KTM 350 EXC-F EU 2012

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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

Main Page

Table of Contents4
Means of Representation8
Important Notes9
Serial Numbers10
- Chassis Number10
- Type Label10
- Key Number (All EXC-F Models)10
- Engine Number11
- Fork Part Number11
- Shock Absorber Part Number11
Motorcycle12
- Raising the Motorcycle with the Lift Stand12
- Removing the Motorcycle from the Lift Stand12
- Starting12
- Starting the Motorcycle for a Check13
01/Fork, Triple Clamp14
- Adjusting the Compression Damping of the Fork14
- Adjusting the Rebound Damping of the Fork14
- Adjusting the Spring Preload of the Fork14
- Bleeding Fork Legs15
- Cleaning the Dust Boots of the Fork Legs15
- Loosening the Fork Protector16
- Positioning the Fork Protection16
- Removing the Fork Legs16
- Installing the Fork Legs17
- Removing the Fork Protector18
- Installing the Fork Protector18
- Performing a Fork Service18
- Disassembling the Fork Legs19
- Cartridge Disassembly22
- Disassembling the Compression Damping Fitting23
- Checking the Fork Legs24
- Assembling the Compression Damping Fitting25
- Assembling the Cartridge26
- Assembling the Fork Legs28
- Greasing the Steering Head Bearing32
- Removing the Lower Triple Clamp (EXC-F SIX DAYS)32
- Installing the Lower Triple Clamp (EXC-F SIX DAYS)33
- Removing the Lower Triple Clamp (EXC-F EU/AUS/USA, XCF-W)34
- Installing the Lower Triple Clamp (EXC-F EU/AUS/USA, XCF-W)35
- Checking the Steering Head Bearing Play37
- Adjusting the Play of the Steering Head Bearing (EXC-FSIX DAYS)37
- Adjusting the Play of the Steering Head Bearing (EXC-F EU/AUS/USA, XCF-W)38
02/Handlebar, Instruments39
- Handlebar Position39
- Adjusting Handlebar Position39
- Adjusting the Basic Position of the Clutch Lever39
- Checking the Throttle Cable Routing40
- Checking the Play in the Throttle Cable40
- Adjusting the Play in the Throttle Cable41
03/Frame42
- Removing the Engine Guard (EXC-F AUS, EXC-F SIX DAYS)42
- Installing the Engine Guard (EXC-F AUS, EXC-F SIX DAYS)42
04/Shock Absorber, Swingarm43
- Adjusting the High-Speed Compression Damping of the Shock Absorber43
- Adjusting the Low-Speed Compression Damping of the Shock Absorber43
- Adjusting the Rebound Damping of the Shock Absorber44
- Measuring Rear Wheel Sag Unloaded44
- Checking the Static Sag of the Shock Absorber44
- Checking the Riding Sag of the Shock Absorber45
- Adjusting the Spring Preload of the Shock Absorber45
- Adjusting the Riding Sag46
- Removing the Shock Absorber46
- Installing the Shock Absorber46
- Servicing the Shock Absorber47
- Removing the Spring47
- Disassembling the Damper48
- Disassembling the Piston Rod49
- Disassembling the Seal Ring Retainer50
- Replacing the Pilot Bushing51
- Checking the Damper52
- Disassembling the Rebound Adjuster52
- Removing the Heim Joint53
- Installing the Heim Joint54
- Assembling the Rebound Adjuster55
- Assembling the Seal Ring Retainer55
- Assembling the Piston Rod56
- Assembling the Damper57
- Bleeding and Filling the Damper60
- Filling the Damper with Nitrogen62
- Installing the Spring63
- Changing the Heim Joint64
05/Exhaust66
- Removing the Manifold66
- Installing the Manifold66
- Removing Main Silencer67
- Installing the Main Silencer67
- Changing the Glass Fiber Yarn Filling of the Main Silencer67
06/Air Filter69
- Removing the Air Filter Box Lid69
- Installing the Air Filter Box Lid69
- Removing the Air Filter69
- Installing the Air Filter69
- Cleaning the Air Filter and Air Filter Box70
07/Fuel Tank, Seat, Trim71
- Opening Filler Cap71
- Closing Filler Cap71
- Removing the Seat71
- Mounting the Seat72
- Removing the Fuel Tank72
- Installing the Fuel Tank73
- Changing the Fuel Screen74
- Changing the Fuel Filter75
- Changing the Fuel Pump77
- Checking the Fuel Pressure78
08/Mask, Fender80
- Removing the Front Fender80
- Installing the Front Fender80
- Removing Headlight Mask with Headlight80
- Refitting the Headlight Mask with the Headlight80
09/Front Wheel82
- Removing the Front Wheel82
- Installing the Front Wheel82
- Checking the Brake Discs83
- Removing the Front Brake Disc83
- Installing the Front Brake Disc84
- Checking the Tire Condition84
- Checking Tire Air Pressure84
- Checking Spoke Tension85
10/Rear Wheel86
- Removing the Rear Wheel86
- Installing the Rear Wheel86
- Removing the Rear Brake Disc87
- Installing the Rear Brake Disc87
- Checking the Chain Tension87
- Adjusting the Chain Tension88
- Adjusting the Chain Guide89
- Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide89
- Checking for Chain Dirt Accumulation91
- Cleaning the Chain91
11/Wiring Harness, Battery92
- Removing the Main Fuse92
- Installing the Main Fuse92
- Changing the Fuses of Individual Power Consumers92
- Changing the Fuse of the Radiator Fan (EXC-F SIX DAYS)93
- Removing the Battery94
- Installing the Battery94
- Charging the Battery94
13/Brake System96
- Checking the Front Brake Linings96
- Changing the Front Brake Linings96
- Checking Free Travel of Hand Brake Lever98
- Adjusting the Basic Position of the Hand Brake Lever (XCF-W)98
- Adjusting Free Travel of Hand Brake Lever (All EXC-F Models)98
- Checking the Front Brake Fluid Level99
- Adding Front Brake Fluid99
- Changing the Front Brake Fluid100
- Checking the Rear Brake Linings101
- Changing the Rear Brake Linings101
- Checking the Free Travel of Foot Brake Lever103
- Adjusting the Basic Position of the Foot Brake Lever103
- Checking the Rear Brake Fluid Level104
- Adding Brake Fluid to the Rear Brake Circuit104
- Changing the Rear Brake Fluid105
14/Lighting System, Instruments107
- Adjusting the Speedometer Functions107
- Setting Kilometers or Miles107
- Activating the Additional Functions108
- Setting the Wheel Circumference108
- Setting the Clock109
- Checking the Headlight Setting109
- Adjusting the Headlight Range110
30/Engine111
- Removing the Engine111
- Installing the Engine115
30/Disassembling the Engine120
- Preparations120
- Removing the Clutch Push Rod120
- Removing the Spacer120
- Draining the Engine Oil120
- Removing the Oil Filter121
- Removing the Spark Plug121
- Removing the Valve Cover121
- Removing the Kick Starter122
- Removing the Alternator Cover122
- Removing the Torque Limiter122
- Positioning the Engine at Ignition Top Dead Center123
- Removing the Timing Chain Tensioner123
- Removing the Camshaft123
- Removing the Cylinder Head124
- Removing the Piston124
- Removing the Starter Drive125
- Removing the Suction Pump126
- Removing the Water Pump Wheel127
- Removing the Clutch Cover127
- Removing the Clutch Discs127
- Removing the Outer Clutch Hub128
- Removing the Intermediate Kick Starter Gear129
- Removing the Shift Shaft129
- Removing the Shift Drum Locating Unit129
- Removing the Locking Lever129
- Removing the Force Pump130
- Removing the Primary Gear130
- Removing the Timing Chain131
- Removing the Spacer131
- Removing the Left Section of the Engine Case131
- Removing the Shift Rails132
- Removing the Shift Drum132
- Removing the Shift Forks132
- Removing the Transmission Shafts132
- Removing the Crankshaft133
30/Engine - Work on the Individual Parts134
- Work on the Right Section of the Engine Case134
- Working on the Left Section of the Engine Case135
- Work on the Clutch Cover136
- Checking the Oil Pressure Regulator Valve137
- Checking the Lubrication System138
- Removing the Crankshaft Bearing Inner Race138
- Installing the Crankshaft Bearing Inner Race138
- Changing the Connecting Rod, Conrod Bearing and Crank Pin139
- Checking the Crankshaft Run-Out at the Bearing Pin140
- Removing the Drive Wheel of the Balancer Shaft140
- Installing the Drive Wheel of the Balancer Shaft140
- Cylinder - Nikasil ® Coating141
- Checking/Measuring the Cylinder141
- Checking/Measuring the Piston141
- Measuring the Piston/Cylinder Mounting Clearance142
- Checking the Piston Ring End Gap142
- Changing the Camshaft Bearing143
- Checking the Camshafts143
- Checking the Pivot Points of the Camshafts143
- Removing the Valves144
- Checking the Valves145
- Checking the Valve Springs146
- Checking the Valve Spring Seat146
- Checking the Cam Levers146
- Checking the Cylinder Head146
- Installing the Valves147
- Checking the Freewheel148
- Preassembling the Kick Starter Shaft148
- Checking the Electric Starter Drive149
- Checking the Timing Assembly150
- Preparing the Timing Chain Tensioner for Installation151
- Checking the Clutch151
- Checking the Shift Mechanism153
- Preassembling the Shift Shaft154
- Disassembling the Main Shaft154
- Disassembling the Countershaft155
- Checking the Transmission155
- Assembling the Main Shaft157
- Assembling the Countershaft157
30/Engine Assembly159
- Installing the Crankshaft159
- Installing the Transmission Shafts159
- Installing the Shift Forks159
- Installing the Shift Drum160
- Installing the Shift Rails160
- Installing the Left Engine Case160
- Installing the Spacer161
- Installing the Timing Chain161
- Installing the Primary Gear162
- Installing the Force Pump162
- Installing the Suction Pump163
- Installing the Locking Lever164
- Installing the Shift Drum Locating Unit164
- Installing the Shift Shaft164
- Installing the Intermediate Kick Starter Gear164
- Installing the Kick Starter Shaft164
- Installing the Outer Clutch Hub165
- Installing the Clutch Discs166
- Installing the Clutch Cover167
- Installing the Water Pump Cover167
- Installing the Starter Drive168
- Installing the Piston169
- Installing the Cylinder Head170
- Installing the Camshafts171
- Checking the Valve Timing172
- Adjusting the Valve Timing172
- Installing the Timing Chain Tensioner173
- Checking the Valve Clearance174
- Adjusting the Valve Clearance175
- Installing the Torque Limiter175
- Installing the Alternator Cover175
- Installing the Kick Starter176
- Installing the Valve Cover176
- Installing the Spark Plug177
- Installing the Oil Filter177
- Installing the Oil Screen177
- Installing the Spacer178
- Installing the Clutch Push Rod178
- Removing the Engine from the Work Stand178
32/Clutch179
- Checking the Fluid Level of the Hydraulic Clutch179
- Changing the Hydraulic Clutch Fluid179
35/Water Pump, Cooling System180
- Cooling System180
- Checking the Antifreeze and Coolant Level180
- Checking the Coolant Level181
- Draining the Coolant181
- Refilling Coolant182
38/Lubrication System183
- Oil Circuit183
- Checking the Engine Oil Level183
- Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen184
39/Ignition System188
- Ignition Coil - Checking the Secondary Winding188
- Checking the Spark Plug Connector188
- Alternator - Checking the Stator Winding188
- Removing the Stator and Ignition Pulse Generator189
- Installing the Stator and Ignition Pulse Generator190
40/Electric Starter191
- Checking the Starter Motor191
41/Throttle Valve Body192
- Throttle Position Sensor Circuit a - Checking the Basic Settings192
- Throttle Position Sensor - Adjusting the Basic Settings192
Technical Data - Engine194
- Capacity - Engine Oil194
- Capacity - Coolant194
Technical Data - Tolerance, Wear Limits of Engine195
Technical Data - Engine Tightening Torques196
Technical Data - Chassis198
- Lighting Equipment199
- Tires199
- Capacity - Fuel199
Technical Data - Fork200
Technical Data - Shock Absorber201
Technical Data - Chassis Tightening Torques202
Cleaning, Care203
- Cleaning the Motorcycle203
- Checks and Maintenance Steps for Winter Operation204
Storage205
- Preparing for Use after Storage205
Service Schedule206
- Service Work (as Additional Order)207
Wiring Diagram208
- Exc-F Eu, Exc-F Six Days)208
- Exc-F Eu, Exc-F Six Days)210
- Exc-F Eu, Exc-F Six Days)212
- Exc-F Eu, Exc-F Six Days)214
- Exc-F Eu, Exc-F Six Days)216
- Exc-F Eu, Exc-F Six Days)218
- Exc-F Eu, Exc-F Six Days)220
- Exc-F Eu, Exc-F Six Days)222
- Exc-F Aus)224
- Exc-F Aus)226
- Exc-F Aus)228
- Exc-F Aus)230
- Exc-F Aus)232
- Exc-F Aus)234
- Exc-F Aus)236
- Exc-F Aus)238
- Exc-F Usa)240
- Exc-F Usa)242
- Exc-F Usa)244
- Exc-F Usa)246
- Exc-F Usa)248
- Exc-F Usa)250
- Exc-F Usa)252
- Exc-F Usa)254
- Xcf-W)256
- Xcf-W)258
- Xcf-W)260
- Xcf-W)264
- Xcf-W)266
- Xcf-W)268
Substances270
Auxiliary Substances272
Special Tools274
Standards287
Index288

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KTM 350 EXC-F EU 2012 Specifications

General

Engine Type	Single cylinder, 4-stroke
Displacement	349.7 cc
Bore x Stroke	88 mm x 57.5 mm
Compression Ratio	12.3:1
Cooling System	Liquid cooled
Transmission	6-speed
Front Tire	90/90-21
Rear Tire	140/80-18
Fuel Capacity	9.5 L
Starter	Electric starter
Front Suspension	WP USD Ø 48 mm
Rear Suspension	WP PDS
Front Brake	Disc brake, 260 mm
Wheelbase	1485 mm
Seat Height	970 mm
Fuel System	Keihin EFI, 42mm throttle body