. 171
18.5.4 Installing the shift drum ............................ 171
18.5.5 Installing the shift rails ............................. 171
18.5.6 Installing the left engine case section ......... 171
18.5.7 Installing the reed valve housing ................ 172
18.5.8 Installing the rotor .................................... 172
18.5.9 Installing the locking lever ......................... 173
18.5.10 Installing the shift drum locating unit ......... 173
18.5.11 Installing the shift shaft ............................ 173
18.5.12 Installing the intermediate kick starter
gear......................................................... 173
18.5.13 Installing the kick starter shaft................... 173
18.5.14 Installing the clutch basket........................ 174
18.5.15 Installing the clutch discs.......................... 175
18.5.16 Installing the clutch cover ......................... 176
18.5.17 Installing the water pump cover.................. 177
18.5.18 Installing the piston .................................. 177
18.5.19 Installing the cylinder................................ 178
18.5.20 Checking the X-distance ............................ 179
18.5.21 Adjusting the X-distance............................ 180
18.5.22 Adjusting the Z-distance............................ 180
18.5.23 Installing the cylinder head........................ 182
18.5.24 Installing the kick starter ........................... 182
18.5.25 Installing the starter motor......................... 182
18.5.26 Installing the spacer.................................. 184
18.5.27 Installing the engine sprocket .................... 184
18.5.28 Installing the shift lever............................. 184
18.5.29 Installing the clutch push rod .................... 185
18.5.30 Installing the gear oil drain plug................. 185
18.5.31 Removing the engine from the work stand ... 185
19 CARBURETOR ......................................................... 186
19.1 Choke .......................................................... 186
19.2 Carburetor - adjusting the idle speed .............. 186
19.3 Emptying the carburetor float chamber ........... 187
19.4 Removing the carburetor................................ 187
19.5 Installing the carburetor ................................ 188
19.6 Checking/adjusting the carburetor
components.................................................. 189
19.7 Disassembling the carburetor ......................... 190
19.8 Checking the choke slide ............................... 191
19.9 Checking the jet needle ................................. 191
19.10 Checking the throttle slide ............................. 191
19.11 Checking the float needle valve ...................... 192
19.12 Assembling the carburetor ............................. 192
19.13 Checking/adjusting the float level ................... 193
20 CLUTCH.................................................................. 194
20.1 Checking/correcting the fluid level of the
hydraulic clutch............................................ 194
20.2 Changing the hydraulic clutch fluid ................ 194
21 WATER PUMP, COOLING SYSTEM ............................ 195
21.1 Cooling system ............................................. 195
21.2 Checking the antifreeze and coolant level ........ 195
21.3 Checking the coolant level ............................. 195
21.4 Draining the coolant...................................... 196
21.5 Refilling with coolant .................................... 196
22 EXHAUST CONTROL ................................................ 198
22.1 Engine characteristic - setting the auxiliary
spring .......................................................... 198
23 LUBRICATION SYSTEM............................................ 199
23.1 Changing the gear oil..................................... 199
23.2 Draining the gear oil...................................... 199
23.3 Refilling with gear oil .................................... 200
23.4 Checking the gear oil level ............................. 200
23.5 Adding gear oil ............................................. 200
24 IGNITION SYSTEM................................................... 202
24.1 Checking the ignition system.......................... 202