KTM Forums banner

1 - 20 of 1186 Posts

·
Super Moderator
Joined
·
1,814 Posts
Discussion Starter #1 (Edited)
I just recently acquired a 92' EXC 300 in really nice condition.
I do not have a manual for it and did not know if it is even possible to buy one? Or get information about it somewhere?
Some simple things that I do not know about are what the mix ratio is for this and what type of two stroke oil is recommended? Also what type/weight of gear oil and how much? What type of radiator fluid and is it 50/50 mix?
Is there a good place to buy used parts online? Can you even get used parts? Can you even get any new parts?
Any help with these questions would be greatly appreciated.
I am trying to get this up and running and this information along with any other suggestions would help.
Thanks.:yes:







Update...
Here is a (very) short video of the first voyage of the finished (complete) 1992 KTM 300EXC that I started with as a project not really knowing what the outcome would be.
It was much better than what I had expected...
Here is a short video of the first ride.















Rangerman:ricky:
 

·
Administrator
Joined
·
14,818 Posts
Cheers and welcome to the forum.


I do not have a manual for it and did not know if it is even possible to buy one? Or get information about it somewhere?

That's going to only be something on ebay.

Some simple things that I do not know about are what the mix ratio is for this and what type of two stroke oil is recommended?

I'd start at 32:1 with some non synthetic (Belray or).

Also what type/weight of gear oil and how much?
There is a fill plug and a fill level plug. Add oil until it starts
coming out of the fill level plug. Any regular "non energy conserving"
engine oil works.


What type of radiator fluid and is it 50/50 mix?

I like Coolanol premix.


Is there a good place to buy used parts online? Can you even get used parts? Can you even get any new parts?


With a bike that age, you will need to scour ebay.
 

·
Super Moderator
Joined
·
1,814 Posts
Discussion Starter #3
Thanks for the information bajadog, I appreciate it.
Rangerman
 

·
Administrator
Joined
·
14,818 Posts
If you get lucky our resident vintage 2 stroke guru will appear and help
you when you have jetting or electrical gremlins (Hookuspookus).
 

·
Registered
Joined
·
76 Posts
As far as pre-mix, KTM back in the day recommended Dura-lube.
Champion now owns the Dura-lube formula. They make it in air cooled
and water pumper. I run it 50:1 and always Have for about 25 years.

Any good gear oil will work fine, just change it often. I run Rotella
15W-40 in all my bikes with good results. I change it every 10-15
hours.

I've never had any overheating issues with my smokers running 50/50
Prestone. Again keep it clean and full. You probably have a vent plug
on the radiator without the cap. Be sure to take it out when you fill.

Parts cans sometimes be tricky. UFO might have plastic and I've had
other manufactures parts match up as well. Find a good local parts
that can help you out. They can be worth their weight on gold. I've
purchased bearings from my local industrial shop.

Old KTM 2T's will go a long time if taken care of. I rode my 360 for 16
years and 30,000 miles before retiring it. I just hope I can get that
out of my 500!
 

·
Super Moderator
Joined
·
1,814 Posts
Discussion Starter #6
Thanks for the info, this gives me what I need to get started. The PO thought that he had a manual for it but was not able to find it. That would have been helpful to have since I know very little (except what I have learned from here so far) about this KTM. I had a 71' Penton Six Day 125 when I was a teenager in the early 80's and had alot of fun with it (riding and repairing it). Parts were hard to find for it and I did not have a manual for it either, but it was a one of a kind bike that was worth the extra effort.
Thanks again for the information.:yes:
 

·
Super Moderator
Joined
·
1,814 Posts
Discussion Starter #7
I had another question(s). Is it necessary to flush the radiator before I put in new coolant and if so how? This EXC has been sitting in a garage for about five years and there is not any coolant in it right now. I was planning on filling with new 50/50 Prestone and draining old gear oil and filling with fresh oil (75W Bel-Ray Gearsaver) and mixing a fresh batch of high octane (93) gas 50:1 with Bel-Ray 2T Mineral Oil.
About draining the gear oil, do I drain that out of the fill level plug while slightly tipping the bike sideways?
Any other suggestions from you more experienced KTM riders would be greatly appreciated. I am in the process of trying to locate a manual so I can possibly answer some if not most of these questions for myself, but until then as always any input/info/help is greatly appreciated!:yes:
 

·
Super Moderator
Joined
·
1,814 Posts
Discussion Starter #8
By the way here is a picture of my 92'EXC.

 

·
Administrator
Joined
·
14,818 Posts
Nice bike!!!

Think how ahead of the curve it was with inverted forks. Ya I know
factory race bikes had them in '92, but not many production bikes.:yes:
 

·
Super Moderator
Joined
·
1,814 Posts
Discussion Starter #10
Thanks bajadog.
I had been looking for a KTM for quite sometime and found this one.
I really want to do it right to get this back on its feet (tires) again, so the more helpful information I can gather about it the better.
It looks as though it has been well maintained and it does somehow remind me of that Penton Six Day 125 I had years ago that had KTM stickers on each side of the tank.
All my friends would razz me and say what is a KTM? I thought it was really cool to have a motorcycle that was different and and somewhat unkown at the time and then little by little I started seeing more about KTM's in the dirt bike magazines as they started to become more popular.
Fast forward about 35 years and I'm ready to ride!:thumbup:
 

·
Registered
Joined
·
76 Posts
Some of the older bikes had a coolant drain plug in the water pump
cover, if not just pull the lower hose off of the engine.

You will have a drain for the engine oil as well. I would change it again
after the first ride also because it has been sitting so long.

Be sure to check the air filter as well, it might fall apart when you
clean it and need to replaced. Does the bike run now? Is there old gas
Still in it? You may need to clean the carburetor, inspect the reeds and
replace the spark.
 

·
Super Moderator
Joined
·
1,814 Posts
Discussion Starter #12
Some of the older bikes had a coolant drain plug in the water pump
cover, if not just pull the lower hose off of the engine.

You will have a drain for the engine oil as well. I would change it again
after the first ride also because it has been sitting so long.

Be sure to check the air filter as well, it might fall apart when you
clean it and need to replaced. Does the bike run now? Is there old gas
Still in it? You may need to clean the carburetor, inspect the reeds and
replace the spark.
Thanks for your help Orangeblood,
I looked at the radiator and could not locate a drain plug. Do you mean pull this lower hose here?


Is that it, just drain it? Do I need to flush it out with a hose? Or boiling water?
It seems to be completely is dry inside.
 

·
Registered
Joined
·
76 Posts
The water pump is on the engine at the other end of that hose. You
want to drain the water at the lowest part of the coolant system. If it
is dry there might be deposits left inside the engine and radiators and
would be wise to flush.
 

·
Super Moderator
Joined
·
1,814 Posts
Discussion Starter #14
You will have a drain for the engine oil as well. I would change it again
after the first ride also because it has been sitting so long.



I also checked underneath the engine and did not see/could not locate a drain plug like I have on my KLR650 or my XR250L?
The check level screw is all I can locate along with the filler cap?




Any certain amount of ounces or just fill until it begins to weep out of the oil level hole?
Again I appreciate the help.
Rangerman
 

·
Super Moderator
Joined
·
1,814 Posts
Discussion Starter #15
The water pump is on the engine at the other end of that hose. You
want to drain the water at the lowest part of the coolant system. If it
is dry there might be deposits left inside the engine and radiators and
would be wise to flush.

Understood, thanks.:yes:
 

·
Registered
Joined
·
76 Posts
The first picture is the coolant drain. There is most defiantly a drain
plug on the bottom of the crank case. Lay the bike on the side if your
having trouble finding it. Otherwise I would pull off the clutch cover to
drain, but there has to be a drain plug. Good luck!

And nice bike by the way! I especially like the Penton!
 

·
Super Moderator
Joined
·
1,814 Posts
Discussion Starter #17
Be sure to check the air filter as well, it might fall apart when you
clean it and need to replaced. Does the bike run now? Is there old gas
Still in it? You may need to clean the carburetor, inspect the reeds and
replace the spark.

Air filter looks good. Maybe just clean and re-oil it. I am wondering if there is supposed to be a cover over the top, if so there is not one? Is this some sort of mod or do I need to be looking for one on e-bay?


No old gas in the tank.
I definitely will clean the carb.
New spark plug already in.
Inspect the reeds? How?
Yes it ran well, he said that he had a really bad crash that destroyed the subframe and wheel bearings, both were replaced. He just did not have the time to work on it anymore.
 

·
Registered
Joined
·
76 Posts
There is a cover with holes in it for extremely wet conditions but I've
never needed to use it. The reeds will not lay flat against the cage and
will start to crack and split when they wear out.
 

·
Administrator
Joined
·
14,818 Posts
Any certain amount of ounces or just fill until it begins to weep out of the oil level hole?
Again I appreciate the help.
Rangerman
Yes!

Just pull the fill level plug and add oil into the top
fill hole (with the black plug). Go slow and as
oil starts to weep out plug her back up and your done.:yes:
 

·
Registered
Joined
·
76 Posts
Yes!

Just pull the fill level plug and add oil into the top
fill hole (with the black plug). Go slow and as
oil starts to weep out plug her back up and your done.:yes:
That will work, it should take about 1 quart. My 360 took .8L.
 
1 - 20 of 1186 Posts
Top