KTM 300SX manual

Art.Nr . 3.210.49 04/2002 125/200/250/300 SX, MXC, EXC OWNERS HANDBOOK MANUALE D’USO MANUEL D’UTILISA TION MANUAL DE INSTRUCCIONES 2003 BEDIENUNGSANLEITUNG[...]

ENGLISH 1 IMPOR T ANT PLEASE READ THIS MANUAL CAREFULL Y AND COMPLETEL Y BEFORE GOING ON YOUR FIRST RIDE. IT CONT AINS A GREA T DEAL OF INFORMA TION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERL Y . IN YOUR OWN INTE- REST , PLEASE P A Y P ARTICULAR A TTENTION TO NOTICES THA T ARE MARKED AS FOLLOWS:  WARNING  IGNORING THESE I[...]

ENGLISH 2 Introduction We would like to congratulate you on your purchase of a KTM motorcycle. Y ou are now the owner of a state-of-the-art sports motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appropriately . Before you go for your first ride, be sure to read this manual carefully and tho[...]

ENGLISH 3 IMPOR T ANT W ARRANTY AND GUARANTEE INFORMA TION KTM sports motorcycles are designed and constructed to r esist the usual wear and tear of normal use in competitions. The motorcycles comply with the regulations and categories curr ently in effect with the leading international motor cycle associations. Observance of the service, maintenan[...]

ENGLISH 4 Page SERIAL NUMBER LOCATIONS .............................................5 Chassis number ................................................................5 Engine number, engine type (125/200)............................5 Engine number, engine type (250/300)............................5 OPERATION INSTRUMENTS .............................[...]

ENGLISH 5 Chassis number The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 1. Engine number , engine type (125/200) The engine number and the engine type are stamped into the left side of the engine below the engine sprocket. Enter this number on page 1. Engine number , engine type [...]

ENGLISH 6 Electronic speedometer , indicator lamp (EXC) The green control lamp 1 flashes in the same rhythm as the flashing indicator when the indicator is working. The blue control lamp 2 lights up when the high beam is on. Electronic speedometer The electronic speedometer display is activated as soon as the engine is switched on and the motorcycl[...]

ENGLISH 7 + – MODE Tr ipmaster switch The switch has three buttons: MODE, + (plus) and – (minus).  WARNING  D O NOT TRY TO CHANGE THE MODE OR READ THE SETTINGS WHILE DRIVING . Y OUR ATTENTION WILL BE DISTRACTED FROM THE TRAFFIC WHICH CAN EASILY LEAD TO AN ACCIDENT . Electronic speedometer functions provided by the T ripmaster switch The d[...]

ENGLISH 8 SPEED/CLK (clock) display mode CLK will display time in hours, minutes and seconds. + BUTTON no function – BUTTON no function press the MODE BUTTON to change to the next mode. press and hold the MODE BUTTON 3 SECONDS to set the time in the menu (see SETTING THE CLOCK) SPEED/H (hours) display mode When you stop driving and no impulses ar[...]

ENGLISH 9 SPEED/TRP2 (trip 2) display mode The TRP2 trip meter is always active and counts to 999.9. Contrary to TRP1, the displayed figure can be changed using the + and – buttons. This is a very useful function for trips taken according to a roadbook. TRP2 is activated by the first impulse received from the wheel sensor and stops automatically [...]

ENGLISH 10 X X X X X X X X X X X X X X X X X X X X X no function no function starts / stops LAP figure LAP remains next figure no function no function no function no function no function increases TRP2 figure no function starts / stops STP2 Press + Display SPEED / ODO SPEED / MAX SPEED / LAP LAP / LAP SPEED / CLK SPEED / H SPEED / TRP1 SPEED / AVS1[...]

ENGLISH 11 Short circuit button (SX) The short circuit button 1 turns off the engine. When pressing this button, the ignition circuit is short-circuited. Combination switch (EXC) The light switch has 2, respectively 3 switch positions. A = Light off (this function is not available in all models) B = Low beam on C = High beam on You may use button 2[...]

ENGLISH 12 Filler cap To open it: turn filler cap counter-clockwise. To close it: put filler cap back on and tighten it by turning it clockwise. Install tank breather hose 1 without kinks. Fuel tap OFF In this position the fuel tap is closed. No fuel can flow to the carburetor. ON During operation the twist grip must be turned to ON. This means tha[...]

ENGLISH 13 Kickstarter The kickstarter is mounted on the left side of the engine. Its upper part can be swivelled. Foot brake pedal The foot brake pedal is disposed in front of the right foot rest. Its basic posi- tion can be adjusted to your seat position (see maintenance work). Side stand Push the side stand to the ground with your foot and load [...]

ENGLISH 14 Compression damping of fork Hydraulic compression damping determines the reaction when the fork is compressed. The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs.Remove the protecting cap 1 . Turn the knob 2 clockwise to increase damping, turn it counterclockwise to reduce damping during compre[...]

ENGLISH 15 Compression damping of shock absorber (MXC, EXC) The compression damping (during compression) can be adjusted for the MXC and EXC shock absorbers (Mono Compression Control). The degree of damping can be adjusted by turning adjusting screw 1 with a screwdriver. Turning in a clockwise direction will increase the damping, turning in a count[...]

ENGLISH 16  WARNING  –W EAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE . SMART KTM DRIVERS ALWAYS WEAR A HELMET , BOOTS , GLOVES , AND A JACKET , REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST GO FOR A SHORT RIDE . T HE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY COLORED SO THAT OTHER USERS OF THE ROADS CAN SEE YOU AS EARLY AS POSSIBLE . O FC OU[...]

ENGLISH 17 What you should check before each start When you start off, the motorcycle must be in a perfect technical condition. For safety reasons, you should make it a habit to perform an overall check of your motorcycle before each start. The following checks should be performed: 1 CHECK TRANSMISSION OIL LEVEL Too little transmission oil leads to[...]

ENGLISH 18 Starting when the engine is cold 1 Open fuel tap 2 Turn on ignition or emergency OFF switch 3 Put the gear in neutral 4 Activate cold-starting aid (choke) 5 Leave throttle closed or open it no more than 1 / 3 and kick down kickstar- ter vigorously all the way.  WARNING  –F OR STARTING ALWAYS PUT ON YOUR MOTORCYCLE BOOTS TO AVOID [...]

ENGLISH 19 Refueling, fuel 125-300: Unleaded premium gasoline RON 95 mixed with high grade two stroke oil. Mixture ratio 1:40 - 1:60 Fuel and engine oil should only be mixed immediately before use. KTM recommends SHELL ADVANCE RACING X.  WARNING  G ASOLINE IS HIGHLY FLAMMABLE AND POISONOUS . E XTREME CAUTION SHOULD BE USED WHEN HANDLING GASOL[...]

ENGLISH 20 PERIODIC MAINTENANCE SCHEDULE after 20 hours or 2000 kilometers 1st service after 10 hours or 1000 kilometers after 4000 kilometer or once a year IF MOTORCYCLE IS USED FOR COMPETITION 4000KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! S ERVICE I NTERVALS SHOULD NEVER BE EXCEEDED BY MORE THAN 5 HOURS OR 500 KM ! M AINTENANCE WORK DONE[...]

ENGLISH 21 I MPORT ANT C HECKS AND M AINTENANCE TO BE C ARRIED OUT BY THE R IDER Check gear box oil level ● Check brake fluid level ● Check brake pads for wear ● Check lights for function ● Check horn for function ● Lubricate and adjust cables and nipples ● Bleed fork legs regulary ● Remove and clean dust bellows regularly ● Clean a[...]

ENGLISH 22 R ECOMMENDED INSPECTION OF THE 125/200/250/300 SX AND EXC ENGINE USED FOR ENDURO COMPETITIONS BY YOUR KTM WORKSHOP ( ADDITIONAL ORDER FOR THE KTM WORKSHOP ) Check the reed-type intake valve for wear ●●● ● ● ● Check the clutch shoes for wear ●●● ● ● ● Check the length of the clutch springs ●●● ● ● ● Che[...]

ENGLISH 23[...]

ENGLISH 24  WARNING  MAINTENANCE AND ADJUSTING WORK MARKED WITH AN ASTERISK (*) REQUIRES EXPERT SKILLS AND TECHNICAL KNOW-HOW. FOR YOUR OWN SAFETY, ALWAYS HAVE SUCH WORK PERFORMED BY A SPECIALIZED KTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED, SKILLED STAFF. ! CAUTION ! –W HEN CLEANING THE MOTORCYCLE[...]

ENGLISH 25 How to change the handlebar position The handlebar position can be readjusted by 22 mm. Thus, you can put the handlebar in the position that is the most convenient for you. The upper tri- ple clamp 1 includes 2 bores arranged at a distance of 15 mm (0.6 in) from one another. The bores at the handlebar support 2 are offset from the cen- t[...]

ENGLISH 26 Basic suspension setup for the weight of the driver To achieve maximum handling performance and to prevent the fork, shock absorber, swing arm and frame from being damaged, the basic setup of the suspension components must be suitable for your weight. At delivery, KTM's offroad motorcycles are set to accommodate a driver weighing 70[...]

ENGLISH 27 According to our experience, the damping rate of the compression stage can remain unchanged. The damping rate of the rebound stage can be reduced by a few clicks for a softer spring or increased by a few clicks for a harder spring. Checking the basic setup of the telescopic fork The precise riding sag of the telescopic fork cannot be det[...]

ENGLISH 28 Adjusting the spring preload on the fork (SX) The spring preload on the SX models can be adjusted (changed) by 10 mm by turning adjusting screw 1 . Turning in a clockwise direction will increase the prestress, turning in a counterclockwise direction will decrease the prestress. Changing the spring preload will not affect the rebound damp[...]

ENGLISH 29 Check chain tension To check the chain tension, park the motorcycle. Press the chain upward at the end of the chain sliding component. The distance between the chain and the swing arm should be approx. 15 mm (0.6 in). In the course of this procedure, the upper chain portion A must be taut (see drawing). If necessary, correct the chain te[...]

ENGLISH 30 Chain maintenance For long chain life, good maintenance is very important. X-ring chains require only modest maintenance. The best way is to use lots of water, but never use brushes or solvents. After letting the chain dry, you can use a special X-ring chain spray (Shell Advance Bio Chain).  WARNING  N O LUBRICATION IS ALLOWED TO R[...]

ENGLISH 31 General information about KTM disc brakes BRAKE CALIPERS: The brake calipers of this series use a ”floating” mount. This means that the brake calipers are not solidly attached to the caliper support, which enables them to ”float” for maximum braking contact.Secure the screws of the cali- per support with Loctite 243 and tighten t[...]

ENGLISH 32 Adjusting the free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustment screw 1 . In this way, the position of the point of pressure (i.e. the resis- tance you feel on the hand brake lever when the brake pads are pressed against the brake disc) can be adjusted for any hand size. ! CAUTI[...]

ENGLISH 33 Replacing the front brake pads * Press the brake caliper toward the brake disk, to put the brake piston in its basic position. Remove clips 1 and pull out bolt 2 . Remove brake pads from the brake caliper. Clean the brake caliper and the brake caliper support with compressed air. Check the sleeves of the guide bolts for damage, and greas[...]

ENGLISH 34 Checking the rear brake pads The brake pads can be inspected from the rear. The thickness of the linings may not be less than 1 mm (0.04 in).  WARNING  A T THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM , OTHERWISE THEY COULD LEAD TO BRAKE FAILURE . F OR YOUR OWN SAFETY DON ’ T PUT OFF HAVING YOUR BRAKE P[...]

ENGLISH 35  WARNING  –I F YOU DON ’ T HAPPEN TO HAVE A TORQUE WRENCH AT HAND , MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE . A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE . –A FTER MOUNTING THE FRONT WHEEL , KEEP OPERATING THE HAND BRAKE UNTIL THE PRESSURE POINT RETUR[...]

ENGLISH 36 Ti res, air pressure Tire type, tire condition, and air pressure level affect the way your motorcy- cle rides and must therefore be checked whenever you are getting ready to go anywhere on your motorcycle. – Tire size can be found in the technical specifications and in the homolo- gation certificate – Tire condition has to be checked[...]

ENGLISH 37 Setting the clock To set the clock, switch the ignition off and select the SPEED/CLK mode. Press and hold the MODE button for 3 seconds. The blinking digits can be changed using the + and – buttons. Press the MODE button to move to the next digit. If no button is pressed for 20 seconds, the settings will be stored automati- cally and t[...]

ENGLISH 38 Check/set distance of the magnetic sensor The distance between the magnet 2 and the sensor 1 must be 2-4 mm, otherwise malfunctions on the speedometer might occur. This distance can be corrected by screwing the sensor 1 in or off. mm x 3,14 KMH: WS = mm x 3.14 MPH: WS = (mm x 3.14) : 1.61 1 2 Wheel circumference with standar d tires = 22[...]

ENGLISH 39 Cooling system The water pump in the engine circulates the cooling liquid. However, the cooling liquid can only circulate properly if the cooling circuit contains no air bubbles. Bleeding of the cooling system is therefore required a) after adding more than 0.25 l cooling liquid and b) after refilling the entire cooling system. (see Blee[...]

ENGLISH 40 Refilling/Bleeding the cooling system The cooling system must be bled as described below after draining the cooling liquid or after adding more than 0.25 l (0.06 US gallons) cooling liquid. Make sure that the drain screw 1 is fastened. Pour approx. 0.5 litres (0.13 US gallons) coolant into the system. Remove screw 2 at the cylinder head.[...]

ENGLISH 41 Changing the original position of the clutch lever The adjusting screw 1 can be used for individual adjustment of the original position of the clutch lever, thus allowing adjustment to an optimal position for every hand size. Turning the adjusting screw clockwise reduces the distance between the clutch lever and the handlebar. Turning th[...]

ENGLISH 42 Cleaning the spark arrestor (EXC USA) * With these models, the spark arrestor is part of the exhaust silencer. Clean it every 4000 km (2500 miles) to guarantee proper functioning. Also clean the spark arrestor when replacing the glassfiber yarn filling. After assembling the silencer, remove the plug 1 and start the motorcycle. Close the [...]

ENGLISH 43 Opening up B Engine behavior when the throttle opens. The idle jet and the shape of the throttle valve influences this range. If, despite good idling-speed and part- throttle setting, the engine sputters and smokes when the throttle is fully opened and develops its full power not smoothly but suddenly at high engine speeds, the mixture t[...]

ENGLISH 44 Check transmission oil level (125/200) In order to check the transmission oil level the control screw 1 on the clutch cover is to be removed. Oil should just barely escape from the inspection opening when the motorcycle is in an upright position. If necessary, remove the plug 2 and top up with oil (see technical data engine). ! CAUTION ![...]

ENGLISH 45 Should you wish to make a pause over a longer space of time, please observe the following instructions: – Clean motorcycle thoroughly (see chapter: CLEANING) – Change engine oil (old engine oil contains aggressive contaminants). – Check antifreeze and amount of cooling liquid. – Let the engine warm up again, close fuel cock and w[...]

ENGLISH 46 125 SX 125 EXC 200 SX 200 MXC 200 EXC Frame Central chrome-moly-steel frame Fork W hite P ower – U pside down 48 MA Wheel travel front/rear 300/335 mm (11.8/13.2 in) Rear suspension WP PDS 5018 ( P rogressive D amping S ystem) shock absorber, aluminium swingarm Front brake Disc brake with carbon-steel brake disc Ø 260 mm (10.2 in), br[...]

ENGLISH 47 WP 5018 PDS-DCC WP 5018 PDS-MCC 1218X756 1218X757 Compression adjuster 17 LS (low speed) 17 2 HS (high speed) Rebound adjuster 28 28 Spring 71-90/260 66-86/260 Spring preload 6 mm (0.2 in) 7 mm (0.2 in) S T ANDARD A DJUSTMENT - S HOCK A BSORBER WP 4860 MXMA WP 4860 MXMA 1418X725 1418X735 Compression adjuster 20 22 Rebound adjuster 20 20 [...]

ENGLISH 48 Engine 125 SX 125 EXC 200 SX 200 MXC 200 EXC Design Liquid-cooled, single-cylinder, two-stroke engine with intake and exhaust control Piston displacement 124.8 ccm 193 ccm Bore / stroke 54 / 54.5 mm (2.126 / 2.145 in) 64 / 60 mm (2.52 / 2.362 in) Fuel unleaded SUPER fuel, research octane no 95, mixed with high grade, two- stroke oil Oil [...]

ENGLISH 49 TIGHTENING TORQUES - ENGINE Flange bolts - cylinder-head M 7 18 Nm Nuts-cylinder base M 8 30 Nm Flywheel collar nut M 1 2 x1 60 Nm Nut for primary sprocket (LH thread) M 1 6x1 .5 180 Nm Nut for inner clutch hub M 1 8 x1 .5 120 Nm Crankcase and clutch cover bolts M 6 8 Nm Spark plug M 14x1.25 20 Nm Swingarm pivot M 14x1.5 100 Nm Other scr[...]

ENGLISH 50 WP 5018-MCC 1218X759 Compression adjuster 17 Rebound adjuster 26 Spring 71-90/260 Spring preload 7 mm (0.27 in) S T ANDARD A DJUSTMENT - S HOCK A BSORBER WP 4860 MXMA 1418X736 Compression adjuster 20 Rebound adjuster 20 Spring 4,0 N/mm Spring preload 5 mm (0.20in) Air chamber length 110 mm (4,3 in) Fork oil SAE 5 S T ANDARD A DJUSTMENT -[...]

ENGLISH 51 Collar screw, front wheel spindle M 24x1,5 40 Nm Brake caliper, front M 8 Loctite 243 + 25 Nm Brake disk, front M 6 10.9 Loctite 243 + 15 Nm Brake disk, rear M 6 Loctite 243 + 15 Nm Clamping screws, upper fork bridge M 8 20 Nm Clamping screws, lower fork bridge M 8 15 Nm Clamping screws, fork stubs M 8 10 Nm Collar nut, rear wheel spindl[...]

ENGLISH 52 Engine 250 MXC/EXC 300 MXC/EXC Desgin Liquid-cooled single-cylinder two-stroke engine with KTM T win V alve C ontrol exhaust system and K TM T orque C hamber Piston displacement 249 ccm 297 ccm Bore / stroke 66,4 / 72 mm (2.62 / 2.84 in) 72 / 73 mm (2.84 / 2.88 in) Fuel unleaded SUPER fuel, research octane no 95, mixed with high-grade, t[...]

ENGLISH 53 TIGHTENING TORQUES Flange bolts - cylinder-head M 8 35 Nm (25 ft.lb) Nuts-cylinder base M 1 0 35 Nm (25 ft.lb) Flywheel collar nut M 1 2 x1 60 Nm (44 ft.lb) Nut for primary sprocket (LH thread) M 1 8 x1 .5 Loctite 243 150 Nm (110 ft.lb) Nut for inner clutch hub M 1 8 x1 .5 Loctite 243 100 Nm (74 ft.lb) Crankcase and cover bolts M 6 8 Nm [...]

ENGLISH 54 Page Adjusting the free travel at the hand brake lever .................32 Adjusting the spring preload on the fork (SX)......................28 Basic suspension setup for the weight of the driver .............26 Bleeding of the hydraulic clutch ..........................................41 Braking ........................................[...]

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