2003 KTM 300 EXC Build

900 Cat

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I picked up a mountain horse skid and wanted to put on my 2003 KTM 300 EXC. I have searched around and have not found much guidance for an older 300. Wondered if anyone out there has any experience and could give me some pointers. Thanks in advance!
 
Dec 20, 2007
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Mostly everything will be the same as the new ones except yours has the potential of making more power. Your swing arm bolt is 1mm smaller so will need custom spacers and because of pds your strut will be angled slightly. Most will tell you you need a lectron -not true your 38pwk will work great and less likely to freeze up then lectron.
 
Dec 20, 2007
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Most 03 should have the fat front axle but better check, the 300 was a year late on some upgrades that year. If it is fat the Fit kit for the 07 will fit your fork and you can possibly wrap a mm of beer can inside the sa spacers if you can't custom build them.
 

900 Cat

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Thanks for the information and support eric83930! I should have the fit kit here by week‘s end. The skid came with a TSS as well. I have seen some threads about this with the PDS suspension. But nothing definitive. Anyone done the TSS with the older PDS suspension?
 

HalfBrit

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Thanks for the information and support eric83930! I should have the fit kit here by week‘s end. The skid came with a TSS as well. I have seen some threads about this with the PDS suspension. But nothing definitive. Anyone done the TSS with the older PDS suspension?
Shouldn't be any difference. PDS shocks can be swapped out through all the years I believe. I've swapped 2001 shock with 2009 for sure.
 

900 Cat

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Writting to update and ask for help. Timberuled did not have listed a fit kit for my specific model of Bike; so ordered a fit kit for a 2003 450 EXC. Putting it together and the swing arm bolt is apparently smaller and looks like I will have to have the bushings custom machined. Has anyone out their done this and have the specs on the bushings? Please Help!
 

900 Cat

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So I have had go have swing arm bushings made and should have them tomorrow. I am putting on some AME heated grips, but am worried the system on my EXC may not have enough juice. Says its 40 watts and the AME says they need 45 watts. Any used the AME on a two stroke? Any issues?
 
Dec 20, 2007
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Yup that's what I use. Just wire them in parallel straight to the stator without the control box they come with. Don't use any regulator. They will be just warm enough with gauntlets to wear light gloves.
 

900 Cat

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My EXC already has a thermostat. I have not been able to find the technical data to know what the temp is though. I see on the carb heater, eric82930 has experience that the 38 mm peak is not as prone to freezing. I will take out and sort that out. Thanks for all the help!
 
Dec 20, 2007
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The thermostat on that year only shuts off the right radiator so on deep days you need to block of the left radiator. I just cut a sheet of plastic and slide it between the louvers and the radiator.
 

900 Cat

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I finally got my custom bushings to hook in the skid. Now dealing with chain issues. Kit had changed rear gearing in skid to 18 back 18 top of case from the 17/17. I have a 13 front sprocket and 70 link chain is too short and 72 link is too long. Looks like a half link would do it. Other option is putting 14 front sprocket, but wanted to keep 13 front for lower gearing. What has been your guys experience with this mountain horse skid and the chain length/gearing. Your assistance will be greatly appreciated.
 

chumbilly1

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Such a PIA on MT horse. If you have 18 on top 14t wont be far off. TS wanted us to use 12t in the day, probably just to make the chain fit.
 

900 Cat

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The chain was a PIA. I decided to just go back to the 17, then the 70 tooth worked. When I opened up the case, they had gone to a 16t on top with stock 17 on bottom. However, chain tensioner was out all the way and still really loose. So I went back to the stock 17/17 in the case. I will just have to see how the gearing is and go from there. Attached a picture of it finally all together. The 13 on the number plates is for Lucky 13, because I totally rebuilt it in 2016 and it was its 13th birthday. Hence, lucky 13! I will see how she does! Thanks for all the great advice!
 

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900 Cat

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I was able to take it out for a bit Wednesday night. Gearing seemed fine and should be good in steep and trees. Thanks for the advice.
 
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