Ktm 300 exc tpi руководство

Brand: KTM
|
Category: Motorcycle
|
Size: 19.58 MB

• Table of Contents

  4

• 1 Means of Representation 1

  9

  • Symbols Used

    9

  • Formats Used

    9

• 2 Safety Advice

  10

  • Repair Manual

    10

  • Degrees of Risk and Symbols

    10

  • Work Rules

    10

• 3 Important Notes 3

  11

  • Manufacturer and Implied Warranty

    11

  • Operating and Auxiliary Substances

    11

  • Spare Parts, Accessories

    11

  • Figures

    11

• 4 Serial Numbers

  12

  • Chassis Number

    12

  • Type Label

    12

  • Engine Number

    12

  • Fork Part Number

    12

  • Shock Absorber Article Number

    13

• 5 Motorcycle

  14

  • Raising the Motorcycle with a Lift Stand

    14

  • Removing the Motorcycle from the Lift Stand

    14

  • Starting the Vehicle

    14

  • Starting the Motorcycle to Check the Function

    15

• 6 Fork, Triple Clamp

  16

  • Adjusting the Compression Damping of the Fork

    16

  • Adjusting the Rebound Damping of the Fork

    17

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

    18

  • Bleeding the Fork Legs

    18

  • Cleaning the Dust Boots of the Fork Legs

    19

  • Removing the Fork Legs

    19

  • Installing the Fork Legs

    20

  • Removing the Fork Protector

    21

  • Installing the Fork Protector

    21

  • All Standard EXC/XC-W Models

    22

  • Servicing the Fork

    22

  • Disassembling the Fork Legs

    22

  • Disassembling the Cartridge

    25

  • Disassembling the Tap Compression

    28

  • Checking the Fork Legs

    29

  • Assembling the Tap Compression

    30

  • Assembling the Cartridge

    31

  • Assembling the Fork Legs

    35

  • Lubricating the Steering Head Bearing

    39

  • Removing the Lower Triple Clamp

    39

  • Installing the Lower Triple Clamp

    40

  • Changing the Steering Head Bearing

    42

  • Checking the Play of the Steering Head Bearing

    44

  • Adjusting the Steering Head Bearing Play

    44

  • All Six Days Models

    45

  • Servicing the Fork

    45

  • Disassembling the Fork Legs

    45

  • Disassembling the Cartridge

    48

  • Disassembling the Tap Compression

    51

  • Checking the Fork Legs

    52

  • Assembling the Tap Compression

    53

  • Assembling the Cartridge

    54

  • Assembling the Fork Legs

    58

  • Lubricating the Steering Head Bearing

    63

  • Removing the Lower Triple Clamp

    63

  • Installing the Lower Triple Clamp

    64

  • Changing the Steering Head Bearing

    66

  • Checking the Play of the Steering Head Bearing

    67

  • Adjusting the Steering Head Bearing Play

    68

• 7 Handlebar, Controls 7

  69

  • Handlebar Position

    69

  • Adjusting the Handlebar Position

    69

  • Adjusting the Basic Position of the Clutch Lever

    71

  • Checking the Rubber Grip

    72

  • Checking Throttle Cable Routing

    72

  • Checking the Play in the Throttle Cable

    73

  • Adjusting the Play in the Throttle Cable

    73

  • Setting the Characteristic Map of the Throttle Response

    74

• 8 Frame

  76

  • Checking the Frame

    76

  • Removing the Engine Guard (All Six Days Models)

    76

  • Installing the Engine Guard (All Six Days Models)

    76

  • Changing the Footrests

    76

• 9 Shock Absorber, Swingarm

  80

  • Adjusting the High-Speed Compression Damping of the Shock Absorber

    80

  • Adjusting the Low-Speed Compression Damping of the Shock Absorber

    80

  • Adjusting the Rebound Damping of the Shock Absorber

    81

  • Measuring the Rear Wheel Dimension Unloaded

    82

  • Checking the Static Sag of the Shock Absorber

    82

  • Checking the Riding Sag of the Shock Absorber

    83

  • Adjusting the Spring Preload of the Shock Absorber

    83

  • Adjusting the Riding Sag

    84

  • Removing the Shock Absorber

    85

  • Installing the Shock Absorber

    85

  • Servicing the Shock Absorber

    85

  • Removing the Spring

    86

  • Disassembling the Damper

    87

  • Disassembling the Seal Ring Retainer

    88

  • Disassembling the Piston Rod

    89

  • Replacing the Pilot Bushing

    90

  • Checking the Damper

    91

  • Removing the Heim Joint

    92

  • Installing the Heim Joint

    93

  • Assembling Seal Ring Retainer

    93

  • Assembling the Piston Rod

    94

  • Assembling the Damper

    96

  • Bleeding and Filling the Damper

    98

  • Filling Damper with Nitrogen

    101

  • Installing the Spring

    102

  • Checking the Swingarm

    103

  • Checking the Heim Joint for Play

    103

  • Changing the Heim Joint

    104

  • Changing the Heim Joint on the Swingarm

    105

  • Checking the Swingarm Bearing for Play

    107

  • Removing the Swingarm

    107

  • Installing the Swingarm

    108

  • Changing the Swingarm Bearing

    110

• 10 Exhaust 10

  113

  • Removing the Manifold

    113

  • Installing the Manifold

    114

  • Removing the Main Silencer

    115

  • Installing the Main Silencer

    116

  • Changing the Glass Fiber Yarn Filling in the Main Silencer

    116

• 11 Air Filter

  118

  • Air Filter

    118

  • Removing the Air Filter Box Cover

    118

  • Installing the Air Filter Box Cover

    118

  • Removing the Air Filter

    119

  • Installing the Air Filter

    119

  • Cleaning the Air Filter and Air Filter Box

    120

  • Preparing Air Filter Box Cover for Securing

    120

  • Sealing the Air Filter Box

    121

• 12 Fuel Tank, Seat, Trim

  122

  • Opening the Filler Cap

    122

  • Closing the Filler Cap

    122

  • Removing the Seat

    123

  • Mounting the Seat

    123

  • Removing the Fuel Tank

    124

  • Installing the Fuel Tank

    125

  • Changing the Fuel Screen

    127

  • Changing the Fuel Filter

    128

  • Changing the Fuel Pump

    131

  • Checking the Fuel Pressure

    134

• 13 Mask, Fender

  136

  • Removing Front Fender

    136

  • Installing Front Fender

    136

  • Removing the Headlight Mask with the Headlight

    137

  • Installing the Headlight Mask with the Headlight

    137

• 14 Wheels 14

  139

  • Checking the Tire Air Pressure

    139

  • Checking the Tire Condition

    139

  • Checking the Wheel Bearing for Play

    140

  • Checking the Brake Discs

    141

  • Checking the Rim Run-Out

    141

  • Checking Spoke Tension

    142

  • Front Wheel

    143

  • Removing the Front Wheel

    143

  • Installing the Front Wheel

    144

  • Changing the Front Brake Disc

    144

  • Changing Front Wheel Bearing

    145

  • Rear Wheel

    146

  • Removing the Rear Wheel

    146

  • Installing the Rear Wheel

    147

  • Changing the Rear Brake Disc

    148

  • Changing the Rear Wheel Bearing

    149

  • Checking the Chain for Dirt

    151

  • Cleaning the Chain

    151

  • Checking the Chain Tension

    152

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

    153

  • Adjusting the Chain Tension

    155

  • Changing the Drivetrain Kit

    156

• 15 Wiring Harness, Battery 15

  159

  • Ignition Curve Plug-In Connector

    159

  • Changing the Main Fuse

    159

  • Changing the Fuses of Individual Power Consumers

    161

  • Disconnecting the Negative Cable of the Battery

    162

  • Connecting the Negative Cable of the Battery

    163

  • Removing the Battery

    163

  • Installing the Battery

    164

  • Recharging the Battery

    165

  • Checking the Charging Voltage

    166

  • Checking the Open-Circuit Current

    167

  • Checking the Starter Relay

    167

  • Diagnostics Connector

    168

• 16 Brake System 16

  169

  • Checking the Front Brake Linings

    169

  • Changing the Front Brake Linings

    169

  • Checking the Free Travel of the Hand Brake Lever

    171

  • Adjusting Free Travel of Hand Brake Lever (All EXC Models)

    172

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

    172

  • Checking the Front Brake Fluid Level

    172

  • Adding Front Brake Fluid

    173

  • Changing the Front Brake Fluid

    174

  • Checking the Brake Linings of the Rear Brake

    176

  • Changing the Rear Brake Linings

    176

  • Checking the Free Travel of Foot Brake Lever

    178

  • Adjusting the Basic Position of the Foot Brake Lever

    179

  • Checking the Rear Brake Fluid Level

    180

  • Adding Rear Brake Fluid

    180

  • Changing the Rear Brake Fluid

    181

• 17 Lighting System, Instruments

  184

  • Changing the Headlight Bulb

    184

  • Changing the Turn Signal Bulb (All EXC Models)

    184

  • Checking the Headlight Setting

    185

  • Adjusting the Headlight Range

    186

  • Changing the Combination Instrument

    186

  • Combination Instrument Overview

    187

  • Activation and Test

    187

  • Setting the Kilometers or Miles

    187

  • Adjusting the Combination Instrument Function

    188

  • Setting the Clock

    189

  • Activating Additional Functions

    189

  • Setting the Wheel Circumference

    190

  • Viewing the Lap Time

    190

• 18 Engine

  192

  • Cleaning the Pressure Sensor Hose

    192

  • Removing the Engine

    192

  • Installing the Engine

    198

  • Engine Disassembly

    205

  • Clamping the Engine into the Engine Work Stand

    205

  • Removing the Shift Lever

    205

  • Removing the Clutch Push Rod

    205

  • Draining the Gear Oil

    205

  • Removing the Spacer

    206

  • Removing the Alternator Cover

    206

  • Removing the Kick Starter

    207

  • Removing Injection Valves

    207

  • Removing the Cylinder Head

    207

  • Removing the Cylinder

    208

  • Removing the Piston

    210

  • Removing the Water Pump Cover

    211

  • Removing the Clutch Cover

    211

  • Removing the Clutch Discs

    212

  • Removing the Clutch Basket

    213

  • Removing the Balancer Shaft

    214

  • Removing the Kick Starter Shaft

    215

  • Removing the Intermediate Kick Starter Gear

    215

  • Removing the Shift Shaft

    216

  • Removing the Shift Drum Locating Unit

    216

  • Removing the Locking Lever

    216

  • Removing the Rotor

    216

  • Removing the Starter Motor

    217

  • Removing the Reed Valve Housing

    218

  • Removing the Left Engine Case Section

    219

  • Removing the Shift Rails

    219

  • Removing the Shift Drum

    219

  • Removing the Shift Forks

    220

  • Removing the Transmission Shafts

    220

  • Removing the Crankshaft

    220

  • Working on Individual Parts

    221

  • Working on the Right Section of the Engine Case

    221

  • Working on the Left Section of the Engine Case

    222

  • Removing the Crankshaft Bearing Inner Race

    224

  • Installing the Crankshaft Bearing Inner Race

    224

  • Changing the Connecting Rod, Conrod Bearing, and Crank Pin

    225

  • Checking the Crankshaft Run-Out at the Bearing Pin

    226

  • Checking/Measuring the Cylinder

    226

  • Cleaning the Pressure Sensor Cylinder Connection

    227

  • Removing the Exhaust Control

    227

  • Checking the Exhaust Control

    229

  • Installing the Exhaust Control

    231

  • Cylinder — Nikasil Coating

    234

  • Checking/Measuring the Piston

    234

  • Checking the Piston Ring End Gap

    235

  • Measuring the Piston/Cylinder Mounting Clearance

    235

  • Disassemble the Reed Valve Housing

    236

  • Checking the Reed Valve Housing, Reed Valve and Intake Flange

    237

  • Assemble the Reed Valve Housing

    237

  • Working on the Clutch Cover

    239

  • Checking the Clutch

    242

  • Preassembling Shift Shaft

    243

  • Checking the Shift Mechanism

    244

  • Disassembling the Main Shaft

    245

  • Disassembling the Countershaft

    246

  • Checking the Transmission

    246

  • Assembling the Main Shaft

    248

  • Assembling the Countershaft

    248

  • Checking the Kick Starter

    250

  • Preassembling the Kick Starter Shaft

    250

  • Checking the Electric Starter Drive

    251

  • Engine Assembly

    252

  • Installing the Crankshaft

    252

  • Installing the Transmission Shafts

    253

  • Installing the Shift Forks

    253

  • Installing the Shift Drum

    254

  • Installing the Shift Rails

    254

    • Installing the Left Engine Case Section

      254

    • Installing the Reed Valve Housing

      255

    • Installing the Starter Motor

      256

    • Installing the Rotor

      257

    • Installing the Locking Lever

      257

    • Installing the Shift Drum Locating Unit

      258

    • Installing the Shift Shaft

      258

    • Installing the Intermediate Kick Starter Gear

      258

    • Installing the Kick Starter Shaft

      258

    • Installing the Balancer Shaft

      259

    • Installing the Clutch Basket

      260

    • Installing the Clutch Discs

      261

    • Installing the Clutch Cover

      263

    • Installing the Water Pump Cover

      265

    • Installing the Piston

      266

    • Installing the Cylinder

      267

    • Checking the X-Distance

      269

    • Adjusting the X-Distance

      269

    • Adjusting the Z-Distance

      271

    • Installing the Cylinder Head

      273

    • Installing Injection Valves

      274

    • Installing the Kick Starter

      274

    • Installing the Alternator Cover

      274

    • Installing the Spacer

      275

    • Installing the Gear Oil Drain Plug

      275

    • Installing the Clutch Push Rod

      276

    • Installing the Shift Lever

      276

    • Removing the Engine from the Engine Work Stand

      276

• 19 Clutch 19

  277

  • Checking/Correcting the Fluid Level of the Hydraulic Clutch

    277

  • Changing the Hydraulic Clutch Fluid

    278

  • Checking the Clutch

    279

• 20 Water Pump, Cooling System

  288

  • Cooling System

    288

  • Checking the Antifreeze and Coolant Level

    288

  • Checking the Coolant Level

    289

  • Draining the Coolant

    289

  • Refilling with Coolant

    290

• 21 Exhaust Control 21

  293

  • Checking/Adjusting the Exhaust Control

    293

• 22 Lubrication System

  296

  • Changing the Gear Oil

    296

  • Checking the Gear Oil Level

    297

  • Adding Gear Oil

    297

  • Checking 2-Stroke Oil Level

    298

  • Opening 2-Stroke Oil Tank Cap

    299

  • Adding 2-Stroke Oil

    299

  • Closing 2-Stroke Oil Tank Cap

    299

  • Priming the Oil Pump

    300

  • Replacing the Oil Pump

    301

• 23 Ignition System

  304

  • Checking the Ignition System

    304

  • Ignition Coil — Checking the Primary Winding

    305

  • Checking the Spark Plug Connector

    306

  • Alternator — Checking the Stator Winding

    306

  • Checking the Crankshaft Position Sensor

    307

  • Changing the Spark Plug

    308

  • Changing the Spark Plug and Spark Plug Connector

    309

  • Removing the Stator

    309

  • Installing the Stator

    310

• 24 Electric Starter 24

  311

  • Checking the Starter Motor

    311

• 25 Throttle Valve Body

  312

  • Adjusting the Idle Speed

    312

  • Programming Ambient Pressure

    312

  • Cold Start Button

    313

• 26 Technical Data

  314

  • Engine

    314

  • All 250 Models

    314

  • All 300 Models

    314

  • Tolerance, Engine Wear Limits

    315

  • Engine Tightening Torques

    316

  • Capacities

    317

  • Gear Oil

    317

  • Engine Oil

    317

  • Coolant

    317

  • Fuel

    318

  • Chassis

    318

  • Electrical System

    319

  • Tires

    319

  • Fork

    319

  • All Standard EXC/XC-W Models

    319

  • All Six Days Models

    320

  • Shock Absorber

    320

  • Chassis Tightening Torques

    321

• 27 Cleaning, Care

  324

  • Cleaning, Care

    324

  • Cleaning the Motorcycle

    324

  • Checks and Maintenance Steps for Winter Operation

    325

• 28 Storage

  326

  • Preparing for Use after Storage

    327

• 29 Service Schedule

  328

  • Additional Information

    328

  • Required Work

    328

  • Recommended Work

    329

• 30 Wiring Diagram

  332

  • All EXC Models)

    332

  • All EXC Models)

    334

  • All EXC Models)

    336

  • All EXC Models)

    338

  • All EXC Models)

    340

  • All EXC Models)

    342

  • All EXC Models)

    344

  • All EXC Models)

    346

  • All XC-W Models)

    348

  • All XC-W Models)

    350

  • All XC-W Models)

    352

  • All XC-W Models)

    354

  • All XC-W Models)

    356

  • All XC-W Models)

    358

• 31 Substances

  360

• 32 Auxiliary Substances

  362

• 33 Special Tools

  364

• 34 Standards 34

  379

• 35 Index of Special Terms

  380

• 36 List of Abbreviations 36

  381

  • Index

    382