KTM 350 2012 EXC-F,XCF-W, EXC-F SIX DAYS , EXC‐F Factory Workshop Repair Manual

Language: English/German/Spanish/French/Italian

This is the same manual your local dealer will use when doing a repair. The manual for the KTM 350 2012 EXC-F,XCF-W, EXC-F SIX DAYS , EXC‐F has detailed illustrations as well as step by step instructions. All pages are printable, so run off what you need and take it with you into the garage or workshop. These manuals are your number one source for repair and service information. They are specifically written for the do-it-yourself as well as the experienced mechanic. Using this repair manual is an inexpensive way to keep your bike working properly. Each manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of illustrations, that guide the reader through each service and repair procedure.


Models Covered
2012 KTM 350 EXC‐F EU
2012 KTM 350 EXC‐F AUS
2012 KTM 350 EXC‐F SIX DAYS EU
2012 KTM 350 XCF‐W USA
2012 KTM 350 EXC‐F USA


Topics Covered
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
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
Checking the timing assembly ...................................... 148
Preparing the timing chain tensioner for installation ....... 149
Checking the clutch..................................................... 149
Checking the shift mechanism ...................................... 151

and much more

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