KTM 300 MXC Dirt Bike Refresh: Off-Road.com

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KTM 300 MXC Dirt Bike Refresh

29, 2010 By Matt Allred

used dirt bikes, the one in your garage, may be the best for 2011. Laying out more for a new bike may be financially unwise. My is to keep the old, make it new and yourself some financial

A good stable dirt such as a KTM 300 MXC, model year is worth keeping because it has giddy up and delivers a satisfactory Generally, there is no shame in through the backcounty on an eight-year-old The dirt bike featured is my own; I am its third owner. before getting specific my KTM refresh, let me explain the other world I operate in.

For a gazillion and counting, I have evaluated and about mountain snowmobiles. I am doing such for this sister website, Snowmobile.com.

snowmobilers are a strange brood. The model year mountain is, for psych purposes, crucial for acceptance; no one wants to be the blockhead on the steep-n-deep aboard a snowmobile may be, gasp, three model old. Simply, if I were to up at a trail head strapped to a X, Y or Z, eyeballs would roll and would scatter, regardless of how my 2003 X, Y or Z performed. There is a law in the Rockies: ride current.

For on non-currents, forgiveness is extended to who throttle two-, maybe year-old snowmobiles. Beyond respect wanes.

However, the snow melts, my KTM receives doses of respect on the mountainous track trails. Dudes cue up and say, “Dude, nice On any given day, I may spend my time straddling other bikes, as others ride But, I never tempt a 2003 mountain snowmobile.

In mid-November, winter walloped the Rockies with voracity. tumbled down and I swapped my KTM for five mountain sleds. As the piled up, I battled the pros and of selling my KTM to purchase a newer bike. During my labor-intensive a one word question clunked in my “Why?” In true bean fashion, I knew I couldn’t my KTM with a two- or three-year old without laying out more

Also, the economy and its stench my nostrils. So, the idea sprang to this a project bike, and so a was born, and so too was this story.

As any project, I took the time to a budget. Any refresh can bounce a account. Before whipping a refresh project, conduct a analysis. For me, my cost-benefit analysis was In May 2008 I bought the bike for $3K (in condition), three years November 2010, my KTM’s value dipped down to $1,800 and $2,000.

Given I limited my project to $500.00. that, cost-benefit goes I might as well sell the and roll my … onto a bike. Now, being us bike riders are smart and gals, you and I know I can’t my $500.00, but I could recover at half – increase the KTM’s by $250.

Of course the pride and fun increases beyond that, but is an unrealized appreciation.


a $500 budget, my refresh was to installing new plastic, graphics and and giving a good cleaning and up. To help me perform this, I the help of two trusted speed Jones Eastern Idaho Sports, and Starting Line (SLP), both located in Falls, ID.

Matt Jones, owner of Eastern Idaho Power has a long motorbike, ATV, and snowmobile tuning résumé. He has in the Sunbelt and Snowbelt states lie in and next to the Rocky Mountains. vast experience is what I to install the plastic and rubber, and and adjust the KTM’s drive

Starting Line Products ) is a forward-thinking aftermarket company specializes in performance products for ATVs, UTVs and dirt Within SLP’s doors is a technical advisor and race Dustin Pancheri (pronounced who is a KTM wise guy. Also, his acumen for two-… motors is he understands a motor’s limitations trying to build power on to two-mile high air; and he how to squeeze that last of oomph from a motor amping it up in thin air.


Like you would do, I searched the for new plastic and graphics for the KTM 300 MXC, having success. I wanted to take it an all-orange bike to an all-black My luck ratio was 50/50, the KTM’s attire was to consist of an mix of black and orange plastic; my research and that of Jones’ we able to locate some bolt-ons.

The color scheme out with black down the orange on the sides.

Also, bolting on the new plastic, I hunted new graphics to adorn the bike; FX for a cost of $56.00 was slapped on the panels.

The side number (orange), radiator shrouds front number plate and fenders (black) came to a cost of $151.00. Parts purchased from the Motorcycle (motorcycle-superstore.com) and Western Power – WPS (wps-inc.com).

The front and rear Michelin were missing a few lugs and the scars of wrestling with lava rocks – they the battle. Jones pulled the and rim combos from the bike, the tires from their and installed new Pirelli MT All-Terrain Cost $120.00.

With the void of its rubber, spokes and rim were checked over; all well. Prior to reinstalling the and rims to the bike, mounting / brackets were cleaned, as as the chain tensioner.

After reinstalled the wheel sets, he the O-ring drive chain and it to be in good condition. He also set the tension to a proper setting and the rear wheel tracked to avoid chewing up the sprocket misalignment.

To give the bike a more … appeal, a brake disc cover and bracket were added; is cheap protection for the front Cost, $60.00.

To compliment the new and to protect my hands and hand from brutal ground Jones installed some Rally Pro-X Strong orange in color. Now, was a huge must-do for me, as this summer, while scouring a steep descent on flour-like my KTM washed on a sharp left When bike and rider hit the the hydraulic clutch lever and the clutch’s reservoir’s inner-components laying on the trail.

Riding pal “Hey Allred, brush would have prevented Lesson learned. Cost,

After Jones completed his I loaded up the bike and drove to SLP to with Pancheri. While at Pancheri and I chose to install carburetor power pack

The Power Pack from Line Products gives motorcycles improved throttle fuel economy and smoother delivery. It consists of a system of dividers which increase air for better fuel atomization. In detail, the Power Pack, per literature, should give my Faster throttle response; low-end and midrange horsepower; low-end to midrange power allowance to pull a higher when coming out of a corner; for the engine to pull through the RPM quicker; reduction in low-end easy engine tuning; fuel consumption.


Pancheri, latex surgical gloves, the new panels from the bike housed the intake system, and the carb from the motor and it. As the carb sat dissected on Pancheri’s he cleaned and inspected it, making repairs. With the carb in working order, he installed the Pak behind the slide.

According to air as it is flows under the carb’s moving from a large to a smaller area and back to a area, reduces in speed due to The Power Pak channels the air and ushers the oxygen to the motor’s crankcase in a fashion. On SLP’s website is a

Cost for the Power Pak,

After installing the Power Pancheri ensured the needle jet and its were properly set for this and altitude. Following this, the was pulled from the motor and high-temp RTV gasket goop – – was applied to the pipe and header, to the pipe to the motor’s header.

reinstalling the carb, Pancheri lit up the and began tuning the motor for a idle speed. Then, the motor warm, he twisted the and hammered the gear box to test mid-range and high-end throttle Air and fuel adjustments after passes around the SLP complex.

The day this occurred, Pancheri the bike to perform in the day’s and dang cold November This Spring, when the air and the humidity drops, Pancheri and I adjust the fuel and air mixture for summertime atomization. Given we may install a different needle, an which is often used on YZ 250’s for this area.

I this is the direction the KTM will go. stated to me, “The needle up the 1/4 throttle area which the bike better throttle off the bottom to mid. Makes it to puck up the front tire in a if you need to; also improves end grunt out of a corner. Seams to better with mid- to riders, but also works for the low-elevation guys.”

After two smart guys worked on my I returned it to my garage where I the air filter, bathed it in hot water and and gave it a good inspection to it was sound. Once dried, I new air cleaner oil to its surface. My final job was adding chain wax, a to the O-ring chain.

In Summation

is presented here is a simple project that you can do yourself. is money, and if a sweet dirt has your affection, keeping it is not a bad thing. Adding new plastic, and rubber, as well as cleaning up system inefficiencies are good

A little bit of money was spent, but the model-year 2003 bike perform admirably, and will no shame on the mountain, even its build sheet broadcasts a 2002 date.

As winter my riding areas with which is not a bad thing, my KTM sits in my garage. My cash outlay $522.00; 22 bucks beyond my Yes, I overshot my target, but not bad.

As my bike sat in the garage to my Harley and Polaris Sportsman my riding pals gave the ol’ crush KTM a standing ovation. this winter I’ll be as I wade through the steep-n-deep on new And it turn, when Summer I’ll be stylin’ on my eight-year-old

So, examine your bike’s and too, what tickles fun button. I performed this to improve its thin air fuel and atomization (improve motor to make it … looking, to its hand controls, to give it bite for the steep ascents and to clean and adjust the drive to clean crucial pivot and points, and to seal up a leaky pipe connection. My bike and I am

I made my choices, and stuck my budget.

Go forth and be happy


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