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fork ............................................................... 46
11.13 Adjusting the rebound damping of the fork ........ 47
(EXC US) ....................................................... 48
11.15 Handlebar position.......................................... 48
12 SERVICE WORK ON THE CHASSIS.............................. 51
12.1
Raising the motorcycle with the lift stand .......... 51
12.2
12.3
Bleeding the fork legs...................................... 51
12.4
Cleaning the dust boots of the fork legs............. 52
12.5
12.6
12.7
Removing the fork protector ............................. 54
12.8
Installing the fork protector.............................. 54
12.9
(EXC Six Days US) .......................................... 55
(EXC Six Days US) .......................................... 57
12.13 Checking the steering head bearing play............ 59
(EXC US) ........................................ 59
(EXC Six Days US) ........................... 60
12.17 Removing the front fender ............................... 60
12.18 Installing the front fender ................................ 61
12.21 Removing the seat .......................................... 62
12.22 Mounting the seat ........................................... 62
12.23 Removing the air filter box cover ...................... 62
12.24 Installing the air filter box cover ....................... 62
12.29 Removing main silencer................................... 64
12.30 Installing the main silencer.............................. 64
...................................................... 66
12.35 Checking for chain dirt accumulation ................ 69
12.36 Cleaning the chain .......................................... 69
12.37 Checking the chain tension .............................. 70
12.38 Adjusting the chain tension.............................. 71
sprocket, and chain guide ................................ 71
12.42 Checking throttle cable routing......................... 73
12.43 Checking the rubber grip ................................. 74
12.44 Additionally securing the rubber grip................. 74
lever .............................................................. 74
hydraulic clutch.............................................. 75
........................ 49
................................. 52
................................. 53
(EXC US)..... 54
(EXC US) ..... 55
................ 60
....................... 61
........................ 61
................................. 63
.................................. 63
.......... 63
............................... 64
................................ 65
................................ 66
................................. 68
..................................... 73
................................ 73
............... 75
(EXC Six Days US) .......................................... 76
13 BRAKE SYSTEM ........................................................ 77
13.1
Checking free travel of hand brake lever ............ 77
13.2
Adjusting free travel of hand brake lever............ 77
13.3
Checking the brake discs ................................. 77
13.4
brake ............................................................. 78
13.5
13.6
Checking the front brake linings ....................... 79
13.7
13.8
Checking the free travel of foot brake lever ........ 81
13.9
........................................................... 81
13.10 Checking the rear brake fluid level.................... 81
13.12 Checking the rear brake linings ........................ 83
14 WHEELS, TIRES ........................................................ 86
14.1
14.2
14.3
14.4
14.5
Checking the tire condition .............................. 88
14.6
Checking the tire air pressure........................... 89
14.7
Checking spoke tension ................................... 89
15 ELECTRICAL SYSTEM ................................................ 91
15.1
15.2
15.3
15.4
Changing the main fuse ................................... 93
15.5
consumers...................................................... 94
15.6
Removing headlight mask with headlight........... 94
15.7
headlight........................................................ 95
15.8
Changing the headlight bulb ............................ 95
15.9
Changing the turn signal bulb .......................... 96
15.10 Checking the headlight setting ......................... 96
15.11 Adjusting the headlight range........................... 97
15.12 Changing the speedometer battery .................... 97
16 COOLING SYSTEM ..................................................... 98
16.1
Cooling system ............................................... 98
16.2
Checking the antifreeze and coolant level .......... 98
16.3
Checking the coolant level ............................... 99
16.4
16.5
17 TUNING THE ENGINE.............................................. 101
17.1
Checking the play in the throttle cable ............ 101
17.2
17.3
17.4
17.5
......................................................... 103
18 SERVICE WORK ON THE ENGINE ............................. 104
18.1
18.2
Checking the engine oil level.......................... 104
18.3
18.4
Adding engine oil .......................................... 107
............................... 78
................... 79
................................ 82
..................... 83
............................. 86
............................. 86
.............................. 87
............................... 88
................................... 91
.................................... 91
.................................... 92
.................................... 99
........................................ 100
........ 101
............................. 102
............................ 104
............................. 105
3
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