KTM 300 SX Owner'S Handbook Manual Download Page 56

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KTM SPOR

MOTORCYCLE AG

5230 Mattighofen

Austria

Internet: www

.ktm.at

321049

Summary of Contents for 300 SX

Page 1: ...Art Nr 3 210 49 04 2002 125 200 250 300 SX MXC EXC OWNERS HANDBOOK MANUALE D USO MANUEL D UTILISATION MANUAL DE INSTRUCCIONES 2003 BEDIENUNGSANLEITUNG...

Page 2: ...ing inoperative by any person other than for purposes of mainte nance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior...

Page 3: ...marked with an asterisk in the chapter Maintenance work on the chassis and engine must be performed by a KTM workshop If mainten ance work should become necessary during a competition it must be perf...

Page 4: ...ith equivalent specifications must be used in accordance with the maintenance schedule No claims can be filed under the warranty for damage or consequential damage caused by manipulations or conversio...

Page 5: ...prings 27 Adjusting the spring preload on the fork SX 28 Changing the spring preloading of the shock absorber 28 Pivot bearing 28 Checking the chain tension 29 Correct the chain tension 29 Chain maint...

Page 6: ...pe 250 300 Engine number and engine type are stamped on the right hand side of the engine in front of the kickstarter Enter this number in the relevant field on page 1 SERIAL NUMBER LOCATIONS OPERATIO...

Page 7: ...H mode If the front wheel turns the display will automatically change to the SPEED ODO mode SPEED H hours display mode When you stop driving and no impulses are sent from the wheel sensor the display...

Page 8: ...MODE BUTTON 3 SECONDS to reset the MAX figure to 0 SPEED LAP display mode LAP displays the stopped lap time in hours minutes and seconds BUTTON Starts and stops the stop watch The lap time is not rese...

Page 9: ...the first impulse received from the wheel sensor when the front wheel starts to turn and stops 3 seconds after the last impulse is received when the front wheel has stopped The TRP1 AVS1 and STP1 fig...

Page 10: ...impulse received from the wheel sensor and stops 3 seconds after the last impulse is received The displayed figure will deviate from the actual average speed if TRP2 was changed manually or if STP2 w...

Page 11: ...d MODE for 3 sec no function no function stops LAP stores LAP figure resets LAP to 0 no function no function no function no function no function no function decreases TRP2 figure no function no functi...

Page 12: ...her switch The flasher switch is a separate unit and is mounted on the left portion of the handlebar The wire harness is designed in a way that whenever you want to use your bike off road you can dism...

Page 13: ...e tank as soon as possible and remember to turn the rotating handle back to the ON position so that you will have backup fuel next time too Reserve of the 9 l tank 1 3 l 0 32 US gallons Reserve of the...

Page 14: ...motorcycle Make sure that you put your bike on solid ground and in a secure position For off road riding you can use the rubber band 1 to additionally secure the center stand in its folded up positio...

Page 15: ...mpression of shock absorber SX The shock absorber on the SX models can synchronize the compression damping in the low and high speed range separately Dual Compression Control Low and high speed refers...

Page 16: ...E THE SHOCK ABSORBER APART OR TO DO ANY MAINTEN ANCE WORK YOURSELF SEVERE INJURIES COULD BE THE RESULT NEVER UNSCREW THE BLACK SCREW 2 CONNECTION 24MM Rebound damping of shock absorber SX MXC EXC By u...

Page 17: ...your first ride Verify that your KTM dealer performed the PREPARATION OF VEHICLE jobs see Customer Service Manual Thoroughly read the whole instruction manual before starting for your first tour Fami...

Page 18: ...there is sufficient brake fluid in the reservoir The reservoirs have been designed in such a way that brake fluid does not need to be refilled even when the brake pads are worn If the level of brake...

Page 19: ...y it 3 Once the engine is running open fuel tap again Starting off Pull the clutch lever Put the engine into first gear slowly release the clutch lever and accelerate at the same time WARNING BEFORE Y...

Page 20: ...SUPPLIED WITH SUFFICIENT LUBRICANT WHICH IS MIXED IN THE FUEL IN THE EVENT THAT WHILE RIDING ON YOUR MOTORCYCLE YOU NOTICE ANY UNUSUAL OPERATION RELATED NOISE STOP IMMEDIA TELY TURN THE ENGINE OFF AND...

Page 21: ...tor indicator lamps speedometer illumination horn emergency OFF switch or button Check brake fluid level lining thickness brake lining Check brake lines for damage and leaks Check adjust smooth operat...

Page 22: ...djust if necessary Clean air filter and filter box Check tires for pressure and wear Check cooling liquid level Check fuel lines for leaks Empty and clean float chamber Check all control elements for...

Page 23: ...ours 45 hours 60 hours 90 hours 120 hours 135 hours RECOMMENDED INSPECTION OF THE 125 200 250 300 EXC ENGINE USED FOR HOBBY ENDURO BY YOUR KTM WORKSHOP ADDITIONAL ORDER FOR THE KTM WORKSHOP Check the...

Page 24: ...ENGLISH 23...

Page 25: ...ING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED DISPOSE OF OILS FATTY MATTERS FILTERS FUELS WASHING DETERGENTS ETC PROPERLY UNDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE S...

Page 26: ...eather plugs 5 a few turns in order to relieve excess pressure from the inside of the fork To do this place the motorcycle on a stand with the front wheel lifted off the ground When riding the motorcy...

Page 27: ...on B The static sag is the difference between dimensions A and B EXAMPLE Motorcycle jacked up dimension A 600 mm Motorcycle on ground unloaded dimension B 565 mm Static sag 35 mm If the static sag is...

Page 28: ...ee spare parts catalog The fork springs may not be pretensioned by more than 20 mm The preload adjuster used in the SX models can easily be retrofitted for the telescopic forks of the MXC EXC models N...

Page 29: ...g e g how many threads are visible above the adjusting ring One rotation of the adjusting ring 2 changes the spring pretension by approximately 1 75 mm 0 07 in Loosen the clamping screw 3 and use the...

Page 30: ...E OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTORCYCLE Correct chain tension Loosen collar nut 1 loosen lock nuts 2 and turn right and left adjusting screws 3 equally far Tighten lock nuts Before tigh...

Page 31: ...eplace if necessary Chain wear To check the chain wear observe the following indications Shift the gear into idling and pull the upper chain strand with approx 10 15 kilograms 33 lb upwards see figure...

Page 32: ...a location B outside the contact face Check wear at several locations WARNING BRAKE DISCS SUFFERING FROM WEAR GREATER THAN 0 4 MM 0 016 IN CONSTI TUTE A SAFETY RISK HAVE THE BRAKE DISCS REPLACED IMME...

Page 33: ...ir Loosen screws 2 and remove lid 3 and membrane 4 Place hand brake cylinder in a horizontal position and fill the brake fluid reservoir to 5 mm 0 2 in below the rim with clean brake fluid DOT 5 1 e g...

Page 34: ...STEM WHEN DRIVING CAUSING THE REAR WHEEL TO BRAKE THE BRAKING SYSTEM OVERHEATS AND MAY EVEN FAIL COMPLETELY IN EXTREME CASES Checking the rear brake fluid level The brake fluid reservoir of the rear d...

Page 35: ...RRECTLY AFTER WORKING ON THE BRAKING SYSTEM ONE MUST ALWAYS ACTUATE THE HAND BRAKE LEVER OR FOOT BRAKE LEVER RESPECTIVELY SO AS TO ENSURE THAT THE BRAKE PADS WILL LIE AGAINST THE BRAKE DISK AND THE PR...

Page 36: ...TION DO NOT OPERATE THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN DISMOUNTED MAKE SURE THE BRAKE DISC IS ALWAYS ON TOP WHEN YOU LAY DOWN THE WHEEL OTHERWISE THE BRAKE DISC CAN BE DAMAGED IF THE AXLE IS...

Page 37: ...AGED TIRES IMMEDIATELY WORN TIRES CAN HAVE A NEGATIVE EFFECT ON HOW YOUR MOTORCYCLE PER FORMS ESPECIALLY ON WET SURFACES IF AIR PRESSURE IS TOO LOW ABNORMAL WEAR AND OVERHEATING OF THE TIRE CAN RESULT...

Page 38: ...ng display BUTTON deactivates the blinking display press the MODE BUTTON to change to the next display without changing any settings press and hold the MODE BUTTON 3 SECONDS to store the settings and...

Page 39: ...lder 3 carefully out of the reflector Pull connector 4 off the headlamp and remove rubber cap 5 Disengage retai ning clip and take the bulb out of the reflector When changing the par king light lamp s...

Page 40: ...IATELY IF COOLANT GETS INTO YOUR EYES RINSE THEM OUT WITH WATER IMMEDIATELY AND GO SEE A DOCTOR A mixture of 40 antifreeze liquid and 60 water is used as coolant However the antifreeze protection must...

Page 41: ...le has been exposed to great quantities of dust For this purpose rotate the two quick release fasteners 4 counter clockwise and pull them outward up to the stop pull the filter box cover forward and r...

Page 42: ...off cover 3 together with rubber bellows 4 At the slave cylinder of the clutch remove the bleeder nipple 5 In its place mount the bleeder syringe 6 which is filled with SAE 10 hydraulic oil Refill oi...

Page 43: ...or adjustment low altitude or low temperatures choose richer carburetor adjustment WARNING ONLY USE PREMIUM GRADE GASOLINE ROZ 95 MIXED WITH HIGH GRADE TWO STROKE ENGINE OIL OTHER TYPES OF GASOLINE CA...

Page 44: ...rt distance of riding flat out a larger main jet is required If the porce lain is dark brown or black with soot the main jet must be replaced by a smaller one Draining the float chamber of the carbure...

Page 45: ...WILL BE SUBJECTED TO EXCESSIVE WEAR AND TEAR IF YOU USE TOO LITTLE OR LOW GRADE OIL USE ONLY HIGH GRADE OIL Check transmission oil level 250 300 In order to check the transmission oil level the contro...

Page 46: ...s The best manner would be to use warm water that has been mixed with a normal brand name washing detergent and a sponge The hard dirt can be removed before washing with the help of a soft water jet C...

Page 47: ...100 90 19 57M 120 90 18 65R Rear tires USA 100 90 19 57M 100 100 18 59M 100 90 19 57M 100 100 18 59M 100 100 18 59M Air pressure offroad 1 0 bar 14psi 1 0 bar 14psi 1 0 bar 14psi 1 0 bar 14psi 1 0 ba...

Page 48: ...9 Loctite 243 15 Nm Brake disk rear M 6 Loctite 243 15 Nm Clamping screws upper fork bridge M 8 20 Nm Clamping screws lower fork bridge M 8 15 Nm Clamping screws fork stubs M 8 10 Nm Collar nut rear...

Page 49: ...ted Shell HF E15 Transmission 5 speed claw actuated 6 speed claw actuated Gear ratio 1st gear 13 32 1S32 12 33 1G33 13 32 1S32 13 33 1G33 2nd gear 2S15 15 30 2S30 2S15 15 31 2G31 2S15 15 30 2S30 2S15...

Page 50: ...U 125 EXC AUS 200 MXC EXC USA 200 EXC AUS 200 EXC EU Carburetor Carburetor setting number Main jet Idling jet Starting jet Jet needle Needle position from top Throttle valve Air adjustment screw open...

Page 51: ...6 in Front tires 90 90 21 54R Front tires USA 80 100 21 51M 80 100 21 51M Air pressure offroad 1 0 bar 14psi 1 0 bar 14psi Air pressure road driver only 1 5 bar 21psi 1 5 bar 21psi Rear tires 140 80 1...

Page 52: ...ut swing arm bolt M 14x1 5 100 Nm Hexagon collar screw handlebar clamp M 8 20 Nm Allan head screw handlebar support M 10 Loctite 243 40 Nm Shock absorber top M 12 60 Nm Shock absorber bottom M 12 60 N...

Page 53: ...plug NGK BR 7 ES Electrode gap 0 60 mm Dimension Z 49 5 mm 0 024 in 46 mm 1 7 in TVC start open 5000 min 5900 min TVC fully open 7000 min 7750 min Primary drive straight cut spur gears primary ratio 2...

Page 54: ...screws M 6 10 Nm 7 ft lb M 8 25 Nm 19 ft lb M 10 45 Nm 33 ft lb BASIC CARBURETOR SETTING Carburetor Carburetor setting number Main jet Idling jet Starting jet Jet needle Needle position from top Slide...

Page 55: ...termining the static sag of the shock absorber 26 Dismounting and mounting the front wheel 34 Dismounting and mounting the rear wheel 35 Draining the float chamber of the carburetor 43 Driving instruc...

Page 56: ...KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria Internet www ktm at 321049...

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