Manual KLX300

[Dirka]

Anyone know where to look up or find service manual etc for said bike??

Was doing a once over on my new toy and it has no grease nipples for the swing arm/suspension etc!! How does one lubricate?? Pull it apart every time??
How many hours will a oil filter be good enough for while just plain sailing trail use??
Plus many other points will be needed in future,

Cheers

[tommorth]

http://www.cyclepedia.com/index.php?s=klx300
heres one not free though

[barty5]

TRY HERE FOR DOWLOAD

http://www.torrentreactor.net/search...&asc=0&x=0&y=0

[pete.ktm]

if you can't find an online copy let me know and i'll send you mine (traded the klx in).

pete

[Dirka]

if you can't find an online copy let me know and i'll send you mine (traded the klx in).pete

That would be great!!
In the hand would be ideal. Ill flick you a bit of dosh eh?
Cheers

[pete.ktm]

if the messaging system here works i've just sent you an e-mail asking for your postal address.

damn, there used to be a good uk klx site with pdf's with a lot of maintenance stuff but it's got a "under construction" page up. pretty sure it was at http://www.klxzone.co.uk. i might have saved the pdf's, i'll flick them on if i find them. ...later... found them! either grab them from http://zaq123.net/klx.zip (approx 3.5meg) or i can e-mail then to you.

cheers

[Dirka]

Sweet!
Downloaded that file, some good pics of that guy doing the work.
Full on mission to get to swingarm grease points!! Most other bikes have grease nipples!!
What do you reckon about chopping out the mesh filter inside airbox??
Or even elargening the intake slot on the airbox lid???

[camchain]

Hey there Dirka.

See photos of some mods I did to my 05 KLX. (Just sold the bike)

I changed oil filter every second oil change. (Oil changes done every 10 or 12 hrs)

I did swingarm/suspension grease job not long after buying bike (at 1 1/2 yrs old). All linkages were well greased by prev owner. Swingarm had never been off but was still very well greased from new. Special attention req. on large bottom linkage bearing where it sits on shaft. Bearing excellent but was loose on shaft (rusty and stodgy) - exposed to lots of water etc. If yours is loose suggest using some brass shim.

If I intended to keep bike would have fitted grease nipples. Used Moreys Super Red grease (ordered from Repco). Super tacky and stringy and well waterproof. I love this stuff.

Airbox: I wouldn't cut the backfire screen out. Best (first mod) thing to do is get a bigger header pipe and open up airbox top. Stock filter is nice and thick but a power thief. Rather than chop up stock airbox lid I made an open topped one out of MDF (painted with tough and flexible bumper paint). Made a prefilter to keep mud splash off air filter. Added Dynojet carb kit as well. All up mods gave better throttle response and healthier bottom end pep.

Discovered Twin air filter for KLX ID is too big and blocks inlet tract. Measure and cut to fit for accurate alignment. (mod doesn't affect flange sealing effectiveness at all)

A mod you really need to do is fill up the steering lock slot with silicone or something similar (same stem for road legal KLX250) in steering stem. Slot tets water onto bearing which stuffs it real quick. Much, much easier than fitting new bearing (trust me).

Shift Star mod: My KLX stopping jumping out of gear and shifted a lot smoother after I did the Stroker shift star mod. Stroker out of biz so did mod myself.

The big KLX curse is the dreaded kick start idle gear. I thought they had sorted this on newer bikes but saw a brand new KLX bust its idler a few months ago. Can be very nasty.

For others looking for KLX manual I found this link to online manual but never tried it. Big file, 15Mb

KLX manual http://www.mediafire.com/?b200n2cdtcq

[pete.ktm]

What do you reckon about chopping out the mesh filter inside airbox??
Or even elargening the intake slot on the airbox lid???

i drilled holes in the top of the air box, but to be honest couldn't notice any diff.

i didn't think there would be enough gain in doing the mesh filter versus the risk of stuff falling in.

just trying to think of things i did to mine when i had it...

did the y-tube trick with the carb breather tubes so you can get across streams.

dynojet carb kit and bigger header pipe - that seems to make a bit of difference. the serious guys replace the carb with a FCR carb.

had the suspension re-valved but i traded it in shortly after that and didn't really get any good rides in to decide if it was worth it.

i think theres still lots of info on the PlanetKLX maillist at yahoogroups.com.

[chop]

I had one an 05 i binned the air box lid and put an aftermarket header and muffler on it from custom chambers in east tamaki,. The header made a good increase in power as stock header is restrictive. I know an old chap(done a couple isde's) that has one and loves it he has raised his pegs as theyre stump eaters and has added a home made hot start quite trick.

[Dirka]

Thanks guys!!
I have eyed up a header/exhaust combo, http://www.trademe.co.nz/Browse/List...x?id=157850662
But no rush for that just yet. Ill get more power when im out-riding the power ive got (im still new to this bike) Carb will be last on my list i think.

The "pre filter" to prevent mud will be great idea in combo with lid chop.
Grease nipple will be top of list for me, along with breather pipe and that steering lock block.

How hard is it to get to shift star??
Cheers

[ali-s]

Dirka - Congrats on purchasing a KLX, a great bike (i owned one for 3 years - gave it hell and it never let me down) however it is what it is, a good old rock solid, heavy as fark,fun four stroker - so with this in mind i didn't bother doing any mods - i just got into the mindset of adapting to the bike rather than trying to make it into something else, there's nothing wrong with mods etc but at the end of the day it will still be a KLX - if something breaks - fix it (just like any other trailie) any $ spent on performance mods could be stashed for higher performance machine in the future....
As for grease nipples on the linkage, well da grease goes in and da grease gotta come out of somewhere - where the grease comes out will let all the water/mud/shit in - believe me it will, it's bad enough on MTB's - maybe think about investing in a torque wrench and keeping on top of greasing the bearings traditionally - an hour job when you get into it.
BTW when doing job you will release the lower shock bolt, undo the top one as well seeing's your there and out pops the shock, good opportunity to inspect the unit for wear etc, don't forget to grease the top shock bearing as this is a moving part as well - above all enjoy the green beastie and remember - it's 90% rider - 10 % bike

[pete.ktm]

Anyone know where to look up or find service manual etc for said bike??

havn't seen your postal address yet, you still want that manual?

[camchain]

Shift star is behind the small cover bottom left of engine, gearshift shaft goes out of it. It's easy to get at and work on. Drain oil first.

I Was a bit dubious about doing the mod at first but the little bastard jumping out of gear was bad news. If you didn't want to modify the shift star you could just add the dowell onto the spring (to sort jumping out of gear ) but you won't get the smoother shifting. Was surprised how well it all worked, very worth while for effort involved.

[Dirka]

Thanks heaps Pete!! Received manual.

Anyone needing specifics or pics let me know Ill share the knowledge.