KTM 300 EXC AUS User Manual

150 pages

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OWNER'S MANUAL 2014

125 EXC EU

125 EXC SIX DAYS EU

200 EXC EU

200 EXC AUS

200 XC‑W USA

250 EXC EU

250 EXC AUS

250 EXC SIX DAYS EU

250 XC‑W USA

300 EXC EU

300 EXC AUS

300 EXC SIX DAYS EU

300 XC‑W USA

300 XC‑W SIX DAYS USA

Art. no. 3213034en

Default Chapter4
- Table of Contents4
1 Means of Representation7
- Symbols Used7
- Formats Used7
2 Safety Advice8
- Use Definition - Intended Use8
- Degrees of Risk and Symbols8
- Tampering Warning8
- Safe Operation9
- Protective Clothing9
- Work Rules9
- Environment9
- Owner's Manual9
3 Important Notes10
- Guarantee, Warranty10
- Operating and Auxiliary Substances10
- Spare Parts, Accessories10
- Service10
- Figures10
- Customer Service10
4 View of Vehicle11
- View of Vehicle, Front Left (Example)11
- View of Vehicle, Rear Right (Example)12
5 Serial Numbers13
- Chassis Number13
- Type Label13
- Key Number (All EXC Models)13
- Engine Number13
- Fork Part Number13
- Shock Absorber Part Number14
6 Controls15
- Clutch Lever15
- Hand Brake Lever15
- Throttle Grip15
- Kill Switch (All EXC Models)15
- Kill Switch (All XC-W Models)16
- Horn Button (All EXC Models)16
- Light Switch (All EXC Models)16
- Light Switch (All XC-W Models)16
- Turn Signal Switch (All EXC Models)16
- Emergency off Switch (EXC AUS)17
- Electric Starter Button (200/250/300 EXC EU, 250/300 SIX DAYS, XC-W)17
- Electric Starter Button (EXC AUS)17
- Overview of Indicator Lamps (EXC EU/AUS)17
- Overview of Indicator Lamps (SIX DAYS EU)17
- Overview of Indicator Lamps (300 XC-W SIX DAYS USA)18
- Opening the Filler Cap18
- Closing the Filler Cap18
- Fuel Tap19
- Choke19
- Shift Lever19
- Kick Starter20
- Foot Brake Lever20
- Side Stand20
- Steering Lock (All EXC Models)20
- Locking the Steering (All EXC Models)21
- Unlocking the Steering (All EXC Models)21
7 Speedometer22
- Exc, XC-W22
- Speedometer Overview22
- Activation and Test22
- Setting Kilometers or Miles22
- Adjusting the Speedometer Functions23
- Setting the Clock23
- Querying Lap Time23
- Display Mode SPEED (Speed)24
- Display Mode SPEED/H (Service Hours)24
- Setup Menu24
- Unit of Measurement Menu25
- Display Mode SPEED/CLK (Time)25
- Setting the Clock25
- Display Mode SPEED/LAP (Lap Time)26
- Viewing the Lap Time26
- Display Mode SPEED/ODO (Odometer)26
- Display Mode SPEED/TR1 (Trip Master 1)26
- Display Mode SPEED/TR2 (Trip Master 2)27
- Setting TR2 (Trip Master 2)27
- Display Mode SPEED/A1 (Average Speed 1)27
- Display Mode SPEED/A2 (Average Speed 2)28
- Display Mode SPEED/S1 (Stop Watch 1)28
- Display Mode SPEED/S2 (Stop Watch 2)28
- Table of Functions28
- Table of Conditions and Menu Activation29
- Six Days29
- Speedometer Overview29
- Activation and Test30
- Setting Kilometers or Miles30
- Setting the Speedometer Functions30
- Setting the Clock31
- Viewing the Lap Time31
- Display Mode SPEED (Speed)32
- Display Mode SPEED/H (Service Hours)32
- Setup Menu32
- Setting the Unit of Measurement33
- Display Mode SPEED/CLK (Time)33
- Setting the Clock33
- Display Mode SPEED/LAP (Lap Time)34
- Viewing the Lap Time34
- Display Mode SPEED/ODO (Odometer)34
- Display Mode SPEED/TR1 (Trip Master 1)34
- Display Mode SPEED/TR2 (Trip Master 2)35
- Setting TR2 (Trip Master 2)35
- Display Mode SPEED/A1 (Average Speed 1)35
- Display Mode SPEED/A2 (Average Speed 2)36
- Display Mode SPEED/S1 (Stop Watch 1)36
- Display Mode SPEED/S2 (Stop Watch 2)36
- Table of Functions37
- Table of Conditions and Menu Activation38
8 Preparing for Use39
- Advice on First Use39
- Running in the Engine40
- Preparing the Vehicle for Difficult Riding Conditions40
- Preparations for Riding on Dry Sand41
- Preparations for Riding on Wet Sand41
- Preparations for Riding on Wet and Muddy Surfaces42
- Preparations for Riding at High Temperatures and Low Speeds42
- Preparing for Riding at Low Temperatures or in Snow43
9 Riding Instructions44
- Checks and Maintenance Work When Preparing for Use44
- Starting44
- Start off45
- Shifting, Riding45
- Braking45
- Stopping, Parking46
- Transport46
- Refueling47
10 Service Schedule48
- Service Work (as Additional Order)49
11 Tuning the Chassis50
- Checking the Basic Chassis Setting with the Rider's Weight50
- Compression Damping of Shock Absorber50
- Adjusting the Low-Speed Compression Damping of the Shock Absorber50
- Adjusting the High-Speed Compression Damping of the Shock Absorber51
- Adjusting the Rebound Damping of the Shock Absorber51
- Measuring the Sag of the Unloaded Rear Wheel52
- Checking the Static Sag of the Shock Absorber52
- Checking the Riding Sag of the Shock Absorber53
- Adjusting the Spring Preload of the Shock Absorber53
- Adjusting the Riding Sag54
- Checking the Basic Setting of the Fork54
- Adjusting the Compression Damping of the Fork55
- Adjusting the Rebound Damping of the Fork56
- Adjusting the Spring Preload of the Fork (EXC, XC-W)57
- Handlebar Position57
- Adjusting the Handlebar Position58
12 Service Work on the Chassis59
- Raising the Motorcycle with the Lift Stand59
- Removing the Motorcycle from the Lift Stand59
- Bleeding the Fork Legs59
- Cleaning the Dust Boots of the Fork Legs60
- Loosening the Fork Protection60
- Positioning the Fork Protection61
- Removing the Fork Legs61
- Installing the Fork Legs61
- Removing the Fork Protector62
- Installing the Fork Protector63
- Removing the Lower Triple Clamp (EXC, XC-W)63
- Removing the Lower Triple Clamp (SIX DAYS)64
- Installing the Lower Triple Clamp (EXC, XC-W)64
- Installing the Lower Triple Clamp66
- Six Days)66
- Checking the Play of the Steering Head Bearing68
- Adjusting the Play of the Steering Head Bearing68
- Greasing the Steering Head Bearing69
- Removing the Front Fender69
- Installing the Front Fender69
- Removing the Shock Absorber70
- Installing the Shock Absorber70
- Removing the Seat71
- Mounting the Seat71
- Removing the Air Filter Box Lid72
- Installing the Air Filter Box Lid72
- Removing the Air Filter72
- Installing the Air Filter72
- Cleaning the Air Filter and Air Filter Box73
- Sealing the Air Filter Box73
- Removing the Main Silencer74
- Installing the Main Silencer74
- Changing the Glass Fiber Yarn Filling of the Main Silencer74
- Removing the Fuel Tank75
- Installing the Fuel Tank76
- Checking the Chain for Dirt77
- Cleaning the Chain77
- Checking the Chain Tension77
- Adjusting the Chain Tension78
- Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide79
- Checking the Frame80
- Checking the Swingarm81
- Checking the Routing of the Throttle Cable81
- Checking the Rubber Grip82
- Additionally Securing the Rubber Grip82
- Adjusting the Basic Position of the Clutch Lever82
- Checking/Correcting the Fluid Level of the Hydraulic Clutch83
- Changing the Hydraulic Clutch Fluid83
- Removing the Engine Guard (SIX DAYS)84
- Installing the Engine Guard (SIX DAYS)85
13 Brake System86
- Checking the Free Travel of the Hand Brake Lever86
- Adjusting Free Travel of Hand Brake Lever (All EXC Models)86
- Adjusting the Basic Position of the Hand Brake Lever (All XC-W Models)86
- Checking the Brake Discs87
- Checking the Front Brake Fluid Level87
- Adding Front Brake Fluid87
- Checking the Front Brake Linings88
- Changing the Front Brake Linings89
- Checking the Free Travel of Foot Brake Lever90
- Adjusting the Basic Position of the Foot Brake Lever90
- Checking the Rear Brake Fluid Level91
- Adding Brake Fluid for the Rear Brake91
- Checking the Rear Brake Linings92
- Changing the Brake Linings of the Rear Brake92
14 Wheels, Tires95
- Removing the Front Wheel95
- Installing the Front Wheel95
- Removing the Rear Wheel96
- Installing the Rear Wheel96
- Checking the Tire Condition97
- Checking the Tire Air Pressure98
- Checking the Spoke Tension98
15 Electrical System100
- Removing the Battery (All 200/250/300 Models)100
- Installing the Battery (All 200/250/300 Models)100
- Recharging the Battery (All 200/250/300 Models)101
- Changing the Main Fuse (All 200/250/300 Models)102
- Removing the Headlight Mask with the Headlight103
- Refitting the Headlight Mask with the Headlight103
- Changing the Headlight Bulb103
- Changing the Turn Signal Bulb (All EXC Models)104
- Checking the Headlight Setting105
- Adjusting the Headlight Range105
- Changing the Speedometer Battery105
16 Cooling System107
- Checking the Antifreeze and Coolant Level107
- Checking the Coolant Level108
- Draining the Coolant108
- Refilling with Coolant109
17 Tuning the Engine111
- Checking the Play in the Throttle Cable111
- Adjusting the Play in the Throttle Cable111
- Carburetor - Idle111
- Carburetor - Adjusting the Idle Speed112
- Emptying the Carburetor Float Chamber113
- Checking the Basic Position of the Shift Lever114
- Adjusting the Basic Position of the Shift Lever114
- Engine Characteristic - Auxiliary Spring (All 250/300 Models)114
- Engine Characteristic - Setting the Auxiliary Spring X (All 250/300 Models)114
18 Service Work on the Engine116
- Checking the Gear Oil Level116
- Changing the Gear Oil116
- Draining the Gear Oil117
- Refilling with Gear Oil117
- Adding Gear Oil118
19 Cleaning, Care120
- Cleaning the Motorcycle120
- Checks and Maintenance Steps for Winter Operation121
20 Storage122
- Preparing for Use after Storage122
21 Troubleshooting123
22 Technical Data125
- Engine125
- All 125 Models125
- All 200 Models125
- All 250 Models126
- All 300 Models126
- Engine Tightening Torques127
- All 125/200 Models127
- All 250/300 Models128
- Capacities129
- Gear Oil129
- Coolant129
- Fuel129
- Chassis129
- Electrical System130
- Tires131
- Fork131
- EXC EU, All 200 Models131
- 250/300 Exc Eu/Aus, XC-W Usa131
- Exc Six Days Eu132
- 250/300 Six Days132
- Shock Absorber133
- All 125/200 Models133
- All 250/300 Models133
- Chassis Tightening Torques134
- Carburetor135
- 22.10.1 All 125 Models135
- 22.10.2 200 Exc Eu135
- 22.10.3 200 Exc aus135
- 22.10.4 200 XC-W Usa135
- 22.10.5 250 Exc Eu, 250 Exc Six Days Eu136
- 22.10.6 250/300 Exc aus136
- 22.10.7 250 XC-W Usa136
- 22.10.8 300 Exc Eu, 300 Exc Six Days Eu137
- 22.10.9 300 XC-W Usa, 300 XC-W Six Days Usa137
- Carburetor Tuning (All 125 Models)137
- Carburetor Tuning (All 200 Models)138
- Carburetor Tuning (All 250 Models)139
- Carburetor Tuning (All 300 Models)140
- General Carburetor Tuning141
23 Substances142
24 Auxiliary Substances144
25 Standards146
- Index147

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Repair Manual289 pages

Questions and Answers:

D
Devin KlineSep 12, 2025
What to do if my KTM 300 EXC AUS Motorcycle engine cannot be cranked with the electric starter?
- H
  Hannah KimSep 12, 2025
  If your KTM Motorcycle engine won't crank with the electric starter, several factors could be at play. It might be due to an operating error during the start procedure. Another cause could be a discharged battery, so you should recharge it and check the charging voltage, closed current, and alternator. Also, inspect the main fuse and replace it if it's blown. The starter relay or the starter motor itself could be faulty, requiring a check.
N
Nancy TurnerSep 12, 2025
What to do if my KTM 300 EXC AUS Motorcycle engine stalls or is popping into the carburetor?
- E
  elizabeth36Sep 12, 2025
  If your KTM Motorcycle engine stalls or pops into the carburetor, it could be due to a lack of fuel. Ensure the fuel tap is in the ON position and refuel if necessary. Another cause could be the engine taking in bad air, so check the intake flange and carburetor for tightness. Also, make sure that the connector or ignition coil is not loose or oxidized, and clean the connector and treat it with contact spray if needed.

KTM 300 EXC AUS Specifications

General

Brand	KTM
Model	300 EXC AUS
Category	Motorcycle
Language	English

Summary

Means of Representation

Symbols Used

Explains the meaning of various symbols used in the manual for clarity and safety.

Formats Used

Describes the typographical formats used in the document for specific terms and names.

Safety Advice

Intended Use

Defines the intended purpose and limitations of the KTM sport motorcycle.

Safe Operation

Provides essential safety instructions for operating the motorcycle responsibly.

Protective Clothing

Emphasizes the importance of wearing appropriate protective gear for rider safety.

Important Notes

Guarantee and Warranty

Details warranty conditions, voiding clauses, and required service procedures.

Service

Highlights the importance of proper service for optimal operation and longevity.

View of Vehicle

Front Left View

Illustrates the front left side of the vehicle with numbered components.

Rear Right View

Illustrates the rear right side of the vehicle with numbered components.

Serial Numbers

Chassis Number

Shows the location of the chassis number stamped on the steering head.

Engine Number

Indicates the location of the engine number stamped on the engine.

Controls

Clutch Lever

Describes the clutch lever operation and adjustment for different models.

Kill Switch

Explains the function and possible states of the kill switch.

Electric Starter Button

Details the operation of the electric starter button for various models.

Fuel Tap

Describes the fuel tap positions and their effect on fuel supply.

Speedometer

EXC, XC-W Speedometer Operation

Covers speedometer overview, activation, tests, and function settings for EXC/XC-W models.

SIX DAYS Speedometer Operation

Details speedometer overview, activation, tests, and function settings for SIX DAYS models.

Preparing for Use

Advice on First Use

Provides crucial initial advice and warnings before the first ride.

Difficult Riding Conditions

Offers preparation tips for riding in challenging conditions like sand or mud.

Riding Instructions

Pre-Ride Checks and Maintenance

Lists essential checks and maintenance tasks before riding.

Starting the Engine

Guides on how to start the engine correctly under various conditions.

Braking

Explains proper braking techniques and warnings for safe stopping.

Service Schedule

Outlines periodic service intervals based on operating hours or time.

Service Work (Additional Order)

Lists additional service tasks that can be performed on request.

Tuning the Chassis

Shock Absorber Adjustment

Covers adjustment of compression and rebound damping, and spring preload.

Fork Adjustment

Details how to adjust fork compression and rebound damping, and spring preload.

Service Work on the Chassis

Removing Fork Legs

Step-by-step guide on how to safely remove the fork legs from the motorcycle.

Removing Shock Absorber

Procedure for safely removing the rear shock absorber.

Cleaning Air Filter

Instructions for removing, cleaning, and installing the air filter.

Adjusting Chain Tension

Details how to check and adjust the drive chain tension correctly.

Brake System

Checking Brake Fluid Level

Guide on checking front and rear brake fluid levels and adding fluid.

Changing Brake Linings

Step-by-step instructions for changing front and rear brake linings.

Checking Rear Brake Fluid Level

Procedure for checking the rear brake fluid level and adding fluid.

Wheels, Tires

Removing Front Wheel

Instructions for safely removing the front wheel.

Checking Tire Air Pressure

Details how to check tire air pressure for optimal riding comfort and tire life.

Electrical System

Recharging Battery

Provides guidance on safely recharging the motorcycle battery.

Changing Main Fuse

Step-by-step instructions for replacing the main fuse.

Changing Headlight Bulb

Instructions for replacing the headlight bulb.

Cooling System

Checking Coolant Level

Guide on checking the coolant level and antifreeze protection.

Refilling with Coolant

Instructions for refilling the cooling system with coolant.

Tuning the Engine

Checking Throttle Cable Play

Describes how to check and adjust the play in the throttle cable.

Adjusting Idle Speed

Provides guidance on adjusting the engine's idle speed for optimal performance.

Emptying Carburetor Float Chamber

Instructions for safely emptying the carburetor float chamber.

Service Work on the Engine

Checking Gear Oil Level

Guide on how to check the engine's gear oil level.

Changing Gear Oil

Step-by-step instructions for changing the engine's gear oil.

Troubleshooting

Technical Data

Engine Specifications

Provides detailed technical specifications for the engine across different models.

Carburetor Settings

Lists carburetor settings for various models based on altitude and temperature.

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KTM 300 EXC AUS User Manual

Table of Contents

Other manuals for KTM 300 EXC AUS

Questions and Answers:

KTM 300 EXC AUS Specifications

Summary

Means of Representation

Symbols Used

Formats Used

Safety Advice

Intended Use

Safe Operation

Protective Clothing

Important Notes

Guarantee and Warranty

Service

View of Vehicle

Front Left View

Rear Right View

Serial Numbers

Chassis Number

Engine Number

Controls

Clutch Lever

Kill Switch

Electric Starter Button

Fuel Tap

Speedometer

EXC, XC-W Speedometer Operation

SIX DAYS Speedometer Operation

Preparing for Use

Advice on First Use

Difficult Riding Conditions

Riding Instructions

Pre-Ride Checks and Maintenance

Starting the Engine

Braking

Service Schedule

Service Schedule

Service Work (Additional Order)

Tuning the Chassis

Shock Absorber Adjustment

Fork Adjustment

Service Work on the Chassis

Removing Fork Legs

Removing Shock Absorber

Cleaning Air Filter

Adjusting Chain Tension

Brake System

Checking Brake Fluid Level

Changing Brake Linings

Checking Rear Brake Fluid Level

Wheels, Tires

Removing Front Wheel

Checking Tire Air Pressure

Electrical System

Recharging Battery

Changing Main Fuse

Changing Headlight Bulb

Cooling System

Checking Coolant Level

Refilling with Coolant

Tuning the Engine

Checking Throttle Cable Play

Adjusting Idle Speed

Emptying Carburetor Float Chamber

Service Work on the Engine

Checking Gear Oil Level

Changing Gear Oil

Troubleshooting

Technical Data

Engine Specifications

Carburetor Settings

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