KTM 2012 350 EXC-F SIX DAYS Owner'S Manual Download

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TROUBLESHOOTING

Faults

Possible cause

Action

The engine cannot be cranked (elec-
tric starter)

Operating error

–

Carry out the start procedure. (

p. 29)

Battery is discharged

–

Charge the battery.

(

p. 78)

–

Check the charging voltage.

–

Check the closed current.

–

Check the stator winding of the alternator.

Main fuse blown

–

Change the main fuse. (

p. 79)

Starter relay defective

–

Check the starter relay.

Starter motor defective

–

Check the starter motor.

Engine turns but does not start

Operating error

–

Carry out the start procedure. (

p. 29)

Coupling of fuel hose connection not
joined together

–

Join the fuel hose connection.

Fuse

blown

–

Change the fuses of individual power
consumers. (

p. 80)

Fuse

blown

–

Change the fuses of individual power
consumers. (

p. 80)

Idle speed is not set correctly

–

Adjust the idle speed.

(

p. 88)

Spark plug oily or wet

–

Clean and dry the spark plug or replace if nec-
essary.

Electrode distance (plug gap) of spark
plug too wide

–

Adjust the plug gap.
Guideline
Spark plug electrode gap
0.8 mm (0.031 in)

Ignition system defective

–

Check the ignition system.

Short-circuit cable in wiring harness
frayed, kill switch or emergency OFF
switch defective

–

Check the wiring harness. (visual check)

–

Check the electrical system.

Plug-in connector of the EFI control
device, ignition pulse generator, or
ignition coil is oxidized

–

Clean the plug connection and treat it with
contact spray.

Defect in fuel injection system

–

Read out the fault memory using the KTM diag-
nostics tool.

Engine does not speed up

Defect in fuel injection system

–

Read out the fault memory using the KTM diag-
nostics tool.

Ignition system defective

–

Ignition coil - check the secondary winding.

–

Check the spark plug connector.

–

Check the stator winding of the alternator.

Engine has too little power

Air filter heavily contaminated

–

Clean the air filter and air filter box.

(

p. 53)

Fuel filter is very dirty

–

Change the fuel filter.

Defect in fuel injection system

–

Read out the fault memory using the KTM diag-
nostics tool.

Exhaust system leaky, deformed or
too little glass fiber yarn filling in
main silencer

–

Check exhaust system for damage.

–

Change the glass fiber yarn filling of the main
silencer.

(

p. 54)

Valve clearance too little

–

Adjust the valve clearance.

Ignition system defective

–

Ignition coil - check the secondary winding.

–

Check the spark plug connector.

–

Check the stator winding of the alternator.

Engine dies during the trip

Lack of fuel

–

Refuel. (

p. 31)

Fuse

blown

–

Change the fuses of individual power
consumers. (

p. 80)

Fuse

blown

–

Change the fuses of individual power
consumers. (

p. 80)

Engine overheats

Coolant level low in cooling system

–

Check the cooling system for leaks.

–

Check the coolant level. (

p. 86)

Summary of Contents for 2012 350 EXC-F SIX DAYS

Page 1: ...OWNER S MANUAL 2012 350 EXC F EU 350 EXC F AUS 350 EXC F SIX DAYS EU 350 XCF W USA Art no 3211721en ...

Page 2: ......

Page 3: ...technical specifica tions prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice KTM accepts no liability for delivery options deviations from illustrations and descriptions as well as misprints and other errors The models portrayed p...

Page 4: ...rides at high temperature and slow speed 27 Preparing for rides at low temperatures or in snow 28 RIDING INSTRUCTIONS 29 Checks and maintenance work when preparing for use 29 Starting 29 Starting off 30 Shifting riding 30 Braking 30 Stopping parking 31 Refueling 31 SERVICE SCHEDULE 33 Service schedule 33 Service work as additional order 34 TUNING THE CHASSIS 35 Checking the basic suspension settin...

Page 5: ...gs 71 Changing the rear brake linings x 72 WHEELS TIRES 74 Removing the front wheel x 74 Installing the front wheel x 74 Removing the rear wheel x 75 Installing the rear wheel x 75 Checking the tire condition 76 Checking tire air pressure 77 Checking spoke tension 77 ELECTRICAL SYSTEM 78 Removing the battery x 78 Installing the battery x 78 Charging the battery x 78 Changing the main fuse 79 Chang...

Page 6: ...l understanding In the interest of your own safety have these jobs done in an authorized KTM workshop There your motorcycle will be serviced optimally by specially trained experts using the specialist tools required Identifies a page reference more information is provided on the specified page Formats used The typographical and other formats used are explained below Proprietary name Denotes a prop...

Page 7: ...e schedule is reached Pay careful attention to the prescribed running in period and service intervals If you observe these exactly you will ensure a much longer service life for your motorcycle Warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer s service record and in the KTM dealer net otherwise all warranty cl...

Page 8: ...fixed to the vehicle Do not remove information warning labels If they are miss ing you or others may not recognize potential hazards and may therefore be injured Grades of risks Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken Warning Identifies a danger that is likely to lead to fatal or serious inj...

Page 9: ...VIEW OF VEHICLE 7 3 1 View of vehicle front left example 101287 10 1 Filler cap 2 Air filter box lid 3 Fork compression adjustment 4 Shift lever p 21 5 Engine number p 9 6 Side stand p 22 7 Chain guide ...

Page 10: ...gnal switch p 12 2 Emergency OFF switch p 12 2 Electric starter button p 13 3 Throttle grip p 11 4 Fork rebound adjustment and spring preload adjustment 5 Shock absorber rebound adjustment 6 Level viewer for brake fluid rear 7 Shock absorber compression adjustment 8 Level viewer engine oil 9 Foot brake lever p 21 10 Kick starter p 21 ...

Page 11: ...label is fixed to the front of the steering head 4 3 Key number All EXC F models 500125 10 The key number is stamped on the key strap 4 4 Engine number 101291 10 The engine number is stamped on the left side of the engine under the engine sprocket 4 5 Fork part number B00265 01 The fork part number is stamped on the inner side of the fork stub ...

Page 12: ...SERIAL NUMBERS 10 4 6 Shock absorber part number 101292 10 The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side ...

Page 13: ...on the left side of the handlebar Possible states Kill switch in basic position In this position the ignition circuit is closed and the engine can be started Kill switch pressed In this position the ignition circuit is interrupted a run ning engine stops and a non running engine will not start 5 5 Kill switch All EXC F models 101297 10 Kill switch is fitted on the left side of the handlebar Possib...

Page 14: ...299 10 Turn signal switch is fitted on the left side of the handlebar Possible states Turn signal light off Turn signal switch is in the central position Turn signal light left on Turn signal switch is turned to the left Turn signal light right on Turn signal switch is turned to the right 5 9 Emergency OFF switch EXC F AUS 101300 10 The emergency OFF switch is fitted on the right side of the handl...

Page 15: ...amp MIL lights up flashes orange The OBD has detected an emission or safety critical fault The fuel level warning lamp lights up orange The fuel level has reached the reserve mark 5 14 Overview of indicator lamps All EXC F models 101304 01 Possible states High beam indicator light lights up blue High beam is switched on FI warning lamp MIL lights up flashes orange The OBD has detected an emission ...

Page 16: ... handlebar Info The trip master is an optional accessory 5 18 Setting kilometers or miles Info If you change the unit of measure the ODO value is retained and converted accordingly The values TR1 TR2 A1 A2 and S1 are cleared when the unit of measure is changed Condition The motorcycle is stationary 400329 01 Press the button briefly and repeatedly until H appears at the bottom right of the display...

Page 17: ...er functions Info When the vehicle is delivered only the SPEED H and SPEED ODO display modes are activated Condition The motorcycle is stationary 400318 01 Press the button briefly and repeatedly until H appears at the bottom right of the display Press the button for 3 5 seconds The Setup menu is displayed and the activated functions are shown Change to the desired function by pressing the button ...

Page 18: ... or Mph Info Making the setting according to the country When an impulse comes from the front wheel the left side of the speedometer display changes to the SPEED mode and the current speed is shown 5 23 Display mode SPEED H service hours 400316 01 Condition The motorcycle is stationary Press the button briefly and repeatedly until H appears at the bottom right of the display In display mode H the ...

Page 19: ...e next lap Press the button for 3 5 seconds The stop watch and the lap time are reset Press the button briefly Next display mode 5 26 Display mode SPEED ODO odometer 400317 01 Press the button briefly and repeatedly until ODO appears at the bottom right of the display The total distance traveled is displayed in the ODO display mode Press the button No function Press the button No function Press th...

Page 20: ...epeatedly until A1 appears at the top right of the display A1 average speed 1 shows the average speed calculated on the basis of TR1 trip mas ter 1 and S1 stop watch 1 The calculation of this value is activated by the first impulse of the wheel speed sensor and ends 3 seconds after the last impulse Press the button No function Press the button No function Press the button for 3 5 seconds The TR1 A...

Page 21: ... service hours No function No function The display changes to the Setup menu of the speedometer functions Next display mode Display mode SPEED CLK clock No function No function The display changes to the Setup menu of the clock Next display mode Display mode SPEED LAP lap time Starts or stops the clock Stops the current lap time and saves it and the stop watch starts the next lap The stop watch an...

Page 22: ...s on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immedi ately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed con tact a doctor immediately Change clothing that has come into contact with fuel...

Page 23: ...ay 5 36 Shift lever 101307 10 Shift lever is mounted on the left side of the engine 101308 10 The gear positions can be seen in the photograph The neutral or idle position is between the first and second gears 5 37 Kick starter 101309 10 The kick starter is fitted on the right of the engine The engine can be started with either the kick starter or the electric starter The upper part of the kick st...

Page 24: ...ring head The steering lock is used to lock the steering Steering and therefore riding is no longer possible 5 41 Locking the steering All EXC F models Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 400732 01 Park the vehicle Turn the handlebar as far as possible to the right Insert the key in the steering lock turn it to the...

Page 25: ... the steering All EXC F models 400731 01 Insert the key in the steering lock turn it to the left pull it out and turn it to the right Remove the key You can now steer the bike again Info Never leave the key in the steering lock ...

Page 26: ...ar brake may fail due to overheating Take your foot off the foot brake lever when you are not braking Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permissible weight and axle loads Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine is running Secure the vehicle against use by unauthorized persons Info When using...

Page 27: ...e throttle 6 3 Preparing the vehicle for difficult riding conditions Info Using a motorcycle in difficult conditions can lead to excessive wear of components such as the power train or brakes For this reason it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached KTM recommends that you use the specified engine oil for difficult riding con...

Page 28: ...ver on the air filter Sand protection device for air filter 59006022000 Info See the KTM PowerParts fitting instructions Adjust the carburetor jetting and the setting Info The specific carburetor tuning can be recommended by your authorized KTM workshop 600868 01 Clean the chain Chain cleaner p 109 Fit the steel sprocket Tip Do not grease the chain Clean the radiator fins Straighten bent radiator ...

Page 29: ...ng device for air filter 59006021000 Info See the KTM PowerParts fitting instructions Adjust the carburetor jetting and settings Info Your authorized KTM workshop has the recommended carburetor tuning settings 600868 01 Fit the steel sprocket Clean the motorcycle p 93 Straighten bent radiator fins carefully 6 7 Preparing for rides at high temperature and slow speed 600872 10 Check the radiator cap...

Page 30: ...n Chain cleaner p 109 Clean the radiator fins Straighten bent radiator fins carefully Check the coolant level p 86 6 8 Preparing for rides at low temperatures or in snow 600870 01 Fit a waterproofing device on the air filter Waterproofing device for air filter 59006021000 Info See the KTM PowerParts fitting instructions Adjust the carburetor jetting and settings Info Your authorized KTM workshop h...

Page 31: ... and ensure that they can be operated smoothly Check all screws nuts and hose clamps regularly for tightness Check the fuel supply 7 2 Starting Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an ...

Page 32: ...ngine can handle abrupt throttle opening increases fuel consumption To shift down brake and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the throttle or shift again Switch off the engine if you expect to be standing for a long time Guideline 2 min Avoid frequent and longer slipping of the clutch This heats the engine...

Page 33: ...e could be damaged and the motorcycle could fall over Brake the motorcycle Shift transmission to neutral XCF W Press and hold the kill switch while the engine is idling until the engine stops All EXC F models Press and hold the kill switch while the engine is idling until the engine stops Park the motorcycle on firm ground 7 7 Refueling Danger Fire hazard Fuel is highly flammable Never refuel the ...

Page 34: ...urement Guideline Measurement of 35 mm 1 38 in Total fuel tank capacity approx XCF W 9 5 l 2 51 US gal Super unleaded ROZ 95 RON 95 PON 91 p 108 Total fuel tank capacity approx All EXC F mod els 9 l 2 4 US gal Super unleaded ROZ 95 RON 95 PON 91 p 108 Close the filler cap p 20 ...

Page 35: ...x Check the fluid level of the hydraulic clutch p 63 Check the front brake fluid level p 66 Check the free travel of the hand brake lever p 65 Check the steering head bearing play p 49 Check the valve clearance x Check the clutch x Change the shaft seal rings of the water pump x Check the fuel pressure x Check all hoses e g fuel cooling bleeding drainage and sleeves for cracking leaks and incorrec...

Page 36: ... the cylinder x Check the cylinder head x Change the valves valve springs and valve spring seats x Check the camshaft and cam lever x Change the connecting rod conrod bearing and crank pin x Check the transmission and shift mechanism x Check the oil pressure regulator valve x Change the suction oil pump x Check the oil pumps and lubrication system x Replace the timing chain x Check the timing asse...

Page 37: ...d of the rear wheel suspension and not to the vehicle speed The high speed setting for example has an effect on the landing after a jump the rear wheel suspension compresses more quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses more slowly These two ranges can be adjusted separately although the transition between high...

Page 38: ...responding to the shock absorber type Guideline Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 25 turns Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 9 5 Adjusting the rebound damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitro...

Page 39: ...ence between measurements and Check the static sag Static sag 34 mm 1 34 in If the static sag is less or more than the specified value Adjust the spring preload of the shock absorber x p 38 9 8 Checking the riding sag of the shock absorber 0 0 A A 0 0 C C 400990 10 Measure distance of rear wheel unloaded p 37 With another person holding the motorcycle the rider wearing full protective cloth ing si...

Page 40: ...ing to measurement Guideline Spring preload 8 mm 0 31 in Info Depending on the static sag and or the riding sag it may be necessary to increase or decrease the spring preload Tighten screw Guideline Screw shock absorber adjusting ring M5 5 Nm 3 7 lbf ft Install the shock absorber x p 51 9 10 Adjusting the riding sag x Remove shock absorber x p 51 After removing the shock absorber clean it thorough...

Page 41: ... screws are located at the bottom end of the fork legs Make the same adjustment on both fork legs Turn back counterclockwise by the number of clicks corresponding to the fork type Guideline Compression damping Comfort 24 clicks Standard 22 clicks Sport 20 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing Mount protection covers 9 13 Adjusting the rebound dampi...

Page 42: ...A A 101318 10 On the upper triple clamp there are two holes at a distance of to each other Hole distance 15 mm 0 59 in The holes on the handlebar supports are placed at a distance of from the center Hole distance 3 5 mm 0 138 in The handlebar supports can be mounted in four different positions 9 16 Adjusting handlebar position x Warning Danger of accidents Handlebar breakage If the handlebar is be...

Page 43: ...ebar supports evenly Position the handlebars Info Make sure cables and wiring are positioned correctly Position the handlebar clamps Fit and evenly tighten the four screws Guideline Screw handlebar clamp M8 20 Nm 14 8 lbf ft Info Make sure the gap width is even ...

Page 44: ...ust be folded up and secured with the rubber band 10 3 Bleeding fork legs Raise the motorcycle with the lift stand p 42 101319 10 Remove bleeder screws briefly Any excess pressure escapes from the interior of the fork Mount and tighten bleeder screws Remove the motorcycle from the lift stand p 42 10 4 Cleaning the dust boots of the fork legs Raise the motorcycle with the lift stand p 42 Loosen the...

Page 45: ...10 Nm 7 4 lbf ft Position the wiring harness Position the brake line Put the clamp on mount and tighten screws Position the fork protection on the right fork leg Mount and tighten the screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 10 7 Removing the fork legs Remove the headlight mask with the headlight p 82 Remove the front wheel x p 74 101322 10 Remove screws and take off the clamp...

Page 46: ...n screws Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Tighten screws Guideline Screw bottom triple clamp M8 12 Nm 8 9 lbf ft 101326 10 Position brake caliper and mount and tighten screws Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Mount cable binder Refit the headlight mask with the headlight p 82 Position the brake line wiring harness and clamp Mount and tighten ...

Page 47: ...or to one side Remove screw and screw Take off the upper triple clamp with the handlebar and set it aside Info Protect the motorcycle and its attachments against damage by covering them Do not bend the cables and lines 101329 10 Remove O ring Remove protective ring Take out the lower triple clamp with the steering stem Take out the upper steering head bearing 10 12 Removing the lower triple clamp ...

Page 48: ...the upper steering head bearing Check whether the top steering head seal is correctly positioned Slide on protective ring and O ring 101427 10 Position the upper triple clamp with the steering Mount screw but do not tighten yet Position the clutch line wiring harness and voltage regulator Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 101332 10 Position the fork le...

Page 49: ...lder 101326 11 Position the brake caliper Mount and tighten screws Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Mount cable binder Position the brake line wiring harness and clamp Mount and tighten screws Install the front fender p 51 Mount the handlebar cushion Refit the headlight mask with the headlight p 82 Install the front wheel x p 74 Check that the wiring harness cab...

Page 50: ...ring and O ring 101337 10 Position the upper triple clamp with the steering Mount screw but do not tighten yet Position the clutch line wiring harness and voltage regulator Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 101338 10 Position the fork legs Info The topmost milled groove in the fork leg must be flush with the top edge of the upper triple clamp Position ...

Page 51: ... 10 15 Checking the steering head bearing play Warning Danger of accidents Unstable vehicle handling from incorrect steering head bearing play Adjust the steering head bearing play without delay Your authorized KTM workshop will be glad to help Info If the bike is ridden with play in the steering head bearing the bearing and the bearing seats in the frame can become dam aged over time Raise the mo...

Page 52: ...4 8 lbf ft Tighten screw Guideline Screw top steering stem M8 20 Nm 14 8 lbf ft Check the steering head bearing play p 49 10 17 Adjusting the play of the steering head bearing x EXC F SIX DAYS Raise the motorcycle with the lift stand p 42 101342 10 Loosen screws Remove screw Loosen and retighten screw Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Using a plastic hammer tap lightly on ...

Page 53: ...nd tighten screw Guideline Screw bottom shock absorber M12 80 Nm 59 lbf ft Loctite 2701 Info The heim joint for the shock absorber at the swing arm is Teflon coated It must not be greased with grease or with other lubricants Lubricants dis solve the Teflon coating thereby drastically reducing the service life Remove the motorcycle from the lift stand p 42 10 21 Removing the front fender 101345 10 ...

Page 54: ... lid 101348 10 Pull off the air filter box lid in area to the side and remove to the front 10 26 Installing the air filter box lid 101349 10 Insert the air filter box lid into the rear area and clip it into the front area 10 27 Removing the air filter x Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never ride the vehicle without an air filter sin...

Page 55: ...e Install the air filter box lid p 52 10 29 Cleaning the air filter and air filter box x Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Do not clean the air filter with fuel or petroleum since these substances attack the foam Remove the air filter x p 52...

Page 56: ...he air and the silencer burns out Not only is the noise level higher the performance characteristic changes Remove the main silencer p 54 0 0 1 1 0 0 2 2 0 0 4 4 0 0 5 5 0 0 6 6 0 0 8 8 0 0 7 7 0 0 3 3 0 0 4 4 0 0 8 8 101425 10 All EXC F models Remove screws of connecting cap Take off the connecting cap with the perforated pipe O ring and glass fiber yarn filling Remove screws and take off silence...

Page 57: ...er Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See the notes on refueling Warning Danger of poisoning Fuel is poisonous a...

Page 58: ...can escape if the tank is overfilled See the notes on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact of the fuel with skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse imme diately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doctor immediately Chan...

Page 59: ...ystem Mount the seat p 52 10 35 Checking for chain dirt accumulation 400678 01 Check the chain for coarse dirt accumulation If the chain is very dirty Clean the chain p 57 10 36 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced braking efficiency due to oil or grea...

Page 60: ...e lower chain section must be taut When the chain guard is mounted it must be possible to pull up the chain at least to the point where it makes contact with chain guard Chain wear is not always even so you should repeat this measurement at different chain positions Chain tension 55 58 mm 2 17 2 28 in If the chain tension does not meet specifications Adjust the chain tension p 58 Remove the motorc...

Page 61: ...chain rear sprocket engine sprocket and chain guide Raise the motorcycle with the lift stand p 42 400227 01 Shift gear to neutral Check the rear sprocket and engine sprocket for wear If the rear sprocket or engine sprocket is worn Change the rear sprocket or engine sprocket x Info The engine sprocket rear sprocket and chain should always be replaced together 1 2 3 16 17 18 0 0 0 B B 0 0 A A 400987...

Page 62: ...is in line with or below the chain sliding piece Change the chain sliding piece x Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten the chain sliding piece Guideline Screw chain sliding piece M8 15 Nm 11 1 lbf ft 400985 01 Check the chain guide for wear Info Wear is visible on the front of the chain guide If the light part of the chain guide is worn Ch...

Page 63: ... Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount the nut on screw and tighten Guideline Remaining nuts chassis M6 10 Nm 7 4 lbf ft 10 41 Checking the frame x 401340 01 Check the frame for cracking and deformation If the frame exhibits cracking or deformation due to a mechanical impact Change the frame x Info A frame that has been damaged due to a mechanical impact must always be changed Repair ...

Page 64: ...062030051 p 110 10 45 Additionally securing the rubber grip Check the rubber grip p 62 401198 01 Secure the rubber grip at two points using the securing wire Securing wire 54812016000 Wire twister forceps U6907854 The twisted wire ends face away from the hands and are bent toward the rub ber grip 10 46 Adjusting the basic position of the clutch lever 101364 10 Adjust the basic setting of the clutc...

Page 65: ...substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations 101365 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane 101366 10 Fill bleeding syringe with the appropriate hydraulic fluid Bleed syringe 50329050000 Brake fluid DOT 4 DOT 5...

Page 66: ...IX DAYS 101368 10 Turn quick release counterclockwise until it disengages Remove the engine guard 10 50 Installing the engine guard EXC F AUS EXC F SIX DAYS 101369 10 Attach the engine guard on the frame at the rear and swing up at the front Turn quick release clockwise all the way ...

Page 67: ...ravel of the hand brake lever p 65 Adjust the basic setting of the hand brake lever to your hand size by turning adjust ing screw Info Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the handlebar The range of adjustment is limited Turn the ...

Page 68: ...t brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help 101373 10 Move the brake fluid reservoir mounted on the handlebar to a h...

Page 69: ...osition the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilt brake fluid immediately with water 11 7 Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad to help 101375 10 Check the brake linings for minimum thickness ...

Page 70: ...valid Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brak...

Page 71: ...lever pressure builds up on the rear brake circuit The rear brake can fail due to overheating Adjust free travel on foot brake lever according to specifications 101377 10 Disconnect spring Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in If the free trav...

Page 72: ...e riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help 101379 10 Stand the vehicle upright Check the brake fluid level in the viewer When in the viewer an air bubble is visible Add bra...

Page 73: ...ks paint Use only clean brake fluid from a sealed container 101380 10 Stand the vehicle upright Remove screw cap with membrane and the O ring Add brake fluid to level Brake fluid DOT 4 DOT 5 1 p 107 Mount the screw cap with the membrane and the O ring Info Clean up overflowed or spilt brake fluid immediately with water 11 13 Checking the rear brake linings Warning Danger of accidents Reduced braki...

Page 74: ... for use on KTM vehicles The construc tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings If brake linings are used that differ from the originals there is no guarantee that they comply with the origi nal license The vehicle no longer corresponds to the condition at delivery and the warranty is no longer valid Warn...

Page 75: ...ngs insert the bolt and mount the locking split pins Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point 101380 10 Add brake fluid to level Brake fluid DOT 4 DOT 5 1 p 107 Mount screw cap with membrane and the O ring Info Clean up overflowed or spilt brake fluid immediately with water ...

Page 76: ... fork Info Do not pull the hand brake lever when the front wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged 101388 10 Remove spacers 12 2 Installing the front wheel x Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when nece...

Page 77: ...disc in order to press back the brake piston Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove nut Remove chain adjuster Withdraw wheel spindle only enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Remove the chain from the rear sprocket Holding the rear wheel withdraw the wheel spin...

Page 78: ... the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Remove the motorcycle from the lift stand p 42 12 5 Checking the tire condition Info Only mount tires approved and or recommended by KTM Other tires could have a negative effect on handling characteristics The type condition and air pressure of the tires all have a significant ...

Page 79: ... Rear 2 0 bar 29 psi If the tire pressure does not meet specifications Correct the tire air pressure Fit the dust cap 12 7 Checking spoke tension Warning Danger of accidents Instable handling due to incorrect spoke tension Ensure that the spoke tension is correct Your authorized KTM workshop will be glad to help Info A loose spoke can cause wheel imbalance which leads to more loose spokes in a sho...

Page 80: ...m Lift the battery up and out 13 2 Installing the battery x 101394 10 Insert battery into the battery compartment with the terminals facing to the front Battery YTX4L BS p 102 Reconnect rubber band Connect positive cable and negative cable Guideline Screw battery terminal M5 2 5 Nm 1 84 lbf ft Info Contact disks must be mounted between battery terminals and cable sockets with the claws facing up S...

Page 81: ...stroying the battery The battery is maintenance free which means that the acid level does not need to be checked Switch off all power consumers and switch off the engine Remove the seat p 52 Disconnect the negative cable of the battery to avoid damage to the onboard elec tronics 400240 10 Connect the battery charger to the battery Switch on the battery charger Battery charger 58429074000 You can a...

Page 82: ...ipment is functioning properly Tip Insert the spare fuse so that it is available if needed Mount the protection caps Mount the starter relay onto the bracket and lay the cable Position the rear fairing Mount and tighten the screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Install the air filter box lid p 52 13 5 Changing the fuses of individual power consumers Info The fuse box contain...

Page 83: ...s with the correct rating only Fuse 58011109110 p 102 Tip Replace the spare fuse in the fuse box so that it is available if needed Check that the power consumer is functioning properly Close the fuse box cover Mount the seat p 52 13 6 Changing the fuse of the radiator fan EXC F SIX DAYS Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the ...

Page 84: ...ask and fix it with the rubber band Info Ensure that the retaining lugs engage in the fender Position the brake line and wiring harness Put the clamp on mount and tighten screw Check the headlight setting p 83 13 9 Changing the headlight bulb Note Damage to reflector Reduced luminance Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it fre...

Page 85: ...ition the vehicle vertically a distance away from the wall Guideline Distance 5 m 16 ft The rider now sits down on the motorcycle Switch on the low beam Check the headlight setting The boundary between light and dark must be exactly on the lower mark for a motorcycle with driver If the light dark border does not meet specifications Adjust the headlight range p 83 13 11 Adjusting the headlight rang...

Page 86: ...Check that the O ring of the locking cap is seated properly 101407 10 Position locking cap and using a coin turn it clockwise all the way Press any button on the speedometer The speedometer is activated Position the speedometer in the bracket Mount and tighten the screws with washers Refit the headlight mask with the headlight p 82 Set kilometers or miles p 14 Adjust the speedometer functions p 15...

Page 87: ...ne and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immediately with water and con tact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immedi...

Page 88: ...evel does not meet specifications Correct the coolant level Alternative 1 Coolant p 107 Alternative 2 Coolant mixed ready to use p 107 Mount the radiator cap 14 4 Draining the coolant x Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow t...

Page 89: ...iately with soap and water If coolant is swallowed contact a doctor immedi ately Change clothes that have come into contact with coolants Keep coolant out of the reach of children 101410 10 Make sure that the screw is tightened Stand the vehicle upright Pour coolant in up to measurement above the radiator fins Guideline 10 mm 0 39 in Coolant 1 2 l 1 3 qt Coolant p 107 Coolant mixed ready to use p ...

Page 90: ... the idle speed changes Adjust the play in the throttle cable x p 88 15 2 Adjusting the play in the throttle cable x Check the throttle cable routing p 62 101411 10 Move the handlebar to the straight ahead position Push back sleeves Loosen nut Turn adjusting screw in as far as possible Loosen nut Turn adjusting screw so that there is play in the throttle cable at the throttle grip Guideline Play i...

Page 91: ...s Adjust the basic position of the shift lever x p 89 15 5 Adjusting the basic position of the shift lever x 101412 10 Remove screw and take off shift lever 101413 10 Clean gear teeth of the shift lever and shift shaft Mount the shift lever on the shift shaft in the required position and engage the gearing Info The range of adjustment is limited The shift lever must not come into contact with any ...

Page 92: ... If the engine oil is not up to the middle of the level viewer Add engine oil p 92 16 2 Changing the engine oil and oil filter cleaning the oil screen x Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water Warning Environmental hazard Hazardous subs...

Page 93: ...e oil drain plug with the magnet and a new seal ring Guideline Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft 101419 10 Remove screws Remove the oil filter cover with the O ring 101420 10 Pull oil filter out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing area 101421 10 Lay the motorcycle on its side and fill...

Page 94: ...not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and check that it is oil tight EXC F AUS EXC F SIX DAYS Install the engine guard p 64 Check the engine oil level p 90 16 3 Adding engine oil Info Too little engine oil or poor quality engine oil results in premature wear to the engine 101423 10 Remove screw cap from the clutch cover and...

Page 95: ...normal motorcycle cleaner and then clean with a paintbrush Motorcycle cleaner p 109 Info Use warm water containing normal motorcycle cleaner and a soft sponge After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Warning Danger of accidents Reduced braking efficiency due to wet or dirty brakes Clean or dry dirty or wet brakes by riding and braking gently After cleani...

Page 96: ...e brakes Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings with cold water and dry carefully This should be done after the parts are cooled down and while they are installed After riding on salted roads thoroughly wash the motorcycle with cold water and dry it well Treat the engine swingarm and all other bright and zinc plated parts except for the brake dis...

Page 97: ...orcycle p 93 Change the engine oil and oil filter clean the oil screen x p 90 Check the antifreeze and coolant level p 85 Drain the fuel from the tank into a suitable container Check the tire air pressure p 77 Remove the battery x p 78 Charge the battery x p 78 Guideline Storage temperature of battery without direct sunlight 0 35 C 32 95 F Store the vehicle in a dry location that is not subject to...

Page 98: ...the EFI control device ignition pulse generator or ignition coil is oxidized Clean the plug connection and treat it with contact spray Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool x Engine does not speed up Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool x Ignition system defective Ignition coil check the second...

Page 99: ...TM diag nostics tool x High oil consumption Engine vent hose bent Route the vent hose without bends or replace it if necessary Engine oil level too high Check the engine oil level p 90 Engine oil too thin low viscosity Change the engine oil and oil filter clean the oil screen x p 90 Piston and cylinder worn Measure the piston cylinder mounting clear ance x Battery discharged Battery is not being c...

Page 100: ...l too low Engine coolant temperature sensor input signal too high Blink code FI warning lamp MIL 13 FI warning lamp MIL flashes 1x long 3x short Error level condition Intake air temperature sensor input signal too low Intake air temperature sensor input signal too high Blink code FI warning lamp MIL 15 FI warning lamp MIL flashes 1x long 5x short Error level condition Rollover sensor A D type inpu...

Page 101: ...scraper ring Engine lubrication Pressure circulation lubrication with two Eaton pumps Primary transmission 24 73 Clutch Multidisc clutch in oil bath hydraulically activated Transmission ratio 1st gear 14 32 2nd gear 16 26 3rd gear 20 25 4th gear 22 23 5th gear 25 22 6th gear 26 20 Alternator 12 V 168 W Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment Spar...

Page 102: ...e case M6 10 Nm 7 4 lbf ft Screw exhaust flange M6 10 Nm 7 4 lbf ft Loctite 243 Screw kick starter stop M6 10 Nm 7 4 lbf ft Loctite 243 Screw oil filter cover M6 10 Nm 7 4 lbf ft Screw shift drum locating M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 Screw starter motor M6 10 Nm 7 4 lbf ft Screw timing chain guide rail M6 10 Nm 7 4 lbf ft Loctite 243 Screw timi...

Page 103: ... ft Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Plug oil pressure regulator valve M12x1 5 20 Nm 14 8 lbf ft Oil drain plug M14x1 5 15 Nm 11 1 lbf ft Nut inner clutch hub M18x1 5 100 Nm 73 8 lbf ft Loctite 243 Nut primary gear M18LHx1 5 100 Nm 73 8 lbf ft Loctite 243 Screw plug oil screen M20x1 5 15 Nm 11 1 lbf ft Plug timing chain tensioner M24x1 5 25 Nm 18 4 lbf ft Screw alternator cover...

Page 104: ... 48 49 50 51 52 Steering head angle 63 5 Wheelbase 1 482 10 mm 58 35 0 39 in Seat height unloaded 970 mm 38 19 in Ground clearance unloaded 345 mm 13 58 in Weight without fuel approx All EXC F models 108 5 kg 239 2 lb Weight without fuel approx XCF W 107 kg 236 lb Maximum permissible front axle load 145 kg 320 lb Maximum permissible rear axle load 190 kg 419 lb Maximum permissible overall weight 3...

Page 105: ... 21 51M TT Dunlop GEOMAX MX51 110 100 18 64M TT Dunlop GEOMAX MX51 Additional information is available in the Service section under http www ktm com 23 3 Capacity fuel Total fuel tank capacity approx XCF W 9 5 l 2 51 US gal Super unleaded ROZ 95 RON 95 PON 91 p 108 Total fuel tank capacity approx All EXC F models 9 l 2 4 US gal Super unleaded ROZ 95 RON 95 PON 91 p 108 Fuel reserve approx 1 5 l 1 ...

Page 106: ... turns Spring length with preload spacer s Weight of rider 65 75 kg 143 165 lb 513 mm 20 2 in Weight of rider 75 85 kg 165 187 lb 513 mm 20 2 in Weight of rider 85 95 kg 187 209 lb 513 mm 20 2 in Spring rate Weight of rider 65 75 kg 143 165 lb 4 0 N mm 22 8 lb in Weight of rider 75 85 kg 165 187 lb 4 2 N mm 24 lb in Weight of rider 85 95 kg 187 209 lb 4 4 N mm 25 1 lb in Fork length 940 mm 37 01 i...

Page 107: ... 25 turns Rebound damping Comfort 28 clicks Standard 24 clicks Sport 22 clicks Spring preload 8 mm 0 31 in Spring rate Weight of rider 65 75 kg 143 165 lb 66 N mm 377 lb in Weight of rider 75 85 kg 165 187 lb 69 N mm 394 lb in Weight of rider 85 95 kg 187 209 lb 72 N mm 411 lb in Spring length 250 mm 9 84 in Gas pressure 10 bar 145 psi Static sag 34 mm 1 34 in Riding sag 110 mm 4 33 in Fitted leng...

Page 108: ...15 Nm 11 1 lbf ft Screw chain sliding piece M8 15 Nm 11 1 lbf ft Screw engine brace M8 33 Nm 24 3 lbf ft Screw fork stub M8 15 Nm 11 1 lbf ft Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Screw handlebar clamp M8 20 Nm 14 8 lbf ft Screw side stand attachment M8 45 Nm 33 2 lbf ft Loctite 2701 Screw subframe M8 35 Nm 25 8 lbf ft Loctite 2701 Screw top steering stem EXC F SIX DAYS M8 17 ...

Page 109: ...n inhibitor antifreeze 50 distilled water Coolant mixed ready to use Antifreeze 40 C 40 F Supplier Motorex Anti Freeze Engine oil SAE 10W 60 00062010035 According to JASO T903 MA p 111 SAE p 111 SAE 10W 60 KTM LC4 2007 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corre sponding properties KTM recommends Motorex pro...

Page 110: ...ing to SAE p 111 SAE 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that possess the corresponding properties Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel ...

Page 111: ...products Supplier Motorex Protect Shine High viscosity grease Guideline KTM recommends SKF products Supplier SKF LGHB 2 Long life grease Guideline KTM recommends Motorex products Supplier Motorex Bike Grease 2000 Motorcycle cleaner Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Off road chain spray Guideline KTM recommends Motorex products Supplier Motorex Chainlube Offr...

Page 112: ...hes bare metal and plastic surfaces Guideline KTM recommends Motorex products Supplier Motorex Clean Polish Rubber grip adhesive 00062030051 Supplier KTM Sportmotorcycle AG GRIP GLUE Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Synthetic ...

Page 113: ...ice intervals are demanded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils...

Page 114: ...osition adjusting 62 Compression damping fork adjusting 39 Compression damping high speed shock absorber adjusting 36 Compression damping low speed shock absorber adjusting 35 Coolant draining 86 refilling 87 Coolant level checking 85 86 Cooling system 85 D Difficult operating conditions low temperature 28 muddy surfaces 27 snow 28 wet surfaces 27 Difficult riding conditions 25 dry sand 26 high te...

Page 115: ...ss fiber yarn filling changing 54 installing 54 removing 54 Motorcycle cleaning 93 raising with lift stand 42 removing from lift stand 42 O Oil filter changing 90 Oil screen cleaning 90 Overview of indicator lamps 13 Owner s manual 6 P Play in throttle cable checking 88 Preparing for use advice on first use 24 after storage 95 checks and maintenance work when preparing for use 29 R Rear sprocket c...

Page 116: ...tening torques 106 engine 99 engine tightening torques 100 101 fork 104 shock absorber 105 Throttle cable play adjusting 88 Throttle cable routing checking 62 Throttle grip 11 Tire condition checking 76 Tire pressure checking 77 Transport 6 Troubleshooting 96 97 Turn signal switch 12 Type label 9 U Use definition 5 V View of vehicle front left side 7 rear right side 8 W Warranty 5 Winter operation...

Page 117: ... 3211721en 3211721en KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 04 2011 Photo Mitterbauer ...

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KTM 2012 350 EXC-F SIX DAYS, Owner'S Manual

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