KTM 350 EXC-F EU 2012 Operating instructions

REPAIR MANUAL 2012
350 EXC‑F EU
350 EXC‑F AUS
350 EXC‑F SIX DAYS EU
350 XCF‑W USA
350 EXC‑F USA
Art. no. 3206111en

INTRODUCTION 1
INTRODUCTION
It is important that you read this repair manual carefully and completely before the start of work.
Only use ORIGINAL KTM SPARE PARTS.
This vehicle can only fulfill the demands placed on it in the long run if the specified service work is performed regularly by qualified
experts.
The repair manual was written to correspond to the most current state of this model series. We reserve the right to make changes in
the interest of technical advancement without, at the same time, updating this repair manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that repair work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete 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 deliv-
ery options, deviations from illustrations and descriptions, as well as for printing and other errors. The models portrayed partly contain
special equipment that does not belong to the regular scope of delivery.
© 2011 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright
owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria

TABLE OF CONTENTS 2
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

TABLE OF CONTENTS 3
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

TABLE OF CONTENTS 4
Preassembling the shift shaft........................................ 152
Disassembling the main shaft ....................................... 152
Disassembling the countershaft .................................... 153
Checking the transmission............................................ 153
Assembling the main shaft ........................................... 155
Assembling the countershaft......................................... 155
30/ENGINE ASSEMBLY ................................................... 157
Installing the crankshaft............................................... 157
Installing the transmission shafts.................................. 157
Installing the shift forks ............................................... 157
Installing the shift drum............................................... 158
Installing the shift rails ................................................ 158
Installing the left engine case....................................... 158
Installing the spacer .................................................... 159
Installing the timing chain............................................ 159
Installing the primary gear............................................ 160
Installing the force pump ............................................. 160
Installing the suction pump.......................................... 161
Installing the locking lever............................................ 162
Installing the shift drum locating unit............................ 162
Installing the shift shaft ............................................... 162
Installing the intermediate kick starter gear.................... 162
Installing the kick starter shaft ..................................... 162
Installing the outer clutch hub...................................... 163
Installing the clutch discs ............................................ 164
Installing the clutch cover ............................................ 165
Installing the water pump cover .................................... 165
Installing the starter drive ............................................ 166
Installing the piston..................................................... 167
Installing the cylinder head .......................................... 168
Installing the camshafts............................................... 169
Checking the valve timing ............................................ 170
Adjusting the valve timing ............................................ 170
Installing the timing chain tensioner ............................. 171
Checking the valve clearance........................................ 172
Adjusting the valve clearance........................................ 173
Installing the torque limiter .......................................... 173
Installing the alternator cover ....................................... 173
Installing the kick starter.............................................. 174
Installing the valve cover .............................................. 174
Installing the spark plug............................................... 175
Installing the oil filter .................................................. 175
Installing the oil screen................................................ 175
Installing the spacer .................................................... 176
Installing the clutch push rod ....................................... 176
Removing the engine from the work stand...................... 176
32/CLUTCH .................................................................... 177
Checking the fluid level of the hydraulic clutch .............. 177
Changing the hydraulic clutch fluid............................... 177
35/WATER PUMP, COOLING SYSTEM .............................. 178
Cooling system ............................................................ 178
Checking the antifreeze and coolant level ...................... 178
Checking the coolant level............................................ 179
Draining the coolant .................................................... 179
Refilling coolant .......................................................... 180
38/LUBRICATION SYSTEM .............................................. 181
Oil circuit ................................................................... 181
Checking the engine oil level ........................................ 181
Changing the engine oil and oil filter, cleaning the oil
screen ........................................................................ 182
Adding engine oil ........................................................ 184
Checking the engine oil pressure................................... 184
39/IGNITION SYSTEM ..................................................... 186
Ignition coil - checking the secondary winding................ 186
Checking the spark plug connector................................ 186
Alternator - checking the stator winding......................... 186
Removing the stator and ignition pulse generator............ 187
Installing the stator and ignition pulse generator............. 188
40/ELECTRIC STARTER................................................... 189
Checking the starter motor ........................................... 189
41/THROTTLE VALVE BODY............................................. 190
Throttle position sensor circuit A - checking the basic
settings ...................................................................... 190
Throttle position sensor - adjusting the basic settings...... 190
TECHNICAL DATA - ENGINE............................................ 192
Capacity - engine oil .................................................... 192
Capacity - coolant........................................................ 192
TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF
ENGINE ......................................................................... 193
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........ 194
TECHNICAL DATA - CHASSIS .......................................... 196
Lighting equipment ..................................................... 197
Tires .......................................................................... 197
Capacity - fuel............................................................. 197
TECHNICAL DATA - FORK................................................ 198
TECHNICAL DATA - SHOCK ABSORBER ........................... 199
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 200
CLEANING, CARE ........................................................... 201
Cleaning the motorcycle............................................... 201
Checks and maintenance steps for winter operation ........ 202
STORAGE ....................................................................... 203
Storage....................................................................... 203
Preparing for use after storage ...................................... 203
SERVICE SCHEDULE....................................................... 204
Service schedule ......................................................... 204
Service work (as additional order).................................. 205
WIRING DIAGRAM .......................................................... 206
Page 1 of 8 (EXC‑F EU, EXC-F SIX DAYS)...................... 206
Page 2 of 8 (EXC‑F EU, EXC-F SIX DAYS)...................... 208
Page 3 of 8 (EXC‑F EU, EXC-F SIX DAYS)...................... 210
Page 4 of 8 (EXC‑F EU, EXC-F SIX DAYS)...................... 212
Page 5 of 8 (EXC‑F EU, EXC-F SIX DAYS)...................... 214
Page 6 of 8 (EXC‑F EU, EXC-F SIX DAYS)...................... 216
Page 7 of 8 (EXC‑F EU, EXC-F SIX DAYS)...................... 218
Page 8 of 8 (EXC‑F EU, EXC-F SIX DAYS)...................... 220
Page 1 of 8 (EXC‑F AUS) ............................................. 222
Page 2 of 8 (EXC‑F AUS) ............................................. 224
Page 3 of 8 (EXC‑F AUS) ............................................. 226
Page 4 of 8 (EXC‑F AUS) ............................................. 228
Page 5 of 8 (EXC‑F AUS) ............................................. 230
Page 6 of 8 (EXC‑F AUS) ............................................. 232
Page 7 of 8 (EXC‑F AUS) ............................................. 234
Page 8 of 8 (EXC‑F AUS) ............................................. 236
Page 1 of 8 (EXC-F USA) ............................................. 238
Page 2 of 8 (EXC-F USA) ............................................. 240
Page 3 of 8 (EXC-F USA) ............................................. 242
Page 4 of 8 (EXC-F USA) ............................................. 244
Page 5 of 8 (EXC-F USA) ............................................. 246
Page 6 of 8 (EXC-F USA) ............................................. 248
Page 7 of 8 (EXC-F USA) ............................................. 250
Page 8 of 8 (EXC-F USA) ............................................. 252
Page 1 of 7 (XCF‑W) .................................................... 254
Page 2 of 7 (XCF‑W) .................................................... 256
Page 3 of 7 (XCF‑W) .................................................... 258

TABLE OF CONTENTS 5
Page 4 of 7 (XCF‑W) .................................................... 260
Page 5 of 7 (XCF‑W) .................................................... 262
Page 6 of 7 (XCF‑W) .................................................... 264
Page 7 of 7 (XCF‑W) .................................................... 266
SUBSTANCES................................................................. 268
AUXILIARY SUBSTANCES................................................ 270
SPECIAL TOOLS.............................................................. 272
STANDARDS................................................................... 285
INDEX ............................................................................ 286

MEANS OF REPRESENTATION 6
Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Denotes a voltage measurement.
Denotes a current measurement.
Denotes a resistance measurement.
Formats used
The typographical formats used in this document are explained below.
Proprietary name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a trademark.

IMPORTANT NOTES 7
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 claims will be void. No warranty claim can be honored for damage
resulting from manipulation and/or other changes to the vehicle.
Fuel, oils, etc.
You should use the fuels, oils and greases according to specifications as listed in the repair manual.
Spare parts, accessories
Only use spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other products and any
resulting damage or loss.
You will find the current KTM PowerParts for your vehicle on the KTM website.
International KTM Website: http://www.ktm.com
Work rules
Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in
parentheses. Ex: valve spring compressor (59029019000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be
replaced by new parts.
If thread lock (e.g. Loctite®) is used for screw connections, be sure to comply with the manufacturer's specific instructions on its
usage.
Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or
worn parts.
Ensure that the vehicle is safe to operate after completing repair and maintenance work.
Notes/warnings
Pay close attention to the notes/warnings.
Info
Various information and warning labels are affixed 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 injury if the appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
Repair manual
–It is imperative that you read this owner's manual carefully and completely before the start of work. It contains useful information
and many tips on how to repair and maintain your vehicle.
–This manual assumes that the necessary special KTM tools and workplace and workshop equipment are available.

SERIAL NUMBERS 8
3.1Chassis number
C00125-10
The chassis number 1is stamped on the steering head on the right.
3.2Type label
101290-10
(XCF‑W, EXC‑F EU/AUS, EXC-F SIX DAYS)
The type label 1is fixed to the front of the steering head.
101477-10
(EXC-F USA)
The type label USA 1is fixed to the front of the steering head.
101478-10
(EXC-F USA)
The type label Canada 2is fixed to the front of the front pipe.
3.3Key number (All EXC‑F models)
500125-10
(EXC‑F EU/AUS, EXC-F SIX DAYS)
The key number 1for the steering lock is stamped onto the key connector.

SERIAL NUMBERS 9
101543-10
(EXC-F USA)
Key number 1for the ignition and steering lock is indicated on the KEYCODECARD.
Info
You need the key number to order a replacement key. Keep the KEYCODE-
CARD in a safe place.
3.4Engine number
101291-10
The engine number 1is stamped on the left side of the engine under the engine
sprocket.
3.5Fork part number
B00265-01
The fork part number 1is stamped on the inner side of the fork stub.
3.6Shock absorber part number
101292-10
The shock absorber part number 1is stamped on the top of the shock absorber above
the adjusting ring on the engine side.

MOTORCYCLE 10
4.1Raising the motorcycle with the lift stand
101424-01
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
–Raise the motorcycle at the frame underneath the engine.
Lift stand (54829055000) ( p. 273)
The wheels should no longer touch the ground.
–Secure the motorcycle against falling over.
4.2Removing the motorcycle from the lift stand
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
101311-10
–Remove the motorcycle from the lift stand.
–Remove the lift stand.
–To park the motorcycle, press the side stand 1to the ground with your foot and
lean the motorcycle on it.
Info
When you are riding, the side stand must be folded up and secured with the
rubber band.
4.3Starting
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 effective exhaust extraction system.
Note
Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.
–Always warm up the engine at low engine speeds.
101312-11
–Raise the motorcycle off of the stand and secure the stand with the rubber band 1.
–Shift transmission to neutral.
(EXC-F USA)
–Turn the key in the ignition lock to the position .
–Turn the emergency OFF switch to the position .
(EXC‑F AUS)
–Turn the emergency OFF switch to the position .
400733-01
–Press the electric starter button or press the kickstarter robustly through its full
range.
Info
Press the electric starter button for at most 5 seconds. Wait for a least 5
seconds before trying again.
FI warning lamp lights up briefly as a functional control when starting.

MOTORCYCLE 11
4.4Starting the motorcycle for a check
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 effective exhaust extraction system.
Info
Press the starter for a maximum of 5 seconds. Wait for at least 5 seconds before trying again.
–Shift transmission to neutral.
(EXC-F USA)
–Turn the key in the ignition lock to the position .
–Turn the emergency OFF switch to the position .
(EXC‑F AUS)
–Turn the emergency OFF switch to the position .
–Press the electric starter button or press the kickstarter robustly through its full range.
Info
Do not open the throttle.

01/FORK, TRIPLE CLAMP 12
5.1Adjusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
100020-10
–Remove protection caps 1.
–Turn adjusting screws 2clockwise all the way.
Info
Adjusting screws 2are 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 1.
5.2Adjusting the rebound damping of the fork
Info
The hydraulic rebound damping determines the fork suspension behavior.
101316-10
–Turn adjusting screws 1clockwise all the way.
Info
Adjusting screws 1are located at the top 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
Rebound damping
Comfort 22 clicks
Standard 20 clicks
Sport 18 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
5.3Adjusting the spring preload of the fork
101317-01
–Turn the adjusting screws counterclockwise all the way.
Info
Make the same adjustment on both fork legs.
–Turn back clockwise by the number of turns corresponding to the fork type.
Guideline
Spring preload - Preload Adjuster
Comfort 1 turn
Standard 2 turns
Sport 2 turns

01/FORK, TRIPLE CLAMP 13
Info
Turn clockwise to increase spring preload; turn counterclockwise to reduce
spring preload.
Adjusting the spring preload has no influence on the absorption setting of
the rebound damping.
Basically, however, you should set the rebound damping higher with a
higher spring preload.
5.4Bleeding fork legs
Preliminary work
–Raise the motorcycle with the lift stand. ( p. 10)
101319-10
Main work
–Remove bleeder screws 1briefly.
Any excess pressure escapes from the interior of the fork.
–Mount and tighten bleeder screws.
Follow-up work
–Remove the motorcycle from the lift stand. ( p. 10)
5.5Cleaning the dust boots of the fork legs
Preliminary work
–Raise the motorcycle with the lift stand. ( p. 10)
–Loosen the fork protector. ( p. 14)
101320-10
Main work
–Push dust boots 1of both fork legs downwards.
Info
The dust boots should remove dust and coarse dirt particles from the fork
tubes. Over time, there is an ingress of dirt inside the boots. If this dirt is
not removed, it may cause the oil seals to leak.
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 necessary.
–Clean and oil the dust boots and inner fork tube of both fork legs.
Universal oil spray ( p. 271)
–Press the dust boots back into their normal position.
–Remove excess oil.
Follow-up work
–Position the fork protection. ( p. 14)
–Remove the motorcycle from the lift stand. ( p. 10)

01/FORK, TRIPLE CLAMP 14
5.6Loosening the fork protector
101321-10
–Remove screws 1and remove the clamp.
–Remove screws 2on the left fork leg. Push the fork protector downwards.
–Remove the screws on the right fork leg. Push the fork protector downwards.
5.7Positioning the fork protection
101321-11
–Position the fork protection on the left fork leg. Mount and tighten screws 1.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
–Position the wiring harness.
–Position the brake line. Put the clamp on, mount and tighten screws 2.
–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)
5.8Removing the fork legs
Preliminary work
–Remove the headlight mask with the headlight. ( p. 78)
–Raise the motorcycle with the lift stand. ( p. 10)
–Remove the front wheel. ( p. 80)
101322-10
Main work
–Remove screws 1and take off the clamp.
–Remove cable binder 2.
–Remove screws 3and take off the brake caliper.
–Allow the brake caliper and brake line to hang tension-free to the side.
101323-10
(XCF‑W, EXC‑F EU/AUS)
–Release screws 4. Take out the left fork leg.
–Release screws 5. Take out the right fork leg.
101489-10
(EXC-F USA)
–Release screws 4. Take out the left fork leg.
–Release screws 5. Take out the right fork leg.

01/FORK, TRIPLE CLAMP 15
101324-10
(EXC-F SIX DAYS)
–Release screws 4. Take out the left fork leg.
–Release screws 5. Take out the right fork leg.
5.9Installing the fork legs
101325-10
Main work
–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 bleeder screws 1toward the front.
101323-11
(XCF‑W, EXC‑F EU/AUS)
–Tighten screws 2.
Guideline
Screw, top triple clamp M8 20 Nm
(14.8 lbf ft)
–Tighten screws 3.
Guideline
Screw, bottom triple clamp M8 15 Nm
(11.1 lbf ft)
101489-11
(EXC-F USA)
–Tighten screws 2.
Guideline
Screw, top triple clamp M8 20 Nm
(14.8 lbf ft)
–Tighten screws 3.
Guideline
Screw, bottom triple clamp M8 15 Nm
(11.1 lbf ft)
101324-11
(EXC-F SIX DAYS)
–Tighten screws 2.
Guideline
Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
–Tighten screws 3.
Guideline
Screw, bottom triple clamp M8 12 Nm
(8.9 lbf ft)
101326-10
–Position brake caliper, and mount and tighten screws 4.
Guideline
Screw, front brake caliper M8 25 Nm
(18.4 lbf ft)
Loctite®243™
–Mount cable binder 5.
–Refit the headlight mask with the headlight. ( p. 78)

01/FORK, TRIPLE CLAMP 16
–Position the brake line, wiring harness, and clamp. Mount and tighten screws 6.
Subsequent work
–Install the front wheel. ( p. 80)
5.10Removing the fork protector
Preliminary work
–Remove the headlight mask with the headlight. ( p. 78)
–Raise the motorcycle with the lift stand. ( p. 10)
–Remove the front wheel. ( p. 80)
–Remove the fork legs. ( p. 14)
101327-10
Main work
–Remove screws 1on the left fork leg. Remove the fork protector upwards.
–Remove the screws on the right fork leg. Remove the fork protector upwards.
5.11Installing the fork protector
101327-10
Main work
–Position the fork protection on the left fork leg. Mount and tighten screws 1.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
–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)
Subsequent work
–Install the fork legs. ( p. 15)
–Install the front wheel. ( p. 80)
5.12Performing a fork service
Info
These operations are the same on both fork legs.
Condition
The fork legs have been removed.

01/FORK, TRIPLE CLAMP 17
200979-01
–Disassemble the fork legs. ( p. 17)
–Disassemble the cartridge. ( p. 20)
–Check the fork legs. ( p. 22)
–Assemble the cartridge. ( p. 24)
–Assemble the fork legs. ( p. 26)
5.13Disassembling the fork legs
Info
The steps are identical for both fork legs.
Condition
The fork legs are disassembled.
200736-10
–Remove protective cover A.
–Note down the present state of rebound damping 1and compression damping 2.
–Note down of the present state of the spring preload.
–Completely open the adjusters of the rebound damping and compression damping.
201347-10
–Clamp the fork leg in the area of lower triple clamp.
Clamping stand (T1403S) ( p. 283)
200737-10
–Loosen Preload Adjuster 3.
Pin wrench (T103) ( p. 279)
Info
The Preload Adjuster cannot be taken off yet.

01/FORK, TRIPLE CLAMP 18
200690-10
–Take out the fork leg and clamp with the axle clamp.
Info
Use soft jaws.
200738-10
–Push the outer tube downward.
–Pull the spring downward. Place the special tool on the hexagonal part.
Open-end wrench (T14032) ( p. 283)
Info
The preload spacers 4should be above the special tool.
200739-10
–Clamp the special tool in the bench vise. Loosen Preload Adjuster 3.
200740-10
–Remove Preload Adjuster 3with preload spacers 4.
–Remove adjustment tube 5.
201348-10
–Pull the spring downward. Remove the special tool.
–Remove the spring.
201349-10
–Drain the fork oil.
Info
Pull out and push in the piston rod a few times to empty the cartridge.