KTM 350 EXC-F / 350 XCF-W 2013 Repair Manual (P/N 3206148en)

KTM's factory repair manual, P/N 3206148en, covers the 2013 350 EXC-F EU, AUS, USA and Six Days EU, plus the 350 XCF-W USA.

Search Coverage, Bookmarks and Wiring Detail

Navigation and readability: Embedded PDF bookmarks cover the main chapters, all four wiring groups and the index. Existing OCR contains recognition errors; many workshop pages and diagram labels have no usable searchable text. Small component codes, pin numbers and wire-color labels are best read with zoom.

One printable English PDF contains 310 pages, including the front cover and one otherwise blank page numbered 225; the remaining 308 pages contain the manual's text, illustrations and reference material. There are no separate supplements.

Engine, WP Suspension and Fuel-System Repair

These selected workshop topics highlight the repair coverage rather than reproduce the full contents. Other topics include silencer repacking and speedometer setup.

• Engine repair: Engine removal, crankcase separation, crankshaft and bearing replacement, piston and cylinder inspection, and complete engine assembly.

• Valve train: Camshaft service, timing-chain replacement, valve-timing checks and adjustment, cylinder-head inspection, and valve-clearance adjustment with shims.

• Transmission and clutch: Mainshaft and countershaft disassembly, shift-mechanism inspection, clutch-pack checks, and hydraulic clutch fluid replacement and bleeding.

• WP suspension: Separate standard and Six Days fork overhaul procedures, plus PDS shock disassembly, vacuum bleeding, nitrogen filling, and sag adjustment.

• Fuel and ignition: Fuel-pressure testing, fuel-pump replacement, throttle position sensor basic settings, ignition-coil checks, and stator winding tests.

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

• Diagrams and references: Regional wiring diagrams, the engine oil-circuit schematic, connector views, component wear limits, and engine and chassis torque tables.

This manual is suited to mechanics familiar with internal engine and suspension repair; KTM assumes access to its special tools and workshop equipment.

Engine Repair, Valve Timing and Transmission

Step-by-step engine repair procedures extend to connecting-rod, conrod-bearing and crankpin replacement, crankshaft bearing inner races, and piston-to-cylinder clearance checks for the Nikasil-coated cylinder. Size I and Size II piston and cylinder specifications are distinguished.

Camshaft and cylinder-head work: Valve-timing procedures use the adjustment bush bridge (77229050044) and timing-chain tensioner insert (77229035000). Cylinder-head installation illustrations accompany staged tightening specifications.

Transmission and starter drive: Mainshaft and countershaft assembly views support gear and shift-dog inspection. Clutch repair covers the spring washer, damping rubbers and disc pack; starter-drive coverage includes freewheel testing and replacement, the kickstarter mechanism and torque limiter.

WP Forks, PDS Shock and Chassis

The standard models use the WP 4860 MXMA PA fork; the Six Days uses the WP 4860 4CS. Their separate sections distinguish cartridge construction, spring-preload arrangements and damping settings. The Six Days procedures identify the compression and rebound legs and their different hydrostop needles.

Shock service: The WP PDS 5018 DCC section includes shim-stack assembly views, seal-retainer and pilot-bushing work, and reservoir filling. It specifies vacuum pump T1240S and nitrogen filling tool T170S1.

An incorrectly positioned floating piston can damage the shock during compression and rebound. The swingarm heim-joint notes also explain how grease or other lubricants damage its Teflon coating.

Throttle-cable routing views and chain/sprocket wear checks complement the steering-head and brake procedures.

Fuel Injection and Electrical Diagnosis

The fuel-pressure procedure uses the KTM diagnostics tool's fuel-pump actuator test. Its checks distinguish tank-vent restrictions from fuel-line, filter and pump problems, helping narrow down low fuel pressure before replacement parts are selected.

Throttle position sensor: The basic-setting procedure covers THAD and ATP readings, trouble-code handling and an initialization run. A running diagnostics tool is required for these checks.

Ignition-coil, spark-plug connector and stator tests include electrical resistance specifications and connector-pin illustrations. Stator testing also covers shorts to ground.

Cooling and Lubrication

Water-pump coverage includes impeller removal and installation, with cooling-system explanations, coolant replacement and level checks. The manual identifies the thermostat-controlled circuits and the Six Days radiator fan.

The oil-circuit schematic identifies the force and suction pumps, lubrication jets and timing-chain tensioner. Oil-pressure testing and pressure-regulator inspection accompany the engine's internal repair procedures.

Regional Wiring and Service Data

Separate wiring sets cover EXC-F EU/Six Days, EXC-F AUS, EXC-F USA and XCF-W. The EU/Six Days set identifies the lambda sensor, while the USA set includes the fuel evaporation valve.

Service references provide fluid capacities, inspection tolerances, suspension setup data and operating-hour maintenance schedules. The illustrated special-tool catalog identifies equipment by its KTM article number.

Working on high-pressure fuel systems and internal engine parts carries inherent risks. Follow the manual's safety instructions, including those for the nitrogen-charged shock.

A Preview of Valve Clearances and Piston-Fit Limits

For the covered engines, valve-clearance specifications at 20 °C (68 °F) are 0.10–0.15 mm for the intake valves and 0.13–0.18 mm for the exhaust valves. These accompany the inspection and shim-adjustment procedures.

The piston/cylinder mounting-clearance section distinguishes Size I and Size II fits and specifies a wear limit of 0.070 mm for comparison with measured clearance.