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

This five-language KTM factory repair manual set is specific to the 2012 350 EXC-F EU, 350 EXC-F AUS, 350 EXC-F SIX DAYS EU, 350 EXC-F USA, and 350 XCF-W USA. It covers the shared 349.7 cc liquid-cooled DOHC four-valve single, six-speed transmission, EFI system, and hydraulically operated wet clutch. KTM states that the repair work assumes a fully trained mechanic with the necessary special tools and workshop equipment, so these manuals are suited to trained technicians rather than first-time DIY repair.

• Five OEM PDFs, 1,476 pages total: German - 294 pages (article no. 3206111de); English - 292 pages (3206111en); Spanish - 298 pages (3206111es); French - 298 pages (3206111fr); Italian - 294 pages (3206111it).
• Engine overhaul coverage runs from removal and complete strip-down through inspection and reassembly. Procedures address the cylinder head, valves and cam levers, camshafts and timing drive, piston and Nikasil-coated cylinder, crankshaft and connecting rod, balancer drive, starter drive, water pump, and dual-pump lubrication system.
• Clutch and transmission chapters cover clutch-pack removal and inspection, hydraulic clutch-fluid service, shift-shaft and drum mechanisms, shift forks and rails, mainshaft and countershaft disassembly, gear and shift-dog checks, shaft assembly, and six-speed gearbox installation.
• WP suspension service includes the 4860 MXMA PA fork cartridge and compression-damping fitting, plus the PDS 5018 DCC shock damper, piston rod, seal-ring retainer, rebound adjuster, pilot bushing, and heim joint. The manual covers bleeding, oil filling, nitrogen charging, sag and preload setup, spring selection, and Comfort/Standard/Sport damping data.
• Fuel and electrical procedures include fuel-screen, filter, and pump replacement; a KTM diagnostic-tool fuel-pressure actuator test; throttle-position-sensor basic-setting checks and adjustment followed by initialization; and specified tests for the ignition coil, spark-plug connector, alternator stator, and starter motor.
• Regional wiring documentation provides 31 model-specific schematic sheets: eight each for EXC-F EU/SIX DAYS, EXC-F AUS, and EXC-F USA, plus seven for XCF-W. Component legends trace EFI/injector/fuel-pump and CAN-bus circuits, starting and charging, radiator-fan and low-fuel systems, speedometer connections, and lighting and turn-signal circuits.

Model-specific chassis coverage

Coverage changes with the model. The SIX DAYS version has its own lower-triple-clamp removal, installation, and steering-head adjustment instructions, while separate brake-lever settings distinguish XCF-W from the EXC-F models. The manual also identifies the SIX DAYS radiator-fan fuse procedure and model-specific exhaust, spark-arrestor, tire, final-drive, fuel-capacity, type-label, and switch arrangements.

Chassis repair content covers steering-head service, handlebar setup, wheels and brake discs, brake-pad and fluid work, wheel bearings, spoke tension, chain and sprocket inspection, fuel-tank and air-filter work, battery and fuse service, lighting and speedometer setup, and silencer repacking. The scheduled-service tables connect these jobs to KTM's operating-hour and annual service categories.

Specifications, tools, and repair cautions

Factory data includes valve-clearance and valve-timing checks, piston/cylinder and piston-ring limits, crankshaft runout, camshaft and valve inspection criteria, clutch and transmission wear limits, oil-pressure checks, fluid capacities, approved substances, and separate engine and chassis torque tables. The cylinder-head entry includes the diagonal multi-stage tightening sequence, while the suspension tables supply clicker baselines, spring data, air-chamber and oil specifications, shock sag, and charging data.

Special-tool references appear at the relevant procedures and again in an illustrated catalog. Engine work calls out tools such as the 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.

Scope and workshop safety

Electrical repair coverage is component-test and schematic based; this set is not a stand-alone catalog of EFI diagnostic trouble codes. Brake work covers discs, pads, fluid, and lever adjustment, but not internal caliper or master-cylinder overhaul. KTM also states that general workshop methods and shop safety rules are not taught in the manual.

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.