KTM 350 EXC-F XCF-W (2012) - Service Manual - Manual de Taller - Manuel de Reparation - Manuale di Officina - Reparaturanleitung

KTM 350 EXC-F XCF-W (2012) - REPAIR MANUAL - REPARACION - REPARATION - RIPARAZIONE

- Multilanguage (English, Español, Deutsch, Français, Italiano) Repair Manual, to motorcycles KTM 350 EXC-F XCF-W (2012).


CONTENTS:

MEANS OF REPRESENTATION
IMPORTANT NOTES
SERIAL NUMBERS
- Chassis number
- Type label
- Key number (All EXC F models)
- Engine number
- Fork part number
- Shock absorber part number
MOTORCYCLE
- Raising the motorcycle with the lift stand
- Removing the motorcycle from the lift stand
- Starting
- Starting the motorcycle for a check
01/FORK, TRIPLE CLAMP
- Adjusting the compression damping of the fork
- Adjusting the rebound damping of the fork
- Adjusting the spring preload of the fork
- Bleeding fork legs
- Cleaning the dust boots of the fork legs
- Loosening the fork protector
- Positioning the fork protection
- Removing the fork legs
- Installing the fork legs
- Removing the fork protector
- Installing the fork protector
- Performing a fork service
- Disassembling the fork legs
- Cartridge disassembly
- Disassembling the compression damping fitting
- Checking the fork legs
- Assembling the compression damping fitting
- Assembling the cartridge
- Assembling the fork legs
- Greasing the steering head bearing
- Removing the lower triple clamp (EXC-F SIX DAYS)
- Installing the lower triple clamp (EXC-F SIX DAYS)
- Removing the lower triple clamp (EXC F EU/AUS/USA, XCF W)
- Installing the lower triple clamp (EXC F EU/AUS/USA, XCF W)
- Checking the steering head bearing play
- Adjusting the play of the steering head bearing (EXC-F SIX DAYS)
- Adjusting the play of the steering head bearing (EXC F EU/AUS/USA, XCF W)
02/HANDLEBAR, INSTRUMENTS
- Handlebar position
- Adjusting handlebar position
- Adjusting the basic position of the clutch lever
- Checking the throttle cable routing
- Checking the play in the throttle cable
- Adjusting the play in the throttle cable
03/FRAME
- Removing the engine guard (EXC F AUS, EXC-F SIX DAYS)
- Installing the engine guard (EXC F AUS, EXC-F SIX DAYS)
04/SHOCK ABSORBER, SWINGARM
- Adjusting the high-speed compression damping of the shock absorber
- Adjusting the low-speed compression damping of the shock absorber
- Adjusting the rebound damping of the shock absorber
- Measuring rear wheel sag unloaded
- Checking the static sag of the shock absorber
- Checking the riding sag of the shock absorber
- Adjusting the spring preload of the shock absorber
- Adjusting the riding sag
- Removing the shock absorber
- Installing the shock absorber
- Servicing the shock absorber
- Removing the spring
- Disassembling the damper
- Disassembling the piston rod
- Disassembling the seal ring retainer
- Replacing the pilot bushing
- Checking the damper
- Disassembling the rebound adjuster
- Removing the heim joint
- Installing the heim joint
- Assembling the rebound adjuster
- Assembling the seal ring retainer
- Assembling the piston rod
- Assembling the damper
- Bleeding and filling the damper
- Filling the damper with nitrogen
- Installing the spring
- Changing the heim joint
05/EXHAUST
- Removing the manifold
- Installing the manifold
- Removing main silencer
- Installing the main silencer
- Changing the glass fiber yarn filling of the main silencer
06/AIR FILTER
- Removing the air filter box lid
- Installing the air filter box lid
- Removing the air filter
- Installing the air filter
- Cleaning the air filter and air filter box
07/FUEL TANK, SEAT, TRIM
- Opening filler cap
- Closing filler cap
- Removing the seat
- Mounting the seat
- Removing the fuel tank
- Installing the fuel tank
- Changing the fuel screen
- Changing the fuel filter
- Changing the fuel pump
- Checking the fuel pressure
08/MASK, FENDER
- Removing the front fender
- Installing the front fender
- Removing headlight mask with headlight
- Refitting the headlight mask with the headlight
09/FRONT WHEEL
- Removing the front wheel
- Installing the front wheel
- Checking the brake discs
- Removing the front brake disc
- Installing the front brake disc
- Checking the tire condition
- Checking tire air pressure
- Checking spoke tension
10/REAR WHEEL
- Removing the rear wheel
- Installing the rear wheel
- Removing the rear brake disc
- Installing the rear brake disc
- Checking the chain tension
- Adjusting the chain tension
- Adjusting the chain guide
- Checking the chain, rear sprocket, engine sprocket and chain guide
- Checking for chain dirt accumulation
- Cleaning the chain
11/WIRING HARNESS, BATTERY
- Removing the main fuse
- Installing the main fuse
- Changing the fuses of individual power consumers
- Changing the fuse of the radiator fan (EXC-F SIX DAYS)
- Removing the battery
- Installing the battery
- Charging the battery
13/BRAKE SYSTEM
- Checking the front brake linings
- Changing the front brake linings
- Checking free travel of hand brake lever
- Adjusting the basic position of the hand brake lever (XCF W)
- Adjusting free travel of hand brake lever (All EXC F models)
- Checking the front brake fluid level
- Adding front brake fluid
- Changing the front brake fluid
- Checking the rear brake linings
- Changing the rear brake linings
- Checking the free travel of foot brake lever
- Adjusting the basic position of the foot brake lever
- Checking the rear brake fluid level
- Adding brake fluid to the rear brake circuit
- Changing the rear brake fluid
14/LIGHTING SYSTEM, INSTRUMENTS
- Adjusting the speedometer functions
- Setting kilometers or miles
- Activating the additional functions
- Setting the wheel circumference
- Setting the clock
- Checking the headlight setting
- Adjusting the headlight range
30/ENGINE
- Removing the engine
- Installing the engine
30/DISASSEMBLING THE ENGINE
- Preparations
- Removing the clutch push rod
- Removing the spacer
- Draining the engine oil
- Removing the oil filter
- Removing the spark plug
- Removing the valve cover
- Removing the kick starter
- Removing the alternator cover
- Removing the torque limiter
- Positioning the engine at ignition top dead center
- Removing the timing chain tensioner
- Removing the camshaft
- Removing the cylinder head
- Removing the piston
- Removing the starter drive
- Removing the suction pump
- Removing the water pump wheel
- Removing the clutch cover
- Removing the clutch discs
- Removing the outer clutch hub
- Removing the intermediate kick starter gear
- Removing the intermediate kick starter gear
- Removing the shift shaft
- Removing the shift drum locating unit
- Removing the locking lever
- Removing the force pump
- Removing the primary gear
- Removing the timing chain
- Removing the spacer
- Removing the left section of the engine case
- Removing the shift rails
- Removing the shift drum
- Removing the shift forks
- Removing the transmission shafts
- Removing the crankshaft
30/ENGINE - WORK ON THE INDIVIDUAL PARTS
- Work on the right section of the engine case
- Working on the left section of the engine case
- Work on the clutch cover
- Checking the oil pressure regulator valve
- Checking the lubrication system
- Removing the crankshaft bearing inner race
- Installing the crankshaft bearing inner race
- Changing the connecting rod, conrod bearing and crank pin
- Checking the crankshaft run-out at the bearing pin
- Removing the drive wheel of the balancer shaft
- Installing the drive wheel of the balancer shaft
- Cylinder - Nikasil® coating
- Checking/measuring the cylinder
- Checking/measuring the piston
- Measuring the piston/cylinder mounting clearance
- Checking the piston ring
- Changing the camshaft bearing
- Checking the camshafts
- Checking the pivot points of the camshafts
- Removing the valves
- Checking the valves
- Checking the valve springs
- Checking the valve spring seat
- Checking the cam levers
- Checking the cylinder head
- Installing the valves
- Checking the freewheel
- Preassembling the kick starter shaft
- Checking the electric starter drive
- Checking the timing assembly
- Preparing the timing chain tensioner for installation
- Checking the clutch
- Checking the shift mechanism
- Preassembling the shift shaft
- Disassembling the main shaft
- Disassembling the countershaft
- Checking the transmission
- Assembling the main shaft
- Assembling the countershaft
30/ENGINE ASSEMBLY
- Installing the crankshaft
- Installing the transmission shafts
- Installing the shift forks
- Installing the shift drum
- Installing the shift rails
- Installing the left engine case
- Installing the spacer
- Installing the timing chain
- Installing the primary gear
- Installing the force pump
- Installing the suction pump
- Installing the locking lever
- Installing the shift drum locating unit
- Installing the shift shaft
- Installing the intermediate kick starter gear
- Installing the kick starter shaft
- Installing the outer clutch hub
- Installing the clutch discs
- Installing the clutch cover
- Installing the water pump cover
- Installing the starter drive
- Installing the piston
- Installing the cylinder head
- Installing the camshafts
- Checking the valve timing
- Adjusting the valve timing
- Installing the timing chain tensioner
- Checking the valve clearance
- Adjusting the valve clearance
- Installing the torque limiter
- Installing the alternator cover
- Installing the kick starter
- Installing the valve cover
- Installing the spark plug
- Installing the oil filter
- Installing the oil screen
- Installing the spacer
- Installing the clutch push rod
- Removing the engine from the work stand
32/CLUTCH
- Checking the fluid level of the hydraulic clutch
- Changing the hydraulic clutch fluid
35/WATER PUMP, COOLING SYSTEM
- Cooling system
- Checking the antifreeze and coolant level
- Checking the coolant level
- Draining the coolant
- Refilling coolant
38/LUBRICATION SYSTEM
- Oil circuit
- Checking the engine oil level
- Changing the engine oil and oil filter, cleaning the oil screen
- Adding engine oil
- Checking the engine oil pressure
39/IGNITION SYSTEM
- Ignition coil - checking the secondary winding
- Checking the spark plug connector
- Alternator - checking the stator winding
- Removing the stator and ignition pulse generator
- Installing the stator and ignition pulse generator
40/ELECTRIC STARTER
- Checking the starter motor
41/THROTTLE VALVE BODY
- Throttle position sensor circuit A - checking the basic settings
- Throttle position sensor - adjusting the basic settings
TECHNICAL DATA - ENGINE
- Capacity - engine oil
- Capacity - coolant
TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE
TECHNICAL DATA - ENGINE TIGHTENING TORQUES
TECHNICAL DATA - CHASSIS
- Lighting equipment
- Tires
- Capacity - fuel
TECHNICAL DATA - FORK
TECHNICAL DATA - SHOCK ABSORBER
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES
CLEANING, CARE
- Cleaning the motorcycle
- Checks and maintenance steps for winter operation
STORAGE
- Storage
- Preparing for use after storage
SERVICE SCHEDULE
- Service schedule
- Service work (as additional order)
WIRING DIAGRAM
- Page 1 of 8 (EXC F EU, EXC-F SIX DAYS)
- Page 2 of 8 (EXC F EU, EXC-F SIX DAYS)
- Page 3 of 8 (EXC F EU, EXC-F SIX DAYS)
- Page 4 of 8 (EXC F EU, EXC-F SIX DAYS)
- Page 5 of 8 (EXC F EU, EXC-F SIX DAYS)
- Page 6 of 8 (EXC F EU, EXC-F SIX DAYS)
- Page 7 of 8 (EXC F EU, EXC-F SIX DAYS)
- Page 8 of 8 (EXC F EU, EXC-F SIX DAYS)
- Page 1 of 8 (EXC F AUS)
- Page 2 of 8 (EXC F AUS)
- Page 3 of 8 (EXC F AUS)
- Page 4 of 8 (EXC F AUS)
- Page 5 of 8 (EXC F AUS)
- Page 6 of 8 (EXC F AUS)
- Page 7 of 8 (EXC F AUS)
- Page 8 of 8 (EXC F AUS)
- Page 1 of 8 (EXC-F USA)
- Page 2 of 8 (EXC-F USA)
- Page 3 of 8 (EXC-F USA)
- Page 4 of 8 (EXC-F USA)
- Page 5 of 8 (EXC-F USA)
- Page 6 of 8 (EXC-F USA)
- Page 7 of 8 (EXC-F USA)
- Page 8 of 8 (EXC-F USA)
- Page 1 of 7 (XCF W)
- Page 2 of 7 (XCF W)
- Page 3 of 7 (XCF W)
- Page 4 of 7 (XCF W)
- Page 5 of 7 (XCF W)
- Page 6 of 7 (XCF W)
- Page 7 of 7 (XCF W)
SUBSTANCES
AUXILIARY SUBSTANCES
SPECIAL TOOLS
STANDARDS
INDEX