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CONTENTS
EXC-R AUS/UK, EXC-R USA, XCR-W ZA) ......................... 44
XCR-W USA) ................................................................. 44
EXC-R AUS/UK, EXC-R USA, XCR-W ZA) ......................... 45
Dismounting the front fender .......................................... 46
Installing the front fender............................................... 46
XCR-W ZA).................................................................... 46
EXC-R USA, XCR-W ZA) ................................................. 47
Dismount the start number plate (XCR-W USA) ................ 47
Fitting the start number plate (XCR-W USA)..................... 47
Handlebar position ........................................................ 47
Checking gas Bowden cable route ................................... 49
Checking play in the gas Bowden cable ........................... 50
Checking chain dirt ....................................................... 50
Cleaning the chain......................................................... 50
Checking the chain tension ............................................ 51
Checking the chain tension when fitting rear wheel........... 51
Checking chain wear...................................................... 52
Adjusting the chain tension ............................................ 52
Adjusting chain tension - after checking .......................... 53
x
Adjusting chain tension - fitting rear wheel ...................... 54
............................................... 54
Brake fluid reservoir....................................................... 54
Brake calipers ............................................................... 55
Checking brake discs ..................................................... 55
Checking free play of hand brake lever............................. 55
models) ........................................................................ 56
models) ........................................................................ 56
Checking the front brake fluid level ................................. 56
Checking the front brake linings...................................... 57
Checking free play of foot brake lever .............................. 59
x
Checking the rear brake fluid level .................................. 60
Checking rear brake linings ............................................ 61
x
x
................................................ 63
x
.................................................... 64
x
................................................. 65
...................................................... 65
Tire condition checking.................................................. 66
Checking tire air pressure............................................... 66
x
Checking spoke tension.................................................. 67
................................................ 67
x
x
x
x
............................. 46
x
...................................... 48
x
.......................... 50
x
................................. 56
x
x
...................................... 58
x
................................. 58
................................. 59
x
................... 60
.............................................. 61
x
x
....................................... 62
x
.................................. 62
.................................. 63
x
x
................................................. 67
Removing a fuse............................................................ 69
Replacing the fuse......................................................... 69
Removing the seat ......................................................... 69
Mounting the seat ......................................................... 69
x
Cooling system .............................................................. 71
Checking antifreeze and coolant level .............................. 71
x
Checking the coolant level.............................................. 72
x
....................................................... 72
....................................................... 73
Glass fiber yarn filling of main silencer ............................ 73
Removing main silencer ................................................. 73
Fitting the main silencer ................................................ 74
Dismounting the air filter box lid..................................... 74
x
Installing the air filter box lid.......................................... 74
x
............................................... 74
x
............................................... 75
...................................................... 75
Adjusting basic position of clutch lever............................ 75
Checking fluid level of hydraulic clutch ........................... 75
Carburetor - idle ............................................................ 77
Checking engine oil level................................................ 79
x
..................................................................... 79
x
x
............................................... 80
x
..................................................... 80
Topping up engine oil .................................................... 81
Checking gear oil level ................................................... 81
x
x
............................................... 83
TROUBLESHOOTING......................................................... 84
CLEANING........................................................................ 86
Cleaning motorcycle ...................................................... 86
STORAGE ......................................................................... 87
Storage......................................................................... 87
Putting into operation after storage ................................. 87
TECHNICAL DATA - ENGINE .............................................. 88
Capacity - engine oil ...................................................... 88
Capacity - gear oil.......................................................... 88
Capacity - coolant.......................................................... 89
TECHNICAL DATA - ENGINE TIGHTENING TORQUES.......... 90
TECHNICAL DATA - CARBURETOR..................................... 92
450 EXC-R EU, 450 EXC-R AUS/UK (3900I) ................... 92
(3900L) ....................................................................... 92
530 EXC-R EU, 530 EXC-R AUS/UK (3900J)................... 93
(3900M) ...................................................................... 93
TECHNICAL DATA - CHASSIS ............................................ 94
Lighting equipment ....................................................... 95
Tires ............................................................................ 95
.............................................. 68
x
......................................... 70
.............................................. 70
x
...................... 76
x
x
......................................... 77
....................... 78
x
............ 79
........................................... 81
x
x
.................. 82
................... 82
............................................ 83
3
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