KTM 300SX Owner's Handbook Manual
Ktm motorcycle user manual
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Also See for 300SX:
- Repair manual (154 pages) ,
- Owner's handbook manual (45 pages) ,
- Owner's manual (39 pages)
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Summary of Contents for KTM 300SX
- Page 2 IGNORING THESE INSTRUCTIONS, CAN BE DANGEROUS TO LIFE AND LIMB. IGNORING THESE INSTRUCTIONS MAY DAMAGE PARTS OF THE MOTORCYCLE OR IMPAIR THE MOTORCYCLE’S TRAFFIC SAFETY. Please insert the serial numbers of your motorcycle in the boxes below Chassis number Engine number Key number Stamp of dealer...
- Page 3 We expressly point out that work 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 performed by a trained mechanic.
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Page 4: Important Warranty And Guarantee Information
(see chapter on checking the basic chassis setting). The service work specified in the "Lubrication and Maintenance Schedule" must be performed by a KTM workshop and recorded in the service manual otherwise claims under the warranty shall become void. The fuels and lubricants specified in the Owner's Manual or automotive fluids with equivalent specifications must be used in accordance with the maintenance schedule. -
Page 5: Table Of Contents
Correct the chain tension ...29 Chain maintenance ...30 Chain wear...30 General information about KTM disc brakes...31 Adjusting the free travel at the hand brake lever ...32 Checking the brake fluid level - front brake...32 Refilling the front brake fluid reservoir...32 Checking the front brake pads ...32... -
Page 6: Serial Number Locations
SERIAL NUMBER LOCATIONS Chassis number The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 1. Engine number, engine type (125/200) The engine number and the engine type are stamped into the left side of the engine below the engine sprocket. -
Page 7: Electronic Speedometer, Indicator Lamp (Exc)
The operating hour counter starts to count as soon as you start the engine. The displayed figure cannot be cleared. Service intervals are indicated in operating hours for some KTM offroad motorcycles, making the operating hour counter a very practical function. -
Page 8: Tripmaster Switch
The lap number is shown at the top and the lap time in hours, minutes and seconds at the bottom of the display. If no lap time is stored or the motorcycle is driving, the LAP/LAP mode will be skipped. - Page 9 The operating hour counter starts to count as soon as you start the engine. The displayed figure cannot be cleared. Service intervals are indicated in operating hours for some KTM offroad motorcycles, making the operating hour counter a very practical function.
- Page 10 SPEED/TRP2 (trip 2) display mode The TRP2 trip meter is always active and counts to 999.9. Contrary to TRP1, the displayed figure can be changed using the + and – buttons. This is a very useful function for trips taken according to a roadbook. TRP2 is activated by the first impulse received from the wheel sensor and stops automatically 3 seconds after the last impulse is received.
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Page 11: Overview Of Tripmaster Functions
OVERVIEW OF TRIPMASTER FUNCTIONS Display no function SPEED / ODO no function SPEED / MAX starts / stops LAP SPEED / LAP figure LAP remains next figure LAP / LAP no function SPEED / CLK SPEED / H no function SPEED / TRP1 no function SPEED / AVS1... -
Page 12: Short Circuit Button (Sx)
Short circuit button (SX) The short circuit button turns off the engine. When pressing this button, the ignition circuit is short-circuited. Combination switch (EXC) The light switch has 2, respectively 3 switch positions. = Light off (this function is not available in all models) = Low beam on = High beam on You may use button... -
Page 13: Filler Cap
2,3,4,5 (6) Filler cap To open it: turn filler cap counter-clockwise. To close it: put filler cap back on and tighten it by turning it clockwise. Install tank breather hose Fuel tap OFF In this position the fuel tap is closed. No fuel can flow to the carburetor. ON During operation the twist grip must be turned to ON. -
Page 14: Kickstarter
Push the side stand to the ground with your foot and load it with the 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 additionally secure the center stand in its folded-up position. -
Page 15: Compression Damping Of Fork
Control). Low and high speed refers to the movement of the shock absorber during compression and not to the speed of the motorcycle. The low and high-speed technology overlaps. The low-speed setting is primarily for slow to normal shock absorber compression rates.The high-speed setting is effective at fast compression... -
Page 16: Compression Damping Of Shock Absorber (Mxc, Exc)
Compression damping of shock absorber (MXC, EXC) The compression damping (during compression) can be adjusted for the MXC and EXC shock absorbers (Mono Compression Control). The degree of damping can be adjusted by turning adjusting screw a screwdriver. Turning in a clockwise direction will increase the damping, turning in a counterclockwise direction will decrease the damping. -
Page 17: General Tips And Warnings For Starting The Motorcycle
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Instructions for 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. -
Page 18: Driving Instructions
Arrange for the braking system to be checked by an authorized KTM dealer, as complete failure of the braking system can be expected. Also check the state of the brake hose and the thickness of the brake linings. -
Page 19: Starting When The Engine Is Cold
FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH LWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING CAUTION O NOT RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DO NOT REV UP THE ENGINE WHEN COLD INCE THE PISTON WARMS UP AND EXPANDS FASTER THAN THE WATER... -
Page 20: Braking
Mixture ratio 1:40 - 1:60 E RECOMMEND YOU RUN Fuel and engine oil should only be mixed immediately before use. KTM recommends SHELL ADVANCE RACING X. ASOLINE IS HIGHLY FLAMMABLE AND POISONOUS SHOULD BE USED WHEN HANDLING GASOLINE... -
Page 21: Periodic Lubrication - And Maintenance-Schedule
Treat electric contacts and switches with contact grease Change hydraulic clutch fluid Change break fluid IF MOTORCYCLE IS USED FOR COMPETITION 4000KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! ERVICE NTERVALS SHOULD NEVER BE EXCEEDED BY MORE THAN AINTENANCE WORK DONE BY... - Page 22 MPORTANT HECKS AND AINTENANCE TO BE ARRIED OUT BY THE IDER Check gear box oil level Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regulary Remove and clean dust bellows regularly Clean and lubricate chain, check tension and adjust if necessary Clean air filter and filter box...
- Page 23 ECOMMENDED INSPECTION OF THE USED FOR ENDURO COMPETITIONS BY YOUR Check the reed-type intake valve for wear Check the clutch shoes for wear Check the length of the clutch springs Check the cylinder and piston for wear Check the exhaust control for proper functioning and smooth running Check the eccentricity of the crankshaft journal Check the radial clearance of the conrod bearings Check the radial clearance of the piston pin main bearing...
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Page 25: Maintenance Work On Chassis And Engine
MAINTENANCE AND ADJUSTING WORK MARKED WITH AN ASTERISK (*) REQUIRES EXPERT SKILLS AND TECHNICAL KNOW-HOW. FOR YOUR OWN SAFETY, ALWAYS HAVE SUCH WORK PERFORMED BY A SPECIALIZED KTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED, SKILLED STAFF. -
Page 26: How To Change The Handlebar Position
To do this, place the motorcycle on a stand with the front wheel lifted off the ground. When riding the motorcycle mainly on the road, it will suffice to have this job performed in the course of the periodical mainte- nance service. -
Page 27: Basic Suspension Setup For The Weight Of The Driver
EXAMPLE: Motorcycle jacked up (dimension A) ......600 mm Motorcycle on ground, unloaded (dimension B) ....– 565 mm Static sag . -
Page 28: Checking The Basic Setup Of The Telescopic Fork
The type number of the telescopic fork is embossed on the caps on the top of the telescopic fork. If you are uncertain which spring to use, contact your KTM workshop. According to our experience, the damping rate of the compression stage can remain unchanged. -
Page 29: Adjusting The Spring Preload On The Fork (Sx)
Adjusting the spring preload on the fork (SX) The spring preload on the SX models can be adjusted (changed) by 10 mm by turning adjusting screw Turning in a clockwise direction will increase the prestress, turning in a counterclockwise direction will decrease the prestress. Changing the spring preload will not affect the rebound damping adjustment. -
Page 30: Checking The Chain Tension
JUMPING OFF THE CHAIN WHEELS F THIS HAPPENS THE REAR WHEEL OR DAMAGE THE ENGINE – I N EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTORCYCLE Correct chain tension Loosen collar nut , loosen lock nuts screws equally far. -
Page 31: Chain Maintenance
O LUBRICATION IS ALLOWED TO REACH THE REAR TIRE OR THE BRAKE DISK THE ROAD ADHERENCE AND THE REAR WHEEL BRAKING EFFECTS WOULD BE STRONGLY REDUCED AND THE MOTORCYCLE COULD EASILY GET OUT OF CONTROL HEN MOUNTING THE CHAIN JOINT POINT IN RUNNING DIRECTION Also check sprockets and chain guides for wear, and replace if necessary. -
Page 32: General Information About Ktm Disc Brakes
In this case, consult an authorized KTM dealer immediately. BRAKE FLUID: KTM fills the brake systems with SHELL ADVANCE BRAKE DOT 5.1 brake fluid, one of the best brake fluids is currently available. We recommend that you continue to use it. DOT 5.1 brake fluid is based on glycol ether and of an amber color. -
Page 33: Adjusting The Free Travel At The Hand Brake Lever
min. 1 mm Adjusting the free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustment screw . In this way, the position of the point of pressure (i.e. the resis- tance you feel on the hand brake lever when the brake pads are pressed against the brake disc) can be adjusted for any hand size. -
Page 34: Replacing The Front Brake Pads
The brake fluid reservoir of the rear disc brake is located on the right side of the motorcycle next to the kickstarter. The brake fluid level must not drop below the ”MlN” marking when the vehicle is in an upright position. -
Page 35: Checking The Rear Brake Pads
PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRESSURE POINT IS ESTABLISHED Dismounting and mounting the front wheel To remove the front wheel, jack the motorcycle up on its frame so that the front wheel no longer touches the ground. -
Page 36: Dismounting And Mounting The Rear Wheel
T IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS OTHERWISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED Dismounting and mounting the rear wheel Jack the motorcycle up on its frame so that the rear wheel no longer tou- ches the ground. Loosen the collar nut... -
Page 37: Tires-Air Pressure
(see photo). A clear tone must be the result. Dull tones are indicators of loose spokes. If necessary, have the spokes retightened and the wheel centered by a KTM dealer. -
Page 38: Setting The Clock Of The Electronic Speedometer
SETUP menu NOTE: If you retrofit this Tripmaster on another motorcycle, the power can also be supplied by the 12 V vehicle electric system. You will need an additional cable harness, spare part no. 583.14.069.210, which you can order from your KTM dealer. -
Page 39: Checking/Setting The Distance Of The Magnetic Sensor
Wheel circumference with standard tires = 2205 mm Check/set distance of the magnetic sensor The distance between the magnet otherwise malfunctions on the speedometer might occur. This distance can be corrected by screwing the sensor KMH: WS = mm x 3.14 mm x 3,14 MPH: WS = (mm x 3.14) : 1.61... -
Page 40: Cooling System
Remount the radiator protection. NOTE: The radiator shutter can be obtained from your KTM dealer Checking the coolant level The coolant should be 10 mm (0.4 in) above the radiator fins when the engine is cold (see diagram). -
Page 41: Refilling/Bleeding The Cooling System
Check the coolant level again after a short ride. Cleaning the air filter * The air filter must be cleaned prior to every race or whenever the motorcycle has been exposed to great quantities of dust. For this purpose, rotate the two quick-release fasteners and pull them outward up to the stop, pull the filter box cover forward and remove it. -
Page 42: Changing The Original Position Of The Clutch Lever
SAE 10 hydraulic oil. Refill oil, until oil is discharged from the bore of the master cylinder in a bubble-free state. Make sure that the oil does not overflow. The bleeder syringe can be purchased at your KTM dealer.Having completed the bleeding procedure, you have to verify that the oil level in the master cylinder is correct.If necessary, fill up with biode-... -
Page 43: Cleaning The Spark Arrestor (Exc Usa)
(basic position of the air control screw = open by 1.5 turns). Then adjust to the normal idling speed by means of the air control screw. and start the motorcycle. choose leaner carburetor adjustment choose richer carburetor adjustment... -
Page 44: Draining The Float Chamber Of The Carburetor
main jet jet needle jet needle idle jet throttle valve air control screw idle adjusting screw JET NEEDLE RANGE OF ACTION TYPE RICHER NOZD NOZE NOZF NOZG NOZH 60° Opening up Engine behavior when the throttle opens. The idle jet and the shape of the throttle valve influences this range. -
Page 45: Checking The Transmission Oil Level (125/200)
TOO LITTLE OR LOW GRADE OIL Changing the transmission oil (125/200) * To change the gear oil warm up the engine and park the motorcycle on a horizontal surface. Remove oil drain plugs into an appropriate container. Clean the magnets of the oil drain plugs and mount them together with the appropriate gaskets. -
Page 46: Cleaning
– After the motorcycle has been rinsed with a soft water jet, it should be dried by air pressure and a cloth. Then take a short drive until the engine has reached the working temperature and also use the brakes. By warming these components, the residual water can evaporate from inaccessable parts of the engine and the brakes. - Page 48 TANDARD DJUSTMENT WP 4860 MXMA 1418X725 Compression adjuster Rebound adjuster Spring 4.0 N/mm Spring preload 5 mm (0.2in) Air chamber length 100 mm (5.1in) Fork oil SAE 5 IGHTENING ORQUES Collar screw, front wheel spindle Brake caliper, front Brake disk, front Brake disk, rear Clamping screws, upper fork bridge Clamping screws, lower fork bridge...
- Page 50 TIGHTENING TORQUES - ENGINE Flange bolts - cylinder-head Nuts-cylinder base Flywheel collar nut Nut for primary sprocket (LH thread) Nut for inner clutch hub Crankcase and clutch cover bolts Spark plug Swingarm pivot Other screws BASIC CARBURETOR SETTING 125 SX Carburetor Keihin PWK 39 Carburetor setting number...
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Page 51: Technical Specifications - Chassis (250/300)
TECHNICAL SPECIFICATIONS CHASSIS Frame Fork Wheel travel front/rear Rear suspension Front brake Rear brake Brake discs Front tires Front tires USA Air pressure offroad Air pressure road driver only Rear tires Rear tires USA Air pressure offroad Air pressure road driver only Fuel tank capacity Final drive ratio Final drive ratio USA... - Page 52 IGHTENING ORQUES Collar screw, front wheel spindle Brake caliper, front Brake disk, front Brake disk, rear Clamping screws, upper fork bridge Clamping screws, lower fork bridge Clamping screws, fork stubs Collar nut, rear wheel spindle Hexagon nut, swing arm bolt Hexagon collar screw, handlebar clamp Allan head screw, handlebar support Shock absorber, top...
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Page 54: Tightening Torques
TIGHTENING TORQUES Flange bolts - cylinder-head Nuts-cylinder base Flywheel collar nut Nut for primary sprocket (LH thread) Nut for inner clutch hub Crankcase and cover bolts Swingarm pivot Flat head screw release plate kickstarter Other screws BASIC CARBURETOR SETTING 250/300 EXC throttled Carburetor Keihin PWK 38 AG... -
Page 55: Periodic Lubrication - And Maintenance-Schedule
Filler cap ...12 Flasher switch ...11 Foot brake pedal...13 Fuel tap ...12 General information about KTM disc brakes ...31 General tips and warnings for starting the motorcYcle ...16 Hand brake lever ...5 Headlamp switch (EXC USA)...11 How to change the handlebar position ...25 Index ...54... - Page 56 321049...