2011 KTM 350 SX-F Service Manual (PN 3206091en)

This 220-page PDF contains KTM's 2011 Repair Manual for the 350 SX-F EU and 350 SX-F USA, identified as KTM Art. no. 3206091en. It comprises 217 numbered manual pages plus the front cover, one blank page, and the back cover. KTM states that repair work is assumed to be performed by a fully trained mechanic, and the manual assumes access to the necessary KTM special tools and workshop equipment.

• Full engine repair coverage runs from engine removal and installation through complete teardown and assembly, including the cylinder head, valves, camshafts, piston and cylinder, crankshaft and connecting rod, timing drive, oil pumps, electric starter drive, clutch, shift mechanism, and five-speed transmission.
• WP suspension service covers the 4860 MXMA CC closed-cartridge fork and 5018 BAVP DCC shock, with adjustment, removal, disassembly, inspection, seal and bushing work, bleeding, vacuum filling, nitrogen charging, and reassembly procedures.
• Electronic fuel-injection work includes fuel-pressure testing through the KTM diagnostics fuel-pump actuator test, tank-vent and fuel-line fault isolation, fuel-filter and pump service, plus throttle-position-sensor Circuit A checking, adjustment, initialization, and trouble-code clearing.
• Chassis and brake procedures address the triple clamp and steering-head bearing, swingarm linkage, wheel and brake-disc removal, disc wear inspection, brake-lining and fluid service, spoke checks, and inspection or adjustment of the chain, sprockets, sliding guard, sliding piece, and chain guide.
• Electrical diagnosis covers the battery, charging voltage, quiescent current, capacitor, starter relay and starter motor, ignition coil, spark-plug connector, and stator windings, backed by wiring diagrams with component legends.
• Factory reference data includes the service schedule, engine and chassis tightening-torque tables, fluid and fuel specifications, electrical test values, engine clearances and wear limits, fork technical data, and distinct EU/USA shock setup tables.

WP Suspension and Chassis Work

The fork chapter goes well beyond routine seal replacement. It documents the cartridge, piston rod, screw cap with membrane holder, screw sleeve, pilot bushing, inner and outer tubes, steering-head bearing, and lower triple clamp. Inspection criteria cover tube condition, piston-rod condition, spring length, bushings, and the parts used in minor and major fork service.

The technical data identifies fork part no. 14.18.7K.05 and separate shock absorbers for the two regional builds: 18.18.7K.03 for the EU model and 18.18.7K.55 for the USA model. EU- and USA-specific entries distinguish rear suspension travel, spring installation, preload, static sag, and riding sag. Shock repair reaches into damper, piston-rod, seal-ring-retainer, pilot-bushing, and heim-joint work before bleeding, filling, and nitrogen charging.

Fork and shock work involves pressurized nitrogen and dedicated filling equipment. These operations, along with brake and fuel-system service, should be handled with normal professional shop safeguards and left to a qualified technician when the specified equipment or training is unavailable.

Engine, EFI, and Electrical Service Depth

Internal engine coverage is specific to the DOHC four-valve single, five-speed gearbox, hydraulically operated wet multi-disc clutch, and pressure-circulation lubrication system with two Eaton pumps. Inspection work covers the oil-pressure regulator, crankshaft and connecting rod, Nikasil-coated cylinder, piston fit and ring gaps, camshafts and valve train, clutch pack, shift components, and transmission gears.

During engine assembly, the manual warns against using the case screws to draw the two case halves together. It also notes that the piston rings can be damaged if they catch during cylinder installation.

Factory Tools and Circuit Documentation

Special-tool callouts identify the fuel-pressure testing tool 61029094000 with testing hose 61029093000, engine work stand 61229001000, and complete crankshaft pressing device 75029047000. Suspension work references vacuum pump T1240S, fork nitrogen charging tool T14019, and shock nitrogen filling tool T170S1.

Named visual references include the engine oil-circuit diagram and three electrical sheets. One maps the battery, alternator, regulator, starter relay, capacitor, starter motor, and diagnostics connector; another covers the EFI control unit, fuel pump, injector, FI warning lamp, CAN-bus terminating resistor, and kill switch. The third traces the throttle-position, intake-air, coolant-temperature, rollover, crankshaft-position, and manifold-pressure sensors together with the ignition coil and optional Map-Select switch.