2012 KTM 350 EXC-F Service & Repair Manual

REPAIR MANUAL 2012 350 EXC‑F EU 350 EXC‑F AUS 350 EXC‑F SIX DAYS EU 350 XCF‑W USA 350 EXC‑F USA Art. no. 3206111en

INTRODUCTION 1 INTRODUCTION It is important that you read this repair manual carefully and completely before the start of work. Only use ORIGINAL KTM SPARE PARTS. This vehicle can only fulfill the demands placed on it in the long run if the specified service work is performed regularly by qualified experts. The repair manual was written to correspond to the most current state of this model series. We reserve the right to make changes in the interest of technical advancement without, at the same time, updating this repair manual. We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here. It is assumed that repair work will be performed by a fully trained mechanic. All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as for printing and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery. © 2011 KTM-Sportmotorcycle AG, Mattighofen Austria All rights reserved Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products. Issued by: TÜV Management Service KTM-Sportmotorcycle AG 5230 Mattighofen, Austria

TABLE OF CONTENTS 2 TABLE OF CONTENTS MEANS OF REPRESENTATION ............................................ 6 IMPORTANT NOTES ............................................................ 7 SERIAL NUMBERS.............................................................. 8 Chassis number ............................................................... 8 Type label ....................................................................... 8 Key number (All EXC‑F models) ........................................ 8 Engine number................................................................ 9 Fork part number............................................................. 9 Shock absorber part number ............................................. 9 MOTORCYCLE................................................................... 10 Raising the motorcycle with the lift stand ........................ 10 Removing the motorcycle from the lift stand .................... 10 Starting ........................................................................ 10 Starting the motorcycle for a check ................................. 11 01/FORK, TRIPLE CLAMP.................................................. 12 Adjusting the compression damping of the fork ................ 12 Adjusting the rebound damping of the fork....................... 12 Adjusting the spring preload of the fork ........................... 12 Bleeding fork legs .......................................................... 13 Cleaning the dust boots of the fork legs ........................... 13 Loosening the fork protector ........................................... 14 Positioning the fork protection ........................................ 14 Removing the fork legs................................................... 14 Installing the fork legs ................................................... 15 Removing the fork protector............................................ 16 Installing the fork protector ............................................ 16 Performing a fork service ................................................ 16 Disassembling the fork legs ............................................ 17 Cartridge disassembly .................................................... 20 Disassembling the compression damping fitting ............... 21 Checking the fork legs.................................................... 22 Assembling the compression damping fitting.................... 23 Assembling the cartridge ................................................ 24 Assembling the fork legs ................................................ 26 Greasing the steering head bearing.................................. 30 Removing the lower triple clamp (EXC-F SIX DAYS) .......... 30 Installing the lower triple clamp (EXC-F SIX DAYS) ........... 31 Removing the lower triple clamp (EXC‑F EU/AUS/USA, XCF‑W) ......................................................................... 32 Installing the lower triple clamp (EXC‑F EU/AUS/USA, XCF‑W) ......................................................................... 33 Checking the steering head bearing play .......................... 35 Adjusting the play of the steering head bearing (EXC-F SIX DAYS) .................................................................... 35 Adjusting the play of the steering head bearing (EXC‑F EU/AUS/USA, XCF‑W) ......................................... 36 02/HANDLEBAR, INSTRUMENTS....................................... 37 Handlebar position ........................................................ 37 Adjusting handlebar position .......................................... 37 Adjusting the basic position of the clutch lever................. 37 Checking the throttle cable routing.................................. 38 Checking the play in the throttle cable............................. 38 Adjusting the play in the throttle cable ............................ 39 03/FRAME ........................................................................ 40 Removing the engine guard (EXC‑F AUS, EXC-F SIX DAYS) .......................................................................... 40 Installing the engine guard (EXC‑F AUS, EXC-F SIX DAYS) .......................................................................... 40 04/SHOCK ABSORBER, SWINGARM................................... 41 Adjusting the high-speed compression damping of the shock absorber .............................................................. 41 Adjusting the low-speed compression damping of the shock absorber .............................................................. 41 Adjusting the rebound damping of the shock absorber....... 42 Measuring rear wheel sag unloaded ................................. 42 Checking the static sag of the shock absorber .................. 42 Checking the riding sag of the shock absorber .................. 43 Adjusting the spring preload of the shock absorber ........... 43 Adjusting the riding sag ................................................. 44 Removing the shock absorber ......................................... 44 Installing the shock absorber .......................................... 44 Servicing the shock absorber .......................................... 45 Removing the spring ...................................................... 45 Disassembling the damper ............................................. 46 Disassembling the piston rod .......................................... 47 Disassembling the seal ring retainer ................................ 48 Replacing the pilot bushing ............................................ 49 Checking the damper ..................................................... 50 Disassembling the rebound adjuster ................................ 50 Removing the heim joint ................................................ 51 Installing the heim joint ................................................. 52 Assembling the rebound adjuster .................................... 53 Assembling the seal ring retainer .................................... 53 Assembling the piston rod .............................................. 54 Assembling the damper .................................................. 55 Bleeding and filling the damper ...................................... 58 Filling the damper with nitrogen ..................................... 60 Installing the spring ....................................................... 61 Changing the heim joint ................................................. 62 05/EXHAUST .................................................................... 64 Removing the manifold .................................................. 64 Installing the manifold ................................................... 64 Removing main silencer ................................................. 65 Installing the main silencer ............................................ 65 Changing the glass fiber yarn filling of the main silencer ... 65 06/AIR FILTER.................................................................. 67 Removing the air filter box lid ......................................... 67 Installing the air filter box lid.......................................... 67 Removing the air filter ................................................... 67 Installing the air filter .................................................... 67 Cleaning the air filter and air filter box ............................ 68 07/FUEL TANK, SEAT, TRIM.............................................. 69 Opening filler cap .......................................................... 69 Closing filler cap ........................................................... 69 Removing the seat ......................................................... 69 Mounting the seat ......................................................... 70 Removing the fuel tank .................................................. 70 Installing the fuel tank ................................................... 71 Changing the fuel screen ................................................ 72 Changing the fuel filter .................................................. 73 Changing the fuel pump ................................................. 75 Checking the fuel pressure ............................................. 76 08/MASK, FENDER ........................................................... 78 Removing the front fender .............................................. 78 Installing the front fender ............................................... 78 Removing headlight mask with headlight ......................... 78 Refitting the headlight mask with the headlight ................ 78 09/FRONT WHEEL ............................................................ 80 Removing the front wheel ............................................... 80 Installing the front wheel................................................ 80 Checking the brake discs................................................ 81 Removing the front brake disc ........................................ 81 Installing the front brake disc ......................................... 82

TABLE OF CONTENTS 3 Checking the tire condition............................................. 82 Checking tire air pressure ............................................... 82 Checking spoke tension.................................................. 83 10/REAR WHEEL .............................................................. 84 Removing the rear wheel ................................................ 84 Installing the rear wheel ................................................. 84 Removing the rear brake disc.......................................... 85 Installing the rear brake disc .......................................... 85 Checking the chain tension ............................................ 85 Adjusting the chain tension ............................................ 86 Adjusting the chain guide............................................... 87 Checking the chain, rear sprocket, engine sprocket and chain guide................................................................... 87 Checking for chain dirt accumulation .............................. 89 Cleaning the chain......................................................... 89 11/WIRING HARNESS, BATTERY ....................................... 90 Removing the main fuse................................................. 90 Installing the main fuse ................................................. 90 Changing the fuses of individual power consumers............ 90 Changing the fuse of the radiator fan (EXC-F SIX DAYS) .... 91 Removing the battery ..................................................... 92 Installing the battery ...................................................... 92 Charging the battery ...................................................... 92 13/BRAKE SYSTEM........................................................... 94 Checking the front brake linings...................................... 94 Changing the front brake linings ..................................... 94 Checking free travel of hand brake lever........................... 96 Adjusting the basic position of the hand brake lever (XCF‑W) ........................................................................ 96 Adjusting free travel of hand brake lever (All EXC‑F models) ........................................................................ 96 Checking the front brake fluid level ................................. 97 Adding front brake fluid ................................................. 97 Changing the front brake fluid ........................................ 98 Checking the rear brake linings ....................................... 99 Changing the rear brake linings ....................................... 99 Checking the free travel of foot brake lever ..................... 101 Adjusting the basic position of the foot brake lever ......... 101 Checking the rear brake fluid level ................................ 102 Adding brake fluid to the rear brake circuit .................... 102 Changing the rear brake fluid........................................ 103 14/LIGHTING SYSTEM, INSTRUMENTS ........................... 105 Adjusting the speedometer functions ............................. 105 Setting kilometers or miles ........................................... 105 Activating the additional functions ................................ 106 Setting the wheel circumference ................................... 106 Setting the clock ......................................................... 107 Checking the headlight setting ...................................... 107 Adjusting the headlight range ....................................... 108 30/ENGINE..................................................................... 109 Removing the engine ................................................... 109 Installing the engine .................................................... 113 30/DISASSEMBLING THE ENGINE................................... 118 Preparations................................................................ 118 Removing the clutch push rod ...................................... 118 Removing the spacer ................................................... 118 Draining the engine oil ................................................. 118 Removing the oil filter.................................................. 119 Removing the spark plug .............................................. 119 Removing the valve cover ............................................. 119 Removing the kick starter ............................................. 120 Removing the alternator cover ....................................... 120 Removing the torque limiter ......................................... 120 Positioning the engine at ignition top dead center........... 121 Removing the timing chain tensioner ............................. 121 Removing the camshaft ................................................ 121 Removing the cylinder head.......................................... 122 Removing the piston .................................................... 122 Removing the starter drive ............................................ 123 Removing the suction pump ......................................... 124 Removing the water pump wheel ................................... 125 Removing the clutch cover ........................................... 125 Removing the clutch discs............................................ 125 Removing the outer clutch hub ..................................... 126 Removing the intermediate kick starter gear ................... 127 Removing the intermediate kick starter gear ................... 127 Removing the shift shaft .............................................. 127 Removing the shift drum locating unit ........................... 127 Removing the locking lever ........................................... 127 Removing the force pump ............................................ 128 Removing the primary gear ........................................... 128 Removing the timing chain ........................................... 129 Removing the spacer ................................................... 129 Removing the left section of the engine case .................. 129 Removing the shift rails ............................................... 130 Removing the shift drum .............................................. 130 Removing the shift forks .............................................. 130 Removing the transmission shafts ................................. 130 Removing the crankshaft .............................................. 131 30/ENGINE - WORK ON THE INDIVIDUAL PARTS ............. 132 Work on the right section of the engine case .................. 132 Working on the left section of the engine case ................ 133 Work on the clutch cover .............................................. 134 Checking the oil pressure regulator valve........................ 135 Checking the lubrication system.................................... 136 Removing the crankshaft bearing inner race ................... 136 Installing the crankshaft bearing inner race .................... 136 Changing the connecting rod, conrod bearing and crank pin ............................................................................. 137 Checking the crankshaft run-out at the bearing pin ......... 138 Removing the drive wheel of the balancer shaft .............. 138 Installing the drive wheel of the balancer shaft ............... 138 Cylinder - Nikasil ® coating ............................................ 139 Checking/measuring the cylinder ................................... 139 Checking/measuring the piston ..................................... 139 Measuring the piston/cylinder mounting clearance .......... 140 Checking the piston ring end gap .................................. 140 Changing the camshaft bearing ..................................... 141 Checking the camshafts ............................................... 141 Checking the pivot points of the camshafts .................... 141 Removing the valves .................................................... 142 Checking the valves ..................................................... 143 Checking the valve springs ........................................... 144 Checking the valve spring seat ...................................... 144 Checking the cam levers .............................................. 144 Checking the cylinder head .......................................... 144 Installing the valves ..................................................... 145 Checking the freewheel ................................................ 146 Preassembling the kick starter shaft .............................. 146 Checking the electric starter drive ................................. 147 Checking the timing assembly ...................................... 148 Preparing the timing chain tensioner for installation ....... 149 Checking the clutch ..................................................... 149 Checking the shift mechanism ...................................... 151

TABLE OF CONTENTS 4 Preassembling the shift shaft........................................ 152 Disassembling the main shaft ....................................... 152 Disassembling the countershaft .................................... 153 Checking the transmission............................................ 153 Assembling the main shaft ........................................... 155 Assembling the countershaft......................................... 155 30/ENGINE ASSEMBLY ................................................... 157 Installing the crankshaft............................................... 157 Installing the transmission shafts .................................. 157 Installing the shift forks ............................................... 157 Installing the shift drum............................................... 158 Installing the shift rails ................................................ 158 Installing the left engine case ....................................... 158 Installing the spacer .................................................... 159 Installing the timing chain............................................ 159 Installing the primary gear ............................................ 160 Installing the force pump ............................................. 160 Installing the suction pump .......................................... 161 Installing the locking lever............................................ 162 Installing the shift drum locating unit ............................ 162 Installing the shift shaft ............................................... 162 Installing the intermediate kick starter gear.................... 162 Installing the kick starter shaft ..................................... 162 Installing the outer clutch hub ...................................... 163 Installing the clutch discs ............................................ 164 Installing the clutch cover ............................................ 165 Installing the water pump cover .................................... 165 Installing the starter drive ............................................ 166 Installing the piston ..................................................... 167 Installing the cylinder head .......................................... 168 Installing the camshafts ............................................... 169 Checking the valve timing ............................................ 170 Adjusting the valve timing ............................................ 170 Installing the timing chain tensioner ............................. 171 Checking the valve clearance ........................................ 172 Adjusting the valve clearance........................................ 173 Installing the torque limiter .......................................... 173 Installing the alternator cover ....................................... 173 Installing the kick starter.............................................. 174 Installing the valve cover .............................................. 174 Installing the spark plug............................................... 175 Installing the oil filter .................................................. 175 Installing the oil screen ................................................ 175 Installing the spacer .................................................... 176 Installing the clutch push rod ....................................... 176 Removing the engine from the work stand ...................... 176 32/CLUTCH .................................................................... 177 Checking the fluid level of the hydraulic clutch .............. 177 Changing the hydraulic clutch fluid ............................... 177 35/WATER PUMP, COOLING SYSTEM .............................. 178 Cooling system ............................................................ 178 Checking the antifreeze and coolant level ...................... 178 Checking the coolant level ............................................ 179 Draining the coolant .................................................... 179 Refilling coolant .......................................................... 180 38/LUBRICATION SYSTEM .............................................. 181 Oil circuit ................................................................... 181 Checking the engine oil level ........................................ 181 Changing the engine oil and oil filter, cleaning the oil screen ........................................................................ 182 Adding engine oil ........................................................ 184 Checking the engine oil pressure ................................... 184 39/IGNITION SYSTEM ..................................................... 186 Ignition coil - checking the secondary winding................ 186 Checking the spark plug connector ................................ 186 Alternator - checking the stator winding ......................... 186 Removing the stator and ignition pulse generator ............ 187 Installing the stator and ignition pulse generator............. 188 40/ELECTRIC STARTER................................................... 189 Checking the starter motor ........................................... 189 41/THROTTLE VALVE BODY............................................. 190 Throttle position sensor circuit A - checking the basic settings ...................................................................... 190 Throttle position sensor - adjusting the basic settings...... 190 TECHNICAL DATA - ENGINE ............................................ 192 Capacity - engine oil .................................................... 192 Capacity - coolant ........................................................ 192 TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE ......................................................................... 193 TECHNICAL DATA - ENGINE TIGHTENING TORQUES ........ 194 TECHNICAL DATA - CHASSIS .......................................... 196 Lighting equipment ..................................................... 197 Tires .......................................................................... 197 Capacity - fuel............................................................. 197 TECHNICAL DATA - FORK................................................ 198 TECHNICAL DATA - SHOCK ABSORBER ........................... 199 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 200 CLEANING, CARE ........................................................... 201 Cleaning the motorcycle ............................................... 201 Checks and maintenance steps for winter operation ........ 202 STORAGE ....................................................................... 203 Storage....................................................................... 203 Preparing for use after storage ...................................... 203 SERVICE SCHEDULE....................................................... 204 Service schedule ......................................................... 204 Service work (as additional order) .................................. 205 WIRING DIAGRAM .......................................................... 206 Page 1 of 8 (EXC‑F EU, EXC-F SIX DAYS) ...................... 206 Page 2 of 8 (EXC‑F EU, EXC-F SIX DAYS) ...................... 208 Page 3 of 8 (EXC‑F EU, EXC-F SIX DAYS) ...................... 210 Page 4 of 8 (EXC‑F EU, EXC-F SIX DAYS) ...................... 212 Page 5 of 8 (EXC‑F EU, EXC-F SIX DAYS) ...................... 214 Page 6 of 8 (EXC‑F EU, EXC-F SIX DAYS) ...................... 216 Page 7 of 8 (EXC‑F EU, EXC-F SIX DAYS) ...................... 218 Page 8 of 8 (EXC‑F EU, EXC-F SIX DAYS) ...................... 220 Page 1 of 8 (EXC‑F AUS) ............................................. 222 Page 2 of 8 (EXC‑F AUS) ............................................. 224 Page 3 of 8 (EXC‑F AUS) ............................................. 226 Page 4 of 8 (EXC‑F AUS) ............................................. 228 Page 5 of 8 (EXC‑F AUS) ............................................. 230 Page 6 of 8 (EXC‑F AUS) ............................................. 232 Page 7 of 8 (EXC‑F AUS) ............................................. 234 Page 8 of 8 (EXC‑F AUS) ............................................. 236 Page 1 of 8 (EXC-F USA) ............................................. 238 Page 2 of 8 (EXC-F USA) ............................................. 240 Page 3 of 8 (EXC-F USA) ............................................. 242 Page 4 of 8 (EXC-F USA) ............................................. 244 Page 5 of 8 (EXC-F USA) ............................................. 246 Page 6 of 8 (EXC-F USA) ............................................. 248 Page 7 of 8 (EXC-F USA) ............................................. 250 Page 8 of 8 (EXC-F USA) ............................................. 252 Page 1 of 7 (XCF‑W) .................................................... 254 Page 2 of 7 (XCF‑W) .................................................... 256 Page 3 of 7 (XCF‑W) .................................................... 258

TABLE OF CONTENTS 5 Page 4 of 7 (XCF‑W) .................................................... 260 Page 5 of 7 (XCF‑W) .................................................... 262 Page 6 of 7 (XCF‑W) .................................................... 264 Page 7 of 7 (XCF‑W) .................................................... 266 SUBSTANCES ................................................................. 268 AUXILIARY SUBSTANCES................................................ 270 SPECIAL TOOLS.............................................................. 272 STANDARDS ................................................................... 285 INDEX ............................................................................ 286

MEANS OF REPRESENTATION 6 Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). Indicates a page reference (more information is provided on the specified page). Indicates information with more details or tips. Indicates the result of a testing step. Denotes a voltage measurement. Denotes a current measurement. Denotes a resistance measurement. Formats used The typographical formats used in this document are explained below. Proprietary name Identifies a proprietary name. Name ® Identifies a protected name. Brand™ Identifies a trademark.

IMPORTANT NOTES 7 Warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claim can be honored for damage resulting from manipulation and/or other changes to the vehicle. Fuel, oils, etc. You should use the fuels, oils and greases according to specifications as listed in the repair manual. Spare parts, accessories Only use spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other products and any resulting damage or loss. You will find the current KTM PowerParts for your vehicle on the KTM website. International KTM Website: http://www.ktm.com Work rules Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in parentheses. Ex: valve spring compressor (59029019000) During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced by new parts. If thread lock (e.g. Loctite ® ) is used for screw connections, be sure to comply with the manufacturer's specific instructions on its usage. Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or worn parts. Ensure that the vehicle is safe to operate after completing repair and maintenance work. Notes/warnings Pay close attention to the notes/warnings. Info Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are miss- ing, you or others may not recognize potential hazards and may therefore be injured. Grades of risks Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Identifies a danger that may lead to minor injuries if the appropriate measures are not taken. Note Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken. Warning Identifies a danger that will lead to environmental damage if the appropriate measures are not taken. Repair manual – It is imperative that you read this owner's manual carefully and completely before the start of work. It contains useful information and many tips on how to repair and maintain your vehicle. – This manual assumes that the necessary special KTM tools and workplace and workshop equipment are available.

SERIAL NUMBERS 8 3.1 Chassis number C00125-10 The chassis number 1 is stamped on the steering head on the right. 3.2 Type label 101290-10 (XCF‑W, EXC‑F EU/AUS, EXC-F SIX DAYS) The type label 1 is fixed to the front of the steering head. 101477-10 (EXC-F USA) The type label USA 1 is fixed to the front of the steering head. 101478-10 (EXC-F USA) The type label Canada 2 is fixed to the front of the front pipe. 3.3 Key number (All EXC‑F models) 500125-10 (EXC‑F EU/AUS, EXC-F SIX DAYS) The key number 1 for the steering lock is stamped onto the key connector.

2012 KTM 350 EXC-F Service & Repair Manual

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