KTM 350 XCF-W / EXC-F 2012 Repair Manual Set (P/N 3206111de)

These are five language editions of the same factory repair manual. They cover the shared four-stroke DOHC four-valve single, six-speed transmission, EFI system, and hydraulically operated wet clutch.

The documented EFI actuator tests and throttle-position-sensor settings require KTM diagnostics equipment. This set is not a stand-alone EFI fault-code catalog. Brake coverage includes discs, pads, fluid, and lever adjustment, but does not provide internal caliper or master-cylinder overhaul procedures.

Searchable PDFs and Language Editions

Text search and diagram detail: All five PDFs have searchable text and embedded bookmarks for chapters and individual procedures. Small wiring-diagram labels require zooming for comfortable reading.

The ZIP contains five printable PDFs totaling 1,476 pages, including ten front/back cover pages and eight blank or header-only pages. A separate JPG cover and TXT model list are also included.

Engine Overhaul, WP Suspension and EFI Testing

The following selected contents highlight the repair coverage rather than reproduce the complete table of contents. Other topics include winter-operation care and preparation for use after storage.

• Engine overhaul: Step-by-step procedures for engine removal, disassembly, inspection, and reassembly, including cylinder-head, valve, cam-lever, camshaft, and timing-drive work.

• Clutch and transmission: Clutch-pack inspection, hydraulic clutch-fluid replacement, mainshaft and countershaft disassembly, gear and shift-dog checks, and gearbox assembly.

• WP suspension: Fork-cartridge and compression-damping-fitting service, plus shock-damper, piston-rod, and seal-ring-retainer disassembly and reassembly.

• Fuel-system service: Fuel-screen, filter, and pump replacement, a diagnostic-tool fuel-pressure actuator test, and throttle-position-sensor basic settings followed by initialization.

• Electrical testing: Specified checks for the ignition-coil secondary winding, spark-plug connector, alternator stator, and starter motor, with illustrated measurement points.

• Chassis and brakes: Steering-head service, wheel-bearing checks, spoke tension, chain and sprocket inspection, brake-disc and pad replacement, and brake-fluid changes.

• Regional wiring diagrams: Separate EXC-F EU/SIX DAYS, AUS, USA, and XCF-W schematics with component legends, connector references, and wire-color codes.

KTM assumes repair work will be performed by a fully trained mechanic with the necessary special tools and workshop equipment; general workshop methods and safety rules are not taught in these manuals.

Internal Engine Inspection and Workshop Data

Internal repair coverage extends to the piston and Nikasil-coated cylinder, crankshaft and connecting rod, balancer drive, starter drive, water pump, and dual-pump lubrication system.

Factory inspection data covers piston/cylinder fit, piston-ring limits, crankshaft runout, camshaft and valve condition, and clutch and transmission wear limits. The shift-mechanism sections address the shift shaft, drum, forks, and rails.

Valve-clearance and valve-timing checks are supported by illustrations and adjustment procedures. Separate engine and chassis torque tables include the cylinder head’s diagonal, multi-stage tightening requirements. Oil-pressure checks, coolant service, fluid capacities, approved substances, and an oil-circuit illustration support maintenance and internal engine work.

WP Fork and PDS Shock Service

Suspension procedures apply to the 4860 MXMA PA fork and PDS 5018 DCC shock absorber. Shock work includes the rebound adjuster, pilot bushing, and heim joint, together with bleeding, oil filling, and nitrogen charging.

Setup information covers sag, spring preload, spring selection, and Comfort/Standard/Sport damping settings. The reference tables also provide fork air-chamber, oil, spring, and shock-charging specifications.

Fuel-Pressure Diagnosis and Electrical References

The fuel-pressure procedure compares readings with the filler cap open and closed to help distinguish tank-ventilation problems from fuel-supply restrictions before filter or pump work.

The wiring section contains 31 schematic sheets: eight each for EXC-F EU/SIX DAYS, AUS, and USA, plus seven for XCF-W. Their legends identify EFI, injector, fuel-pump, and CAN-bus circuits alongside starting, charging, radiator-fan, low-fuel, speedometer, lighting, and turn-signal connections.

Regional Chassis Differences and Scheduled Service

The SIX DAYS version has separate lower-triple-clamp removal, installation, and steering-head adjustment instructions. Brake-lever settings distinguish XCF-W from the EXC-F models, and the radiator-fan fuse procedure is identified for SIX DAYS.

Regional differences also cover exhaust arrangements, tires, final-drive ratios, fuel capacity, type labels, and switches. The service schedule specifically lists spark-arrestor cleaning for XCF-W and EXC-F USA.

Additional chassis content includes handlebar setup, fuel-tank and air-filter work, battery and fuse service, lighting and speedometer setup, and silencer repacking. Scheduled-service tables connect these jobs to operating-hour and annual service categories.

Special Tools and Repair Cautions

Tool references appear beside the procedures and in an illustrated catalog. Examples include engine assembly stand 61229001000, clutch holder 51129003000, valve spring compressor 59029019000, and timing-chain-tensioner release device 77329051000. Shock service specifies vacuum pump T1240S and nitrogen filling tool T170S1.

The manual warns that crankcase bearings can be damaged if pressing force is applied anywhere other than the outer race. It also identifies the PDS shock heim joint as Teflon-coated: grease or other lubricant attacks that coating and sharply reduces the joint’s service life.

Secure the motorcycle on a stable lift stand before wheel, suspension, or engine removal. Follow the manual’s warnings for fuel and brake-fluid handling, hot pressurized coolant, hot exhaust components, spring preload, and nitrogen-charged shock service.

Examples of Fuel-Pressure and Valve-Clearance Data

The fuel-pressure test specifies 3.35–3.65 bar with the fuel pump active, with readings evaluated under the documented filler-cap conditions.

For the covered engine, valve-clearance specifications at 20 °C are 0.10–0.15 mm at the intake and 0.13–0.18 mm at the exhaust. These values accompany the inspection and shim-adjustment procedures.