KTM 300 EXC TPI 2019 Repair Manual

TABLE OF CONTENTS
2
TABLE OF CONTENTS
1 MEANS OF REPRESENTATION ...................... 7
1.1 Symbols used .................................... 7
1.2 Formats used..................................... 7
2 SAFETY ADVICE............................................ 8
2.1 Repair Manual ................................... 8
2.2 Safety advice..................................... 8
2.3 Degrees of risk and symbols................ 8
2.4 Work rules......................................... 8
3 IMPORTANT NOTES...................................... 9
3.1 Manufacturer and implied warranty...... 9
3.2 Operating and auxiliary substances ...... 9
3.3 Spare parts, accessories ..................... 9
3.4 Figures ............................................. 9
4 SERIAL NUMBERS ..................................... 10
4.1 Chassis number ............................... 10
4.2 Type label ....................................... 10
4.3 Engine number ................................ 10
4.4 Fork part number ............................. 10
4.5 Shock absorber article number .......... 11
5 MOTORCYCLE ............................................ 12
5.1 Raising the motorcycle with a lift
stand .............................................. 12
5.2 Removing the motorcycle from the
lift stand ......................................... 12
5.3 Starting the vehicle .......................... 12
5.4 Starting the motorcycle to check the
function .......................................... 13
6 FORK, TRIPLE CLAMP ................................ 14
6.1 Adjusting the compression damping
of the fork ....................................... 14
6.2 Adjusting the rebound damping of
the fork........................................... 15
6.3 Adjusting the spring preload of the
fork (All Six Days models) ................. 16
6.4 Bleeding the fork legs....................... 16
6.5 Cleaning the dust boots of the fork
legs ................................................ 17
6.6 Removing the fork legs ..................... 17
6.7 Installing the fork legs...................... 18
6.8 Removing the fork protector .............. 19
6.9 Installing the fork protector............... 19
6.10 All standard EXC/XC-W models .......... 20
6.10.1 Servicing the fork......................... 20
6.10.2 Disassembling the fork legs .......... 20
6.10.3 Disassembling the cartridge.......... 23
6.10.4 Disassembling the tap
compression................................ 26
6.10.5 Checking the fork legs.................. 27
6.10.6 Assembling the tap compression ... 28
6.10.7 Assembling the cartridge .............. 29
6.10.8 Assembling the fork legs............... 33
6.10.9 Lubricating the steering head
bearing ....................................... 37
6.10.10 Removing the lower triple clamp ... 37
6.10.11 Installing the lower triple clamp .... 38
6.10.12 Changing the steering head
bearing ....................................... 40
6.10.13 Checking the play of the steering
head bearing ............................... 42
6.10.14 Adjusting the steering head
bearing play ................................ 42
6.11 All Six Days models.......................... 43
6.11.1 Servicing the fork......................... 43
6.11.2 Disassembling the fork legs .......... 43
6.11.3 Disassembling the cartridge.......... 46
6.11.4 Disassembling the tap
compression................................ 49
6.11.5 Checking the fork legs.................. 50
6.11.6 Assembling the tap compression ... 51
6.11.7 Assembling the cartridge .............. 52
6.11.8 Assembling the fork legs............... 56
6.11.9 Lubricating the steering head
bearing ....................................... 61
6.11.10 Removing the lower triple clamp ... 61
6.11.11 Installing the lower triple clamp .... 62
6.11.12 Changing the steering head
bearing ....................................... 64
6.11.13 Checking the play of the steering
head bearing ............................... 65
6.11.14 Adjusting the steering head
bearing play ................................ 66
7 HANDLEBAR, CONTROLS............................ 67
7.1 Handlebar position........................... 67
7.2 Adjusting the handlebar position ....... 67
7.3 Adjusting the basic position of the
clutch lever ..................................... 69
7.4 Checking the rubber grip .................. 70
7.5 Checking throttle cable routing.......... 70
7.6 Checking the play in the throttle
cable .............................................. 71
7.7 Adjusting the play in the throttle
cable .............................................. 71
7.8 Setting the characteristic map of the
throttle response.............................. 72
8 FRAME ...................................................... 74
8.1 Checking the frame .......................... 74
8.2 Removing the engine guard (All
Six Days models) ............................. 74
8.3 Installing the engine guard (All
Six Days models) ............................. 74
8.4 Changing the footrests...................... 74

KTM 300 EXC TPI 2019 Specifications

General

Displacement	293.2 cm³
Bore x Stroke	72 mm x 72 mm
Starter	Electric starter
Transmission	6-speed
Cooling	Liquid cooled
Rear Suspension	WP XPLOR PDS shock absorber
Seat Height	960 mm
Ground Clearance	370 mm
Fuel Tank Capacity	9.5 liters
Engine Type	2-stroke
Fuel System	Transfer Port Injection (TPI)
Frame	Central double-cradle type 25CrMo4 steel
Front Suspension	WP Xplor 48
Front Brake	Disc brake
Rear Brake	Disc brake 220 mm