Table of Contents
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Table of Contents
Related Manuals for KTM 300 XC TPI
Summarization of Contents
Means of Representation
Symbols Used
Explains the meaning of various symbols used in the manual.
Formats Used
Describes the typographical formats used for emphasis and clarity in the document.
Safety Advice
Use Definition - Intended Use
Defines the intended purpose and design of the vehicle for racing.
Misuse
Details the dangers and consequences of using the vehicle not as intended.
Safety Advice
Emphasizes the importance of following safety instructions for safe operation.
Degrees of Risk and Symbols
Explains risk levels (Danger, Warning, Caution, Note) and associated symbols.
Tampering Warning
Prohibits tampering with the noise control system and lists presumed tampering acts.
Safe Operation
Provides essential advice for safe riding, including rider condition and environmental factors.
Protective Clothing
Highlights the importance of wearing appropriate and well-maintained protective gear.
Work Rules
Outlines rules for performing maintenance, including special tools and part replacement.
Environment
Advises on responsible motorcycle use and environmental consciousness.
Owner's Manual
Stresses the importance of reading the manual for operation, handling, and service.
Important Notes
Manufacturer and Implied Warranty
Details warranty conditions, requiring authorized workshop service to avoid voiding claims.
Fuel, Auxiliary Substances
Provides notes on fuel handling and environmental hazards.
Spare Parts, Accessories
Recommends using KTM-approved parts and accessories for safety and liability.
Service
Emphasizes proper service and tuning for optimal operation and wear prevention.
Figures
Notes that manual figures may show special equipment or disassembled parts.
Customer Service
Informs about contacting authorized dealers for vehicle-related questions.
View of Vehicle
View of Vehicle, Front Left (example)
Illustrates the front left view of the motorcycle with key components labeled.
View of Vehicle, Rear Right (example)
Illustrates the rear right view of the motorcycle with key components labeled.
Serial Numbers
Vehicle Identification Number
Shows the location of the vehicle identification number stamped on the steering head.
Type Label
Indicates the location of the type label fixed to the front of the steering head.
Engine Number
Shows the location of the engine number embossed on the engine case.
Fork Part Number
Details the location of the fork part number stamped on the axle clamp.
Shock Absorber Article Number
Specifies the location of the shock absorber article number on the shock absorber.
Controls
Clutch Lever
Describes the clutch lever on the left handlebar and its hydraulic operation.
Hand Brake Lever
Identifies the hand brake lever on the right handlebar for the front brake.
Throttle Grip
Locates the throttle grip on the right side of the handlebar.
Switch-off Button
Explains the function and states of the handlebar-mounted switch-off button.
Start Button
Describes the location and function of the start button on the right handlebar.
Overview of Indicator Lamps
Details the meaning of various indicator lamps and their possible states.
Opening the Fuel Tank Filler Cap
Provides safety warnings and instructions for opening the fuel tank filler cap.
Closing the Fuel Tank Filler Cap
Instructs on how to properly close the fuel tank filler cap, including hose routing.
Opening 2-stroke Oil Tank Cap
Details the procedure for opening the 2-stroke oil tank cap.
Closing 2-stroke Oil Tank Cap
Explains how to properly close the 2-stroke oil tank cap.
Cold Start Button
Describes the location and function of the cold start button for engine starting.
Idle Speed Adjusting Screw
Explains the idle speed adjusting screw's function and its impact on engine performance.
Shift Lever
Locates the shift lever on the left side of the engine.
Foot Brake Lever
Identifies the foot brake lever for activating the rear brake.
Side Stand
Describes the location of the side stand and its use for parking.
Service Hour Counter
Explains the function of the service hour counter for tracking engine operating hours.
Preparing for Use
Advice on Preparing for First Use
Provides crucial advice for initial preparation, rider fitness, and controls familiarization.
Running in the Engine
Details the engine break-in phase, specifying maximum performance limits.
Starting Power of Lithium-Ion Batteries at Low Temperatures
Explains the performance of lithium-ion batteries in cold conditions and starting procedures.
Preparing the Vehicle for Difficult Operating Conditions
Advises on preparing the vehicle for challenging conditions like sand or mud.
Preparing the Vehicle for Riding on Dry Sand
Provides specific preparation steps for riding the motorcycle on dry sand.
Preparing the Vehicle for Riding on Wet Sand
Outlines preparations needed for riding on wet sand conditions.
Preparing the Vehicle for Riding on Wet and Muddy Circuits
Details preparations for operating the motorcycle on wet and muddy terrain.
Preparing Vehicle for High Temperatures or Slow Riding
Offers advice on preparing the vehicle for hot conditions or slow riding.
Preparing the Vehicle for Low Temperatures or Snow
Provides guidance on preparing the motorcycle for cold weather or snow riding.
Riding Instructions
Checks and Maintenance Measures When Preparing for Use
Lists pre-ride checks covering fluids, tires, chain, and fasteners for safety.
Starting
Provides instructions and safety warnings for starting the motorcycle's engine.
Starting Off
Details the procedure for starting off from a standstill, including clutch and throttle use.
Shifting, Riding
Explains gear shifting techniques and riding advice, including downshifting warnings.
Applying the Brakes
Offers guidance on brake application, emphasizing smooth operation and avoiding hazards.
Stopping, Parking
Provides instructions and warnings for stopping and parking the motorcycle safely.
Transporting
Gives advice on safely transporting the motorcycle, including securing it.
Refueling
Covers safety precautions and procedures for refueling the vehicle.
Adding 2-stroke Oil
Instructs on when and how to add 2-stroke oil, emphasizing the oil level warning.
Service Schedule
Additional Information
Provides context on service schedules, including country variations and updates.
Required Work
Details mandatory maintenance tasks required at specified operating hour intervals.
Recommended Work
Lists recommended maintenance tasks performed at various operating hour or time intervals.
Tuning the Chassis
Checking the Basic Chassis Setting with Rider's Weight
Explains how rider weight affects chassis settings and how to adjust them.
Air Suspension XACT 5548
Describes the WP XACT 5548 air suspension system used in the fork.
Compression Damping of the Shock Absorber
Explains high-speed and low-speed compression damping for the shock absorber.
Adjusting the Low-Speed Compression Damping of the Shock Absorber
Provides steps and guidelines for adjusting the shock absorber's low-speed compression.
Adjusting the High-Speed Compression Damping of the Shock Absorber
Details how to adjust the high-speed compression damping of the shock absorber.
Adjusting the Rebound Damping of the Shock Absorber
Explains the procedure for adjusting the shock absorber's rebound damping.
Measuring the Rear Wheel Dimension Unloaded
Outlines the method for measuring rear wheel dimension with the motorcycle unloaded.
Checking the Static Sag of the Shock Absorber
Describes how to check the static sag of the shock absorber and adjust spring preload.
Checking the Riding Sag of the Shock Absorber
Explains how to check the riding sag of the shock absorber and adjust it.
Adjusting the Spring Preload of the Shock Absorber
Provides step-by-step instructions for adjusting the shock absorber's spring preload.
Adjusting the Riding Sag
Details how to adjust the riding sag by selecting or adjusting the spring.
Checking the Basic Setting of the Fork
Offers guidance on checking and adjusting the basic fork settings, including air pressure.
Adjusting the Fork Air Pressure
Explains how to adjust the air pressure in the fork for optimal suspension performance.
Adjusting the Compression Damping of the Fork
Details the procedure for adjusting the fork's hydraulic compression damping.
Adjusting the Rebound Damping of the Fork
Provides instructions for adjusting the fork's hydraulic rebound damping.
Handlebar Position
Describes how handlebar position can be adjusted for rider comfort.
Adjusting the Handlebar Position
Warns about risks of repaired handlebars and instructs on replacement if bent.
Service Work on the Chassis
Raising the Motorcycle with a Lift Stand
Provides instructions and safety notes for raising the motorcycle using a lift stand.
Removing the Motorcycle from the Lift Stand
Details the procedure for safely removing the motorcycle from the lift stand.
Bleeding the Fork Legs
Explains the preparatory steps for bleeding the fork legs.
Cleaning the Dust Boots of the Fork Legs
Instructs on cleaning fork dust boots to prevent oil seal leaks and warns about brake discs.
Removing the Fork Legs
Provides step-by-step instructions for removing the front fork legs.
Installing the Fork Legs
Details the process of installing the front fork legs, including tightening torques.
Removing the Fork Protector
Explains how to remove the fork protectors, including screws and clamps.
Installing the Fork Protector
Provides instructions for installing the fork protectors and associated screws.
Removing the Lower Triple Clamp
Lists preparatory steps required before removing the lower triple clamp.
Installing the Lower Triple Clamp
Details the process of installing the lower triple clamp, including cleaning and greasing.
Removing the Start Number Plate
Instructs on removing the start number plate and disconnecting the brake line.
Installing the Start Number Plate
Details the procedure for installing the start number plate and securing it.
Removing Front Fender
Explains how to remove the front fender after removing the start number plate.
Installing Front Fender
Provides instructions for mounting and tightening the front fender.
Removing the Shock Absorber
Guides through the process of removing the shock absorber, including related components.
Installing the Shock Absorber
Details the steps for carefully positioning and mounting the shock absorber.
Removing the Seat
Explains how to remove the motorcycle seat by undoing the screw.
Mounting the Seat
Provides instructions for correctly mounting the motorcycle seat.
Removing the Air Filter Box Cover
Instructs on removing the air filter box cover, noting conditions for secured/unsecured state.
Installing the Air Filter Box Cover
Details the process for installing the air filter box cover, with specific screw instructions.
Removing the Air Filter
Warns against using the vehicle without an air filter and advises on disposal of used filters.
Cleaning the Air Filter and Air Filter Box
Provides instructions for cleaning the air filter and box, warning against fuel cleaning.
Installing the Air Filter
Explains how to mount the clean air filter and grease it for proper installation.
Preparing Air Filter Box Cover for Securing
Details drilling a hole in the air filter box cover for securing purposes.
Removing the Main Silencer
Warns about hot exhaust system parts and instructs on removing the main silencer.
Installing the Main Silencer
Provides instructions for positioning and mounting the main silencer with screws.
Changing the Glass Fiber Yarn Filling of the Main Silencer
Instructs on changing the silencer's filling, noting noise and performance changes.
Removing the Fuel Tank
Details safety warnings for fuel handling and the procedure for removing the fuel tank.
Installing the Fuel Tank
Provides instructions for installing the fuel tank, checking cable routing and attachments.
Checking the Chain for Dirt
Explains how to check the chain for dirt and clean it if necessary.
Cleaning the Chain
Provides instructions for cleaning the chain, warning about lubricants on tires and discs.
Checking the Chain Tension
Explains how to check chain tension and the risks of incorrect tension.
Adjusting the Chain Tension
Details the procedure for adjusting chain tension, alignment, and tightening nuts.
Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide
Guides on checking wear of chain, sprockets, and chain guides, and when to replace them.
Checking the Frame
Instructs on checking the frame for cracks or deformation and the policy on repairs.
Checking the Link Fork
Details how to check the link fork for damage and the policy on its replacement.
Checking the Throttle Cable Routing
Emphasizes correct throttle cable routing to prevent speed control issues.
Checking the Rubber Grip
Advises on checking rubber grips for damage, wear, looseness, and replacement.
Adjusting the Basic Position of the Clutch Lever
Explains how to adjust the clutch lever position for rider comfort.
Checking/Correcting the Fluid Level of the Hydraulic Clutch
Guides on checking and correcting the hydraulic clutch fluid level, with safety warnings.
Changing the Hydraulic Clutch Fluid
Provides instructions and safety precautions for changing the hydraulic clutch fluid.
Brake System
Checking the Free Travel of the Hand Brake Lever
Explains how to check hand brake lever free travel and adjust basic position.
Adjusting the Basic Position of the Hand Brake Lever
Details adjusting the hand brake lever position for rider comfort and hand size.
Checking the Brake Discs
Warns about worn brake discs reducing braking effect and advises immediate replacement.
Checking the Front Brake Fluid Level
Instructs on checking front brake fluid level and warnings about insufficient levels.
Adding Front Brake Fluid
Provides instructions for adding front brake fluid, with safety and substance warnings.
Checking the Front Brake Linings
Explains how to check front brake lining thickness and for damage or cracking.
Changing the Brake Linings of the Front Brake
Warns about incorrect servicing and the need for professional brake lining replacement.
Checking the Free Travel of Foot Brake Lever
Details how to check foot brake lever free travel and adjust its basic position.
Adjusting the Basic Position of the Foot Brake Lever
Explains how to adjust the foot brake lever's basic position for optimal control.
Checking the Rear Brake Fluid Level
Instructs on checking the rear brake fluid level and related warnings.
Adding Rear Brake Fluid
Provides guidance on adding rear brake fluid, including safety and substance warnings.
Checking the Brake Linings of the Rear Brake
Explains how to check rear brake lining thickness and for damage or cracking.
Changing the Rear Brake Linings
Warns about incorrect servicing and emphasizes professional replacement of rear brake linings.
Wheels, Tires
Removing the Front Wheel
Provides step-by-step instructions for removing the front wheel, including brake caliper.
Installing the Front Wheel
Details the process for installing the front wheel, including bearing checks and tightening.
Removing the Rear Wheel
Guides through the procedure for removing the rear wheel, including chain and spindle.
Installing the Rear Wheel
Explains how to install the rear wheel, including chain tension and brake lining seating.
Checking the Tire Condition
Advises on checking tires for damage, wear, and age, recommending replacement as needed.
Checking Tire Pressure
Details how to check tire pressure when cold and correct it to specifications.
Checking Spoke Tension
Explains how to check spoke tension by sound and the importance of correct tension.
Diagnostics Connector
Indicates the location of the diagnostics connector under the seat.
Electrical System
Removing the 12 V Battery
Provides instructions and safety warnings for removing the 12 V battery.
Installing the 12 V Battery
Details the procedure for installing the 12 V battery and connecting cables.
Charging the 12-V Battery
Explains how to charge the 12-V battery, including safety and maintenance information.
Changing Main Fuse
Instructs on changing the main fuse, warning against improper fuse use.
Changing the Fuses of Individual Power Consumers
Details how to change fuses for individual power consumers located in the fuse box.
Cooling System
Cooling System
Explains the function of the water pump and radiator cap in coolant circulation.
Checking the Antifreeze and Coolant Level
Provides safety warnings and instructions for checking antifreeze and coolant levels.
Checking the Coolant Level
Details how to check the coolant level in the radiator and associated warnings.
Draining the Coolant
Provides safety warnings for draining the coolant, emphasizing caution with hot fluids.
Refilling with Coolant
Instructs on refilling the cooling system with coolant, including thermostat replacement.
Tuning the Engine
Checking Throttle Cable Play
Explains how to check throttle cable play and the importance of correct play.
Adjusting the Throttle Cable Play
Details the procedure for adjusting throttle cable play for smooth operation.
Adjusting the Characteristic Map of the Throttle Response
Describes changing throttle response by swapping guide plates on the grip tube.
Adjusting the Idle Speed
Provides instructions and warnings for adjusting the engine's idle speed.
Programming Ambient Pressure
Explains how to reprogram ambient pressure settings for altitude changes.
Plug-in Connector of Ignition Timing Map Adjustment
Describes the plug-in connector for adjusting ignition timing maps (Soft/Performance).
Changing the Ignition Timing Map
Details how to switch between ignition timing maps for different performance characteristics.
Checking the Basic Position of the Shift Lever
Explains how to check the shift lever position to avoid excessive load on the transmission.
Adjusting the Basic Position of the Shift Lever
Provides instructions for adjusting the shift lever's basic position for rider comfort.
Service Work on the Engine
Changing the Fuel Screen
Details the procedure for changing the fuel screen, including safety warnings.
Checking 2-stroke Oil Level
Explains how to check the 2-stroke oil level and the engine failure warning.
Priming Oil Pump
Guides on priming the oil pump, emphasizing engine failure warnings.
Cleaning the Oil Screen in the Oil Tank
Provides instructions for cleaning the oil screen, including safety and disposal warnings.
Checking the Gear Oil Level
Explains how to check the gear oil level when the engine is cold.
Changing the Gear Oil
Provides instructions and warnings for changing the gear oil, emphasizing hot fluid caution.
Adding the Gear Oil
Details how to add gear oil, warning about premature wear from low or poor quality oil.
Cleaning, Care
Cleaning the Motorcycle
Provides instructions for cleaning the motorcycle, warning against high pressure and environmental hazards.
Storage
Storage
Offers advice on preparing the motorcycle for long-term storage, including fluid additives.
Preparing for Use After Storage
Details the steps required to prepare the motorcycle for use after a storage period.
Troubleshooting
The engine cannot be cranked (starter motor)
Lists possible causes and actions for the engine not cranking.
The engine turns but does not start
Covers issues when the engine cranks but fails to start, and their solutions.
The engine has no idle speed
Addresses problems with the engine not maintaining idle speed and their causes.
Engine does not speed up
Troubleshoots issues where the engine fails to accelerate properly.
Engine has too little power
Identifies causes for reduced engine power, like dirty filters or fuel supply issues.
The engine dies during the trip
Addresses situations where the engine stops running during a ride.
Engine overheats
Explains causes of engine overheating, such as low coolant or blocked radiator fins.
White smoke emission (steam in exhaust gas)
Covers potential causes for white smoke from the exhaust, like head gasket issues.
Gear oil exits at the vent hose
Addresses issues of gear oil exiting the vent hose, possibly due to overfilling.
Water in the gear oil
Identifies causes for water contamination in the gear oil, such as seal damage.
Technical Data
Engine
Provides detailed technical specifications for the motorcycle's engine.
Engine Tightening Torques
Lists tightening torques for various engine screws and bolts.
Capacities
Specifies capacities for essential fluids like gear oil, coolant, and fuel.
Chassis
Details technical specifications related to the motorcycle's chassis components.
Electrical System
Provides technical data for the motorcycle's electrical system components.
Tires
Lists specifications for front and rear tires, including recommended brands.
Fork
Details technical specifications for the fork, including air pressure and damping settings.
Shock Absorber
Provides technical data for the shock absorber, including damping and spring settings.
Chassis Tightening Torques
Lists tightening torques for various chassis screws and bolts.
Substances
Brake Fluid DOT 4 / DOT 5.1
Specifies standards, guidelines, and recommended suppliers for brake fluids.
Coolant
Provides guidelines on coolant types, antifreeze protection, and recommended suppliers.
Engine Oil (15W/50)
Details standards, guidelines, and recommended suppliers for 15W/50 engine oil.
Engine Oil, 2-stroke
Specifies standards, guidelines, and recommended suppliers for 2-stroke engine oil.
Auxiliary Substances
Air Filter Cleaner
Lists recommended air filter cleaner products.
Chain Cleaner
Lists recommended chain cleaner products.
Fuel Additive
Lists recommended fuel additive products.
High Viscosity Grease
Lists recommended high viscosity grease products.
Long-life Grease
Lists recommended long-life grease products.
Motorcycle Cleaner
Lists recommended motorcycle cleaner products.
Off-road Chain Spray
Lists recommended off-road chain spray products.
Oil for Foam Air Filter
Lists recommended oils for foam air filters.
Preserving Materials for Paints, Metal and Rubber
Lists recommended preserving materials for paints, metal, and rubber.
Special Cleaner for Glossy and Matte Paint Finishes, Metal and Plastic Surfaces
Lists recommended special cleaners for various surfaces.
Special Grease (00062010053)
Lists recommended special grease.
Universal Oil Spray
Lists recommended universal oil spray.
Standards
JASO T903 MA2
Explains the JASO T903 MA2 standard for motorcycle engine oils.
SAE
Describes the SAE viscosity classes for classifying oils by viscosity.
JASO FD
Defines JASO FD as a classification for high-performance 2-stroke engine oil.
List of Symbols
Red Symbols
Indicates error conditions requiring immediate intervention, such as oil level warnings.
Yellow and Orange Symbols
Indicates error conditions requiring prompt intervention or active driving aids.
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