Ktm 350 Service Manual
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KTM 350 EXC-F EXC-F SIX DAYS XCF-W Workshop Service Repair Manual 2013 IMPROVED PDF manuals have: Bookmarks + Searchable Text + Index --BEST ORGANIZATION! This Workshop Service repair manual offers detailed servicing instructions and will give you complete step by step information on repair, servicing, preventat. — Cycle Guide) $9.95. Descriptive flyer available. Postage: $1.50, 50C each additional order. Puch, Hercules, KTM. Work on other frames as well I work from five tables to service different types of cycle frames and build jigs. Racing tires: Goodyear D1636A 350 x 19 $45.00 each; Carlisle 400 x 19.
KTM WP SUSPENSION MANUALS:. 2007. (via QSprings.com) OTHER.
KTM 350 EXC-F EXC-F SIX DAYS XCF-W Workshop Service Repair Manual 2013 IMPROVED PDF manuals have: Bookmarks + Searchable Text + Index -BEST ORGANIZATION! This Workshop Service repair manual offers detailed servicing instructions and will give you complete step by step information on repair, servicing, preventative maintenance & troubleshooting procedures for your Ktm. This comprehensive service manual features photos and illustrations along with step-by-step instructions that will guide you through the entire repair process. This manual contains all you need to know to keep your Motorcycle working correctly. Models covered: 350 EXC-F EU 350 EXC-F AUS 350 EXC-F SIX DAYS EU 350 XCF-W USA 350 EXC-F USA Table Of Contents: MEANS OF REPRESENTATION.
6 1.1 Symbols used. 6 1.2 Formats used.
6 SAFETY ADViCE. 7 2.1 Repair Manual. 7 2.2 Safety advice. 7 2.3 Degrees of risk and symbols.
7 2.4 Work rules. 7 IMPORTANT NOTES. 8 3.1 Guarantee, warranty.
8 3.2 Operating and auxiliary substances. 8 3.3 Spare parts, accessories. 8 3.4 Figures. 8 SERIAL NUMBERS. 9 4.1 Chassis number. 9 4.2 Type label. 9 4.3 Key number (All EXC-F models).
9 4.4 Engine number. 10 4.5 Fork part number. 10 4.6 Shock absorber part number.
10 MOTORCYCLE. 11 5.1 Raising the motorcycle with the lift stand. 11 5.2 Removing the motorcycle from the lift stand. 11 5.3 Starting. 11 5.4 Starting the motorcycle for a check.
12 FORK, TRIPLE CLAMP. 13 6.1 EXC-F EU/AUS/USA, XCF-W. 13 6.1.1 Adjusting the compression damping of the fork. 13 Adjusting the rebound damping of the fork. 13 Adjusting the spring preload of the fork.
13 Bleeding fork legs. 14 Cleaning the dust boots of the fork legs. 14 Loosening the fork protector. 15 Positioning the fork protection. 15 Removing the fork legs. 15 Install i ng the fork legs.
16 Removing the fork protector. 16 Install i ng the fork protector. 17 Perform i ng a fork service. 17 Disassembling the fork legs. 17 Cartridge disassembly. 20 Disassembling the compression damping fitting. 22 Checking the fork legs.
22 Assembling the compression damping fitting. 24 Assembling the cartridge. 24 Assembling the fork legs. 26 Greasing the steering head bearing. 30 Removing the lower triple clamp. 30 Installing the lower triple clamp. 31 Checking the steering head bearing play.
33 Adjusting the play of the steering head bearing. 33 EXC-F S IX DAYS. 34 Adjusting the compression damping of the fork. 34 Adjusting the rebound damping of the fork. 34 Bleeding fork legs.
34 Cleaning the dust boots of the fork legs. 35 Loosening the fork protector. 35 Positioning the fork protection. 36 Removing the fork legs.
36 Installing the fork legs. 36 Removing the fork protector. 37 Installing the fork protector. 37 Performing a fork service. 37 Disessembling the fork legs. 38 Removing the spring. 40 Disassembling the cartridge.
41 Disassembling the piston rod. 42 Disassembling the hydrostop unit. 43 Disassembling the seal ring retainer. 43 Checki ng the fork legs. 44 Assembling the seal ring retainer. 45 Assembling the hydrostop unit. 45 Assembling the piston rod.
46 Assembling the cartridge. 47 Assembling the fork legs. 48 Greasing the steering head bearing. 52 Removing the lower triple clamp. 52 Installing the lower triple clamp. 53 Checking the steering head bearing play.
54 6.2.28 Adjusting the play of the steering head bearing. 55 HANDLEBAR, CONTROLS.
56 7.1 Handlebar position. 56 7.2 Adjusting handlebar position.
56 7.3 Adjusting the basic position of the clutch lever. 56 7.4 Checking the throttle cable routing. 57 7.5 Checking the play in the throttle cable.
57 7.6 Adjusting the play in the throttle cable. 58 FRAME. 59 8.1 Removing the engine guard (EXC-F AUS, EXC-F SIX DAYS). 59 8.2 Installing the engine guard (EXC-F AUS, EXC-F SIX DAyS). 59 SHOCK ABSORBER, SWINGARM.
60 9.1 Adjusting the high-speed compression damping of the shock absorber. 60 9.2 Adjusting the low-speed compression damping of the shock absorber.
60 9.3 Adjusting the rebound damping of the shock absorber. 61 9.4 Measuring rear wheel sag unloaded. 61 9.5 Checking the static sag of the shock absorber. 61 9.6 Checking the riding sag of the shock absorber. 62 9.7 Adjusting the spring preload of the shock absorber.
62 9.8 Adjusting the riding sag. 63 9.9 Removing the shock absorber. 63 9.10 Installing the shock absorber. 63 9.11 Servicing the shock absorber. 64 9.12 Removing the spring.
64 9.13 Disassembling the damper. 65 9.14 Disassembling the piston rod. 66 9.15 Disassembling the seal ring retainer. 67 9.16 Replacing the pilot bushing. 68 9.17 Checking the damper. 69 9.18 Disassembling the rebound adjuster.
69 9.19 Removing the heim join!. 70 9.20 Installing the heim join!. 71 9.21 Assembling the rebound adjuster. 72 15.2 Installing the main fuse. 110 9.22 Assembling the seal ring retainer. 72 15.3 Changing the fuses of individual power 9.23 Assembling the piston rod.
73 consumers. 110 9.24 Assembling the damper. 74 15.4 Changing the fuse of the radiator fan (EXC-F 9.25 Bleeding and filling the damper. 77 SIX DAYS). 111 9.26 Filling the damper with nitrogen. 79 15.5 Removing the battery. 112 9.27 Installing the spring.
80 15.6 Installing the battery. 112 9.28 Changing the heim joint. 81 15.7 Charging the battery.
113 10 EXHAUST. 83 16 BRAKE SYSTEM. 114 10.1 Removing the manifold. 83 16.1 Checking the front brake linings. 114 10.2 Installing the manifold. 83 16.2 Changing the front brake linings.
114 10.3 Removing main silencer. 84 16.3 Checking free travel of hand brake lever. 116 10.4 Installing the main silencer.
84 10.5 Changing the glass fiber yarn filling of the main silencer. 84 16.4 Adjusting the basic position of the hand brake lever (XCF-W). 116 16.5 Adjusting free travel of hand brake lever (All 11 AIR FILTER.
86 EXC-F models). 116 11.1 Removing the air filter box lid. 86 11.2 Installing the air filter box lid. 86 11.3 Removing the air filter. 86 11.4 Installing the air filter. 86 11.5 Cleaning the air filter and air filter box.
87 12 FUEL TANK, SEAT, TRIM. 88 12.1 Opening filler cap. 88 12.2 Closing filler cap. 88 12.3 Removing the seat. 88 12.4 Mounting the sea!. 89 12.5 Removing the fuel tank. 89 12.6 Installing the fuel tank.
90 12.7 Changing the fuel screen. 91 12.8 Changing the fuel filter. 92 12.9 Changing the fuel pump. 94 12.10 Checking the fuel pressure. 95 13 MASK, FENDER. 97 13.1 Removing the front fender. 97 13.2 Installing the front fender.
97 13.3 Removing headlight mask with headligh!. 97 13.4 Refitting the headlight mask with the headlight. 97 14 WHEELS. 99 16.6 Checking the front brake fluid level. 117 16.7 Adding front brake fluid. 117 16.8 Changing the front brake fluid. 118 16.9 Checking the rear brake linings.
119 16.10 Changing the rear brake linings. 119 16.11 Checking the free travel of foot brake lever. 121 16.12 Adjusting the basic position of the foot brake lever. 121 16.13 Checking the rear brake fluid level. 122 16.14 Adding brake fluid to the rear brake circui! 122 16.15 Changing the rear brake fluid. 123 17 LIGHTING SYSTEM, INSTRUMENTS.
125 17.1 Adjusting the speedometer functions. 125 17.2 Setting kilometers or miles. 125 17.3 Activating the additional functions.
126 17.4 Setting the wheel circumference. 126 17.5 Setting the clock. 127 17.6 Checking the headlight setting. 127 17.7 Adjusting the headlight range.
128 18 ENGINE. 129 18.1 Removing the engine. 129 18.2 Installing the engine. 133 18.3 Engine disassembly.
137 14.1 Checking the tire air pressure. 99 14.2 Checking the tire condition. 99 14.3 Checking the brake discs. 100 14.4 Checking spoke tension.
100 14.5 Front wheel. 101 18.3.1 Preparations. 137 18.3.2 Removing the clutch push rod. 137 18.3.3 Removing the spacer. 137 18.3.4 Draining the engine oil. 137 18.3.5 Removing the oil filter.
138 14.5.1 Removing the front wheel. 101 14.5.2 Installing the front wheel. 101 14.5.3 Removing the front brake disc. 102 14.5.4 Installing the front brake disc. 102 14.6 Rear wheel. 102 18.3.6 Removing the spark plug. 138 18.3.7 Removing the valve cover.
138 18.3.8 Removing the kick starter. 139 18.3.9 Removing the alternator cover. 139 18.3.10 Removing the torque limiter. 140 14.6.1 Removing the rear wheel. 102 14.6.2 Installing the rear wheel. 103 14.6.3 Removing the rear brake disc. 104 14.6.4 Installing the rear brake disc.
104 14.6.5 Checking the chain tension. 105 14.6.6 Adjusting the chain tension. 105 14.6.7 Adjusting the chain guide. 106 14.6.8 Checking the chain, rear sprocket, engine sprocket and chain guide. 106 14.6.9 Checking for chain dirt accumulation. 108 14.6.10 Cleaning the chain. 108 15 WIRING HARNESS, BATTERy.
110 18.3.11 Positioning the engine at ignition top dead center. 140 18.3.12 Removing the timing chain tensioner. 140 18.3.13 Removing the camshaft.
141 18.3.14 Removing the cylinder head. 141 18.3.15 Removing the piston.
142 18.3.16 Removing the starter drive. 142 18.3.17 Removing the suction pump.
143 18.3.18 Removing the water pump wheel. 144 18.3.19 Removing the clutch cover. 144 18.3.20 Removing the clutch discs. 145 18.3.21 Removing the outer clutch hub. 146 15.1 Removing the main fuse.
110 18.3.22 Removing the intermediate kick starter 18.4.34 Checking the shift mechanism. 171 gear.
146 18.4.35 Preassembling Ihe shift shaft. 172 18.3.23 Removing the intermediate kick starter 18.4.36 Disassembling Ihe main shaft.
172 gear. 146 18.4.37 Disassembling Ihe counlershaft. 173 18.3.24 Removing the shift shaft.
Ktm 350 Sx Service Manual
147 18.4.38 Checking Ihe Iransmission. 173 18.3.25 Removing the shift drum localing unil. 147 18.4.39 Assembling Ihe main shaft. 174 18.3.26 Removing the locking lever. 147 18.4.40 Assembling the counlershaft. 175 18.3.27 Removing the force pump. 147 18.5 Engine assembly.
176 18.3.28 Removing the primary gear. 148 18.5.1 Installing the crankshaft. 176 18.3.29 Removing Ihe liming chain. 148 18.5.2 Installing Ihe Iransmission shafts. 177 18.3.30 Removing Ihe spacer.
149 18.5.3 Installing Ihe shift lorks. 177 18.3.31 Removing Ihe left seclion 01 Ihe engine case.
149 18.3.32 Removing the shift rails. 149 18.3.33 Removing the shift drum. 150 18.3.34 Removing the shift lorks.
150 18.3.35 Removing Ihe lransmission shafts. 150 18.3.36 Removing Ihe crankshaft. 151 18.4 Work on individual parts. 151 18.4.1 Work on Ihe righl seclion of Ihe engine case. 151 18.4.2 Working on the left seclion 01 the engine case. 152 18.5.4 Installing Ihe shift drum.
177 18.5.5 Installing the shift rails. 178 18.5.6 Installing the left engine case.
178 18.5.7 Installing the spacer. 179 18.5.8 Installing the timing chain. 179 18.5.9 Installing Ihe primary gear. 179 18.5.10 Installing Ihe lorce pump. 180 18.5.11 Installing Ihe suclion pump.
180 18.5.12 Installing the locking lever. 181 18.5.13 Installing the shift drum locating unil. 181 18.5.14 Installing the shift shaft. 182 18.4.3 Work on Ihe clulch cover. 153 18.4.4 Checking Ihe oil pressure regulalor valve. 154 18.4.5 Checking Ihe lubricalion system.
155 18.4.6 Removing the crankshaft bearing inner race. 156 18.5.15 Installing Ihe inlermediale kick starter gear. 182 18.5.16 Installing Ihe kick starter shaft. 182 18.5.17 Installing Ihe ouler clulch hub. 182 18.5.18 Installing the clutch discs.
183 18.4.7 Installing the crankshaft bearing inner race. 156 18.5.19 Installing the clutch cover. 184 18.5.20 Installing the water pump cover. 185 18.4.8 Changing Ihe connecling rod, conrod 18.5.21 Installing Ihe starter drive. 185 bearing and crank pin. 156 18.5.22 Installing Ihe pislon. 186 18.4.9 Checking Ihe crankshaft run-oul allhe 18.5.23 Installing Ihe cylinder head.
188 bearing pin. 158 18.5.24 Installing Ihe camshafts.
189 18.4.10 Removing the drive wheel of the balancer 18.5.25 Checking the valve liming. 189 shaft. 158 18.5.26 Adjusting Ihe valve timing. 190 18.4.11 Installing the drive wheel of Ihe balancer 18.5.27 Installing the timing chain tensioner. 191 shaft. 158 18.5.28 Checking Ihe valve clearance.
192 18.4.12 Cylinder - Nikasil' coaling. 158 18.5.29 Adjusting Ihe valve clearance. 192 18.4.13 Checking/measuring Ihe cylinder.
158 18.5.30 Installing Ihe lorque limiler. 193 18.4.14 Checking/measuring Ihe piston. 159 18.5.31 Installing the alternator cover. 193 18.4.15 Measuring the piston/cylinder mounting clearance. 160 18.4.16 Checking Ihe piston ring end gap.
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2014 Ktm 350 Service Manuals
160 18.4.17 Changing the camshaft bearing. 160 18.4.18 Checking Ihe camshafts. 161 18.4.19 Checking Ihe pivol points 01 Ihe camshafts.
161 18.4.20 Removing Ihe valves. 162 18.4.21 Checking Ihe valves. 163 18.4.22 Checking Ihe valve springs. 163 18.5.32 Installing the kick starter. 193 18.5.33 Installing the valve cover. 194 18.5.34 Installing Ihe spark plug. 194 18.5.35 Installing Ihe oil liller.
194 18.5.36 Installing Ihe oil screen. 195 18.5.37 Installing Ihe spacer. 195 18.5.38 Installing the clutch push rod. 196 18.5.39 Removing Ihe engine from the engine assembly stand. 196 19 CLUTCH. 197 18.4.23 Checking Ihe valve spring seal.
163 18.4.24 Checking Ihe cam levers. 164 19.1 Checking/correcling Ihe Iluid level ollhe hydraulic clulch. 197 18.4.25 Checking Ihe cylinder head. 164 19.2 Changing Ihe hydraulic clulch fluid.
197 18.4.26 Inslalling Ihe valves. 164 20 WATER PUMP, COOLING SYSTEM.
198 18.4.27 Checking Ihe Ireewheel. 165 20.1 Cooling system. 198 18.4.28 Changing the free wheel. 166 20.2 Checking the anlifreeze and cool ani level. 198 18.4.29 Preassembling the kick starter shaft. 166 20.3 Checking Ihe coolanl level.
2015 Ktm 350 Sxf Service Manual
199 18.4.30 Checking Ihe eleclric slarter drive. 167 20.4 Draining Ihe coolanl. 199 18.4.31 Checking Ihe liming assembly. 168 20.5 Refilling coolanl.
200 18.4.32 Preparing the timing chain tensioner for 21 LUBRICATION SySTEM. 201 inslallalion. 169 21.1 Oil circuil. 201 18.4.33 Checking Ihe clulch. 169 21.2 Checking the engine oil level. 201 And Much More.
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