KTM 350 EXC-F EU Repair Manual

KTM 350 EXC-F EU

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REPAIR MANUAL 2015

350 EXC‑F EU

350 EXC‑F SIX DAYS EU

350 EXC‑F AU

350 EXC‑F BR

350 EXC‑F US

350 XCF‑W US

350 XCF‑W SIX DAYS US

Art. no. 3206200en

Table of Contents

Default Chapter4
- Table of Contents4
- Table of Contents 24
1 Means of Representation8
- Symbols Used8
- Formats Used8
2 Safety Advice9
- Repair Manual9
- Degrees of Risk and Symbols9
- Work Rules9
3 Important Notes10
- Guarantee, Warranty10
- Operating and Auxiliary Substances10
- Spare Parts, Accessories10
- Figures10
4 Serial Numbers11
- Chassis Number11
- Type Label11
- Key Number (All EXC-F Models)11
- Engine Number12
- Fork Part Number12
- Shock Absorber Part Number12
5 Motorcycle13
- Raising the Motorcycle with the Lift Stand13
- Removing the Motorcycle from the Lift Stand13
- Starting13
- Starting the Motorcycle for a Check14
6 Fork, Triple Clamp15
- Adjusting the Compression Damping of the Fork15
- Adjusting the Rebound Damping of the Fork15
- Adjusting the Spring Preload of the Fork (EXC-F EU/AUS/BR/US, XCF-W)16
- Bleeding Fork Legs17
- Cleaning the Dust Boots of the Fork Legs17
- Loosening the Fork Protector18
- Positioning the Fork Protector18
- Removing the Fork Legs18
- Installing the Fork Legs19
- Removing the Fork Protector20
- Installing the Fork Protector20
- Exc-F Eu/Aus/Br/Us, Xcf-W21
- Performing a Fork Service21
- Disassembling the Fork Legs21
- Cartridge Disassembly24
- Disassembling the Compression Damping Fitting26
- Checking the Fork Legs26
- Assembling the Compression Damping Fitting27
- Assembling the Cartridge28
- Assembling the Fork Legs29
- Greasing the Steering Head Bearing33
- Removing the Lower Triple Clamp34
- Installing the Lower Triple Clamp34
- Checking the Steering Head Bearing Play36
- Adjusting the Play of the Steering Head Bearing37
- All SIX DAYS Models37
- Performing a Fork Service37
- Disassembling the Fork Legs38
- Removing the Spring40
- Disassembling the Cartridge41
- Disassembling the Piston Rod42
- Disassembling the Hydrostop Unit43
- Disassembling the Seal Ring Retainer43
- Checking the Fork Legs44
- Assembling the Seal Ring Retainer45
- Assembling the Hydrostop Unit45
- Assembling the Piston Rod46
- Assembling the Cartridge47
- Assembling the Fork Legs48
- Greasing the Steering Head Bearing52
- Removing the Lower Triple Clamp52
- Installing the Lower Triple Clamp53
- Checking the Steering Head Bearing Play54
- Adjusting the Play of the Steering Head Bearing55
7 Handlebar, Controls56
- Handlebar Position56
- Adjusting Handlebar Position56
- Adjusting the Basic Position of the Clutch Lever56
- Checking the Throttle Cable Routing57
- Checking the Play in the Throttle Cable57
- Adjusting the Play in the Throttle Cable58
8 Frame59
- Checking the Frame59
- Removing the Engine Guard (EXC-F AU, All SIX DAYS Models)59
- Installing the Engine Guard (EXC-F AU, All SIX DAYS Models)59
9 Shock Absorber, Swingarm60
- Adjusting the High-Speed Compression Damping of the Shock Absorber60
- Adjusting the Low-Speed Compression Damping of the Shock Absorber60
- Adjusting the Rebound Damping of the Shock Absorber61
- Measuring Rear Wheel Sag Unloaded61
- Checking the Static Sag of the Shock Absorber61
- Checking the Riding Sag of the Shock Absorber62
- Adjusting the Spring Preload of the Shock Absorber62
- Adjusting the Riding Sag63
- Removing the Shock Absorber63
- Installing the Shock Absorber63
- Servicing the Shock Absorber64
- Removing the Spring64
- Disassembling the Damper65
- Disassembling the Piston Rod66
- Disassembling the Seal Ring Retainer67
- Replacing the Pilot Bushing68
- Checking the Damper69
- Disassembling the Rebound Adjuster69
- Removing the Heim Joint70
- Installing the Heim Joint71
- Assembling the Rebound Adjuster72
- Assembling the Seal Ring Retainer72
- Assembling the Piston Rod73
- Assembling the Damper74
- Bleeding and Filling the Damper77
- Filling the Damper with Nitrogen79
- Installing the Spring80
- Changing the Heim Joint81
10 Exhaust83
- Removing the Manifold83
- Installing the Manifold83
- Removing Main Silencer84
- Installing the Main Silencer84
- Changing the Glass Fiber Yarn Filling of the Main Silencer84
- Cleaning Spark Arrestor85
11 Air Filter87
- Removing the Air Filter Box Lid87
- Installing the Air Filter Box Lid87
- Sealing the Air Filter Box87
- Removing the Air Filter88
- Installing the Air Filter88
- Cleaning the Air Filter and Air Filter Box88
12 Fuel Tank, Seat, Trim90
- Opening Filler Cap90
- Closing Filler Cap90
- Removing the Seat90
- Mounting the Seat91
- Removing the Fuel Tank91
- Installing the Fuel Tank92
- Changing the Fuel Screen94
- Changing the Fuel Filter95
- Changing the Fuel Pump97
- Checking the Fuel Pressure98
13 Mask, Fender100
- Removing the Front Fender100
- Installing the Front Fender100
- Removing Headlight Mask with Headlight100
- Refitting the Headlight Mask with the Headlight101
14 Wheels103
- Checking the Tire Air Pressure103
- Checking the Tire Condition103
- Checking the Brake Discs104
- Checking Spoke Tension104
- Front Wheel105
- Removing the Front Wheel105
- Installing the Front Wheel105
- Removing the Front Brake Disc106
- Installing the Front Brake Disc106
- Rear Wheel106
- Removing the Rear Wheel106
- Installing the Rear Wheel107
- Removing the Rear Brake Disc108
- Installing the Rear Brake Disc108
- Checking the Chain Tension109
- Adjusting the Chain Tension109
- Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide110
- Checking for Chain Dirt Accumulation112
- Cleaning the Chain112
15 Wiring Harness, Battery113
- Removing the Main Fuse113
- Installing the Main Fuse113
- Changing the Fuses of Individual Power Consumers113
- Removing the Battery114
- Installing the Battery115
- Charging the Battery115
- Checking the Charging Voltage116
- Checking the Quiescent Current117
16 Brake System118
- Checking the Front Brake Linings118
- Changing the Front Brake Linings118
- Checking Free Travel of Hand Brake Lever120
- Adjusting the Basic Position of the Hand Brake Lever (All XCF-W Models)120
- Adjusting Free Travel of Hand Brake Lever (All EXC-F Models)120
- Checking the Brake Fluid Level of the Front Brake121
- Adding Front Brake Fluid121
- Changing the Front Brake Fluid122
- Checking the Rear Brake Linings123
- Changing the Rear Brake Linings123
- Checking the Free Travel of Foot Brake Lever125
- Adjusting the Basic Position of the Foot Brake Lever125
- Checking the Rear Brake Fluid Level126
- Adding Rear Brake Fluid126
- Changing the Rear Brake Fluid127
17 Lighting System, Instruments129
- Checking the Headlight Setting129
- Adjusting the Headlight Range129
- Speedometer Overview130
- Activation and Test130
- Setting Kilometers or Miles130
- Setting the Speedometer Functions131
- Setting the Clock131
- Activating the Additional Functions131
- Setting the Wheel Circumference132
- Viewing the Lap Time132
18 Engine134
- Removing the Engine134
- Installing the Engine138
- Engine Disassembly143
- Preparations143
- Removing the Clutch Push Rod143
- Removing the Spacer143
- Draining the Engine Oil143
- Removing the Oil Filter144
- Removing the Spark Plug144
- Removing the Valve Cover144
- Removing the Kick Starter145
- Removing the Alternator Cover145
- Removing the Torque Limiter146
- Positioning the Engine at Ignition Top Dead Center146
- Removing the Timing Chain Tensioner146
- Removing the Camshaft147
- Removing the Cylinder Head147
- Removing the Piston148
- Removing the Starter Drive148
- Removing the Suction Pump149
- Removing the Water Pump Wheel150
- Removing the Clutch Cover150
- Removing the Clutch Discs151
- Removing the Clutch Basket152
- Removing the Intermediate Kick Starter Gear152
- Removing the Shift Shaft153
- Removing the Shift Drum Locating Unit153
- Removing the Locking Lever153
- Removing the Force Pump153
- Removing the Primary Gear154
- Removing the Timing Chain154
- Removing the Spacer155
- Removing the Left Section of the Engine Case155
- Removing the Shift Rails155
- Removing the Shift Drum156
- Removing the Shift Forks156
- Removing the Transmission Shafts156
- Removing the Crankshaft157
- Work on Individual Parts157
- Work on the Right Section of the Engine Case157
- Work on the Left Section of the Engine Case158
- Work on the Clutch Cover159
- Checking the Oil Pressure Regulator Valve161
- Checking the Lubrication System162
- Removing the Crankshaft Bearing Inner Race162
- Installing the Crankshaft Bearing Inner Race162
- Changing the Connecting Rod, Conrod Bearing and Crank Pin163
- Checking the Crankshaft Run-Out at the Bearing Pin164
- Measuring the Crankshaft End Play164
- Removing the Drive Wheel of the Balancer Shaft165
- Installing the Drive Wheel of the Balancer Shaft165
- Cylinder - Nikasil ® Coating165
- Checking/Measuring the Cylinder165
- Checking/Measuring the Piston166
- Measuring the Piston/Cylinder Mounting Clearance167
- Checking the Piston Ring End Gap167
- Changing the Camshaft Bearing167
- Checking the Camshafts168
- Checking the Pivot Points of the Camshafts168
- Removing the Valves169
- Checking the Valves170
- Checking the Valve Springs170
- Checking the Valve Spring Seat170
- Checking the Cam Levers171
- Checking the Cylinder Head171
- Installing the Valves171
- Checking the Freewheel172
- Removing the Freewheel173
- Installing the Freewheel173
- Preassembling the Kick Starter Shaft174
- Checking the Electric Starter Drive175
- Checking the Timing Assembly176
- Preparing the Timing Chain Tensioner for Installation177
- Checking the Clutch177
- Checking the Shift Mechanism179
- Preassembling the Shift Shaft180
- Disassembling the Main Shaft180
  - Disassembling the Countershaft181
  - Checking the Transmission181
  - Assembling the Main Shaft182
  - Assembling the Countershaft183
  - Engine Assembly184
  - Installing the Crankshaft184
  - Installing the Transmission Shafts185
  - Installing the Shift Forks185
  - Installing the Shift Drum185
  - Installing the Shift Rails186
  - Installing the Left Engine Case186
  - Installing the Spacer187
  - Installing the Timing Chain187
  - Installing the Primary Gear187
  - Installing the Force Pump188
  - Installing the Suction Pump188
  - Installing the Locking Lever189
  - Installing the Shift Drum Locating Unit189
  - Installing the Shift Shaft190
  - Installing the Intermediate Kick Starter Gear190
  - Installing the Kick Starter Shaft190
  - Installing the Outer Clutch Hub190
  - Installing the Clutch Discs191
  - Installing the Clutch Cover192
  - Installing the Water Pump Cover193
  - Installing the Starter Drive193
  - Installing the Piston194
  - Installing the Cylinder Head196
  - Installing the Camshafts197
  - Checking the Valve Timing197
  - Adjusting the Valve Timing198
  - Installing the Timing Chain Tensioner199
  - Checking the Valve Clearance200
  - Adjusting the Valve Clearance200
  - Installing the Torque Limiter201
  - Installing the Alternator Cover201
  - Installing the Kick Starter201
  - Installing the Valve Cover202
  - Installing the Spark Plug202
  - Installing the Oil Filter202
  - Installing the Oil Screen203
  - Installing the Spacer203
  - Installing the Clutch Push Rod204
  - Removing the Engine from the Engine Assembly Stand204
19 Clutch205
- Checking/Correcting the Fluid Level of the Hydraulic Clutch205
- Changing the Hydraulic Clutch Fluid205
20 Water Pump, Cooling System207
- Cooling System207
- Checking the Antifreeze and Coolant Level207
- Checking the Coolant Level208
- Draining the Coolant208
- Refilling Coolant209
21 Lubrication System210
- Oil Circuit210
- Checking the Engine Oil Level210
- Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen211
- Adding Engine Oil213
- Checking the Engine Oil Pressure213
22 Ignition System215
- Ignition Coil - Checking the Secondary Winding215
- Checking the Spark Plug Connector215
- Alternator - Checking the Stator Winding215
- Removing the Stator and Ignition Pulse Generator216
- Installing the Stator and Ignition Pulse Generator217
23 Electric Starter218
- Checking the Starter Motor218
24 Throttle Valve Body219
- Adjusting the Idle Speed219
- Throttle Position Sensor Circuit a - Checking the Basic Settings219
- Throttle Position Sensor - Adjusting the Basic Settings220
- Executing the Initialization Run220
25 Technical Data222
- Engine222
- Engine Tolerance, Wear Limits222
- Engine Tightening Torques223
- Capacities224
- Engine Oil224
- Coolant224
- Fuel224
- Chassis225
- Electrical System226
- Tires226
- Fork226
- Exc-F Eu/Aus/Br/Us, Xcf-W226
- All SIX DAYS Models227
- Shock Absorber227
- Chassis Tightening Torques228
26 Cleaning, Care230
- Cleaning the Motorcycle230
- Checks and Maintenance Steps for Winter Operation231
27 Storage232
- Preparing for Use after Storage232
28 Service Schedule233
- Service Work (as Additional Order)234
29 Wiring Diagram236
- Exc-F Eu)236
- Exc-F Eu)238
- Page 2 of 8 (EXC‑F EU)238
- Exc-F Eu)240
- Page 3 of 8 (EXC‑F EU)240
- Exc-F Eu)242
- Page 4 of 8 (EXC‑F EU)242
- Exc-F Eu)244
- Page 5 of 8 (EXC‑F EU)244
- Exc-F Eu)246
- Page 6 of 8 (EXC‑F EU)246
- Exc-F Eu)248
- Page 7 of 8 (EXC‑F EU)248
- Exc-F Eu)250
- Page 8 of 8 (EXC‑F EU)250
- Exc-F Au)252
- Page 1 of 8 (EXC‑F AU)252
- Exc-F Au)254
- Page 2 of 8 (EXC‑F AU)254
- Exc-F Au)256
- Page 3 of 8 (EXC‑F AU)256
- Exc-F Au)258
- Page 4 of 8 (EXC‑F AU)258
- Exc-F Au)260
- Page 5 of 8 (EXC‑F AU)260
- Exc-F Au)262
- Page 6 of 8 (EXC‑F AU)262
- Exc-F Au)264
- Page 7 of 8 (EXC‑F AU)264
- Exc-F Au)266
- Exc-F Br)268
- Exc-F Br)270
- Exc-F Br)272
- Exc-F Br)274
- Exc-F Br)276
- Exc-F Br)278
- Exc-F Br)280
- Exc-F Br)282
- Exc-F Us)284
- Exc-F Us)286
- Ye-Rd286
- Exc-F Us)288
- Exc-F Us)290
- Exc-F Us)292
- Exc-F Us)294
- Or or294
- 2 Wh Wh294
- Exc-F Us)296
- Exc-F Us)298
- Exc-F Six Days)300
- Exc-F Six Days)302
- Exc-F Six Days)304
- Exc-F Six Days)306
- Exc-F Six Days)308
- Exc-F Six Days)310
- Exc-F Six Days)312
- Exc-F Six Days)314
- Xcf-W)316
- Xcf-W)318
- Xcf-W)320
- Xcf-W)322
- Xcf-W)324
- Xcf-W)326
- Xcf-W Six Days)328
- Xcf-W Six Days)330
- Xcf-W Six Days)332
- Xcf-W Six Days)334
- Xcf-W Six Days)336
- Xcf-W Six Days)338
30 Substances340
31 Auxiliary Substances342
32 Special Tools344
33 Standards357
- Index358

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Owner's Manual136 pages

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KTM 350 EXC-F EU Specifications

General

Brand	KTM
Model	350 EXC-F EU
Category	Motorcycle
Language	English

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