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KTM 300 EXC TPI - User Manual

KTM 300 EXC TPI
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OWNER'S MANUAL 2020
250 EXC TPI
250 EXC Six Days TPI
250 XC‑W TPI
300 EXC TPI
300 EXC Six Days TPI
300 XC-W TPI
300 XC-W Six Days TPI
300 EXC Erzberg Edition TPI
Art. no. 3214007en

Table of Contents

Questions and Answers

  • D
    dwaynesantanaAug 19, 2025
    What to do if my KTM Motorcycle engine cannot be cranked (starter motor)?
    • J
      Joshua WhiteSep 12, 2025
      If your KTM Motorcycle engine cannot be cranked, start by ensuring you are following the correct start procedure. Then, check the 12-V battery, charging it if discharged, and verify the charging voltage, closed current, and stator winding of the alternator. Inspect the main fuse and replace it if blown. Also, the starter relay or the starter motor itself could be faulty, so check them accordingly.
  • K
    Karen MillerAug 21, 2025
    What to do if my KTM Motorcycle engine does not speed up?
    • R
      Ronald Joyce Jr.Aug 21, 2025
      If your KTM Motorcycle engine does not speed up, there might be a defect in the fuel injection system, so check the cabling for damage and the electrical plug-in connections for corrosion and damage. Also, faulty ignition could be the cause, so check the ignition coil, spark plug connector, and the stator winding of the alternator. Another possibility is that the ambient pressure is incorrectly stored, so program ambient pressure.
  • S
    smithsaraAug 23, 2025
    What to do if my KTM 300 EXC TPI engine turns but does not start?
    • L
      leonard90Aug 23, 2025
      If your KTM Motorcycle engine turns but fails to start, several factors could be at play. First, ensure you are following the correct start procedure. Check that the plug-in connection of the fuel line is properly joined. Verify the idle speed setting and adjust if necessary. Inspect the fuel tank breather for any interruption in fuel supply. Also, the spark plug may be oily or wet, so clean and dry it, or replace it if needed. Ensure the plug gap of the spark plug is correctly adjusted to 0.6 mm (0.024 in). Finally, the issue could stem from a defect in the fuel injection system, so check the cabling for damage and the electrical plug-in connections for corrosion and damage. If the above steps don't resolve the problem, read out the fault memory using the KTM diagnostics tool.
  • V
    Veronica PierceAug 26, 2025
    Why is my KTM 300 EXC TPI Motorcycle engine overheating?
    • M
      Mackenzie AllenAug 26, 2025
      Your KTM Motorcycle engine might be overheating due to several reasons. Check if there is too little coolant in the cooling system and inspect the system for leaks. Ensure there's adequate airflow, and switch off the engine when stationary. Clean the radiator fins if they are dirty. Also, foam formation in the cooling system can cause overheating, so drain and refill the coolant.
  • D
    Daniel GrayAug 27, 2025
    What to do if my KTM 300 EXC TPI engine has too little power?
    • M
      Mary HarrisAug 28, 2025
      If your KTM Motorcycle engine has too little power, several factors could be responsible. Begin by cleaning the air filter and air filter box. Then, check and change the fuel filter and fuel screen if they are very dirty. Also, a defect in the fuel injection system could be the cause, so inspect the cabling for damage and the electrical plug-in connections for corrosion and damage. Ensure there is no interruption in the fuel supply by checking the fuel tank breather. Finally, examine the exhaust system for leaks or deformation, and consider changing the glass fiber yarn filling of the main silencer.
  • R
    Rebecca DeckerAug 29, 2025
    What to do if my KTM 300 EXC TPI Motorcycle engine dies during the trip?
    • D
      David BrownAug 30, 2025
      If your KTM Motorcycle engine dies during a trip, the issue might be due to a lack of fuel, so refuel. Another possibility is that the engine is taking in false air, so check that the intake flange is firmly seated. Also, the connector or ignition coil could be loose or oxidized, so clean the connector and treat it with contact spray. Finally, the ambient pressure might be incorrectly stored, so program the ambient pressure.
  • N
    Nicholas LoganAug 31, 2025
    Why does my KTM Motorcycle engine have no idle?
    • B
      bettypittmanSep 1, 2025
      If your KTM Motorcycle engine has no idle, the spark plug may be defective, so change it. Another possible cause is faulty ignition, so check the ignition coil, spark plug connector, and the stator winding of the alternator. Also, the idle speed might not be set correctly, so adjust the idle speed.
  • S
    Samuel HarrellSep 3, 2025
    What does it mean when my KTM Motorcycle malfunction indicator lamp lights up or flashes?
    • L
      Lisa HumphreySep 3, 2025
      If the malfunction indicator lamp lights up or flashes on your KTM Motorcycle, it indicates a defect in the fuel injection system. Check the cabling for damage and the electrical plug-in connections for corrosion and damage.
  • S
    sperkinsSep 5, 2025
    Why is my KTM 300 EXC TPI 12-V battery discharged?
    • A
      April MccoySep 5, 2025
      If your KTM Motorcycle 12-V battery is discharged, it could be due to the alternator not charging the battery, so check the charging voltage and the stator winding of the alternator. Another reason might be an unwanted power consumer, so check the open-circuit current.
  • T
    thomas46Sep 7, 2025
    Why is there white smoke emission (steam in exhaust gas) from my KTM 300 EXC TPI Motorcycle?
    • D
      Devon JohnsonSep 7, 2025
      If your KTM Motorcycle is emitting white smoke (steam) in the exhaust gas, it may be due to a damaged cylinder head or cylinder head gasket, so check these components.

Summary

Safety Advice

Use Definition - Intended Use

Defines the intended use of the vehicle and any restrictions for different models.

Safety Advice

Highlights the importance of following safety instructions and warning labels.

Degrees of Risk and Symbols

Explains the meaning of different risk symbols like Danger, Warning, Caution, and Note.

Safe Operation

Provides critical safety advice for operating the vehicle, including accident and poisoning risks.

Owners Manual

Stresses the importance of reading the Owner's Manual for safe and proper operation.

Serial Numbers

Controls

Clutch Lever

Describes the clutch lever, its hydraulic activation, and automatic adjustment.

Hand Brake Lever

Explains the function of the hand brake lever for engaging the front brake.

Throttle Grip

Identifies the location of the throttle grip on the right handlebar.

Switch-off Button (All EXC Models)

Details the function and states of the switch-off button for EXC models.

Switch-off Button (All XC-W Models)

Light Switch (All EXC Models)

Light Switch (All XC-W Models)

Emergency OFF Switch (All EXC Models)

Start Button

Overview of Indicator Lamps (All EXC Models)

Lists and explains the various indicator lamps and their meanings for EXC models.

Overview of Indicator Lamps (All XC-W Models)

Lists and explains the various indicator lamps and their meanings for XC-W models.

Idle Speed Adjusting Screw

Steering Lock (All EXC Models)

Locking the Steering (All EXC Models)

Unlocking the Steering (All EXC Models)

Combination Instrument

Combination Instrument Overview

Display Mode SPEED (Speed)

Display Mode SPEED;H (Operating Hours)

Setting the Clock

Display Mode SPEED;ODO (Odometer)

Display Mode SPEED;TR1 (Trip Master 1)

Display Mode SPEED;TR2 (Trip Master 2)

Preparing for Use

Advice on Preparing for First Use

Offers crucial advice for preparing the motorcycle before its first use.

Running in the Engine

Provides instructions and guidelines for properly running in the engine to ensure longevity.

Preparing the Vehicle for Difficult Riding Conditions

Riding Instructions

Checks and Maintenance Measures When Preparing for Use

Essential pre-ride checks and maintenance steps to ensure safe operation.

Starting the Vehicle

Provides instructions and safety warnings for starting the motorcycle's engine.

Starting Off

Guides on how to safely start moving the motorcycle from a standstill.

Shifting, Riding

Instructions on gear shifting, riding techniques, and warnings related to engine lubrication.

Braking

Explains proper braking techniques, warnings about brake system efficiency, and surface conditions.

Stopping, Parking

Refueling

Detailed instructions and safety precautions for refueling the vehicle.

Adding 2-Stroke Oil

Explains how to add 2-stroke oil to the oil tank and warnings related to engine lubrication.

Service Schedule

Required Work

Lists the mandatory service tasks and their recommended intervals based on operating hours.

Recommended Work

Lists recommended service tasks and their intervals, which are not strictly mandatory but advised.

Tuning the Chassis

Checking the Basic Chassis Setting with Riders Weight

Compression Damping of the Shock Absorber

Describes the concept of high-speed and low-speed compression damping for the shock absorber.

Adjusting the Low-Speed Compression Damping of the Shock Absorber

Provides instructions on how to adjust the low-speed compression damping of the rear shock absorber.

Adjusting the High-Speed Compression Damping of the Shock Absorber

Details how to adjust the high-speed compression damping of the rear shock absorber.

Adjusting the Rebound Damping of the Shock Absorber

Explains how to adjust the rebound damping of the rear shock absorber.

Measuring the Dimension of the Rear Wheel Unloaded

Checking the Static Sag of the Shock Absorber

Checking the Riding Sag of the Shock Absorber

Adjusting the Spring Preload of the Shock Absorber

Provides instructions for adjusting the spring preload of the rear shock absorber.

Adjusting the Riding Sag

Adjusting the Compression Damping of the Fork

Details how to adjust the compression damping on both standard and Six Days fork models.

Adjusting the Rebound Damping of the Fork

Explains how to adjust the rebound damping on both standard and Six Days fork models.

Adjusting the Spring Preload of the Fork (All Six Days Models)

Service Work on the Chassis

Bleeding the Fork Legs

Removing the Fork Legs

Installing the Fork Legs

Removing the Lower Triple Clamp (All standard EXC;XC-W Models)

Removing the Lower Triple Clamp (All Special Models)

Installing the Lower Triple Clamp (All standard EXC;XC-W Models)

Checking Steering Head Bearing Play

Explains how to check for play in the steering head bearing and potential damage.

Adjusting the Steering Head Bearing Play

Provides instructions for adjusting the steering head bearing play to correct issues.

Removing the Shock Absorber

Installing the Shock Absorber

Removing the Air Filter

Installing the Air Filter

Cleaning the Air Filter and Air Filter Box

Removing the Fuel Tank

Detailed procedure for removing the fuel tank, including safety warnings about fuel.

Installing the Fuel Tank

Detailed procedure for installing the fuel tank, including safety warnings about fuel and cable routing.

Cleaning the Chain

Checking the Chain Tension

Explains how to check chain tension and the consequences of incorrect tension.

Adjusting the Chain Tension

Detailed instructions for adjusting the drive chain tension to the correct specification.

Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide

Checking;Correcting the Fluid Level of the Hydraulic Clutch

Steps for checking and correcting the hydraulic clutch fluid level, including warnings.

Changing the Hydraulic Clutch Fluid

Detailed procedure for changing the hydraulic clutch fluid, including safety precautions.

Brake System

Checking the Free Travel of the Hand Brake Lever

Adjusting the Free Travel of the Handbrake Lever (All EXC Models)

Adjusting the Basic Position of the Hand Brake Lever (All XC-W Models)

Checking the Brake Discs

Checking the Front Brake Fluid Level

Details how to check the front brake fluid level and identify potential issues.

Adding the Front Brake Fluid

Provides instructions for adding front brake fluid, including safety warnings.

Checking the Front Brake Linings

Explains how to check the minimum thickness and condition of the front brake linings.

Changing the Brake Linings of the Front Brake

Step-by-step guide for changing the front brake linings, including warnings and recommendations.

Checking the Free Travel of Foot Brake Lever

Adjusting the Basic Position of the Foot Brake Lever

Checking the Rear Brake Fluid Level

Details how to check the rear brake fluid level and identify potential issues.

Adding Rear Brake Fluid

Provides instructions for adding rear brake fluid, including safety warnings.

Checking the Brake Linings of the Rear Brake

Explains how to check the minimum thickness and condition of the rear brake linings.

Changing the Brake Linings of the Rear Brake

Step-by-step guide for changing the rear brake linings, including warnings and recommendations.

Wheels, Tires

Removing the Front Wheel

Detailed procedure for removing the front wheel, including brake caliper and spindle steps.

Installing the Front Wheel

Detailed procedure for installing the front wheel, including wheel bearings and spindle.

Removing the Rear Wheel

Step-by-step guide for removing the rear wheel, including chain and spindle steps.

Installing the Rear Wheel

Step-by-step guide for installing the rear wheel, including wheel bearings and spindle.

Checking the Tire Condition

Checking Tire Pressure

Explains how to check tire pressure for street and off-road use.

Electrical System

Removing the 12-V Battery

Detailed instructions for safely removing the 12-V battery, including warnings.

Installing the 12-V Battery

Detailed instructions for safely installing the 12-V battery, including component connections.

Charging the 12-V Battery

Provides instructions and safety precautions for charging the 12-V battery.

Changing Main Fuse

Step-by-step guide for changing the main fuse, including identifying faulty fuses.

Changing the Fuses of Individual Power Consumers

Instructions for changing fuses for various electrical components, with a fuse box location.

Removing the Headlight Mask with the Headlight

Installing the Headlight Mask with the Headlight

Changing the Headlight Bulb

Detailed instructions for changing the headlight bulb, including warnings about touching the bulb.

Changing the Turn Signal Bulb (All EXC Models)

Checking the Headlight Setting

How to check and adjust the motorcycle's headlight beam alignment.

Adjusting the Headlight Range

Provides instructions for adjusting the headlight beam range for optimal visibility.

Changing the Combination Instrument Battery

Cooling System

Cooling System

Checking the Antifreeze and Coolant Level

Provides instructions for checking coolant antifreeze and level, with warnings about hot coolant and toxicity.

Checking the Coolant Level

Details how to check the coolant level in the radiator, with safety warnings.

Draining the Coolant

Provides instructions for draining the coolant from the system, with warnings about hot coolant.

Refilling with Coolant

Step-by-step guide for refilling the cooling system with coolant, including safety notes.

Tuning the Engine

Checking the Throttle Cable Play

Explains how to check the throttle cable play for smooth operation and correct engine response.

Adjusting the Throttle Cable Play

Provides instructions for adjusting the throttle cable play to ensure proper function.

Setting the Characteristic Map of the Throttle Response

Adjusting the Idle Speed

Explains how to adjust the engine's idle speed for optimal performance, with safety warnings.

Checking the Basic Position of the Shift Lever

Adjusting the Basic Position of the Shift Lever

Service Work on the Engine

Changing the Fuel Screen

Step-by-step guide for changing the fuel screen, including warnings about fuel and dirt.

Checking 2-Stroke Oil Level

Instructions for checking the 2-stroke oil level and related warnings.

Priming Oil Pump

Cleaning the Oil Screen in the Oil Tank

Checking the Gear Oil Level

Explains how to check the gear oil level, including the procedure for checking when the engine is cold.

Changing the Gear Oil

Step-by-step guide for changing the gear oil, including warnings about hot oil.

Adding the Gear Oil

Instructions for adding gear oil, emphasizing checking the level when the engine is cold.

Cleaning, Care

Cleaning the Motorcycle

Storage

Storage

Detailed steps and recommendations for storing the motorcycle for extended periods.

Preparing for Use After Storage

Steps to take to prepare the motorcycle for use after it has been stored.

Troubleshooting

Technical Data

Engine

Engine Tightening Torques

Electrical System

Fork

Contains detailed technical specifications for the fork, including damping and spring settings.

Shock Absorber

Lists technical specifications for the shock absorber, including damping, preload, and sag settings.

Chassis Tightening Torques

KTM 300 EXC TPI Specifications

General IconGeneral
Displacement293.2 cc
Bore x Stroke72 mm x 72 mm
StarterElectric starter
Transmission6-speed
CoolingLiquid cooled
Front SuspensionWP XPLOR-USD, Ø 48 mm
Front BrakeDisc brake
Rear BrakeDisc brake
Fuel Tank Capacity9 liters
Ground Clearance370 mm
Seat Height960 mm
Engine Type1-cylinder, 2-stroke
Fuel SystemTPI (Transfer Port Injection)
Rear SuspensionWP Xplor shock absorber
Weight (without fuel)103 kg
FrameCentral double-cradle type 25CrMo4 steel

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