Table Of Contents - KTM 350 EXC-F EU 2012 Repair Manual

TABLE OF CONTENTS

TABLE OF CONTENTS
MEANS OF REPRESENTATION ............................................ 6
IMPORTANT NOTES ............................................................ 7
SERIAL NUMBERS.............................................................. 8
Chassis number............................................................... 8
Type label....................................................................... 8
Key number (All EXC-F models) ........................................ 8
Engine number................................................................ 9
Fork part number............................................................. 9
Shock absorber part number............................................. 9
MOTORCYCLE................................................................... 10
Raising the motorcycle with the lift stand ........................ 10
Removing the motorcycle from the lift stand .................... 10
Starting ........................................................................ 10
Starting the motorcycle for a check ................................. 11
01/FORK, TRIPLE CLAMP.................................................. 12
Adjusting the compression damping of the fork ................ 12
Adjusting the rebound damping of the fork....................... 12
Adjusting the spring preload of the fork ........................... 12
Bleeding fork legs.......................................................... 13
Cleaning the dust boots of the fork legs ........................... 13
Loosening the fork protector ........................................... 14
Positioning the fork protection ........................................ 14
Removing the fork legs................................................... 14
Installing the fork legs ................................................... 15
Removing the fork protector............................................ 16
Installing the fork protector ............................................ 16
Performing a fork service................................................ 16
Disassembling the fork legs ............................................ 17
Cartridge disassembly .................................................... 20
Disassembling the compression damping fitting ............... 21
Checking the fork legs.................................................... 22
Assembling the compression damping fitting.................... 23
Assembling the cartridge ................................................ 24
Assembling the fork legs ................................................ 26
Greasing the steering head bearing.................................. 30
Removing the lower triple clamp (EXC-F SIX DAYS) .......... 30
Installing the lower triple clamp (EXC-F SIX DAYS) ........... 31
Removing the lower triple clamp (EXC-F EU/AUS/USA,
XCF-W)......................................................................... 32
Installing the lower triple clamp (EXC-F EU/AUS/USA,
XCF-W)......................................................................... 33
Checking the steering head bearing play .......................... 35
Adjusting the play of the steering head bearing (EXC-F
SIX DAYS) .................................................................... 35
Adjusting the play of the steering head bearing
(EXC-F EU/AUS/USA, XCF-W) ......................................... 36
02/HANDLEBAR, INSTRUMENTS....................................... 37
Handlebar position ........................................................ 37
Adjusting handlebar position .......................................... 37
Adjusting the basic position of the clutch lever................. 37
Checking the throttle cable routing.................................. 38
Checking the play in the throttle cable............................. 38
Adjusting the play in the throttle cable ............................ 39
03/FRAME........................................................................ 40
Removing the engine guard (EXC-F AUS, EXC-F SIX
DAYS) .......................................................................... 40
Installing the engine guard (EXC-F AUS, EXC-F SIX
DAYS) .......................................................................... 40
04/SHOCK ABSORBER, SWINGARM................................... 41
Adjusting the high-speed compression damping of the
shock absorber .............................................................. 41
Adjusting the low-speed compression damping of the
shock absorber .............................................................. 41
Adjusting the rebound damping of the shock absorber....... 42
Measuring rear wheel sag unloaded ................................. 42
Checking the static sag of the shock absorber .................. 42
Checking the riding sag of the shock absorber .................. 43
Adjusting the spring preload of the shock absorber ........... 43
Adjusting the riding sag ................................................. 44
Removing the shock absorber ......................................... 44
Installing the shock absorber .......................................... 44
Servicing the shock absorber .......................................... 45
Removing the spring ...................................................... 45
Disassembling the damper ............................................. 46
Disassembling the piston rod .......................................... 47
Disassembling the seal ring retainer ................................ 48
Replacing the pilot bushing ............................................ 49
Checking the damper ..................................................... 50
Disassembling the rebound adjuster ................................ 50
Removing the heim joint ................................................ 51
Installing the heim joint ................................................. 52
Assembling the rebound adjuster .................................... 53
Assembling the seal ring retainer .................................... 53
Assembling the piston rod .............................................. 54
Assembling the damper.................................................. 55
Bleeding and filling the damper ...................................... 58
Filling the damper with nitrogen ..................................... 60
Installing the spring....................................................... 61
Changing the heim joint ................................................. 62
05/EXHAUST .................................................................... 64
Removing the manifold .................................................. 64
Installing the manifold ................................................... 64
Removing main silencer ................................................. 65
Installing the main silencer ............................................ 65
Changing the glass fiber yarn filling of the main silencer ... 65
06/AIR FILTER.................................................................. 67
Removing the air filter box lid......................................... 67
Installing the air filter box lid.......................................... 67
Removing the air filter ................................................... 67
Installing the air filter .................................................... 67
Cleaning the air filter and air filter box ............................ 68
07/FUEL TANK, SEAT, TRIM.............................................. 69
Opening filler cap .......................................................... 69
Closing filler cap ........................................................... 69
Removing the seat ......................................................... 69
Mounting the seat ......................................................... 70
Removing the fuel tank .................................................. 70
Installing the fuel tank ................................................... 71
Changing the fuel screen................................................ 72
Changing the fuel filter .................................................. 73
Changing the fuel pump................................................. 75
Checking the fuel pressure ............................................. 76
08/MASK, FENDER ........................................................... 78
Removing the front fender .............................................. 78
Installing the front fender............................................... 78
Removing headlight mask with headlight ......................... 78
Refitting the headlight mask with the headlight................ 78
09/FRONT WHEEL ............................................................ 80
Removing the front wheel ............................................... 80
Installing the front wheel................................................ 80
Checking the brake discs................................................ 81
Removing the front brake disc ........................................ 81
Installing the front brake disc ......................................... 82
2