KTM 300 1998 - Engine Removal and Refitting; Engine Removal Procedure

2.1 Removing the engine
– Thoroughly clean the motorcycle.
– Use a suitable supporting device to jack up the motorcycle.
– Remove the seat and the tank with the spoilers.
– Drain the cooling liquid.
– Remove the exhaust system and the engine brace.
– Disconnect the radiator hoses at the engine.
– Remove the carburetor.
– Remove the engine sprocket cover and the chain.
– Disconnect the electrical wires.
– Unhook the clutch cable from the clutch lever.
– Undo the three screws
1
and remove the compensation chamber
2
of KTC
system including O-ring.
– Undo the engine mounting screws.
– Remove the swingarm pivot and pull the swingarm backwards.
– Lift the engine out of the frame on the left side.
NOTE: THE ENGINE NEED NOT BE REMOVED TO REMOVE THE CYLINDER HEAD AND THE CYLINDER.
I
T IS ALSO POSSIBLE TO WORK ON THE CLUTCH, THE PRIMARY DRIVE AND THE SHIFT MECHA-
NISM WITHOUT PREVIOUSLY REMOVING THE ENGINE.
2
1
2.0 Removing engine / Refitting engine
Chap. Component / Component unit Page
2.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.2 Refitting engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
1
2