KTM 350 EXC-F EU 2012 Repair Manual page 5

TABLE OF CONTENTS
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
Checking the timing assembly ...................................... 148
Preparing the timing chain tensioner for installation ....... 149
Checking the clutch..................................................... 149
Checking the shift mechanism ...................................... 151
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