DIY Clutch Kit Replacement on KTM 300 EXC (2017-2026): Plates, Dampers, Seals, and Gear Oil Service
The KTM 300 EXC series—from the 2017 carbureted model to the TPI-equipped 2018-2026 versions—is a legend in enduro circles for its torquey 2-stroke power. However, the wet multi-plate clutch endures massive abuse from technical terrain and frequent gear changes. Symptoms like slipping, dragging, or notchy shifts signal it's time for a refresh. This guide details replacing the clutch plates, damping rubbers, crankshaft oil seals and O-rings, outer cover O-ring, while inspecting the clutch basket and cover for wear/cracks, and changing gear oil to Motorex 15W50 (0.80 l capacity See Owner Manual (p. 113); consistent across models p. 144).
Recommended every 40 hours or annually per service schedules (p. 40). Expect 2-4 hours for DIY with basic tools. Always work on a level surface with the engine cold.
Diagram positions referenced (Clutch diagram):
- Pos. 1: Outer Clutch Hub/Basket (79232201073)
- Pos. 5: Clutch Damping Rubbers (78132025100)
- Pos. 11: Friction Plates (54832011100)
- Pos. 99: Complete Clutch Kit (54832011110)
Parts You'll Need
- Clutch Kit (54832011110) - Includes plates, steels, springs
- Damping Rubbers (78132025100, Pos. 5)
- Crankshaft Oil Seal 38x52x7 (0760385273)
- Crankshaft Oil Seal 25x35x7 (0760253573)
- Outer Cover O-Ring (0770191015)
- Outer Clutch Cover Gasket (55430027000)
- Inner Clutch Cover Gasket (55430025100)
- Gear Oil Drain Plug w/ Magnet (58030021100)