KTM 250 EXC & 300 EXC: known issues, problems & fixes
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10 سال پیش
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Own a KTM 250 EXC
Own a KTM 250 EXC or 300 EXC, or thinking of buying one? We list the model changes and history, known issues, popular mods and common problems to watch out for. They are great bikes overall so these lists are just a guideline on how to maintain these fine orange beasts! For more info visit http://crosstrainingenduro.com
250 EXC & 300 EXC HISTORY & MODEL CHANGES
If buying a second hand model, there were minor improvements each year but the significant changes tended to be in 2004, 2008, 2011.
1990 - 1998 KTM 250 / 300 EGS
1999 - start of the 250 / 300 EXC models begin
2004 - lighter engine, about 3kg lighter overall, 36mm carb from 04 on (previously 38mm)
2007 - dual mapping switch on handlebars introduced (e-start on some late 07s)
2008 - electric start, different frame & shock angle reduces twitchy handling
2011 - six speed gearbox, clear fuel tank, new pipe & muffler
2012 - improved bendix for starter motor, different airbox, frame & porting
2013 - DDS clutch with lighter pull, stronger starter motor
2014 - new CDI, battery, jetting, brakes & rear shock. also new head & boysen reeds
but some say a step backwards as it can be hard to get the jetting right
KNOWN ISSUES
- starter motors need regular maintenance & overhauls if used a lot
- low air cleaner box can drown the engine in deep water
- switches on bars unreliable with age unless regularly cleaned
- new bikes are set up too rich and need rejetting
- exhaust pipe guard/bashplate needed if doing a lot of logs or rocks
- stock suspension too soft unless you are a featherweight
- re-route the gearbox breather to avoid getting water in the oil
COMMON MODS
Wet mod for the starter motor
Upgrade to the powerful 2013 starter motor & improved 2012 bendix
Jetting kit
Drop one tooth on the front sprocket
New bikes to a suspension specialist (PDS can be tricky to get right)
Force bashplate / exhaust guard
Force radiator guards
Extend & reroute gearbox breather to avoid water in oil.
dual map ignition and 3different interchangeable power valve springs, head mods
jetting, power valve settings,needle choice,map switch ( 07 and newer), exhaust choice, flywheel weights
pipe guard needed
crap sidestands
service the starter motor
wet mod
upgraded bendix from 2012 that is retro
suspension not so good on earlier ones
99% of Kato electrical problems are usually switch block issues.
I dislike standard KTM switches ADR & start/stop switches, they require pedantic maintenance to retain function after every ride and aren't waterproof.
airbox drowning
jetting from new
2011 went to a six speed box
The 2010 model has a slightly different frame, welded a few mm lower at the headstem which allowed them to rotate the engine forward a tad to improve handling and lower the center of gravity. The 2010 also came with lighter rims than 09, and a slightly different airbox - said to give better spread of dust over the filter and help keep water off it.
Extend and re-route the gearbox breather to a better place to avoid getting water in the oil, water gets in there easily with the stock breather (unless they've fixed this for 2013).
Another enduro vlog from the gumbies at http://www.crosstrainingenduro.com
Playlist for our enduro vlogs: All our enduro rides!︱Cross Training ...
Cross Training Enduro Skills Facebook: Facebook: cross.training.enduro.skills
Cross Training Enduro Skills Youtube channel: @crosstrainingenduro Music: https://www.purple-planet.com
Music: www.playonloop.com
Music: https://soundimage.org
Music: https://audionautix.com/
Music by Tobu: https://tobu.io tobuofficial
Music: https://www.bensound.com/royalty-free...
Music: https://soundimage.org
Music by Atch:
SoundCloud: https://bit.ly/AtchSoundCloud
Spotify: https://bit.ly/AtchSpotify
Instagram: www.instagram.com/atchmusic
250 EXC & 300 EXC HISTORY & MODEL CHANGES
If buying a second hand model, there were minor improvements each year but the significant changes tended to be in 2004, 2008, 2011.
1990 - 1998 KTM 250 / 300 EGS
1999 - start of the 250 / 300 EXC models begin
2004 - lighter engine, about 3kg lighter overall, 36mm carb from 04 on (previously 38mm)
2007 - dual mapping switch on handlebars introduced (e-start on some late 07s)
2008 - electric start, different frame & shock angle reduces twitchy handling
2011 - six speed gearbox, clear fuel tank, new pipe & muffler
2012 - improved bendix for starter motor, different airbox, frame & porting
2013 - DDS clutch with lighter pull, stronger starter motor
2014 - new CDI, battery, jetting, brakes & rear shock. also new head & boysen reeds
but some say a step backwards as it can be hard to get the jetting right
KNOWN ISSUES
- starter motors need regular maintenance & overhauls if used a lot
- low air cleaner box can drown the engine in deep water
- switches on bars unreliable with age unless regularly cleaned
- new bikes are set up too rich and need rejetting
- exhaust pipe guard/bashplate needed if doing a lot of logs or rocks
- stock suspension too soft unless you are a featherweight
- re-route the gearbox breather to avoid getting water in the oil
COMMON MODS
Wet mod for the starter motor
Upgrade to the powerful 2013 starter motor & improved 2012 bendix
Jetting kit
Drop one tooth on the front sprocket
New bikes to a suspension specialist (PDS can be tricky to get right)
Force bashplate / exhaust guard
Force radiator guards
Extend & reroute gearbox breather to avoid water in oil.
dual map ignition and 3different interchangeable power valve springs, head mods
jetting, power valve settings,needle choice,map switch ( 07 and newer), exhaust choice, flywheel weights
pipe guard needed
crap sidestands
service the starter motor
wet mod
upgraded bendix from 2012 that is retro
suspension not so good on earlier ones
99% of Kato electrical problems are usually switch block issues.
I dislike standard KTM switches ADR & start/stop switches, they require pedantic maintenance to retain function after every ride and aren't waterproof.
airbox drowning
jetting from new
2011 went to a six speed box
The 2010 model has a slightly different frame, welded a few mm lower at the headstem which allowed them to rotate the engine forward a tad to improve handling and lower the center of gravity. The 2010 also came with lighter rims than 09, and a slightly different airbox - said to give better spread of dust over the filter and help keep water off it.
Extend and re-route the gearbox breather to a better place to avoid getting water in the oil, water gets in there easily with the stock breather (unless they've fixed this for 2013).
Another enduro vlog from the gumbies at http://www.crosstrainingenduro.com
Playlist for our enduro vlogs: All our enduro rides!︱Cross Training ...
Cross Training Enduro Skills Facebook: Facebook: cross.training.enduro.skills
Cross Training Enduro Skills Youtube channel: @crosstrainingenduro Music: https://www.purple-planet.com
Music: www.playonloop.com
Music: https://soundimage.org
Music: https://audionautix.com/
Music by Tobu: https://tobu.io tobuofficial
Music: https://www.bensound.com/royalty-free...
Music: https://soundimage.org
Music by Atch:
SoundCloud: https://bit.ly/AtchSoundCloud
Spotify: https://bit.ly/AtchSpotify
Instagram: www.instagram.com/atchmusic
10 سال پیش
در تاریخ 1393/07/18 منتشر شده
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