2013 KTM 350 SX-F / 350 XC-F Repair Manual (P/N 3206143en)

This KTM Repair Manual, Art. no. 3206143en, covers the 2013 350 SX-F EU, 350 SX-F USA, and 350 XC-F USA, with factory procedures for maintenance, component testing, and internal engine and chassis repair.

PDF Search, Chapter Access, and Wiring Detail

Search and diagram access: Text search works on some pages, but much of the repair material and the wiring sheets lack usable searchable text. Embedded bookmarks provide chapter access and separate SX-F/XC-F wiring entries. The additional “Keyword Search” bookmark has no usable destination. Small connector, pin, and wire-color labels on the checked wiring sheets are readable when enlarged.

Supplied as one printable, English-language, 254-page PDF, including the cover and one blank page at PDF p. 219.

Engine Rebuilding, WP Suspension, and System Testing

The selected topics below outline the main workshop coverage. The manual also includes main-silencer packing replacement and preparation for use after storage.

• Engine repair: Step-by-step procedures for engine removal, crankcase disassembly, crankshaft repair, cylinder-head inspection, valve timing, and shim-based valve-clearance adjustment.

• Transmission and clutch: Separate SX-F and XC-F shaft assembly procedures, gear and shift-mechanism inspection, clutch wear checks, and hydraulic clutch fluid replacement.

• WP suspension: Major and minor fork service, cartridge rebuilding, shock absorber overhaul, vacuum filling, nitrogen charging, and linkage inspection.

• Fuel system: Fuel-pressure testing, fuel-screen and filter replacement, fuel-pump replacement, throttle-cable checks, and throttle-body idle-speed adjustment.

• Brakes and chassis: Brake-pad and disc replacement, brake-fluid changes, wheel-bearing checks, chain adjustment, and steering-head bearing service.

• Electrical testing: Charging-voltage, quiescent-current, capacitor, starter-relay, ignition-coil, and stator checks, supported by separate SX-F and XC-F wiring diagrams.

This manual is suited to experienced mechanics with the necessary KTM special tools and workshop equipment; its repair instructions assume that equipment is available.

Engine, Timing, and Transmission Repair

The engine section documents work on individual parts as well as disassembly and reassembly. Nikasil-coated cylinder inspection, piston sizing, ring-gap checks, and crankshaft end-play measurement provide the reference data needed to evaluate worn parts at the workbench before selecting replacements.

Valve train and balancer shaft: Coverage extends to camshaft bearings, cam levers, valve guides, and the balancer-shaft drive wheel. Hydraulic timing-chain tensioner preparation and release receive dedicated instructions, alongside separate valve-timing checks and adjustment procedures.

Crankshaft repair: The connecting-rod replacement section identifies a specific assembly risk: incorrect crank-pin oil-hole alignment cuts off the conrod bearing’s oil supply and puts the bearing at risk of damage.

Transmission illustrations distinguish the SX-F and XC-F gear arrangements. Inspection covers gear teeth, shift dogs, needle bearings, shaft bearing surfaces, and shift-fork operation. Engine and chassis torque tables include fastener-specific thread-locking and lubrication requirements.

WP Fork and Shock Service

The suspension sections cover the WP 4860 MXMA CC fork and WP 5018 BAVP DCC shock absorber. Fork inspection and assembly instructions distinguish EU, USA, and XC-F settings, while shock coverage includes seal-retainer work, pilot-bushing replacement, and heim-joint service.

The filling procedures call for specialist equipment, including vacuum pump T1240S and shock nitrogen filling tool T170S1. The shock instructions warn that an incorrectly positioned floating piston can cause damage during compression. Pressurized nitrogen also requires the pressure-handling precautions described in the manual.

Fuel, Cooling, and Lubrication Checks

The fuel-pressure procedure uses the KTM diagnostics tool’s fuel-pump actuator test and dedicated pressure-testing equipment. Its checks distinguish tank-vent restrictions from downstream fuel-delivery problems before pump replacement is considered.

Cooling coverage includes antifreeze and coolant-level checks, draining and refilling, plus water-pump impeller and seal work within the engine sections. The oil-circuit view identifies the force and suction pumps, regulator, filter, and lubrication jets; related procedures cover pump inspection and engine oil-pressure testing.

Chassis Maintenance and Electrical Fault Tracing

Steering-head bearing adjustment, handlebar positioning, air-filter service, and fuel-tank, seat, trim, and fender removal support routine workshop access. The service schedule separates regular checks from additional engine and suspension work.

The wiring sets show starting and charging circuits, fuel-pump and injector connections, and sensor and ignition circuits. XC-F drawings also include the fuel-level sensor and low-fuel warning lamp. Component keys, connector IDs, pin numbers, and cable-color legends support circuit tracing alongside the electrical test procedures.

Examples of Valve-Clearance and Oil-Regulator Specifications

At 20°C (68°F), specified valve clearance is 0.10–0.15 mm for the intake and 0.13–0.18 mm for the exhaust. These ranges accompany the engine assembly section’s shim-adjustment procedures.

For the oil-pressure regulator valve, the minimum pressure-spring length is 23.5 mm (0.925 in). The individual-parts section also covers inspection of the regulator ball and sealing seat.