KTM 350 EXC-F EU Repair Manual page 6

TABLE OF CONTENTS
18.3.24 Removing the shift shaft............................ 151
18.3.25 Removing the shift drum locating unit ........ 151
18.3.26 Removing the locking lever ........................ 151
18.3.27 Removing the force pump.......................... 151
18.3.28 Removing the primary gear ........................ 152
18.3.29 Removing the timing chain ........................ 152
18.3.30 Removing the spacer................................. 153
18.3.31 Removing the left section of the engine
case ........................................................ 153
18.3.32 Removing the shift rails............................. 153
18.3.33 Removing the shift drum ........................... 154
18.3.34 Removing the shift forks............................ 154
18.3.35 Removing the transmission shafts............... 154
18.3.36 Removing the crankshaft ........................... 155
18.4 Work on individual parts ................................ 155
18.4.1 Work on the right section of the engine
case ........................................................ 155
18.4.2 Work on the left section of the engine
case ........................................................ 156
18.4.3 Work on the clutch cover ........................... 157
18.4.4 Checking the oil pressure regulator valve ..... 159
18.4.5 Checking the lubrication system ................. 160
18.4.6 Removing the crankshaft bearing inner
race......................................................... 160
18.4.7 Installing the crankshaft bearing inner
race......................................................... 160
18.4.8 Changing the connecting rod, conrod
bearing and crank pin ............................... 161
18.4.9 Checking the crankshaft run-out at the
bearing pin............................................... 162
18.4.10 Measuring the crankshaft end play ............. 162
18.4.11 Removing the drive wheel of the balancer
shaft........................................................ 163
18.4.12 Installing the drive wheel of the balancer
shaft........................................................ 163
18.4.13 Cylinder - Nikasil
18.4.14 Checking/measuring the cylinder ................ 163
18.4.15 Checking/measuring the piston................... 164
18.4.16 Measuring the piston/cylinder mounting
clearance ................................................. 165
18.4.17 Checking the piston ring end gap ............... 165
18.4.18 Changing the camshaft bearing .................. 165
18.4.19 Checking the camshafts ............................ 166
18.4.20 Checking the pivot points of the
camshafts ................................................ 166
18.4.21 Removing the valves.................................. 167
18.4.22 Checking the valves .................................. 168
18.4.23 Checking the valve springs......................... 168
18.4.24 Checking the valve spring seat ................... 168
18.4.25 Checking the cam levers............................ 169
18.4.26 Checking the cylinder head........................ 169
18.4.27 Installing the valves .................................. 169
18.4.28 Checking the freewheel ............................. 170
18.4.29 Removing the freewheel ............................ 171
18.4.30 Installing the freewheel ............................. 171
18.4.31 Preassembling the kick starter shaft ........... 172
18.4.32 Checking the electric starter drive .............. 173
18.4.33 Checking the timing assembly.................... 174
18.4.34 Preparing the timing chain tensioner for
installation ............................................... 175
18.4.35 Checking the clutch .................................. 175
18.4.36 Checking the shift mechanism ................... 177
18.4.37 Preassembling the shift shaft ..................... 178
coating ......................... 163
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18.4.38 Disassembling the main shaft .................... 178
18.4.39 Disassembling the countershaft.................. 179
18.4.40 Checking the transmission ......................... 179
18.4.41 Assembling the main shaft......................... 180
18.4.42 Assembling the countershaft ...................... 181
18.5 Engine assembly ........................................... 182
18.5.1 Installing the crankshaft ............................ 182
18.5.2 Installing the transmission shafts ............... 183
18.5.3 Installing the shift forks............................. 183
18.5.4 Installing the shift drum ............................ 183
18.5.5 Installing the shift rails ............................. 184
18.5.6 Installing the left engine case .................... 184
18.5.7 Installing the spacer.................................. 185
18.5.8 Installing the timing chain ......................... 185
18.5.9 Installing the primary gear ......................... 185
18.5.10 Installing the force pump........................... 186
18.5.11 Installing the suction pump ....................... 186
18.5.12 Installing the locking lever ......................... 187
18.5.13 Installing the shift drum locating unit ......... 187
18.5.14 Installing the shift shaft ............................ 188
18.5.15 Installing the intermediate kick starter
gear......................................................... 188
18.5.16 Installing the kick starter shaft................... 188
18.5.17 Installing the outer clutch hub ................... 188
18.5.18 Installing the clutch discs.......................... 189
18.5.19 Installing the clutch cover ......................... 190
18.5.20 Installing the water pump cover.................. 191
18.5.21 Installing the starter drive.......................... 191
18.5.22 Installing the piston .................................. 192
18.5.23 Installing the cylinder head........................ 194
18.5.24 Installing the camshafts ............................ 195
18.5.25 Checking the valve timing.......................... 195
18.5.26 Adjusting the valve timing ......................... 196
18.5.27 Installing the timing chain tensioner........... 197
18.5.28 Checking the valve clearance ..................... 198
18.5.29 Adjusting the valve clearance ..................... 198
18.5.30 Installing the torque limiter ....................... 199
18.5.31 Installing the alternator cover..................... 199
18.5.32 Installing the kick starter ........................... 199
18.5.33 Installing the valve cover ........................... 200
18.5.34 Installing the spark plug ............................ 200
18.5.35 Installing the oil filter................................ 200
18.5.36 Installing the oil screen ............................. 201
18.5.37 Installing the spacer.................................. 201
18.5.38 Installing the clutch push rod .................... 202
18.5.39 Removing the engine from the engine
assembly stand......................................... 202
19 CLUTCH .................................................................. 203
19.1 Checking/correcting the fluid level of the
hydraulic clutch............................................ 203
19.2 Changing the hydraulic clutch fluid ................ 203
20 WATER PUMP, COOLING SYSTEM ............................ 205
20.1 Cooling system ............................................. 205
20.2 Checking the antifreeze and coolant level ........ 205
20.3 Checking the coolant level ............................. 206
20.4 Draining the coolant ...................................... 206
20.5 Refilling coolant ........................................... 207
21 LUBRICATION SYSTEM............................................ 208
21.1 Oil circuit..................................................... 208
21.2 Checking the engine oil level.......................... 208
21.3 Changing the engine oil and oil filter,
cleaning the oil screen................................... 209
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