KTM 350 EXC-F \ EXC-F SIX DAYS \ XCF-W Workshop Service Repair Manual 2013
KTM 350 EXC-F \ EXC-F SIX DAYS \ XCF-W Workshop Service Repair Manual 2013
IMPROVED PDF manuals have: Bookmarks + Searchable Text + Index --BEST ORGANIZATION!
This Workshop Service repair manual offers detailed servicing instructions and will give you complete step by step information on repair, servicing, preventative maintenance & troubleshooting procedures for your Ktm.
This comprehensive service manual features photos and illustrations along with step-by-step instructions that will guide you through the entire repair process. This manual contains all you need to know to keep your Motorcycle working correctly.
Models covered :
350 EXC-F EU
350 EXC-F AUS
350 EXC-F SIX DAYS EU
350 XCF-W USA
350 EXC-F USA
Table Of Contents:
MEANS OF REPRESENTATION ..................................... 6
1.1 Symbols used ................................................... 6
1.2 Formats used .................................................... 6
SAFETY ADViCE ........................................................... 7
2.1 Repair Manual .................................................. 7
2.2 Safety advice .................................................... 7
2.3 Degrees of risk and symbols ............................... 7
2.4 Work rules ........................................................ 7
IMPORTANT NOTES ..................................................... 8
3.1 Guarantee, warranty .......................................... 8
3.2 Operating and auxiliary substances ..................... 8
3.3 Spare parts, accessories .................................... 8
3.4 Figures ............................................................ 8
SERIAL NUMBERS ...................................................... 9
4.1 Chassis number ................................................ 9
4.2 Type label ........................................................ 9
4.3 Key number (All EXC-F models) .......................... 9
4.4 Engine number ............................................... 10
4.5 Fork part number ............................................ 10
4.6 Shock absorber part number ............................ 10
MOTORCYCLE ........................................................... 11
5.1 Raising the motorcycle with the lift stand .......... 11
5.2 Removing the motorcycle from the lift stand ...... 11
5.3 Starting .......................................................... 11
5.4 Starting the motorcycle for a check ................... 12
FORK, TRIPLE CLAMP ............................................... 13
6.1 EXC-F EU/AUS/USA, XCF-W ............................. 13
6.1.1 Adjusting the compression damping of the
fork ........................................................... 13
Adjusting the rebound damping of the fork .... 13
Adjusting the spring preload of the fork ......... 13
Bleeding fork legs ....................................... 14
Cleaning the dust boots of the fork legs ......... 14
Loosening the fork protector ......................... 15
Positioning the fork protection ..................... 15
Removing the fork legs ................................ 15
Install i ng the fork legs ........ ...... .............. ..... 16
Removing the fork protector ......................... 16
Install i ng the fork protector .............. ...... ...... 17
Perform i ng a fork service.... ...... .............. ..... 17
Disassembling the fork legs ......................... 17
Cartridge disassembly ................................. 20
Disassembling the compression damping
fitting ........................................................ 22
Checking the fork legs ................................. 22
Assembling the compression damping
fitting ........................................................ 24
Assembling the cartridge ............................. 24
Assembling the fork legs .............................. 26
Greasing the steering head bearing ............... 30
Removing the lower triple clamp .................. 30
Installing the lower triple clamp ................... 31
Checking the steering head bearing play ....... 33
Adjusting the play of the steering head
bearing ...................................................... 33
EXC-F S IX DAYS ...... ...... .............. ...... ............. 34
Adjusting the compression damping of the
fork ........................................................... 34
Adjusting the rebound damping of the fork .... 34
Bleeding fork legs ....................................... 34
Cleaning the dust boots of the fork legs ......... 35
Loosening the fork protector ......................... 35
Positioning the fork protection ..................... 36
Removing the fork legs ................................ 36
Installing the fork legs ................................. 36
Removing the fork protector ......................... 37
Installing the fork protector .......................... 37
Performing a fork service ............................. 37
Disessembling the fork legs ......................... 38
Removing the spring ................................... 40
Disassembling the cartridge ......................... 41
Disassembling the piston rod ....................... 42
Disassembling the hydrostop unit ................. 43
Disassembling the seal ring retainer .............. 43
Checki ng the fork legs...... ...... ...... ........ ....... 44
Assembling the seal ring retainer .................. 45
Assembling the hydrostop unit ..................... 45
Assembling the piston rod ........................... 46
Assembling the cartridge ............................. 47
Assembling the fork legs .............................. 48
Greasing the steering head bearing ............... 52
Removing the lower triple clamp .................. 52
Installing the lower triple clamp ................... 53
Checking the steering head bearing play ....... 54
6.2.28 Adjusting the play of the steering head
bearing ...................................................... 55
HANDLEBAR, CONTROLS ........................................... 56
7.1 Handlebar position .......................................... 56
7.2 Adjusting handlebar position ............................ 56
7.3 Adjusting the basic position of the clutch
lever .............................................................. 56
7.4 Checking the throttle cable routing ................... 57
7.5 Checking the play in the throttle cable .............. 57
7.6 Adjusting the play in the throttle cable .............. 58
FRAME ..................................................................... 59
8.1 Removing the engine guard (EXC-F AUS,
EXC-F SIX DAYS) ............................................ 59
8.2 Installing the engine guard (EXC-F AUS, EXC-F
SIX DAyS) ...................................................... 59
SHOCK ABSORBER, SWINGARM ................................ 60
9.1 Adjusting the high-speed compression
damping of the shock absorber ......................... 60
9.2 Adjusting the low-speed compression damping
of the shock absorber .... ...... ........ ...... .............. 60
9.3 Adjusting the rebound damping of the shock
absorber ......................................................... 61
9.4 Measuring rear wheel sag unloaded ................... 61
9.5 Checking the static sag of the shock absorber .... 61
9.6 Checking the riding sag of the shock absorber .... 62
9.7 Adjusting the spring preload of the shock
absorber ......................................................... 62
9.8 Adjusting the riding sag ................................... 63
9.9 Removing the shock absorber ........................... 63
9.10 Installing the shock absorber ............................ 63
9.11 Servicing the shock absorber ............................ 64
9.12 Removing the spring ........................................ 64
9.13 Disassembling the damper ............................... 65
9.14 Disassembling the piston rod ........................... 66
9.15 Disassembling the seal ring retainer .................. 67
9.16 Replacing the pilot bushing ............................. 68
9.17 Checking the damper ...................................... 69
9.18 Disassembling the rebound adjuster .................. 69
9.19 Removing the heim join!.. ................................ 70
9.20 Installing the heim join!.. ................................. 71
9.21 Assembling the rebound adjuster ...................... 72 15.2 Installing the main fuse ................................. 110
9.22 Assembling the seal ring retainer ...................... 72 15.3 Changing the fuses of individual power
9.23 Assembling the piston rod ................................ 73 consumers .................................................... 110
9.24 Assembling the damper ................................... 74 15.4 Changing the fuse of the radiator fan (EXC-F
9.25 Bleeding and filling the damper ....................... 77 SIX DAYS) .................................................... 111
9.26 Filling the damper with nitrogen ....................... 79 15.5 Removing the battery .................................... 112
9.27 Installing the spring ........................................ 80 15.6 Installing the battery ..................................... 112
9.28 Changing the heim joint ................................... 81 15.7 Charging the battery ...................................... 113
10 EXHAUST .................................................................. 83 16 BRAKE SYSTEM ...................................................... 114
10.1 Removing the manifold .................................... 83 16.1 Checking the front brake linings ..................... 114
10.2 Installing the manifold .................................... 83 16.2 Changing the front brake linings ..................... 114
10.3 Removing main silencer ................................... 84 16.3 Checking free travel of hand brake lever .......... 116
10.4 Installing the main silencer .............................. 84
10.5 Changing the glass fiber yarn filling of the
main silencer .................................................. 84
16.4 Adjusting the basic position of the hand
brake lever (XCF-W) ....................................... 116
16.5 Adjusting free travel of hand brake lever (All
11 AIR FILTER ............................................................... 86 EXC-F models) .............. ...... .............. ...... ...... 116
11.1 Removing the air filter box lid .......................... 86
11.2 Installing the air filter box lid ........................... 86
11.3 Removing the air filter ..................................... 86
11.4 Installing the air filter ...................................... 86
11.5 Cleaning the air filter and air filter box .............. 87
12 FUEL TANK, SEAT, TRIM ........................................... 88
12.1 Opening filler cap ........................................... 88
12.2 Closing filler cap ............................................. 88
12.3 Removing the seat .......................................... 88
12.4 Mounting the sea!.. ......................................... 89
12.5 Removing the fuel tank .................................... 89
12.6 Installing the fuel tank .................................... 90
12.7 Changing the fuel screen ................................. 91
12.8 Changing the fuel filter .................................... 92
12.9 Changing the fuel pump .................................. 94
12.10 Checking the fuel pressure ............................... 95
13 MASK, FENDER ......................................................... 97
13.1 Removing the front fender ............................... 97
13.2 Installing the front fender ................................ 97
13.3 Removing headlight mask with headligh!.. ......... 97
13.4 Refitting the headlight mask with the
headlight.. ...................................................... 97
14 WHEELS ................................................................... 99
16.6 Checking the front brake fluid level ................ 117
16.7 Adding front brake fluid ................................. 117
16.8 Changing the front brake fluid ........................ 118
16.9 Checking the rear brake linings ...................... 119
16.10 Changing the rear brake linings ...................... 119
16.11 Checking the free travel of foot brake lever ...... 121
16.12 Adjusting the basic position of the foot brake
lever ............................................................ 121
16.13 Checking the rear brake fluid level .................. 122
16.14 Adding brake fluid to the rear brake circui!.. .... 122
16.15 Changing the rear brake fluid ......................... 123
17 LIGHTING SYSTEM, INSTRUMENTS ......................... 125
17.1 Adjusting the speedometer functions .............. 125
17.2 Setting kilometers or miles ............................. 125
17.3 Activating the additional functions .................. 126
17.4 Setting the wheel circumference .................... 126
17.5 Setting the clock ........................................... 127
17.6 Checking the headlight setting ....................... 127
17.7 Adjusting the headlight range ......................... 128
18 ENGINE .................................................................. 129
18.1 Removing the engine ..................................... 129
18.2 Installing the engine ...................................... 133
18.3 Engine disassembly ....................................... 137
14.1 Checking the tire air pressure ........................... 99
14.2 Checking the tire condition .............................. 99
14.3 Checking the brake discs ............................... 100
14.4 Checking spoke tension ................................. 100
14.5 Front wheel .................................................. 101
18.3.1 Preparations ............................................. 137
18.3.2 Removing the clutch push rod .................... 137
18.3.3 Removing the spacer ................................. 137
18.3.4 Draining the engine oil .............................. 137
18.3.5 Removing the oil filter ............................... 138
14.5.1 Removing the front wheel .......................... 101
14.5.2 Installing the front wheel ........................... 101
14.5.3 Removing the front brake disc .................... 102
14.5.4 Installing the front brake disc .................... 102
14.6 Rear wheel ................................................... 102
18.3.6 Removing the spark plug ........................... 138
18.3.7 Removing the valve cover ........................... 138
18.3.8 Removing the kick starter .......................... 139
18.3.9 Removing the alternator cover .................... 139
18.3.10 Removing the torque limiter ....................... 140
14.6.1 Removing the rear wheel ........................... 102
14.6.2 Installing the rear wheel ............................ 103
14.6.3 Removing the rear brake disc ..................... 104
14.6.4 Installing the rear brake disc ...................... 104
14.6.5 Checking the chain tension ........................ 105
14.6.6 Adjusting the chain tension ....................... 105
14.6.7 Adjusting the chain guide .......................... 106
14.6.8 Checking the chain, rear sprocket, engine
sprocket and chain guide ........................... 106
14.6.9 Checking for chain dirt accumulation .......... 108
14.6.10 Cleaning the chain .................................... 108
15 WIRING HARNESS, BATTERy ................................... 110
18.3.11 Positioning the engine at ignition top dead
center ...................................................... 140
18.3.12 Removing the timing chain tensioner .......... 140
18.3.13 Removing the camshaft ............................. 141
18.3.14 Removing the cylinder head ....................... 141
18.3.15 Removing the piston ................................. 142
18.3.16 Removing the starter drive ......................... 142
18.3.17 Removing the suction pump ....................... 143
18.3.18 Removing the water pump wheel ................ 144
18.3.19 Removing the clutch cover ......................... 144
18.3.20 Removing the clutch discs ......................... 145
18.3.21 Removing the outer clutch hub .................. 146
15.1 Removing the main fuse ................................ 110
18.3.22 Removing the intermediate kick starter 18.4.34 Checking the shift mechanism ................... 171
gear ......................................................... 146 18.4.35 Preassembling Ihe shift shaft ..................... 172
18.3.23 Removing the intermediate kick starter 18.4.36 Disassembling Ihe main shaft .................... 172
gear ......................................................... 146 18.4.37 Disassembling Ihe counlershaft .................. 173
18.3.24 Removing the shift shaft ............................ 147 18.4.38 Checking Ihe Iransmission ......................... 173
18.3.25 Removing the shift drum localing unil ........ 147 18.4.39 Assembling Ihe main shaft ......................... 174
18.3.26 Removing the locking lever ........................ 147 18.4.40 Assembling the counlershaft ...................... 175
18.3.27 Removing the force pump .......................... 147 18.5 Engine assembly ........................................... 176
18.3.28 Removing the primary gear ........................ 148 18.5.1 Installing the crankshaft ............................ 176
18.3.29 Removing Ihe liming chain ........................ 148 18.5.2 Installing Ihe Iransmission shafts ............... 177
18.3.30 Removing Ihe spacer ................................. 149 18.5.3 Installing Ihe shift lorks ............................. 177
18.3.31 Removing Ihe left seclion 01 Ihe engine
case ........................................................ 149
18.3.32 Removing the shift rails ............................. 149
18.3.33 Removing the shift drum ........................... 150
18.3.34 Removing the shift lorks ............................ 150
18.3.35 Removing Ihe lransmission shafts ............... 150
18.3.36 Removing Ihe crankshaft ........................... 151
18.4 Work on individual parts ................................ 151
18.4.1 Work on Ihe righl seclion of Ihe engine
case ........................................................ 151
18.4.2 Working on the left seclion 01 the engine
case ........................................................ 152
18.5.4 Installing Ihe shift drum ............................ 177
18.5.5 Installing the shift rails ............................. 178
18.5.6 Installing the left engine case .................... 178
18.5.7 Installing the spacer .................................. 179
18.5.8 Installing the timing chain ......................... 179
18.5.9 Installing Ihe primary gear ......................... 179
18.5.10 Installing Ihe lorce pump ........................... 180
18.5.11 Installing Ihe suclion pump ....................... 180
18.5.12 Installing the locking lever ......................... 181
18.5.13 Installing the shift drum locating unil ......... 181
18.5.14 Installing the shift shaft ............................ 182
18.4.3 Work on Ihe clulch cover ........................... 153
18.4.4 Checking Ihe oil pressure regulalor valve ..... 154
18.4.5 Checking Ihe lubricalion system ................. 155
18.4.6 Removing the crankshaft bearing inner
race ......................................................... 156
18.5.15 Installing Ihe inlermediale kick starter
gear ......................................................... 182
18.5.16 Installing Ihe kick starter shaft ................... 182
18.5.17 Installing Ihe ouler clulch hub ................... 182
18.5.18 Installing the clutch discs .......................... 183
18.4.7 Installing the crankshaft bearing inner
race ......................................................... 156
18.5.19 Installing the clutch cover ......................... 184
18.5.20 Installing the water pump cover .................. 185
18.4.8 Changing Ihe connecling rod, conrod 18.5.21 Installing Ihe starter drive .......................... 185
bearing and crank pin ............................... 156 18.5.22 Installing Ihe pislon .................................. 186
18.4.9 Checking Ihe crankshaft run-oul allhe 18.5.23 Installing Ihe cylinder head ........................ 188
bearing pin ............................................... 158 18.5.24 Installing Ihe camshafts ............................ 189
18.4.10 Removing the drive wheel of the balancer 18.5.25 Checking the valve liming .......................... 189
shaft ........................................................ 158 18.5.26 Adjusting Ihe valve timing ......................... 190
18.4.11 Installing the drive wheel of Ihe balancer 18.5.27 Installing the timing chain tensioner ........... 191
shaft ........................................................ 158 18.5.28 Checking Ihe valve clearance ..................... 192
18.4.12 Cylinder - Nikasil" coaling ......................... 158 18.5.29 Adjusting Ihe valve clearance ..................... 192
18.4.13 Checking/measuring Ihe cylinder ................ 158 18.5.30 Installing Ihe lorque limiler ....................... 193
18.4.14 Checking/measuring Ihe piston ................... 159 18.5.31 Installing the alternator cover ..................... 193
18.4.15 Measuring the piston/cylinder mounting
clearance ................................................. 160
18.4.16 Checking Ihe piston ring end gap ............... 160
18.4.17 Changing the camshaft bearing .................. 160
18.4.18 Checking Ihe camshafts ............................ 161
18.4.19 Checking Ihe pivol points 01 Ihe
camshafts .................. ....... ............. .......... 161
18.4.20 Removing Ihe valves .................................. 162
18.4.21 Checking Ihe valves .................................. 163
18.4.22 Checking Ihe valve springs ......................... 163
18.5.32 Installing the kick starter ........................... 193
18.5.33 Installing the valve cover ........................... 194
18.5.34 Installing Ihe spark plug ............................ 194
18.5.35 Installing Ihe oil liller ................................ 194
18.5.36 Installing Ihe oil screen ............................. 195
18.5.37 Installing Ihe spacer .................................. 195
18.5.38 Installing the clutch push rod .................... 196
18.5.39 Removing Ihe engine from the engine
assembly stand ......................................... 196
19 CLUTCH .................................................................. 197
18.4.23 Checking Ihe valve spring seal ................... 163
18.4.24 Checking Ihe cam levers ............................ 164
19.1 Checking/correcling Ihe Iluid level ollhe
hydraulic clulch ............................................ 197
18.4.25 Checking Ihe cylinder head ........................ 164 19.2 Changing Ihe hydraulic clulch fluid ................ 197
18.4.26 Inslalling Ihe valves .................................. 164 20 WATER PUMP, COOLING SYSTEM ............................ 198
18.4.27 Checking Ihe Ireewheel ............................. 165 20.1 Cooling system ............................................. 198
18.4.28 Changing the free wheel ............................ 166 20.2 Checking the anlifreeze and cool ani level ........ 198
18.4.29 Preassembling the kick starter shaft ........... 166 20.3 Checking Ihe coolanl level ............................. 199
18.4.30 Checking Ihe eleclric slarter drive .............. 167 20.4 Draining Ihe coolanl.. .................................... 199
18.4.31 Checking Ihe liming assembly .................... 168 20.5 Refilling coolanl ........................................... 200
18.4.32 Preparing the timing chain tensioner for 21 LUBRICATION SySTEM ............................................ 201
inslallalion ............................................... 169 21.1 Oil circuil... .................................................. 201
18.4.33 Checking Ihe clulch .................................. 169 21.2 Checking the engine oil level. ......................... 201
And Much More ...
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KTM 350 EXC-F \ EXC-F SIX DAYS \ XCF-W Workshop Service Repair Manual 2013
KTM 350 EXC-F \ EXC-F SIX DAYS \ XCF-W Workshop Service Repair Manual 2013
IMPROVED PDF manuals have: Bookmarks + Searchable Text + Index --BEST ORGANIZATION!
This Workshop Service repair manual offers detailed servicing instructions and will give you complete step by step information on repair, servicing, preventative maintenance & troubleshooting procedures for your Ktm.
This comprehensive service manual features photos and illustrations along with step-by-step instructions that will guide you through the entire repair process. This manual contains all you need to know to keep your Motorcycle working correctly.
Models covered :
350 EXC-F EU
350 EXC-F AUS
350 EXC-F SIX DAYS EU
350 XCF-W USA
350 EXC-F USA
Table Of Contents:
MEANS OF REPRESENTATION ..................................... 6
1.1 Symbols used ................................................... 6
1.2 Formats used .................................................... 6
SAFETY ADViCE ........................................................... 7
2.1 Repair Manual .................................................. 7
2.2 Safety advice .................................................... 7
2.3 Degrees of risk and symbols ............................... 7
2.4 Work rules ........................................................ 7
IMPORTANT NOTES ..................................................... 8
3.1 Guarantee, warranty .......................................... 8
3.2 Operating and auxiliary substances ..................... 8
3.3 Spare parts, accessories .................................... 8
3.4 Figures ............................................................ 8
SERIAL NUMBERS ...................................................... 9
4.1 Chassis number ................................................ 9
4.2 Type label ........................................................ 9
4.3 Key number (All EXC-F models) .......................... 9
4.4 Engine number ............................................... 10
4.5 Fork part number ............................................ 10
4.6 Shock absorber part number ............................ 10
MOTORCYCLE ........................................................... 11
5.1 Raising the motorcycle with the lift stand .......... 11
5.2 Removing the motorcycle from the lift stand ...... 11
5.3 Starting .......................................................... 11
5.4 Starting the motorcycle for a check ................... 12
FORK, TRIPLE CLAMP ............................................... 13
6.1 EXC-F EU/AUS/USA, XCF-W ............................. 13
6.1.1 Adjusting the compression damping of the
fork ........................................................... 13
Adjusting the rebound damping of the fork .... 13
Adjusting the spring preload of the fork ......... 13
Bleeding fork legs ....................................... 14
Cleaning the dust boots of the fork legs ......... 14
Loosening the fork protector ......................... 15
Positioning the fork protection ..................... 15
Removing the fork legs ................................ 15
Install i ng the fork legs ........ ...... .............. ..... 16
Removing the fork protector ......................... 16
Install i ng the fork protector .............. ...... ...... 17
Perform i ng a fork service.... ...... .............. ..... 17
Disassembling the fork legs ......................... 17
Cartridge disassembly ................................. 20
Disassembling the compression damping
fitting ........................................................ 22
Checking the fork legs ................................. 22
Assembling the compression damping
fitting ........................................................ 24
Assembling the cartridge ............................. 24
Assembling the fork legs .............................. 26
Greasing the steering head bearing ............... 30
Removing the lower triple clamp .................. 30
Installing the lower triple clamp ................... 31
Checking the steering head bearing play ....... 33
Adjusting the play of the steering head
bearing ...................................................... 33
EXC-F S IX DAYS ...... ...... .............. ...... ............. 34
Adjusting the compression damping of the
fork ........................................................... 34
Adjusting the rebound damping of the fork .... 34
Bleeding fork legs ....................................... 34
Cleaning the dust boots of the fork legs ......... 35
Loosening the fork protector ......................... 35
Positioning the fork protection ..................... 36
Removing the fork legs ................................ 36
Installing the fork legs ................................. 36
Removing the fork protector ......................... 37
Installing the fork protector .......................... 37
Performing a fork service ............................. 37
Disessembling the fork legs ......................... 38
Removing the spring ................................... 40
Disassembling the cartridge ......................... 41
Disassembling the piston rod ....................... 42
Disassembling the hydrostop unit ................. 43
Disassembling the seal ring retainer .............. 43
Checki ng the fork legs...... ...... ...... ........ ....... 44
Assembling the seal ring retainer .................. 45
Assembling the hydrostop unit ..................... 45
Assembling the piston rod ........................... 46
Assembling the cartridge ............................. 47
Assembling the fork legs .............................. 48
Greasing the steering head bearing ............... 52
Removing the lower triple clamp .................. 52
Installing the lower triple clamp ................... 53
Checking the steering head bearing play ....... 54
6.2.28 Adjusting the play of the steering head
bearing ...................................................... 55
HANDLEBAR, CONTROLS ........................................... 56
7.1 Handlebar position .......................................... 56
7.2 Adjusting handlebar position ............................ 56
7.3 Adjusting the basic position of the clutch
lever .............................................................. 56
7.4 Checking the throttle cable routing ................... 57
7.5 Checking the play in the throttle cable .............. 57
7.6 Adjusting the play in the throttle cable .............. 58
FRAME ..................................................................... 59
8.1 Removing the engine guard (EXC-F AUS,
EXC-F SIX DAYS) ............................................ 59
8.2 Installing the engine guard (EXC-F AUS, EXC-F
SIX DAyS) ...................................................... 59
SHOCK ABSORBER, SWINGARM ................................ 60
9.1 Adjusting the high-speed compression
damping of the shock absorber ......................... 60
9.2 Adjusting the low-speed compression damping
of the shock absorber .... ...... ........ ...... .............. 60
9.3 Adjusting the rebound damping of the shock
absorber ......................................................... 61
9.4 Measuring rear wheel sag unloaded ................... 61
9.5 Checking the static sag of the shock absorber .... 61
9.6 Checking the riding sag of the shock absorber .... 62
9.7 Adjusting the spring preload of the shock
absorber ......................................................... 62
9.8 Adjusting the riding sag ................................... 63
9.9 Removing the shock absorber ........................... 63
9.10 Installing the shock absorber ............................ 63
9.11 Servicing the shock absorber ............................ 64
9.12 Removing the spring ........................................ 64
9.13 Disassembling the damper ............................... 65
9.14 Disassembling the piston rod ........................... 66
9.15 Disassembling the seal ring retainer .................. 67
9.16 Replacing the pilot bushing ............................. 68
9.17 Checking the damper ...................................... 69
9.18 Disassembling the rebound adjuster .................. 69
9.19 Removing the heim join!.. ................................ 70
9.20 Installing the heim join!.. ................................. 71
9.21 Assembling the rebound adjuster ...................... 72 15.2 Installing the main fuse ................................. 110
9.22 Assembling the seal ring retainer ...................... 72 15.3 Changing the fuses of individual power
9.23 Assembling the piston rod ................................ 73 consumers .................................................... 110
9.24 Assembling the damper ................................... 74 15.4 Changing the fuse of the radiator fan (EXC-F
9.25 Bleeding and filling the damper ....................... 77 SIX DAYS) .................................................... 111
9.26 Filling the damper with nitrogen ....................... 79 15.5 Removing the battery .................................... 112
9.27 Installing the spring ........................................ 80 15.6 Installing the battery ..................................... 112
9.28 Changing the heim joint ................................... 81 15.7 Charging the battery ...................................... 113
10 EXHAUST .................................................................. 83 16 BRAKE SYSTEM ...................................................... 114
10.1 Removing the manifold .................................... 83 16.1 Checking the front brake linings ..................... 114
10.2 Installing the manifold .................................... 83 16.2 Changing the front brake linings ..................... 114
10.3 Removing main silencer ................................... 84 16.3 Checking free travel of hand brake lever .......... 116
10.4 Installing the main silencer .............................. 84
10.5 Changing the glass fiber yarn filling of the
main silencer .................................................. 84
16.4 Adjusting the basic position of the hand
brake lever (XCF-W) ....................................... 116
16.5 Adjusting free travel of hand brake lever (All
11 AIR FILTER ............................................................... 86 EXC-F models) .............. ...... .............. ...... ...... 116
11.1 Removing the air filter box lid .......................... 86
11.2 Installing the air filter box lid ........................... 86
11.3 Removing the air filter ..................................... 86
11.4 Installing the air filter ...................................... 86
11.5 Cleaning the air filter and air filter box .............. 87
12 FUEL TANK, SEAT, TRIM ........................................... 88
12.1 Opening filler cap ........................................... 88
12.2 Closing filler cap ............................................. 88
12.3 Removing the seat .......................................... 88
12.4 Mounting the sea!.. ......................................... 89
12.5 Removing the fuel tank .................................... 89
12.6 Installing the fuel tank .................................... 90
12.7 Changing the fuel screen ................................. 91
12.8 Changing the fuel filter .................................... 92
12.9 Changing the fuel pump .................................. 94
12.10 Checking the fuel pressure ............................... 95
13 MASK, FENDER ......................................................... 97
13.1 Removing the front fender ............................... 97
13.2 Installing the front fender ................................ 97
13.3 Removing headlight mask with headligh!.. ......... 97
13.4 Refitting the headlight mask with the
headlight.. ...................................................... 97
14 WHEELS ................................................................... 99
16.6 Checking the front brake fluid level ................ 117
16.7 Adding front brake fluid ................................. 117
16.8 Changing the front brake fluid ........................ 118
16.9 Checking the rear brake linings ...................... 119
16.10 Changing the rear brake linings ...................... 119
16.11 Checking the free travel of foot brake lever ...... 121
16.12 Adjusting the basic position of the foot brake
lever ............................................................ 121
16.13 Checking the rear brake fluid level .................. 122
16.14 Adding brake fluid to the rear brake circui!.. .... 122
16.15 Changing the rear brake fluid ......................... 123
17 LIGHTING SYSTEM, INSTRUMENTS ......................... 125
17.1 Adjusting the speedometer functions .............. 125
17.2 Setting kilometers or miles ............................. 125
17.3 Activating the additional functions .................. 126
17.4 Setting the wheel circumference .................... 126
17.5 Setting the clock ........................................... 127
17.6 Checking the headlight setting ....................... 127
17.7 Adjusting the headlight range ......................... 128
18 ENGINE .................................................................. 129
18.1 Removing the engine ..................................... 129
18.2 Installing the engine ...................................... 133
18.3 Engine disassembly ....................................... 137
14.1 Checking the tire air pressure ........................... 99
14.2 Checking the tire condition .............................. 99
14.3 Checking the brake discs ............................... 100
14.4 Checking spoke tension ................................. 100
14.5 Front wheel .................................................. 101
18.3.1 Preparations ............................................. 137
18.3.2 Removing the clutch push rod .................... 137
18.3.3 Removing the spacer ................................. 137
18.3.4 Draining the engine oil .............................. 137
18.3.5 Removing the oil filter ............................... 138
14.5.1 Removing the front wheel .......................... 101
14.5.2 Installing the front wheel ........................... 101
14.5.3 Removing the front brake disc .................... 102
14.5.4 Installing the front brake disc .................... 102
14.6 Rear wheel ................................................... 102
18.3.6 Removing the spark plug ........................... 138
18.3.7 Removing the valve cover ........................... 138
18.3.8 Removing the kick starter .......................... 139
18.3.9 Removing the alternator cover .................... 139
18.3.10 Removing the torque limiter ....................... 140
14.6.1 Removing the rear wheel ........................... 102
14.6.2 Installing the rear wheel ............................ 103
14.6.3 Removing the rear brake disc ..................... 104
14.6.4 Installing the rear brake disc ...................... 104
14.6.5 Checking the chain tension ........................ 105
14.6.6 Adjusting the chain tension ....................... 105
14.6.7 Adjusting the chain guide .......................... 106
14.6.8 Checking the chain, rear sprocket, engine
sprocket and chain guide ........................... 106
14.6.9 Checking for chain dirt accumulation .......... 108
14.6.10 Cleaning the chain .................................... 108
15 WIRING HARNESS, BATTERy ................................... 110
18.3.11 Positioning the engine at ignition top dead
center ...................................................... 140
18.3.12 Removing the timing chain tensioner .......... 140
18.3.13 Removing the camshaft ............................. 141
18.3.14 Removing the cylinder head ....................... 141
18.3.15 Removing the piston ................................. 142
18.3.16 Removing the starter drive ......................... 142
18.3.17 Removing the suction pump ....................... 143
18.3.18 Removing the water pump wheel ................ 144
18.3.19 Removing the clutch cover ......................... 144
18.3.20 Removing the clutch discs ......................... 145
18.3.21 Removing the outer clutch hub .................. 146
15.1 Removing the main fuse ................................ 110
18.3.22 Removing the intermediate kick starter 18.4.34 Checking the shift mechanism ................... 171
gear ......................................................... 146 18.4.35 Preassembling Ihe shift shaft ..................... 172
18.3.23 Removing the intermediate kick starter 18.4.36 Disassembling Ihe main shaft .................... 172
gear ......................................................... 146 18.4.37 Disassembling Ihe counlershaft .................. 173
18.3.24 Removing the shift shaft ............................ 147 18.4.38 Checking Ihe Iransmission ......................... 173
18.3.25 Removing the shift drum localing unil ........ 147 18.4.39 Assembling Ihe main shaft ......................... 174
18.3.26 Removing the locking lever ........................ 147 18.4.40 Assembling the counlershaft ...................... 175
18.3.27 Removing the force pump .......................... 147 18.5 Engine assembly ........................................... 176
18.3.28 Removing the primary gear ........................ 148 18.5.1 Installing the crankshaft ............................ 176
18.3.29 Removing Ihe liming chain ........................ 148 18.5.2 Installing Ihe Iransmission shafts ............... 177
18.3.30 Removing Ihe spacer ................................. 149 18.5.3 Installing Ihe shift lorks ............................. 177
18.3.31 Removing Ihe left seclion 01 Ihe engine
case ........................................................ 149
18.3.32 Removing the shift rails ............................. 149
18.3.33 Removing the shift drum ........................... 150
18.3.34 Removing the shift lorks ............................ 150
18.3.35 Removing Ihe lransmission shafts ............... 150
18.3.36 Removing Ihe crankshaft ........................... 151
18.4 Work on individual parts ................................ 151
18.4.1 Work on Ihe righl seclion of Ihe engine
case ........................................................ 151
18.4.2 Working on the left seclion 01 the engine
case ........................................................ 152
18.5.4 Installing Ihe shift drum ............................ 177
18.5.5 Installing the shift rails ............................. 178
18.5.6 Installing the left engine case .................... 178
18.5.7 Installing the spacer .................................. 179
18.5.8 Installing the timing chain ......................... 179
18.5.9 Installing Ihe primary gear ......................... 179
18.5.10 Installing Ihe lorce pump ........................... 180
18.5.11 Installing Ihe suclion pump ....................... 180
18.5.12 Installing the locking lever ......................... 181
18.5.13 Installing the shift drum locating unil ......... 181
18.5.14 Installing the shift shaft ............................ 182
18.4.3 Work on Ihe clulch cover ........................... 153
18.4.4 Checking Ihe oil pressure regulalor valve ..... 154
18.4.5 Checking Ihe lubricalion system ................. 155
18.4.6 Removing the crankshaft bearing inner
race ......................................................... 156
18.5.15 Installing Ihe inlermediale kick starter
gear ......................................................... 182
18.5.16 Installing Ihe kick starter shaft ................... 182
18.5.17 Installing Ihe ouler clulch hub ................... 182
18.5.18 Installing the clutch discs .......................... 183
18.4.7 Installing the crankshaft bearing inner
race ......................................................... 156
18.5.19 Installing the clutch cover ......................... 184
18.5.20 Installing the water pump cover .................. 185
18.4.8 Changing Ihe connecling rod, conrod 18.5.21 Installing Ihe starter drive .......................... 185
bearing and crank pin ............................... 156 18.5.22 Installing Ihe pislon .................................. 186
18.4.9 Checking Ihe crankshaft run-oul allhe 18.5.23 Installing Ihe cylinder head ........................ 188
bearing pin ............................................... 158 18.5.24 Installing Ihe camshafts ............................ 189
18.4.10 Removing the drive wheel of the balancer 18.5.25 Checking the valve liming .......................... 189
shaft ........................................................ 158 18.5.26 Adjusting Ihe valve timing ......................... 190
18.4.11 Installing the drive wheel of Ihe balancer 18.5.27 Installing the timing chain tensioner ........... 191
shaft ........................................................ 158 18.5.28 Checking Ihe valve clearance ..................... 192
18.4.12 Cylinder - Nikasil" coaling ......................... 158 18.5.29 Adjusting Ihe valve clearance ..................... 192
18.4.13 Checking/measuring Ihe cylinder ................ 158 18.5.30 Installing Ihe lorque limiler ....................... 193
18.4.14 Checking/measuring Ihe piston ................... 159 18.5.31 Installing the alternator cover ..................... 193
18.4.15 Measuring the piston/cylinder mounting
clearance ................................................. 160
18.4.16 Checking Ihe piston ring end gap ............... 160
18.4.17 Changing the camshaft bearing .................. 160
18.4.18 Checking Ihe camshafts ............................ 161
18.4.19 Checking Ihe pivol points 01 Ihe
camshafts .................. ....... ............. .......... 161
18.4.20 Removing Ihe valves .................................. 162
18.4.21 Checking Ihe valves .................................. 163
18.4.22 Checking Ihe valve springs ......................... 163
18.5.32 Installing the kick starter ........................... 193
18.5.33 Installing the valve cover ........................... 194
18.5.34 Installing Ihe spark plug ............................ 194
18.5.35 Installing Ihe oil liller ................................ 194
18.5.36 Installing Ihe oil screen ............................. 195
18.5.37 Installing Ihe spacer .................................. 195
18.5.38 Installing the clutch push rod .................... 196
18.5.39 Removing Ihe engine from the engine
assembly stand ......................................... 196
19 CLUTCH .................................................................. 197
18.4.23 Checking Ihe valve spring seal ................... 163
18.4.24 Checking Ihe cam levers ............................ 164
19.1 Checking/correcling Ihe Iluid level ollhe
hydraulic clulch ............................................ 197
18.4.25 Checking Ihe cylinder head ........................ 164 19.2 Changing Ihe hydraulic clulch fluid ................ 197
18.4.26 Inslalling Ihe valves .................................. 164 20 WATER PUMP, COOLING SYSTEM ............................ 198
18.4.27 Checking Ihe Ireewheel ............................. 165 20.1 Cooling system ............................................. 198
18.4.28 Changing the free wheel ............................ 166 20.2 Checking the anlifreeze and cool ani level ........ 198
18.4.29 Preassembling the kick starter shaft ........... 166 20.3 Checking Ihe coolanl level ............................. 199
18.4.30 Checking Ihe eleclric slarter drive .............. 167 20.4 Draining Ihe coolanl.. .................................... 199
18.4.31 Checking Ihe liming assembly .................... 168 20.5 Refilling coolanl ........................................... 200
18.4.32 Preparing the timing chain tensioner for 21 LUBRICATION SySTEM ............................................ 201
inslallalion ............................................... 169 21.1 Oil circuil... .................................................. 201
18.4.33 Checking Ihe clulch .................................. 169 21.2 Checking the engine oil level. ......................... 201
And Much More ...
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