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KTM 300 EXC Manual

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Repair manual KTM 250 / 300 / 380 Art No 3206004 -E
9-31C
TIGHTENING TORQUES
Flange bolts - cylinder-head M 8 35 Nm (25 ft.lb)
Nuts-cylinder base M 10 35 Nm (25 ft.lb)
Flywheel collar nut M 12x1 60 Nm (44 ft.lb)
Nut for primary sprocket (LH thread) M 18x1.5 Loctite 243 150 Nm (110 ft.lb)
Nut for inner clutch hub M 18x1.5 Loctite 243 100 Nm (74 ft.lb)
Crankcase and cover bolts M 6 8 Nm (6 ft.lb)
Swingarm pivot M 14 100 Nm (74 ft.lb)
Flat head bolt release plate kickstarter M 6x16 Loctite 648 19 Nm (14 ft.lb)
Other bolts M 6 10 Nm (7 ft.lb)
M 8 25 Nm (19 ft.lb)
M 10 45 Nm (33 ft.lb)
Piston fitting clearance 0.06 mm (250) 0.06 mm (300) 0.08 mm (380)
Piston ring end gap 0.3– 0.4 mm
Connecting rod bearing - radial clearance
0.021– 0.032 mm
Transmission shafts end float 0.1– 0.2 mm
Clutch springs - length Ø 2.5 new = 43 mm, minimum length = 42 mm
TOLERANCES AND FITTING CLEARANCES
GASKET THICKNESSES
Crankcase 0.5 mm
Clutch cover 0.5 mm
Cylinder bottom gasket as required
Available cylinder bottom gaskets 0.2/0.4/0.5 /0.75 mm
Cylinder-head gasket O-rings
BASIC CARBURETOR SETTING
300 EXC AUS
throttled
Keihin PWK 38 AG
070201
170 (172,168)
45 (48)
85
NOZ G (NOZ H)
II
6,5
1,5
slide stop 36mm
–
250 EXC USA
Keihin PWK 38 AG
030201
178 (175,180)
45 (48)
85
NOZ E (NOZ F)
IV
6,5
1,5
–
–
Carburetor
Carburetor setting number
Main jet
Idling jet
Starting jet
Jet needle
Needle position from top
Slide
Air adjustment screw open
Performance restrictor
Power jet jet
300 MXC/EXC
USA
Keihin PWK 38 AG
040201
175 (178,172)
45 (48)
85
NOZ H (NOZ I)
III
6,5
1,5
–
–
250 SX
380 SX
380 SX USA
BASIC CARBURETOR SETTING
Keihin PWK 38 AG
061200
170 (168,172)
48 (45,50)
85
NOZ E (NOZ F/D)
III
6,5
1,5
–
–
Keihin PWK 38 AG
050201
170 (168,172)
45 (48)
85
NOZ G (NOZ H)
II
6,5
1,5
–
–
250/300 EXC
throttled
Keihin PWK 38 AG
061200
175 (172,178,180)
35 (45/48)
85
R 1475 J (NOZ E/H)
III
6,5
1,5
slide stop 34mm
–
Carburetor
Carburetor setting number
Main jet
Idling jet
Starting jet
Jet needle
Needle position from top
Slide
Air adjustment screw open
Performance restrictor
Power jet jet
… 115 …


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