2012r Repair manual.pdf

(12531 KB) Pobierz
REPAIR MANUAL
2012
350 SX‑F EU
350 SX‑F CAIROLI REPLICA EU
350 SX‑F USA
350 XC-F USA
Art. no. 3206146en
INTRODUCTION
It is important that you read this repair manual carefully and completely before the start of work.
INTRODUCTION
1
This vehicle can only fulfill the demands placed on it in the long run if the specified service work is performed regularly by qualified
experts.
The repair manual was written to correspond to the most current state of this model series. We reserve the right to make changes in
the interest of technical advancement without, at the same time, updating this repair manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that repair work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-
tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-
cial equipment that does not belong to the regular scope of supply.
© 2012 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright
owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
TABLE OF CONTENTS
TABLE OF CONTENTS
2
Greasing the steering head bearing ...................
Removing the lower triple clamp.......................
Installing the lower triple clamp .......................
Checking the steering head bearing play............
Adjusting the play of the steering head
bearing ..........................................................
7
HANDLEBAR, CONTROLS...........................................
7.1
Handlebar position..........................................
7.2
Adjusting the handlebar position ......................
7.3
Adjusting the basic position of the clutch
lever ..............................................................
7.4
Checking the throttle cable routing ...................
7.5
Checking the play in the throttle cable ..............
7.6
Adjusting the play in the throttle cable..............
8
FRAME .....................................................................
8.1
Removing the engine guard (SX‑F CAIROLI
REPLICA).......................................................
8.2
Installing the engine guard (SX‑F CAIROLI
REPLICA).......................................................
9
SHOCK ABSORBER, SWINGARM ................................
9.1
Adjusting the high-speed compression
damping of the shock absorber.........................
9.2
Adjusting the low-speed compression damping
of the shock absorber ......................................
9.3
Adjusting the rebound damping of the shock
absorber.........................................................
9.4
Measuring rear wheel sag unloaded...................
9.5
Checking the static sag of the shock absorber ....
9.6
Checking the riding sag of the shock absorber....
9.7
Adjusting the spring preload of the shock
absorber.........................................................
9.8
Adjusting the riding sag ...................................
9.9
Removing the shock absorber ...........................
9.10 Installing the shock absorber............................
9.11 Checking the shock absorber linkage.................
9.12 Servicing the shock absorber............................
9.13 Removing the spring........................................
9.14 Disassembling the damper ...............................
9.15 Disassembling the piston rod ...........................
9.16 Disassembling the seal ring retainer..................
9.17 Changing the pilot bushing ..............................
9.18 Checking the damper ......................................
9.19 Removing the heim joint..................................
9.20 Installing the heim joint...................................
9.21 Assembling the seal ring retainer ......................
9.22 Assembling the piston rod................................
9.23 Assembling the damper ...................................
9.24 Bleeding and filling the damper .......................
9.25 Filling the damper with nitrogen .......................
9.26 Installing the spring (All SX‑F EU models) .........
9.27 Installing the spring (SX‑F USA) .......................
9.28 Installing the spring (XC‑F) ..............................
10 EXHAUST ..................................................................
10.1 Removing the manifold....................................
10.2 Installing the manifold ....................................
10.3 Removing the main silencer .............................
10.4 Installing the main silencer..............................
10.5 Changing the glass fiber yarn filling of the
main silencer..................................................
11 AIR FILTER ...............................................................
11.1 Removing the air filter box lid ..........................
11.2 Installing the air filter box lid ...........................
11.3 Removing the air filter .....................................
6.32
6.33
6.34
6.35
6.36
46
46
47
48
49
50
50
50
50
51
51
51
53
53
53
54
54
54
55
56
56
56
57
57
58
59
59
61
61
62
63
64
65
66
66
67
68
69
70
72
74
75
76
77
79
79
80
80
81
81
83
83
83
83
1
2
3
4
5
6
MEANS OF REPRESENTATION ..................................... 6
1.1
Symbols used ................................................... 6
1.2
Formats used.................................................... 6
SAFETY ADVICE........................................................... 7
2.1
Repair Manual .................................................. 7
2.2
Safety advice.................................................... 7
2.3
Degrees of risk and symbols ............................... 7
2.4
Work rules........................................................ 7
IMPORTANT NOTES..................................................... 8
3.1
Guarantee, warranty .......................................... 8
3.2
Operating and auxiliary substances ..................... 8
3.3
Spare parts, accessories .................................... 8
3.4
Figures ............................................................ 8
SERIAL NUMBERS ...................................................... 9
4.1
Chassis number ................................................ 9
4.2
Type label ........................................................ 9
4.3
Engine number ................................................. 9
4.4
Fork part number .............................................. 9
4.5
Shock absorber part number .............................. 9
MOTORCYCLE ........................................................... 10
5.1
Raising the motorcycle with the lift stand.......... 10
5.2
Removing the motorcycle from the lift stand...... 10
5.3
Starting.......................................................... 10
5.4
Starting the motorcycle for a check................... 11
FORK, TRIPLE CLAMP ............................................... 12
6.1
Adjusting the compression damping of the
fork ............................................................... 12
6.2
Adjusting the rebound damping of the fork ........ 12
6.3
Bleeding the fork legs...................................... 13
6.4
Cleaning the dust boots of the fork legs............. 13
6.5
Loosening the fork protection ........................... 13
6.6
Positioning the fork protection.......................... 14
6.7
Removing the fork legs .................................... 14
6.8
Installing the fork legs ..................................... 14
6.9
Removing the fork protector ............................. 15
6.10 Installing the fork protector.............................. 15
6.11 Conducting major fork service .......................... 15
6.12 Conducting minor fork service .......................... 16
6.13 Disassembling the fork legs.............................. 16
6.14 Disassembling the cartridge ............................. 19
6.15 Disassembling the piston rod ........................... 21
6.16 Disassembling the screw cap with the
membrane holder............................................ 22
6.17 Disassembling the screw sleeve ........................ 23
6.18 Checking the fork legs (All SX‑F models) ........... 24
6.19 Checking the fork legs (XC‑F) ........................... 25
6.20 Checking the fork legs - during a minor fork
service (All SX‑F models) ................................. 27
6.21 Checking the fork legs - during a minor fork
service (XC‑F) ................................................. 28
6.22 Changing the pilot bushing .............................. 29
6.23 Assembling the screw sleeve ............................ 30
6.24 Assembling the screw cap with the membrane
holder ............................................................ 30
6.25 Assembling the piston rod................................ 31
6.26 Assembling the cartridge ................................. 32
6.27 Assembling the fork legs (All SX‑F EU
models).......................................................... 34
6.28 Assembling the fork legs (SX‑F USA) ................ 37
6.29 Assembling the fork legs (XC‑F) ........................ 41
6.30 Bleeding and filling the cartridge...................... 44
6.31 Filling the cartridge with nitrogen ..................... 45
TABLE OF CONTENTS
12
11.4 Installing the air filter...................................... 83
11.5 Cleaning the air filter and air filter box .............. 84
FUEL TANK, SEAT, TRIM ........................................... 85
12.1 Opening the filler cap...................................... 85
12.2 Closing the filler cap ....................................... 85
12.3 Removing the seat .......................................... 85
12.4 Mounting the seat ........................................... 86
12.5 Removing the fuel tank.................................... 86
12.6 Installing the fuel tank .................................... 87
12.7 Checking the fuel pressure............................... 88
12.8 Changing the fuel screen ................................. 89
12.9 Changing the fuel filter.................................... 90
MASK, FENDER......................................................... 93
13.1 Removing the front fender ............................... 93
13.2 Installing the front fender ................................ 93
13.3 Removing the start number plate ...................... 93
13.4 Installing the start number plate....................... 93
WHEELS ................................................................... 94
14.1 Checking the tire air pressure........................... 94
14.2 Checking the tire condition .............................. 94
14.3 Checking the brake discs ................................. 94
14.4 Checking the spoke tension.............................. 95
14.5 Front wheel .................................................... 95
14.5.1
Removing the front wheel ............................ 95
14.5.2
Installing the front wheel ............................. 96
14.5.3
Removing the brake disc of the front brake.... 97
14.5.4
Installing the brake disc of the front brake .... 97
14.6 Rear wheel ..................................................... 98
14.6.1
Removing the rear wheel ............................. 98
14.6.2
Installing the rear wheel .............................. 98
14.6.3
Removing the brake disc of the rear brake ..... 99
14.6.4
Installing the brake disc of the rear brake...... 99
14.6.5
Checking the chain tension.......................... 99
14.6.6
Adjusting the chain tension ....................... 100
14.6.7
Adjusting the chain guide .......................... 101
14.6.8
Checking the chain, rear sprocket, engine
sprocket and chain guide........................... 101
14.6.9
Checking for chain dirt accumulation.......... 103
14.6.10 Cleaning the chain .................................... 103
WIRING HARNESS, BATTERY................................... 104
15.1 Removing the main fuse ................................ 104
15.2 Installing the main fuse ................................. 104
15.3 Removing the battery .................................... 104
15.4 Installing the battery ..................................... 105
15.5 Charging the battery ...................................... 105
15.6 Checking the charging voltage ........................ 106
15.7 Checking the quiescent current ...................... 107
15.8 Checking the capacitor .................................. 107
15.9 Checking the starter relay .............................. 107
BRAKE SYSTEM ...................................................... 109
16.1 Checking the front brake linings ..................... 109
16.2 Changing the front brake linings ..................... 109
16.3 Checking the free travel of the hand brake
lever ............................................................ 110
16.4 Adjusting the basic position of the hand
brake lever ................................................... 111
16.5 Checking the front brake fluid level ................ 111
16.6 Adding front brake fluid................................. 112
16.7 Changing the front brake fluid ........................ 113
16.8 Checking the rear brake linings ...................... 114
16.9 Changing the rear brake linings ...................... 114
16.10 Checking the free travel of foot brake lever ...... 115
16.11 Adjusting the basic position of the foot brake
lever ............................................................
16.12 Checking the rear brake fluid level..................
16.13 Adding rear brake fluid ..................................
16.14 Changing the rear brake fluid .........................
17 ENGINE ..................................................................
17.1 Removing the engine.....................................
17.2 Installing the engine......................................
17.3 Engine disassembly.......................................
17.3.1
Preparations .............................................
17.3.2
Removing the kick starter (XC‑F) ................
17.3.3
Removing the clutch push rod....................
17.3.4
Removing the spacer.................................
17.3.5
Draining the engine oil ..............................
17.3.6
Removing the oil filter ...............................
17.3.7
Removing the spark plug ...........................
17.3.8
Removing the valve cover...........................
17.3.9
Removing the starter motor........................
17.3.10 Positioning the engine at ignition top dead
center......................................................
17.3.11 Removing the timing chain tensioner ..........
17.3.12 Removing the camshaft .............................
17.3.13 Removing the cylinder head .......................
17.3.14 Removing the piston .................................
17.3.15 Removing the rotor....................................
17.3.16 Removing the starter drive .........................
17.3.17 Removing the suction pump.......................
17.3.18 Removing the water pump wheel ................
17.3.19 Removing the clutch cover.........................
17.3.20 Removing the clutch discs .........................
17.3.21 Removing the outer clutch hub ..................
17.3.22 Removing the kick starter shaft (XC‑F) ........
17.3.23 Removing the shift shaft............................
17.3.24 Removing the shift drum locating unit ........
17.3.25 Removing the force pump..........................
17.3.26 Removing the primary gear ........................
17.3.27 Removing the timing chain ........................
17.3.28 Removing the spacer.................................
17.3.29 Removing the left section of the engine
case ........................................................
17.3.30 Removing the shift rails.............................
17.3.31 Removing the shift drum ...........................
17.3.32 Removing the shift forks............................
17.3.33 Removing the transmission shafts...............
17.3.34 Removing the crankshaft ...........................
17.4 Work on individual parts ................................
17.4.1
Work on the right section of the engine
case ........................................................
17.4.2
Working on the left section of the engine
case ........................................................
17.4.3
Work on the clutch cover ...........................
17.4.4
Checking the oil pressure regulator valve .....
17.4.5
Checking the lubrication system .................
17.4.6
Removing the crankshaft bearing inner
race.........................................................
17.4.7
Installing the crankshaft bearing inner
race.........................................................
17.4.8
Changing the connecting rod, conrod
bearing and crank pin ...............................
17.4.9
Checking the crankshaft run-out at the
bearing pin...............................................
17.4.10 Removing the drive wheel of the balancer
shaft........................................................
3
13
14
116
116
117
117
119
119
123
128
128
129
129
129
129
130
130
130
131
132
132
132
133
133
134
134
135
135
136
136
136
137
137
138
138
139
139
139
139
140
140
140
141
141
141
141
143
144
145
146
146
146
147
148
148
15
16

Plik z chomika:

Inne pliki z tego folderu:

Inne foldery tego chomika:

Zgłoś jeśli naruszono regulamin