KTM 350 EXC-F XCF-W (2012)
MANUAL DE TALLER - SERVICE - MANUEL REPARATION
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
KTM 350 EXC-F XCF-W (2012) Service Manual - Manual de Taller - Manuel de Reparation - Manuale di Officina - Reparaturanleitung
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4x4
quad - buggy
camión - truck
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