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Manuals
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KTM Manuals
Engine
300 1998
Repair manual
KTM 300 1998 Repair Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
1 1 General 2 3
Table of Contents
General
Bleeding the Cooling System
Definitions
Checking the Setting of the TVC System
Special Tools
Removing Engine / Refitting Engine
3.0 Dismantling Engine
Cylinder Head, Cylinder, Piston
Drain Gear Oil
Clutch Cover
Primary Drive
Ignition (Kokusan)
Kickstarter
Clutch Release Shaft
Engine Sprocket
Ignition (SEM)
Intake Flange, Reed Valve Housing
Crankshaft
Shift Mechanism, Transmission
4.0 Servicing on Individual Components
Servicing on Individual Components
Left Housing Half
Crankshaft
Piston
Piston Ring End Gap
Nikasil Coating of Cylinder
Exhaust Control in Clutch Cover
Preassembly of Clutch Cover
Reed Valve Housing, Intake Flange
Kickstarter
Transmission
Assembly of Countershaft
Clutch
Shift Mechanism
Preassembly of Shift Shaft
Ignition (Kokusan)
Spark Plug (NGK BR 8 ECM)
Check Stator and Pulse Generator (Kokusan)
Ignition (SEM)
Spark Plug (NGK BR 8 ECM)
Check Stator (SEM)
5.0 Engine Assembly
Engine Assembly
Assembly of Engine Housing
Clutch Release Shaft
Kickstarter
Primary Drive, Clutch
Clutch Cover
Piston and Cylinder
Clutch Discs, Pressure Cap
Cylinder Head
Mounting Ignition (Kokusan)
Mounting Ignition (SEM)
Adjusting Ignition Point (SEM)
Filling in Gear Oil
Starting Lever/Foot Shift Lever
Electrical
Checking the Voltage Regulator Tympanium
Checking the Voltage Regulator-Rectifier Shindengen
Checking the Voltage Regulator Kokusan
Checking the Capacitor
Ignition Coil Sem/Kokusan
CDI Unit
Trouble Shooting
Technical Data / Maintenance Schedule
Wiring Diagram
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Quick Links
1
Engine Assembly
2
Checking the Voltage Regulator Tympanium
3
Checking the Voltage Regulator-Rectifier Shindengen
4
Technical Data / Maintenance Schedule
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REPARATURANLEITUNG
REPAIR MANUAL
MANUALE DI RIPARAZIONE
MANUEL DE RÉPARATION
MANUAL DE REPARACIÓN
250 / 300 / 380
MOTOR
ENGINE
MOTORE
MOTEUR
MOTOR
'98
7. 97
ART. NR. 3.205.20
Table of
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Chapters
1 1 General 2 3
2
3.0 Dismantling Engine
12
4.0 Servicing On Individual Components
18
5.0 Engine Assembly
30
Table of Contents
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Summarization of Contents
General Maintenance and Setup
Bleeding the Cooling System
Procedure to remove air from the cooling system after refilling.
Carburetor Adjustment Guide
Guidelines for adjusting the carburetor for different altitudes and conditions.
Engine Removal and Refitting Procedures
Removing the Engine from Frame
Step-by-step instructions for detaching the engine from the motorcycle frame.
Refitting the Engine to Frame
Steps for reinstalling the engine into the motorcycle frame.
Engine Dismantling Procedures
Cylinder Head, Cylinder, and Piston Service
Procedures for removing and servicing the cylinder head, cylinder, and piston.
Primary Drive Component Service
Steps to dismantle and service the engine's primary drive components.
Crankshaft Removal and Service
Instructions for removing and servicing the crankshaft.
Servicing Individual Engine Components
Right Engine Housing Half Servicing
Detailed steps for servicing the right-hand engine housing components.
Left Engine Housing Half Servicing
Detailed steps for servicing the left-hand engine housing components.
Piston Inspection and Service
Checks and procedures for inspecting and servicing the engine piston.
Transmission System Servicing
Procedures for assembling and servicing the transmission gears.
Clutch Component Servicing
Inspection and servicing of clutch components, including discs and springs.
Engine Assembly Procedures
Crankshaft Installation
Steps for installing the crankshaft into the engine housing.
Engine Housing Assembly
Instructions for joining the engine housing halves during assembly.
Piston and Cylinder Installation
Procedures for installing the piston into the cylinder.
Electrical System Checks
Voltage Regulator (Tympanium) Check
Guide for testing the voltage regulator's functionality.
Ignition Coil (Kokusan) Resistance Test
Instructions for measuring ignition coil resistance.
Troubleshooting Engine Issues
Comprehensive Troubleshooting Chart
A chart to diagnose and resolve common engine problems and their causes.
Technical Data and Maintenance Schedule
Engine Technical Data (Non-USA)
Specifications and data for engine components across different models.
Tightening Torques
Specified torque values for critical engine fasteners.
Periodic Lubrication and Maintenance Schedule
A schedule outlining regular maintenance tasks and intervals.
Table of Contents
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