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Just got KTM 300 EXC a few ???

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Well I finally got my 2002 KTM 300EXC. I was able to ride it in Mena, Ark this weekend as I met a buddy of mine that picked it up for me. Well I have to say, me being a big fella (6'3 and 235lbs ), this bike has tons of power and the suspension actually handles my weight. It seems to have a nice smooth power curve and plenty of power when you need it.

I did notice that there was fork oil on the front end when I unloaded it from my buddies truck. I am assuming I am going to need new seals. How hard is it to replace those seals? I have done plenty on regular forks but nothing on inverted ones. On the way home I used a piece of PVC pipe to put it on the tire and under the fender so I didn't have to strap it down too hard to blow the seals anymore.

Also what should I look for as far as top end replacement? How much time on motor should I do this maintenance? Thanks for any input.............peace

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I did notice that there was fork oil on the front end when I unloaded it from my buddies truck. I am assuming I am going to need new seals.

Clean the any grit from the seals and ride it and see if it still leaks - mine usually leaks a bit when transporting but not riding - the forks probably get torqued by the tie-down straps (am going with the foot peg tie-down next)

Regarding top end - replace piston/rings gaskets if you don't know when the previous owner did so. Ater break-in - note compression, and replace top end when compression starts to go down. As a matter of maintainace - need to clean power valve once a year - alot of guys just replace rings, or piston and rings, at that point as insurance since you have the jug off anyway. Oh yea - you have to know about the X dimension (base basket thickness that governs squish) and Z dimension (piston distance from powervalve). KTMTalk and an EBAY shop manual CD are good resources.

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KTM seals are known leakers. Do as Ray said and clean them using the film method. If they still leak get Synergy seals from KTMTALK>COM and that will do it. They are easy to do with basic tools and following the instructions. I would take the top end off and clean the pv. Measure the rings and that will tell you if its worn out on top.

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