KTM 300 1998 - User Manual

‘98
7. 97 ART. NR. 3.205.20
250 / 300 / 380
REPARATURANLEITUNG MOTOR
REPAIR MANUAL ENGINE
MANUALE DI RIPARAZIONE MOTORE
MANUEL DE RÉPARATION MOTEUR
MANUAL DE REPARACIÓN MOTOR

Summary

Introduction and General Information

General Safety Precautions

Covers essential safety advice, warnings, and useful tips for manual usage.

Use of Original KTM Spare Parts

Emphasizes the importance of using genuine KTM spare parts for optimal performance and warranty.

Quality Management System Certification

Information on KTM's ISO 9001 quality system certification.

General Information

Bleeding the Cooling System

Step-by-step guide for correctly bleeding the motorcycle's cooling system after maintenance.

Carburetor Adjustment Basics

Provides fundamental information for adjusting the motorcycle's carburetor for various conditions.

Definitions and Adjustments

Explains engine operation ranges and procedures for checking float level.

TVC System Setting Procedure

Details the process for checking and adjusting the TVC system's advance timing.

Special Tools Required

Lists and illustrates essential specialized tools needed for maintenance tasks.

Engine Removal and Refitting

Engine Removal Procedure

Step-by-step instructions for safely removing the engine from the motorcycle frame.

Engine Refitting Procedure

Detailed steps for correctly reinstalling the engine back into the motorcycle frame.

Engine Dismantling Procedures

Draining Gear Oil

Instructions for draining the engine's gear oil before disassembly.

Cylinder Assembly Removal

Procedure for removing the cylinder head, cylinder, and piston assembly.

Clutch System Service

Covers removal and servicing of the clutch cover and clutch discs.

Primary Drive Removal

Steps for dismantling the primary drive components, including the gear.

Kickstarter and Shift System Dismantling

Details on how to dismantle the kickstarter and shift mechanism.

Ignition System Component Removal

Instructions for removing ignition system components like stator and flywheel.

Engine Housing Separation

Guide on how to carefully separate the engine housing halves.

Crankshaft Removal

Steps for removing the crankshaft from the engine case.

Servicing Individual Engine Components

Housing Halves Bearing Installation

Instructions for installing bearings into the right and left engine housing halves.

Crankshaft, Piston, and Cylinder Checks

Procedures for checking wear on crankshaft, piston, rings, and cylinder.

Cylinder Exhaust Control System Service

Details on dismantling, cleaning, and checking the cylinder exhaust control system.

Ignition System Checks and Adjustments

Guidance on checking spark plugs, ignition coils, and adjusting ignition timing.

Clutch Assembly and Outer Hub Replacement

Covers clutch wear checks, assembly, and replacing the outer clutch hub.

Transmission and Shift Mechanism Service

Instructions for assembling transmission gears and servicing the shift mechanism.

Engine Assembly Procedures

Crankshaft and Transmission Assembly

Steps for assembling the crankshaft and transmission components.

Engine Housing Assembly

Procedure for assembling the engine housing halves with gaskets and seals.

Clutch and Kickstarter Assembly

Guidance on installing the clutch and kickstarter mechanisms.

Piston and Cylinder Installation

Instructions for installing the piston and cylinder, including dimension adjustments.

Cylinder Head and Reed Valve Assembly

Steps for mounting the cylinder head and reed valve housing.

Ignition System Mounting and Timing

Covers mounting ignition components and adjusting the ignition timing point.

Electrical System Checks

Voltage Regulator Checks

Procedures for testing voltage regulators and regulator-rectifiers for proper function.

Capacitor and Ignition Coil Testing

Guidance on checking the capacitor and ignition coils using an ohmmeter.

CDI Unit Functionality

Information on checking the CDI unit, noting limitations of standard testing.

Troubleshooting Guide

Trouble Analysis and Remedies

A chart to diagnose and resolve common engine problems based on symptoms.

Technical Data and Maintenance Schedule

Engine Technical Specifications

Detailed technical data for engine design, dimensions, and performance parameters.

Torque Specs, Gaskets, and Carburetor Settings

Lists tightening torques, gasket thicknesses, and basic carburetor settings.

Periodic Lubrication and Maintenance

Schedule for regular maintenance tasks, lubrication, and inspections.

Wiring Diagrams and Component Identification

Wiring Schematics (Europe Models)

Electrical wiring diagrams and component legends for European market models.

Wiring Schematics (USA;Sixday Models)

Electrical wiring diagrams and component legends for USA and Sixday models.

KTM 300 1998 Specifications