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

Postby E-Ticket » Mon Mar 31, 2014 12:41 am

Installing the KTM HardParts "Low-Profile, Banjo-Style" Fuel Tap
for the Acerbis 3.0 Gas Tank



First off, I think that the stock fuel line routing is utterly ludicrous in how it hangs out in the breeze
just waiting for a stick to come along and rip it off. ](*,)

For example: {insert stick here}


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Or: {smash rock *here* to sever fuel line}


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So to rectify this situation, 'cause I hate walkin' out, .... I ordered the KTM HardParts "Low-Profile, Banjo-Style" Fuel Tap.
Which, by the way, should be the "stock" setup on our KTMs.

"HELLO, KTM-M-M-M-M ... ARE YOU LISTENING OUT THERE....?!!"

I sure hope so. :^)


This is the part that I ordered for my Acerbis 3.0 gas tank:

FUEL CONNECTOR CPL
Part #: 777 079 880 17


IMPORTANT! Remember this part number is specific for the "thinner walled"
Acerbis 3.0 fuel tank.

I *think* the stock EXC-F gas tank for the 350 and 500s is thicker due to the impermeable liner coating.
You will need a different part number/fuel tap for those bikes.

This first picture shows (from the top down):

• the stock fuel tap w/ the stock "molded" fuel line
• the "shorter" fuel tap for the thinner-walled Acerbis 3.0 gas tank w/
the supplied fuel line (which I used)
• the KTM Hardparts "low-profile, banjo-bolt style" fuel tap


Image


CRITICAL! Do not use the "standard" hose clamps supplied with the low-profile connector.
They are *NOT* appropriate for use with high-pressure fuel-injection line. Use only FI-rated hose clamps (shown on the right).

Image
"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 Mar 31, 2014 12:51 am

Here are a couple of pictures showing the height difference between the fuel taps
(to compensate for the thinner-walled Acerbis fuel tank).

Stock is on the right; Acerbis fuel tap in the middle; KTM HardParts low-profile tap on the left:

Image

Image

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I did a "test fit" before installing the fuel line to see how everything was going to line up.

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TIP: I *highly* recommend mounting the fuel line onto the fuel tap and quick-disconnect (QDC) coupler *BEFORE* you install the fuel tap in the gas tank.
That makes it's much easier to man-handle and work the fuel line onto the fittings.
I used a heat gun to warm up and soften up the hose and a little dab of silicone to get the dang thing mounted.
Don't worry, you can still spin the coupler on the fuel line once it's installed (before tightening).

And don't forget to use supplied, new o-ring when installing the banjo-bolt fuel tap!


Ahh-h-h-h .... that's much better!! :^)

Image


TIP: Once the low-profile, banjo-bolt and fuel lines are installed ... it's almost impossible
to get a wrench in there to tighten the banjo-bolt.
I plan on getting some cheap, very thin wrenches that are used for bicycle maintenance for carrying on the trail.
They are ultra-thin for tightening up the headset bearings.
I'll post a pic once I find the right ones.


While I had the gas tank off installing the low-profile fuel tap ... I gave the tank a careful check
looking for any chafe marks, leaks, etc.

And wo-ho!! I did find one, eh! It looks like the frame of the radiator fan was j-u-s-t reaching the gas tank and
heat shield. :shock:

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I simply cleaned it up and put a patch of clear number-plate film over the chafed area.
Both to help protect the gas tank and to supply a "slipperier" spot and hopefully avoid the fan
cage digging in and chafing the tank.

Image

Image


Reinstalled the tank, filled and tested ... yay! it works great. :^)
"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 Mar 31, 2014 1:04 am

Installing the "All-Metal" Quick-Disconnect Coupler (QDC)


Another KTMTalker posted that he had broken the stock, wimpy, plastic quick-disconnect coupler (QDC)
while kicking at his gearshift trying to straighten it after a crash.
Granted, that's a pretty rare event -- but as we all well know -- poopie happens.
And it typically happens when you are miles and miles from your truck. :(

So time for another upgrade for the Wee Beasty. :D

(I found this part via a post on KTMTalk and on Adventure Rider.
I'm sorry I can't remember the original posters -- otherwise I would have given them credit.)

Apparently, off-road Beemers have the same issue with their plastic QDCs getting busted, etc.,
so they routinely upgrade to the all-metal units.


NOTE!! They didn't have the "KTM-specific" kit that I needed.
So they were kind enough to work with me and swap out the needed parts as necessary.

We started with this kit: http://www.beemerboneyard.com/cpcqkdisconk12s.html

... and substituted out the appropriate 5/16" 90-degree elbow and straight female fitting.


Here's what I ended up with -- it's chrome-plated brass:

Image


NOTE: If there is enough interest in having a "KTM-specific" SKU, I can drop an email back
to the guys at Beemer Boneyard and ask if they could do that for us.


Here's a couple of pics of the stock QDC pieces versus their all-metal counterparts:


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Here is how it looks after swapping out for the new parts:

Image


Best of all, it snaps apart and back together tremendously easier than the stocker!
It's just "snick-snick" .... no wrestling or pulling!
And the stock wash cap set works the same way -- so no change there.



It tucks in *so-o-o-o* much better now!
While nothing is fool-proof, this is miles ahead of the stock setup.


Side view:

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3/4 head-on view:

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And from an oncoming stick's point-of-view: :lol:

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Me likey! :^)
"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 Mar 31, 2014 1:18 am

Next-items on the Wee Beasty list:

== Servicing the Golan fuel filter ... and testing out Motosapien's mods
== Installing the G2 throttle tube
== Installing the Fastway/PMB brush guards
== Servicing/greasing the swingarm

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 » Tue Apr 01, 2014 7:42 pm

Installing the G2 Aluminum Throttle Tube


While I have never destroyed a plastic throttle tube -- I do like the idea of the G2 aluminum throttle tube.
It does give you the option of changing throttle cams for slick, track, different conditions.

But for me, I really like the Delrin plastic inserts in the G2 throttle tubes. The Delrin not only acts like
a bearing surface for really smooth operation -- but it also helps lessen the throttle slop -- which just makes
everything work smoother.

http://www.g2ergo.com/

Here's a shot of the G2 throttle tube:

Image


The following pic shows the Delrin plastic insert. There is also one at the other end of the throttle tube.
Plus the removable end-cap makes installing brush guards one step easier. And I do like easier. :^)

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Installing the throttle tube is super-dooper easy.
Remove the stock throttle, clean things up, lube the throttle cables, and re-install the G2 throttle tube.
Ta-da:

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Here's a good shot of the Delrin insert (it's the white ring):

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TIP: When removing the handgrip from the stock throttle tube -- peel back the inside edge of the
handgrip -- and dribble a little isopropyl rubbing alcohol down in between the handgrip and the throttle tube.
It really loosens things up and helps the handgrip slide right off.

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I pull the handgrip off about an 1" ... and then stop there.
This way the throttle tube can help support the handgrip while you remove trim the end of the handgrip
for the brushguards. I like to use an x-acto knife or box cutter to do most of the trimming.

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I then use a moto-dremel to sand/grind the last of the rubber edge away (so that the handgrip will sit flat
on the throttle tube). Easy-peasy!

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TIP: Try not to remove any more handgrip than absolutely necessary. You want to the handgrip to sit flat -- but
not to have a gap that dirt can get in the end of the grip. I actually went just a "skosh" more than ideal on this one.

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TIP: Before gluing on the handgrip, loosen the throttle assembly bolts ... slide the throttle off the end of the
handlebar about an inch ... and then tighten the bolts again to hold the throttle in place.
Finally, stuff a piece of paper towel down the throttle tube and pack it in real good.

Now you can glue away to your little heart's content and not have to worry about getting excess handgrip glue
down in the interior of the throttle assembly!

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After gluing on and mounting the handgrip ... you simply take some pliers and pull out the paper towel "stopper."
Wipe off any residual glue and ta-da! ... you're done, homie. :^)

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When mounting the handgrip .... I like to leave *just* a touch of the grip extending out over the throttle tube.
As to the "why?" ... that will become more clear when you read about installing the brush guards in the next section.

Image
"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 » Tue Apr 01, 2014 7:52 pm

Installing Pro Moto Billet Hand Guards


The Flying Ant and I have tried out most of the hand guards out there (Acerbis, flag-style, etc.)
I say *MOST* of them ... because of the fact that the wife likes to crash pretty good on a regular basis ...
and she has managed to wad up every one of them *except* the Pro Moto Billet hand guards.
So they now automatically go on every bike we get. \:D/

http://www.promotobillet.com/

We prefer the Version 2 model with the one-piece handlebar clamp.
Yes, it might be a tad heavier than some of the other manufacturer's clamps ... but this is about
the only unit that the wifey-poo hasn't manage to break, wad up, twist, smash, etc. :^)

Image


Image



We also really like how the top handlebar clamp/bar mount doesn't use up any handlebar space
needed for accessories and routing control cables and hoses.

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Remember in the last section, "Installing the G2 Throttle Tube," how I suggested leaving the grip
extending out over the end of the throttle tube by just a smidge?
Good! That means you have been paying at least a modicum of attention.
Which makes my little heart soar like a hawk. But ... I digress. :^)

Doing so allows you to have the grip actually wrap slightly around the end of the brush guard.
This helps keep dirt out of the joint between the throttle tube and handlebar.
And supplies a bit more hand protection from the brush guard itself.
It's not a whole lot .... but hey ... every bit helps.

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TIP: You can trim away the lower 1/4 of the handgrip so that it can actually index *over* the brush guard just a tad.

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IMPORTANT! Just be sure that you do a test-rotate of the throttle before cutting.
You know, to make sure that you don't have any rubbing conflicts.


Editors' Note: Perhaps you're wondering why my brush guards look so beat up.
That's because the Wee Beasty is the FOURTH scoot that the ProMoto Billet hand guards have been on.
Hey! If something works really well ... and you can't kill it ... just keep moving it on to the next bike in line. LOL.


Image
"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 » Tue Apr 01, 2014 7:58 pm

Our State-of-the-Art Rubber HandFlappy Things


Sorry, don't know what else to call them. lol.

The Flying Ant whipped these up for our first "Hooters on Scooters" ride with Baja Bound Adventures.

http://www.bajaboundmoto.com/


We knew that it was going to be cold and snowy at altitude (and we were right!) -- so we wanted some
cold-protection for our hands.

But the dang things worked so well shielding our digits from cactus spines, manaznita 'whips', broken
levers, and the weather -- that we just leave them on all the times.
Yah, we know that they're not pretty ... but we just don't care. They work that well!

They're simply pieces of some fairly stiff, closed-cell neoprene.


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And the mounting system is super high-tech. I think they're call "zip-ties" ....? <g>
We had some pretty good crashes with them and you just can't hurt 'em.
Break a zip-tie? Put another one on. :^)


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Well, that's all for now, homies
Up next should be swingarm maintenance and some Golan fuel filter maintenance and mods testing.

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 Fasnacht » Mon Apr 28, 2014 2:14 pm

Hi. I neither live in Oregon nor own a 350 EXC-F (currently ride a gasser), but I am looking pretty hard and found this thread through ADV and just wanted to register and say thanks to E-Ticket. Really excellent information and no doubt a ton of work to post it all up. :thumbright:

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

Postby Rider1 » Sat May 03, 2014 1:41 pm

[quote="E-Ticket"]The fuel pump assembly:

Image


A fair number of Husaberg owners had a real run of bad luck with failing/failed fuel pump.
The color of the flaky units (Made in China .... of course) were black.
And the new-n-improved models were a brown color.

No guarantees ... but it's nice to see a brown-colored fuel pump here. :^) end of quote

v
v


As an FYI:

Today I cleaned the in the tank fuel pump screen (a small amount of flakes) and replaced the Mahle inline fuel filter. Here's what I found in my bike , 2014 KTM 350EXC-F with 28 hours of use.

I bought from KTM a new in the tank fuel filter and screen which comes in a kit at a ridiculous price of $75 plus tax. And when I went to install the new pickup screen I found it is about 1mm too small in diameter and does not fit. KTM Part#: 81207090000. So I cleaned the original screen....no biggie.....and reinstalled it. Note: My bike has a brown top fuel pump and says "Made in China" which you'll see when you pull it out to change/clean the inlet screen. So there goes the theory that it was Made in the USA which I wish it was.

Also.....this is such a GREAT bike !!! Nimble, excellent control of the significant (IMO) power and just a blast to ride....slow or faster.

Dave

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

Postby Albertus » Tue Dec 09, 2014 1:28 am

Looking good. Excellent build and writeup E-Ticket.

Your KTM 350 build is being featured in the BikeBuilds.net
directory here: E-Ticket's Wee Beasty build

We’re currently displaying only a reduced-size photo (similar to what you’d find in Google
Images). We'd like to ask for your permission to publish the original full-size image with your
build listing.

If anyone would like to have a build of their own listed, just send me a message with a link to
the build thread and we’ll take care of the rest.

Al

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

Postby hedonist222 » Sun Mar 15, 2015 9:38 am

I joined this forum just to say thanks e-ticket.

Your encyclopædia served as a learning tool for me.

It is an institution.

Thank you.

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

Postby Dirt350 » Tue Apr 28, 2015 5:05 pm

Hi E-ticket. Your thread has been a huge help. I thank you for taking the time to build it with all the pics and commentary. I wish you the best. If your ever up here in Tahuya, give us a shout. I believe my girl and I could spring for your meal. Ride on.
Death may be the greatest of all human blessings. Socrates: 399 BC

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

Postby E-Ticket » Tue May 17, 2016 7:35 pm

Dirt350 wrote:Hi E-ticket. Your thread has been a huge help. I thank you for taking the time to build it with all the pics and commentary. I wish you the best. If your ever up here in Tahuya, give us a shout. I believe my girl and I could spring for your meal. Ride on.

Thanks for the kind comments, guys.

Hmmm .... mighty tempting offer, sir! :D
"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 » Tue Jan 03, 2017 1:29 pm

Well, I took "quite a while off" from riding mo-mo's and dirtybikes.
(no medical issue or anything ... just decided to focus on some other life stuff for a while.)

But I've gotten terrible itchy again lately!
Miss doing this! :ride

So I have started the long, arduous trail of bringing the Wee Beasty back to full ride/race form.
Cleaned the fuel injector, flushed/cleaned the tank, and various other items.

So will try to post the procedures and pics for doing those things.
Hopefully over the next couple of days.
(We're having a major cold snap and it is nasty outside right now.)

In the meantime, someone had asked me what my mileage was ... and if I had had any major issues with my tree-fiddy.
See below for my reply.

Cheers! E-Ticket

==========================================

Quote Originally Posted by E-Ticket View Post

The Wee Beasty is now at 2,572 miles / 127 hrs.

Here's the whole list of "issues" to date:

•Three tight valves at 5 hours (easily adjusted)
A couple of chafed wires behind headlight ... easily located, wrapped, rerouted better.
•Burned-out headlight bulb. (vibration, big crash, simply time .... who knows)
•Gas leak from after-market, Golan fuel filter leak (o-ring quit sealing). Replaced with metal body, Can-Am metal fuel filter.
•Cleaned fuel injector after Wee Beasty sat for more than a year. Bike still started and ran fine -- it just ran even better at WFO after cleaning.
•Small weepage of coolant around edge of water pump cover from pinched sealing gasket. Fixed by installing upgraded water pump cover and gasket.

Let's see .... what else .....
Nope. That's it.
And two of the issue were user-caused.
So *very* reliable.

Cheers! E-ticket

===============================================

Well ... rats. I spoke too soon. :^(

I replaced the water pump cover and gasket and thought I had found/fixed the coolant leak.
But nope. There is still just some very slight coolant weepage coming from the small drain hole on the water pump cavity.

So, it looks like I'll be replacing the water pump seals next.
Again, I repeat: rats.

- ET
"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 JimTC » Mon Feb 06, 2017 1:18 pm

Hello ET. I just bought a 2014 350 EXC and was reading your INCREDIBLE posts but now the images are not showing!! Will these come back? Is the photobucket site down???


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