2012 KTM 350 EXC-F: Building the perfect "Wee Beasty"

Technical articles, tips, tricks and advice from the experts (and there are plenty of you!) on jetting, suspension, riding techniques, muffler bearings, powerband installation or anything dirt.

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Re: 2012 KTM 350 EXC-F: Building the perfect "Wee Beasty"

Postby E-Ticket » Sat Feb 09, 2013 10:04 am

wizz wrote:Is it best to have either the cheap motion pro or pricey racetech oil level tool or are there other ways to check oil level?

You can get by with a mm ruler and a small turkey baster if you have nothing else on hand.
You simply need something to measure the oil level from the top of the fork to the oil ... and something to suck out the excess oil.

That being said ... the "tools made for the job" are *much* easier to use and more accurate.
My favorite is the Motion Pro tool. It's also carried by a lot of motorcycle dealers on online places (Bike Bandit, Rocky Mountain ATV, Motorcycle Superstore, CycleBuy.com, etc.):

Motion Pro Fork Oil Level Tool $22.99

http://www.motionpro.com/motorcycle/partno/08-0121/

• For checking and adjusting the oil level on all conventional and single chamber cartridge forks
• Adjustable ring will measure oil levels from 0 to 300mm in 0.5cm increments
• Syringe has a capacity of 60ml
• Can be used on bicycles equipped with front suspension

Image

Hope that helps! - E-Ticket
"AYHIN"

Mine: '12 KTM 350 EXC-F (Wee Beasty); '99 Honda VFR 800i Interceptor
Wife's: '08 KTM 250 XCF-W, '04 Honda CBR600 F4i

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Re: 2012 KTM 350 EXC-F: Building the perfect "Wee Beasty"

Postby wizz » Sat Feb 09, 2013 6:34 pm

It does help, thank you very much. If I am understanding correctly, the air chamber is 110 mm, and that would be the amount of oil removed? I will probably wait for your write up as I still need to check valves, engine ice and BD radiator gaurds. Do you grease the head stock while you have the forks off, and what grease do you use for that?
Again, thanks for the write up as I am the target demographic :D

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Re: 2012 KTM 350 EXC-F: Building the perfect "Wee Beasty"

Postby RiderJC » Thu Mar 28, 2013 1:22 pm

In removal of the SAS you mention removing the rear shock. Why???

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Re: 2012 KTM 350 EXC-F: Building the perfect "Wee Beasty"

Postby E-Ticket » Thu Mar 28, 2013 1:48 pm

wizz wrote:It does help, thank you very much. If I am understanding correctly, the air chamber is 110 mm, and that would be the amount of oil removed? I will probably wait for your write up as I still need to check valves, engine ice and BD radiator gaurds. Do you grease the head stock while you have the forks off, and what grease do you use for that?
Again, thanks for the write up as I am the target demographic :D

Hi Wizz,

My apologies to all for "going dark" the last couple of weeks.

I haven't been riding or working on the Wee Beasty at all due to wrestlin' with some personal 'thangs.'
No, nothing bad or horrible. Just things that took total focus and used up all available bandwidth.
I'll try to get caught up on WeeBea questions and posts over the next couple of days.

== Correct. You set your oil removal tool at 110 mm from the top of the open fork chamber ... and suck out any oil that is above the 110 mm point. This sets the proper size of the "air chamber."
Then you remove or add small amounts of oil to "tune" the air chamber for your suspension needs.

== Yes. After you remove the forks, you're halfway done with greasing the headset stem and bearings.
So you might as well do it while you're there. And if you've never done it before -- you will definitely need more grease in there than what the factory installs.
My choice of grease for all major load and/or "wet" areas is the Bel-Ray Waterproof Grease.
I've been using it for years -- works great, lasts a long time.

Cheers! E-Ticket
"AYHIN"

Mine: '12 KTM 350 EXC-F (Wee Beasty); '99 Honda VFR 800i Interceptor
Wife's: '08 KTM 250 XCF-W, '04 Honda CBR600 F4i

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Re: 2012 KTM 350 EXC-F: Building the perfect "Wee Beasty"

Postby E-Ticket » Thu Mar 28, 2013 1:52 pm

RiderJC wrote:In removal of the SAS you mention removing the rear shock. Why???

To be able to unscrew the SAS spigot from the head ... you need to have enough to room to spin it.
Unfortunately, it runs into the header pipe after a 1/2 turn. So you need to remove the header.

And to do that you need to remove the mid-pipe. Which can't get past the shock. Arghh....

But pulling the shock is so easy -- it's only two bolts.
Which then you gives the opportunity to make sure your shock bolts and seals are properly greased.
So not really a problem .... just an additional step or two.

Cheers! E-Ticket
"AYHIN"

Mine: '12 KTM 350 EXC-F (Wee Beasty); '99 Honda VFR 800i Interceptor
Wife's: '08 KTM 250 XCF-W, '04 Honda CBR600 F4i

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Re: 2012 KTM 350 EXC-F: Building the perfect "Wee Beasty"

Postby E-Ticket » Mon Apr 01, 2013 12:39 pm

Wee Beasty Page Index: Updated 3/29/2013

This is the MASTER INDEX for the 2012 KTM 350 EXC-F: Building the perfect "Wee Beasty."

It lists the page-links to the "starting points" for the following topics.
The topics may run for several pages or be a single entry.

NOTE: This is not an exhaustive list of everything covered.
The page index simply makes it easier to find the starting point for a given topic.
I'll continue to update the index as more material, posts, and tips get posted.

Cheers! E-Ticket
===========================

Page 1: http://www.omraoffroad.com/forum/viewtopic.php?f=40&t=11373
• Prepping/greasing new wheels, axles, and wheel spacers
• Installing KTM Organic brake pads on the rear brake
• Using heat gun to move the end of a graphic "a little"
• Turning KTM "self-retracting" kickstand into a normal kickstand
• Installing footpeg springs
• Removing gas tank and initial internal inspection
• Pics of engine area (w/ gas tank removed), emissions equipment, and below seat
• Pics of air box, filter, and internal view of intake manifold
• Installing Shorai battery
• Routing and zip-tying various wires above air filter
• Anti-seize on seat bolt; using duct tape to keep bolt clean
• Installing KTM, quick-release, plastic skid plate

Page 2: http://www.omraoffroad.com/forum/viewtopic.php?f=40&t=11373&start=15
• Initial start-up of engine and engine break-in procedure
• First engine oil change; cleaning filter screens and drain plug
• Pulling and draining fuel tank; remove fuel pump and wiring assembly

Page 3: http://www.omraoffroad.com/forum/viewtopic.php?f=40&t=11373&start=30
• Remove fuel pump and wiring assembly (cont.)
• Cleaning fuel tank, pics of fuel pump; reassembly of fuel tank
• Installing the 10 micron Golan "Super Mini" filter
• Removing the KTM, black, 10 micron, in-line fuel filter
• Final Golan filter setup tips

Page 4: http://www.omraoffroad.com/forum/viewtopic.php?f=40&t=11373&start=45
• Installing the KTM "sock filter" in the neck of the gas tank
• Installing the Akropovic slip-on exhaust and 92db spark-arrestor insert
• Removing the ECU; remapping the ECU
• Testing de-smogify steps; actual de-smogify procedure
• Relocating horn to location near swingarm

Page 5: http://www.omraoffroad.com/forum/viewtopic.php?f=40&t=11373&start=60
• Starting discussion point on adjusting valves (why it's important, etc.)
• Actual step-by-step procedure for checking and adjusting the valves

>>> 2012 KTM 350 EXC-F: Adjusting/checking the valves on the Wee Beasty
http://www.omraoffroad.com/forum/viewtopic.php?f=40&t=11399

>>> Step-by-step procedure for installing the DJH Manual Cam Chain Tensioner (CCT)
http://www.omraoffroad.com/forum/viewtopic.php?f=40&t=12263

• Preparing cooling system for change-over to Engine Ice coolant
• Installing KTM radiator fan and Engine Ice coolant
• Installing lower-temperature rated sensor in radiator
• Installing Bulletprood Design (BPD) radiator guards

Page 6: http://www.omraoffroad.com/forum/viewtopic.php?f=40&t=11373&start=75
• Installing heat shield on gas tank (behind radiator fan)
• Initial discusson an comments on selecting suspension springs
• More Akropovc pics
• Installing the P3 Exhaust Shield on header pipe

Page 7: http://www.omraoffroad.com/forum/viewtopic.php?f=40&t=11373&start=90
• Changing gearing to 13-52T
• Upgrading to Dirt Tricks' "Ironman" sprockets
• Installing TM Design Chain Guide
• Installing the Bulletproof Design Guard for chain guide

Page 8: http://www.omraoffroad.com/forum/viewtopic.php?f=40&t=11373&start=105
• Modifying the brake pedal (to reduce clutch cover damage)
• Installing KTM HardParts Carbon Fiber (CF) clutch Cover Guard
• Installing the KTM HardParts Billet Oil-Fill Plug
• Swingarm clean up and greasing / Heim joint protection
• Mounting the Bulletproof Designs guard for the rear brake rotor

Page 9: http://www.omraoffroad.com/forum/viewtopic.php?f=40&t=11373&start=120
• Mounting the Bulletproof Designs guard for the rear brake rotor (cont.)
• Installing the KTM HardPart Clutch Slave-Cylinder Guard and Dirt Tricks 13T Countershaft Sprocket• Installing the Side Frame-Guard Protectors
• Installing DID "X-Ring" 520 VT2 Chain (for 13-52T gearing)
• Tightening the Countershaft Sprocket Bolt
• Aligning the Chain (align rear axle to parallel w/ swingarm pivot bolt)

Page 10: http://www.omraoffroad.com/forum/viewtopic.php?f=40&t=11373&start=135
• Setting the Chain Slack (with swingarm "level"/full tight)
• Marking the chain adjuster bolts for easy adjusting (<<< BIG TIP!!)
• Replacing Spring on Shock (from stock to PDS-4) and setting initial preload
• Installing the SAR Flush-Mount LED Turn Signals on the "Stock" Rear Fender
• Installing the 2012 350 XCF-W Rear Sub-Fender on the 2012 350 EXC-F
• Mounting the SAR Flush-Mount, LED Turn Signals on the 2012 350 XCF-W Sub-Fender

Page 11: http://www.omraoffroad.com/forum/viewtopic.php?f=40&t=11373&start=150
• Mounting the SAR Flush-Mount, LED Turn Signals on the 2012 350 XCF-W Sub-Fender (cont.)
• Mounting the License Plate on the 2012 350 XCF-W Sub-Fender
• Installing the "For Troy" Rear Tugger Strap
• Installing the Front, Sicass Racing (SAR) LED Turn Signals
• Installing the SAR LED-Compatible Flasher Unit. (Needed if you run LED turn signals at both front and rear.)
• Why Mount a Scott's Steering Stabilizer and Sub-Mount?
• What Comes in Scott's Steering Stabilizer and Sub-Mount Kit
• Removing the Forks and Triple Clamp
• Installing the Clamp-on Tower for the Scott's Steering Stabilizer
• Reassembling and Torquing the Triple Clamps
• Setting the Height of the SSS Tower Pin

Page 12: http://www.omraoffroad.com/forum/viewtopic.php?f=40&t=11373&start=165
• Check for Clearance Issues on the Scott's Steering Stabilizer
"Low-Profile" Bolt for the Triple Clamp Pinch Bolt
• Fastway / Pro-Moto Billet Handguards ... and big foam rubber, flappy, handguard shields
• CEV Replacement Headlight / Turn Signal /Horn Switch
• Removing the Forks and Triple Clamp
• Malcom Smith Racing (MSR) Folding Mirror
• KTM HardParts Fork Bleeders
• Considering Moving the Ignition Switch ......
• Backup Ignition Key
"AYHIN" Front Tugger Strap
• Example picture of "broken" swingarm at chain guide mounts (... and why you need the BPD Chain Guide Guard).
CORRECTION on type of Honda brand/Loc-Tite type used on Wee Beasty

I will update this Index as more content and links get added.

Cheers! E-Ticket
"AYHIN"

Mine: '12 KTM 350 EXC-F (Wee Beasty); '99 Honda VFR 800i Interceptor
Wife's: '08 KTM 250 XCF-W, '04 Honda CBR600 F4i

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Re: 2012 KTM 350 EXC-F: Building the perfect "Wee Beasty"

Postby davek » Mon Apr 01, 2013 10:05 pm

Somebody in the Motorcycle Industry get this guy to do your Tech Writing!!! In general moto documentation stinks, this flows and reads well.
DK
DK
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2008 530EXC
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Re: 2012 KTM 350 EXC-F: Building the perfect "Wee Beasty"

Postby E-Ticket » Mon Apr 01, 2013 10:20 pm

davek wrote:Somebody in the Motorcycle Industry needs to get this guy to do your Tech Writing!!! In general, moto documentation stinks -- but this flows and reads well.
DK

There. Fixed that for you. :ride
"AYHIN"

Mine: '12 KTM 350 EXC-F (Wee Beasty); '99 Honda VFR 800i Interceptor
Wife's: '08 KTM 250 XCF-W, '04 Honda CBR600 F4i

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Re: 2012 KTM 350 EXC-F: Building the perfect "Wee Beasty"

Postby oregonsage » Tue Apr 02, 2013 12:11 pm

davek wrote:Somebody in the Motorcycle Industry get this guy to do your Tech Writing!!! In general moto documentation stinks, this flows and reads well.
DK


+1

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Re: 2012 KTM 350 EXC-F: Building the perfect "Wee Beasty"

Postby Bengt Phorks » Sat Apr 06, 2013 12:31 am

Instead of moving the Ignition Switch simply re-bend the switch mount into a "Z" shape to tuck it farther behind the headlight. It ends the problem of a bush turning off the ignition and you wondering why your $11k bike quit running. Don't ask me how I know this. #-o
I will post a picture I ever I figure out how to do it.
An alternative is to eliminate the Ignition switch altogether and use a "Ignition lock Demount plug" (Ignition switch eliminator)
KTM part 78111999000 $5.99.
Here's how it works;
Hit start button....
Engine cranks, fuel pump comes on, engine starts, then Lights turn on.
To stop; turn off kill switch, engine stops, lights turn off a few seconds later.
I have one taped to the back of the headlight in case I lose the key.

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Re: 2012 KTM 350 EXC-F: Building the perfect "Wee Beasty"

Postby E-Ticket » Sat Apr 06, 2013 12:50 am

Bengt Phorks wrote:Instead of moving the Ignition Switch simply re-bend the switch mount into a "Z" shape to tuck it farther behind the headlight. It ends the problem of a bush turning off the ignition and you wondering why your $11k bike quit running. Don't ask me how I know this. #-o
I will post a picture I ever I figure out how to do it.
An alternative is to eliminate the Ignition switch altogether and use a "Ignition lock Demount plug" (Ignition switch eliminator)
KTM part 78111999000 $5.99.
Here's how it works;
Hit start button....
Engine cranks, fuel pump comes on, engine starts, then Lights turn on.
To stop; turn off kill switch, engine stops, lights turn off a few seconds later.
I have one taped to the back of the headlight in case I lose the key.

Thanks for the tip, Bengt.
Yup ... that's what I was planning to try first. Just bend that sucker out of the way.
And yes, I carry the eliminator plug as well.

Cheers! E-Ticket
"AYHIN"

Mine: '12 KTM 350 EXC-F (Wee Beasty); '99 Honda VFR 800i Interceptor
Wife's: '08 KTM 250 XCF-W, '04 Honda CBR600 F4i

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Re: 2012 KTM 350 EXC-F: Building the perfect "Wee Beasty"

Postby Danilopucci » Tue May 14, 2013 2:44 am

Just a heads up on the P3 Performance products... I bought mine several months ago and complained a few times with false promises. Now many months down the line emails are not answered, phone not taken, just wondering if its just that bad feedback or I got stolen just over 100 bucks!!

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Re: 2012 KTM 350 EXC-F: Building the perfect "Wee Beasty"

Postby icedvolvo » Wed May 29, 2013 3:06 am

A couple of quick additions to the thread (although I traded my 2012 Kato for a 2013 Husey) they are of course still relevant:

1: You can add a split stream 10um to the fuel tank as well as the inline filter:


2: Zip tie up the water pump so it cant bang into the radiator:
kato1.jpg
kato1.jpg (171.14 KiB) Viewed 7309 times


3: If you have access to a TIG welder you can mod the stand so it just works better by making it shorter and welding a bigger foot on!
kat03.jpg
kat03.jpg (143.94 KiB) Viewed 7309 times


4: Get some of that really thick clear plastic they stick around mudguards and sills on cars and put it on the side covers to protect them from boot wear. Keeps it lookin real prretty like :-)
kat04.jpg
kat04.jpg (183.25 KiB) Viewed 7309 times


5: I also found the combination of Pivot Pegz and Stegz was an amazing improvement on an already awesome machine! The Pivot Pegz alone made my wrists very sore and I was going to chuck them but with the Stegz added just freakin awesome! Now this is not cheap mod at >$500 for the combo but for me it was worth every cent but your mileage may vary so be warned: some people luv em and some hate em!

6: I would like to put a steering damper on the new Husey so if anyone has recommendations please feel free ...

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Re: 2012 KTM 350 EXC-F: Building the perfect "Wee Beasty"

Postby E-Ticket » Wed May 29, 2013 1:30 pm

Nice tips .... thanks!

E-Ticket
"AYHIN"

Mine: '12 KTM 350 EXC-F (Wee Beasty); '99 Honda VFR 800i Interceptor
Wife's: '08 KTM 250 XCF-W, '04 Honda CBR600 F4i

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Re: 2012 KTM 350 EXC-F: Building the perfect "Wee Beasty"

Postby drstk » Mon Jun 17, 2013 10:17 pm

E-Ticket wrote:De-Smogifyin' Testin'


In the spirit of being methodical and *sure*, I decided to see if I could disable (without removing) the emissions
equipment and be able to detect a difference that each component had on performance.

First up was the Secondary Air System (SAS).
It's the long, lateral, rubber tube below the charcoal canister that connects to the aluminum canister that bolts on to the head just above the exhaust port. Together they inject fresh air into the exhaust port (between the exhaust valve and the header.)

snip....


So how to disable the SAS without removing it? Got it! Just plug ... or cap the dang thing. Easy-peesy.

Image


Slap the gas tank back on a go for a short ride. Remember ... I'm only changing one thing at a time.

And EUREKA! NO MORE IRRITATING POPPING ON DE-ACCELERATION!!

Just smooth power up and down. Yes-s-s-s-s-s-sssssss....!



Love this thread! It has helped me a lot. Did a valve adjustment with ease following your guide

Got a question about the SAS. Without removing the SAS and solenoid valve, is it okay to just plug/cap the SAS and ride it for a couple hours? Would like to test the bike a bit before I remove them.


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