KTM 350 EXC-F EU Repair Manual page 5

TABLE OF CONTENTS
10 EXHAUST .................................................................. 81
10.1 Removing the manifold.................................... 81
10.2 Installing the manifold .................................... 81
10.3 Removing main silencer................................... 82
10.4 Installing the main silencer.............................. 82
10.5 Changing the glass fiber yarn filling of the
main silencer.................................................. 82
10.6 Cleaning spark arrestor .................................... 83
11 AIR FILTER ............................................................... 85
11.1 Removing the air filter box lid .......................... 85
11.2 Installing the air filter box lid ........................... 85
11.3 Sealing the air filter box .................................. 85
11.4 Removing the air filter ..................................... 86
11.5 Installing the air filter...................................... 86
11.6 Cleaning the air filter and air filter box .............. 86
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 seat ........................................... 89
12.5 Removing the fuel tank.................................... 89
12.6 Installing the fuel tank .................................... 90
12.7 Changing the fuel screen ................................. 92
12.8 Changing the fuel filter.................................... 93
12.9 Changing the fuel pump .................................. 95
12.10 Checking the fuel pressure............................... 96
13 MASK, FENDER......................................................... 98
13.1 Removing the front fender ............................... 98
13.2 Installing the front fender ................................ 98
13.3 Removing headlight mask with headlight........... 98
13.4 Refitting the headlight mask with the
headlight........................................................ 99
14 WHEELS ................................................................. 101
14.1 Checking the tire air pressure......................... 101
14.2 Checking the tire condition ............................ 101
14.3 Checking the brake discs ............................... 102
14.4 Checking spoke tension ................................. 102
14.5 Front wheel .................................................. 103
14.5.1 Removing the front wheel .......................... 103
14.5.2 Installing the front wheel ........................... 103
14.5.3 Removing the front brake disc.................... 104
14.5.4 Installing the front brake disc .................... 104
14.6 Rear wheel ................................................... 104
14.6.1 Removing the rear wheel ........................... 104
14.6.2 Installing the rear wheel ............................ 105
14.6.3 Removing the rear brake disc ..................... 106
14.6.4 Installing the rear brake disc...................... 106
14.6.5 Checking the chain tension........................ 107
14.6.6 Adjusting the chain tension ....................... 107
14.6.7 Checking the chain, rear sprocket, engine
sprocket and chain guide........................... 108
14.6.8 Checking for chain dirt accumulation.......... 110
14.6.9 Cleaning the chain .................................... 110
15 WIRING HARNESS, BATTERY................................... 111
15.1 Removing the main fuse ................................ 111
15.2 Installing the main fuse ................................. 111
15.3 Changing the fuses of individual power
consumers.................................................... 111
15.4 Removing the battery .................................... 112
15.5 Installing the battery ..................................... 113
15.6 Charging the battery ...................................... 113
15.7 Checking the charging voltage ........................ 114
15.8 Checking the quiescent current ...................... 115
16 BRAKE SYSTEM ...................................................... 116
16.1 Checking the front brake linings ..................... 116
16.2 Changing the front brake linings ..................... 116
16.3 Checking free travel of hand brake lever .......... 118
16.4 Adjusting the basic position of the hand
brake lever (All XCF-W models)....................... 118
16.5 Adjusting free travel of hand brake lever (All
EXC-F models).............................................. 118
16.6 Checking the brake fluid level of the front
brake ........................................................... 119
16.7 Adding front brake fluid................................. 119
16.8 Changing the front brake fluid ........................ 120
16.9 Checking the rear brake linings ...................... 121
16.10 Changing the rear brake linings ...................... 121
16.11 Checking the free travel of foot brake lever ...... 123
16.12 Adjusting the basic position of the foot brake
lever ............................................................ 123
16.13 Checking the rear brake fluid level.................. 124
16.14 Adding rear brake fluid .................................. 124
16.15 Changing the rear brake fluid ......................... 125
17 LIGHTING SYSTEM, INSTRUMENTS ......................... 127
17.1 Checking the headlight setting ....................... 127
17.2 Adjusting the headlight range......................... 127
17.3 Speedometer overview ................................... 128
17.4 Activation and test ........................................ 128
17.5 Setting kilometers or miles............................. 128
17.6 Setting the speedometer functions.................. 129
17.7 Setting the clock........................................... 129
17.8 Activating the additional functions.................. 129
17.9 Setting the wheel circumference .................... 130
17.10 Viewing the lap time...................................... 130
18 ENGINE .................................................................. 132
18.1 Removing the engine..................................... 132
18.2 Installing the engine...................................... 136
18.3 Engine disassembly....................................... 141
18.3.1 Preparations ............................................. 141
18.3.2 Removing the clutch push rod.................... 141
18.3.3 Removing the spacer................................. 141
18.3.4 Draining the engine oil .............................. 141
18.3.5 Removing the oil filter ............................... 142
18.3.6 Removing the spark plug ........................... 142
18.3.7 Removing the valve cover........................... 142
18.3.8 Removing the kick starter .......................... 143
18.3.9 Removing the alternator cover .................... 143
18.3.10 Removing the torque limiter....................... 144
18.3.11 Positioning the engine at ignition top dead
center...................................................... 144
18.3.12 Removing the timing chain tensioner .......... 144
18.3.13 Removing the camshaft ............................. 145
18.3.14 Removing the cylinder head ....................... 145
18.3.15 Removing the piston ................................. 146
18.3.16 Removing the starter drive ......................... 146
18.3.17 Removing the suction pump....................... 147
18.3.18 Removing the water pump wheel ................ 148
18.3.19 Removing the clutch cover......................... 148
18.3.20 Removing the clutch discs ......................... 149
18.3.21 Removing the clutch basket ....................... 150
18.3.22 Removing the intermediate kick starter
gear......................................................... 150
18.3.23 Removing the intermediate kick starter
gear......................................................... 150
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