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TABLE OF CONTENTS
Removing the seat ......................................................... 55
Mounting the seat ......................................................... 55
Removing the air filter box lid......................................... 56
Installing the air filter box lid.......................................... 56
............................................... 56
x
............................................... 56
x
Removing the main silencer............................................ 57
Installing the main silencer ............................................ 58
................................................................... 58
x
x
x
Checking the chain for dirt ............................................. 60
Cleaning the chain......................................................... 60
Checking the chain tension ............................................ 61
chain guide................................................................... 61
Adjusting the chain tension ............................................ 63
................................................... 65
x
x
Checking the throttle cable routing.................................. 65
Checking the rubber grip ................................................ 66
Additionally securing the rubber grip ............................... 66
Adjusting the basic position of the clutch lever................. 66
Checking the fluid level of the hydraulic clutch ................ 67
BRAKES ........................................................................... 69
Checking free travel of hand brake lever........................... 69
(XC-W).......................................................................... 69
models) ........................................................................ 69
Checking the brake discs................................................ 70
Checking the front brake fluid level ................................. 70
x
Checking the front brake linings...................................... 71
Checking the free travel of foot brake lever....................... 73
Checking the rear brake fluid level .................................. 74
Checking the rear brake linings ....................................... 75
WHEELS, TIRES ............................................................... 78
x
x
x
Checking the tire condition............................................. 80
Checking the tire air pressure ......................................... 81
Checking the spoke tension ............................................ 81
ELECTRICAL SYSTEM ....................................................... 83
(All 250/300 models) ................ 83
x
(All 250/300 models)................. 83
x
x
Changing the main fuse (All 250/300 models) ................. 84
x
........................ 57
............................................. 58
.............................................. 59
.......................................... 64
x
............................................. 65
x
............................ 67
............................................ 70
................................. 72
x
x
...... 73
x
.......................... 74
................................. 75
x
x
.................................. 76
.................................. 76
x
.......................................... 78
x
........................................... 78
........................................... 79
............................................ 79
(All 250/300 models) .............. 83
models) ........................................................................ 85
models) ........................................................................ 86
Changing the headlight bulb (All EXC models).................. 86
Checking the headlight setting (All EXC models)............... 87
Adjusting the headlight range (All EXC models) ................ 87
Changing the speedometer battery .................................. 87
COOLING SYSTEM ............................................................ 89
Cooling system .............................................................. 89
Checking the antifreeze and coolant level ........................ 89
Checking the coolant level.............................................. 90
.................................................. 90
x
x
................................................ 91
TUNING THE ENGINE ....................................................... 93
Checking the play in the throttle cable............................. 93
Carburetor .................................................................... 93
Checking the basic position of the shift lever.................... 96
(All 250/300 models) .................................................... 96
(All 250/300 models) .................................................... 96
SERVICE WORK ON THE ENGINE ...................................... 98
Checking the gear oil level.............................................. 98
................................................ 98
x
................................................. 99
x
................................................ 99
x
....................................................... 100
x
CLEANING, CARE ........................................................... 101
Cleaning the motorcycle ............................................... 101
Checks and maintenance steps for winter operation ........ 102
STORAGE ....................................................................... 103
Storage....................................................................... 103
Preparing for use after storage ...................................... 103
TROUBLESHOOTING....................................................... 104
TECHNICAL DATA - ENGINE ............................................ 106
125 EXC EU, 125 EXC SIX DAYS EU ............................ 106
All 200 models ........................................................... 106
All 250 models ........................................................... 107
All 300 models ........................................................... 107
Capacity - transmission oil............................................ 108
Capacity - coolant........................................................ 108
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........ 109
All 125/200 models .................................................... 109
All 250/300 models .................................................... 110
TECHNICAL DATA - CARBURETOR................................... 111
125 EXC EU, 125 EXC SIX DAYS EU ............................ 111
200 EXC EU ............................................................... 111
200 EXC AUS ............................................................. 111
200 XC-W USA ........................................................... 111
250 EXC EU, 250 EXC SIX DAYS EU ............................ 112
250 EXC AUS ............................................................. 112
250 XC-W USA ........................................................... 112
300 EXC EU, 300 EXC SIX DAYS EU ............................ 112
300 EXC AUS ............................................................. 113
300 XC-W USA ........................................................... 113
x
....................... 93
x
.......................... 94
x
....................... 95
x
.............. 96
x
x
.......................................... 113
3
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