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TABLE OF CONTENTS
Preassembling the shift shaft........................................ 152
Disassembling the main shaft ....................................... 152
Disassembling the countershaft .................................... 153
Checking the transmission............................................ 153
Assembling the main shaft ........................................... 155
Assembling the countershaft......................................... 155
30/ENGINE ASSEMBLY ................................................... 157
Installing the crankshaft............................................... 157
Installing the transmission shafts .................................. 157
Installing the shift forks ............................................... 157
Installing the shift drum............................................... 158
Installing the shift rails ................................................ 158
Installing the left engine case ....................................... 158
Installing the spacer .................................................... 159
Installing the timing chain............................................ 159
Installing the primary gear............................................ 160
Installing the force pump ............................................. 160
Installing the suction pump .......................................... 161
Installing the locking lever............................................ 162
Installing the shift drum locating unit............................ 162
Installing the shift shaft ............................................... 162
Installing the intermediate kick starter gear.................... 162
Installing the kick starter shaft ..................................... 162
Installing the outer clutch hub...................................... 163
Installing the clutch discs ............................................ 164
Installing the clutch cover ............................................ 165
Installing the water pump cover .................................... 165
Installing the starter drive ............................................ 166
Installing the piston..................................................... 167
Installing the cylinder head .......................................... 168
Installing the camshafts ............................................... 169
Checking the valve timing ............................................ 170
Adjusting the valve timing ............................................ 170
Installing the timing chain tensioner ............................. 171
Checking the valve clearance ........................................ 172
Adjusting the valve clearance........................................ 173
Installing the torque limiter .......................................... 173
Installing the alternator cover ....................................... 173
Installing the kick starter.............................................. 174
Installing the valve cover .............................................. 174
Installing the spark plug............................................... 175
Installing the oil filter .................................................. 175
Installing the oil screen................................................ 175
Installing the spacer .................................................... 176
Installing the clutch push rod ....................................... 176
Removing the engine from the work stand...................... 176
32/CLUTCH .................................................................... 177
Checking the fluid level of the hydraulic clutch .............. 177
Changing the hydraulic clutch fluid ............................... 177
35/WATER PUMP, COOLING SYSTEM .............................. 178
Cooling system ............................................................ 178
Checking the antifreeze and coolant level ...................... 178
Checking the coolant level............................................ 179
Draining the coolant .................................................... 179
Refilling coolant .......................................................... 180
38/LUBRICATION SYSTEM .............................................. 181
Oil circuit ................................................................... 181
Checking the engine oil level ........................................ 181
screen ........................................................................ 182
39/IGNITION SYSTEM ..................................................... 186
Ignition coil - checking the secondary winding................ 186
Checking the spark plug connector................................ 186
Alternator - checking the stator winding......................... 186
Removing the stator and ignition pulse generator............ 187
Installing the stator and ignition pulse generator............. 188
40/ELECTRIC STARTER................................................... 189
Checking the starter motor ........................................... 189
41/THROTTLE VALVE BODY............................................. 190
settings ...................................................................... 190
TECHNICAL DATA - ENGINE ............................................ 192
Capacity - engine oil .................................................... 192
Capacity - coolant........................................................ 192
ENGINE ......................................................................... 193
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........ 194
TECHNICAL DATA - CHASSIS .......................................... 196
Lighting equipment ..................................................... 197
Tires .......................................................................... 197
Capacity - fuel............................................................. 197
TECHNICAL DATA - FORK................................................ 198
TECHNICAL DATA - SHOCK ABSORBER ........................... 199
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 200
CLEANING, CARE ........................................................... 201
Cleaning the motorcycle ............................................... 201
Checks and maintenance steps for winter operation ........ 202
STORAGE ....................................................................... 203
Storage....................................................................... 203
Preparing for use after storage ...................................... 203
SERVICE SCHEDULE....................................................... 204
Service schedule ......................................................... 204
Service work (as additional order).................................. 205
WIRING DIAGRAM .......................................................... 206
Page 1 of 8 (EXC-F EU, EXC-F SIX DAYS)...................... 206
Page 2 of 8 (EXC-F EU, EXC-F SIX DAYS)...................... 208
Page 3 of 8 (EXC-F EU, EXC-F SIX DAYS)...................... 210
Page 4 of 8 (EXC-F EU, EXC-F SIX DAYS)...................... 212
Page 5 of 8 (EXC-F EU, EXC-F SIX DAYS)...................... 214
Page 6 of 8 (EXC-F EU, EXC-F SIX DAYS)...................... 216
Page 7 of 8 (EXC-F EU, EXC-F SIX DAYS)...................... 218
Page 8 of 8 (EXC-F EU, EXC-F SIX DAYS)...................... 220
Page 1 of 8 (EXC-F AUS) ............................................. 222
Page 2 of 8 (EXC-F AUS) ............................................. 224
Page 3 of 8 (EXC-F AUS) ............................................. 226
Page 4 of 8 (EXC-F AUS) ............................................. 228
Page 5 of 8 (EXC-F AUS) ............................................. 230
Page 6 of 8 (EXC-F AUS) ............................................. 232
Page 7 of 8 (EXC-F AUS) ............................................. 234
Page 8 of 8 (EXC-F AUS) ............................................. 236
Page 1 of 8 (EXC-F USA) ............................................. 238
Page 2 of 8 (EXC-F USA) ............................................. 240
Page 3 of 8 (EXC-F USA) ............................................. 242
Page 4 of 8 (EXC-F USA) ............................................. 244
Page 5 of 8 (EXC-F USA) ............................................. 246
Page 6 of 8 (EXC-F USA) ............................................. 248
Page 7 of 8 (EXC-F USA) ............................................. 250
Page 8 of 8 (EXC-F USA) ............................................. 252
Page 1 of 7 (XCF-W) .................................................... 254
Page 2 of 7 (XCF-W) .................................................... 256
Page 3 of 7 (XCF-W) .................................................... 258
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