KTM 300 EXC - Page 149

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AUXILIARY SUBSTANCES 24

147

Special cleaner for glossy and matte paint finishes, metal and plastic surfaces

Recommended supplier

MOTOREX

– Quick Cleaner

Universal oil spray

Recommended supplier

MOTOREX

– Joker 440 Synthetic

Main Page

Table of Contents4
Means of Representation8
Symbols Used8
Formats Used8
Safety Advice 29
Use Definition - Intended Use9
Misuse9
Degrees of Risk and Symbols9
Tampering Warning10
Safe Operation10
Protective Clothing11
Work Rules11
Environment11
Owner's Manual11
Important Notes12
Manufacturer Warranty, Implied Warranty12
Fuel, Auxiliary Substances12
Spare Parts, Accessories12
Service12
Figures12
Customer Service12
View of Vehicle 413
View of Vehicle, Front Left (Example)13
View of Vehicle, Rear Right (Example)14
Serial Numbers 515
Vehicle Identification Number15
Type Label15
Key Number15
Engine Number15
Fork Part Number16
Shock Absorber Article Number16
Controls 617
Clutch Lever17
Hand Brake Lever17
Throttle Grip17
Switch-Off Button17
Horn Button18
Light Switch18
Turn Signal Switch18
Emergency off Switch18
Start Button19
Overview of Indicator Lamps19
Opening the Fuel Tank Filler Cap19
Closing the Fuel Tank Filler Cap20
Fuel Tap20
Choke21
Shift Lever21
Foot Brake Lever21
Side Stand22
Steering Lock22
Locking the Steering22
Unlocking the Steering23
Combination Instrument24
Combination Instrument Overview24
Activation and Test24
Setting the Kilometers or Miles24
Adjusting Combination Instrument Function25
Setting the Clock26
Viewing the Lap Time26
Display Mode SPEED (Speed)27
Display Mode SPEED/H (Operating Hours)27
Setup Menu27
Adjusting the Unit of Measurement28
Display Mode SPEED/CLK (Time)29
Setting the Clock29
Display Mode SPEED/LAP (Lap Time)29
Viewing the Lap Time30
Display Mode SPEED/ODO (Odometer)30
Display Mode SPEED/TR1 (Trip Master 1)31
Display Mode SPEED/TR2 (Trip Master 2)31
Adjusting TR2 (Trip Master 2)31
Display Mode SPEED/A1 (Average Speed 1)32
Display Mode SPEED/A2 (Average Speed 2)32
Display Mode SPEED/S1 (Stop Watch 1)33
Display Mode SPEED/S2 (Stop Watch 2)33
Table of Functions34
Table of Conditions and Menu Activation35
Preparing for Use36
Advice on Preparing for First Use36
Running in the Engine37
Preparing the Vehicle for Difficult Operating Conditions37
Preparing the Vehicle for Riding on Dry Sand38
Preparing the Vehicle for Riding on Wet Sand39
Preparing the Vehicle for Riding on Wet and Muddy Circuits40
Preparing Vehicle for High Temperatures or Slow Riding41
Preparing the Vehicle for Low Temperatures or Snow41
Riding Instructions42
Checks and Maintenance Measures When Preparing for Use42
Starting the Vehicle42
Starting off43
Shifting, Riding43
Braking44
Stopping, Parking44
Transporting45
Refueling45
Service Schedule 1047
Additional Information47
Required Work47
Recommended Work48
Tuning the Chassis 1149
Checking the Basic Chassis Setting with the Rider's Weight49
Compression Damping of the Shock Absorber49
Adjusting the Low-Speed Compression Damping of the Shock Absorber49
Adjusting the High-Speed Compression Damping of the Shock Absorber50
Adjusting the Rebound Damping of the Shock Absorber51
Measuring the Dimension of the Rear Wheel Unloaded51
Checking the Static Sag of the Shock Absorber52
Checking the Riding Sag of the Shock Absorber52
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 Fork55
Handlebar Position56
Adjusting the Handlebar Position56
12 Service Work on the Chassis58
Raising the Motorcycle with a Lift Stand58
Removing the Motorcycle from the Lift Stand58
Bleeding the Fork Legs58
Cleaning the Dust Boots of the Fork Legs59
Removing the Fork Protector59
Installing the Fork Protector60
Removing the Fork Legs60
Installing the Fork Legs61
Removing the Lower Triple Clamp61
Installing the Lower Triple Clamp62
Checking Steering Head Bearing Play64
Adjusting the Steering Head Bearing Play65
Lubricating the Steering Head Bearing66
Removing Front Fender66
Installing Front Fender66
Removing the Shock Absorber67
Installing the Shock Absorber67
Removing the Seat68
Mounting the Seat68
Removing the Air Filter Box Cover69
Installing the Air Filter Box Cover69
Removing the Air Filter70
Installing the Air Filter70
Cleaning the Air Filter and Air Filter Box71
Preparing Air Filter Box Cover for Securing71
Removing the Main Silencer72
Installing the Main Silencer72
Changing the Glass Fiber Yarn Filling in the Main Silencer72
Removing the Fuel Tank73
Installing the Fuel Tank74
Checking the Chain for Dirt75
Cleaning the Chain76
Checking the Chain Tension76
Adjusting the Chain Tension77
Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide78
Checking the Frame81
Checking the Link Fork81
Checking Throttle Cable Routing81
Checking the Rubber Grip82
Adjusting the Basic Position of the Clutch Lever83
Checking/Correcting the Fluid Level of the Hydraulic Clutch83
Changing the Hydraulic Clutch Fluid84
13 Brake System86
Checking the Free Travel of the Hand Brake Lever86
Adjusting the Free Travel of the Handbrake Lever86
Checking the Brake Discs86
Checking the Front Brake Fluid Level87
Adding Front Brake Fluid88
Checking the Front Brake Linings89
Changing the Brake Linings of the Front Brake89
Checking the Free Travel of Foot Brake Lever92
Adjusting the Basic Position of the Foot Brake Lever92
Checking the Rear Brake Fluid Level93
Adding Rear Brake Fluid93
Checking the Brake Linings of the Rear Brake95
Changing the Brake Linings of the Rear Brake95
14 Wheels, Tires98
Removing the Front Wheel98
Installing the Front Wheel99
Removing the Rear Wheel99
Installing the Rear Wheel100
Checking the Tire Condition102
Checking Tire Pressure102
Checking Spoke Tension103
15 Electrical System104
Removing the 12-V Battery104
Installing the 12-V Battery105
Charging the 12-V Battery105
Changing Main Fuse107
Removing the Headlight Mask with the Headlight108
Installing the Headlight Mask with the Headlight108
Changing the Headlight Bulb109
Changing the Turn Signal Bulb109
Checking the Headlight Setting110
Adjusting the Headlight Range111
Changing the Combination Instrument Battery111
Cooling System 16113
Checking the Antifreeze and Coolant Level113
Checking the Coolant Level114
Draining the Coolant114
Refilling with Coolant115
Changing the Coolant116
17 Tuning the Engine118
Checking the Throttle Cable Play118
Adjusting the Throttle Cable Play118
Carburetor Tuning119
Carburettor - Idle Speed122
Carburetor - Adjusting the Idle Speed122
Ignition Curve Plug-In Connector123
Changing the Ignition Timing Map123
Checking the Basic Position of the Shift Lever124
Adjusting the Basic Position of the Shift Lever124
Engine Characteristic - Auxiliary Spring125
Engine Characteristic - Adjusting the Auxiliary Spring125
Service Work on the Engine 18127
Emptying the Carburetor Float Chamber127
Checking the Gear Oil Level128
Changing the Gear Oil128
Adding the Gear Oil129
Cleaning, Care 19131
Cleaning the Motorcycle131
Checks and Maintenance Steps for Winter Operation132
Storage 20133
Preparing for Use after Storage134
Troubleshooting 21135
Technical Data 22137
Engine137
Engine Tightening Torques137
Carburetor140
Carburetor Tuning140
Capacities141
Gear Oil141
Coolant141
Fuel141
Chassis141
Electrical System142
Tires142
Fork142
Shock Absorber143
Chassis Tightening Torques143
23 Substances146
24 Auxiliary Substances148
25 Standards150
List of Abbreviations 26151

KTM 300 EXC - Page 149

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