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300 XC-W SIX DAYS USA
KTM 300 XC-W SIX DAYS USA Manuals
Manuals and User Guides for KTM 300 XC-W SIX DAYS USA. We have
2
KTM 300 XC-W SIX DAYS USA manuals available for free PDF download: Repair Manual, Owner's Manual
KTM 300 XC-W SIX DAYS USA Repair Manual (289 pages)
Brand:
KTM
| Category:
Motorcycle
| Size: 12.59 MB
Table of Contents
Table of Contents
4
Table of Contents 2
4
1 Means of Representation
8
Symbols Used
8
Formats Used
8
2 Safety Advice
9
Repair Manual
9
Degrees of Risk and Symbols
9
Work Rules
9
3 Important Information
10
Guarantee, Warranty
10
Operating and Auxiliary Substances
10
Spare Parts, Accessories
10
Figures
10
4 Serial Numbers
11
Chassis Number
11
Type Label
11
Engine Number
11
Fork Part Number
11
Shock Absorber Part Number
11
5 Motorcycle
12
Raising the Motorcycle with the Lift Stand
12
Removing the Motorcycle from the Lift Stand
12
Starting
12
Starting the Motorcycle for Checking
13
6 Fork, Triple Clamp
14
Exc Eu/Aus, XC-W
14
Adjusting the Compression Damping of the Fork
14
Adjusting the Rebound Damping of the Fork
14
Adjusting the Spring Preload of the Fork
14
Bleeding the Fork Legs
15
Cleaning the Dust Boots of the Fork Legs
15
Loosening the Fork Protection
16
Positioning the Fork Protection
16
Removing the Fork Legs
16
Installing the Fork Legs
16
Removing the Fork Protector
17
Installing the Fork Protector
17
Performing a Fork Service
18
Disassembling the Fork Legs
18
Cartridge Disassembly
21
Disassembling the Compression Damping Fitting
23
Checking the Fork Legs
23
Assembling the Compression Damping Fitting
24
Assembling the Cartridge
25
Assembling the Fork Legs
26
Greasing the Steering Head Bearing
31
Removing the Lower Triple Clamp
31
Installing the Lower Triple Clamp
32
Checking the Play of the Steering Head Bearing
33
Adjusting the Play of the Steering Head Bearing
34
250/300 Six Days
34
Adjusting the Compression Damping of the Fork
34
Adjusting the Rebound Damping of the Fork
35
Bleeding the Fork Legs
35
Cleaning the Dust Boots of the Fork Legs
35
Loosening the Fork Protection
36
Positioning the Fork Protection
36
Removing the Fork Legs
36
Installing the Fork Legs
37
Removing the Fork Protector
37
Installing the Fork Protector
38
Performing a Fork Service
38
Disassembling the Fork Legs
38
Removing the Spring
40
Disassembling the Cartridge
41
Disassembling the Piston Rod
42
Disassembling the Hydrostop Unit
43
Disassembling the Seal Ring Retainer
44
Checking the Fork Legs
44
Assembling the Seal Ring Retainer
45
Assembling the Hydrostop Unit
46
Assembling the Piston Rod
46
Assembling the Cartridge
48
Assembling the Fork Legs
49
Greasing the Steering Head Bearing
52
Removing the Lower Triple Clamp
53
Installing the Lower Triple Clamp
53
Checking the Play of the Steering Head Bearing
55
Adjusting the Play of the Steering Head Bearing
55
7 Handlebar, Controls
56
Handlebar Position
56
Adjusting the Handlebar Position
56
Adjusting the Basic Position of the Clutch Lever
56
Checking the Routing of the Throttle Cable
57
Checking the Play in the Throttle Cable
57
Adjusting the Play in the Throttle Cable
58
8 Frame
59
Removing the Engine Guard (250/300 SIX DAYS)
59
Installing the Engine Guard (250/300 SIX DAYS)
59
9 Shock Absorber, Swingarm
60
Adjusting the High-Speed Compression Damping of the Shock Absorber
60
Adjusting the Low-Speed Compression Damping of the Shock Absorber
60
Adjusting the Rebound Damping of the Shock Absorber
61
Measuring the Sag of the Unloaded Rear Wheel
61
Checking the Static Sag of the Shock Absorber
61
Checking the Riding Sag of the Shock Absorber
62
Adjusting the Spring Preload of the Shock Absorber
62
Adjusting the Riding Sag
63
Removing the Shock Absorber
63
Installing the Shock Absorber
63
Servicing the Shock Absorber
64
Removing the Spring
64
Disassembling the Damper
65
Disassembling the Piston Rod
66
Disassembling the Seal Ring Retainer
67
Replacing the Pilot Bushing
68
Checking the Damper
69
Disassembling the Rebound Adjuster
69
Removing the Heim Joint
70
Installing the Heim Joint
71
Assembling the Rebound Adjuster
72
Assembling the Seal Ring Retainer
72
Assembling the Piston Rod
73
Assembling the Damper
74
Bleeding and Filling the Damper
77
Filling the Damper with Nitrogen
79
Installing the Spring
80
Changing the Heim Joint
81
10 Exhaust
83
Removing the Main Silencer
83
Installing the Main Silencer
83
Changing the Glass Fiber Yarn Filling of the Main Silencer
83
11 Air Filter
85
Removing the Air Filter Box Lid
85
Installing the Air Filter Box Lid
85
Removing the Air Filter
85
Installing the Air Filter
85
Cleaning the Air Filter and Air Filter Box
86
Sealing the Air Filter Box
86
12 Fuel Tank, Seat, Trim
87
Opening the Filler Cap
87
Closing the Filler Cap
87
Removing the Seat
87
Mounting the Seat
88
Removing the Fuel Tank
88
Installing the Fuel Tank
89
Fuel Tap
90
13 Mask, Fender
91
Removing the Front Fender
91
Installing the Front Fender
91
Removing the Headlight Mask with the Headlight
91
Refitting the Headlight Mask with the Headlight
92
14 Wheels
93
Checking the Tire Air Pressure
93
Checking the Tire Condition
93
Checking the Brake Discs
94
Checking the Spoke Tension
94
Front Wheel
95
Removing the Front Wheel
95
Installing the Front Wheel
95
Removing the Brake Disc of the Front Brake
96
Installing the Brake Disc of the Front Brake
96
Rear Wheel
96
Removing the Rear Wheel
96
Installing the Rear Wheel
97
Removing the Brake Disc of the Rear Brake
98
Installing the Brake Disc of the Rear Brake
98
Checking the Chain for Dirt
98
Cleaning the Chain
99
Checking the Chain Tension
99
Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide
100
Adjusting the Chain Tension
101
15 Wiring Harness, Battery
103
Plug-In Connection, Ignition Timing Map
103
Removing the Main Fuse
103
Installing the Main Fuse
103
Recharging the Battery
103
Disconnecting the Negative Cable of the Battery
104
Connecting the Negative Cable of the Battery
105
Removing the Battery
105
Installing the Battery
106
Checking the Charging Voltage
106
Checking the Closed Current
106
Checking the Starter Relay
107
16 Brake System
108
Checking the Front Brake Linings
108
Changing the Front Brake Linings
108
Checking the Free Travel of the Hand Brake Lever
110
Adjusting Free Travel of Hand Brake Lever (All 250/300 EXC Models)
110
Adjusting the Basic Position of the Hand Brake Lever (All 250/300 XC-W)
110
Checking the Front Brake Fluid Level
111
Adding Front Brake Fluid
111
Changing the Front Brake Fluid
112
Checking the Rear Brake Linings
113
Changing the Brake Linings of the Rear Brake
114
Checking the Free Travel of Foot Brake Lever
115
Adjusting the Basic Position of the Foot Brake Lever
115
Checking the Rear Brake Fluid Level
116
Adding Brake Fluid for the Rear Brake
116
Changing the Rear Brake Fluid
117
17 Lighting System, Instruments
119
Checking the Headlight Setting
119
Adjusting the Headlight Range
119
Exc Eu/Aus, XC-W
119
Speedometer Overview
119
Activation and Test
120
Setting Kilometers or Miles
120
Adjusting the Speedometer Functions
120
Setting the Clock
121
Activating the Additional Functions
121
Setting the Wheel Circumference
122
Querying Lap Time
122
250/300 Six Days
123
Speedometer Overview
123
Activation and Test
123
Setting Kilometers or Miles
123
Setting the Speedometer Functions
124
Setting the Clock
124
Setting the Wheel Circumference
125
Viewing the Lap Time
125
18 Engine
126
Removing the Engine
126
Installing the Engine
130
Engine Disassembly
135
Clamping the Engine into the Engine Work Stand
135
Draining the Gear Oil
135
Removing the Clutch Push Rod
135
Removing the Shift Lever
135
Removing the Engine Sprocket
135
Removing the Spacer
136
Removing the Starter Motor
136
Removing the Kick Starter
137
Removing the Cylinder Head
138
Removing the Cylinder
138
Removing the Piston
139
Removing the Water Pump Cover
140
Removing the Clutch Cover
140
Removing the Clutch Discs
140
Removing the Clutch Basket
141
Removing the Kick Starter Shaft
142
Removing the Intermediate Kick Starter Gear
142
Removing the Shift Shaft
143
Removing the Shift Drum Locating Unit
143
Removing the Locking Lever
143
Removing the Rotor
143
Removing the Reed Valve Housing
144
Removing the Left Engine Case Section
144
Removing the Shift Rails
144
Removing the Shift Drum
145
Removing the Shift Forks
145
Removing the Transmission Shafts
145
Removing the Crankshaft
145
Work on Individual Parts
146
Work on the Right Section of the Engine Case
146
Work on the Left Section of the Engine Case
147
Removing the Crankshaft Bearing Inner Race
147
Installing the Crankshaft Bearing Inner Race
148
Changing the Connecting Rod, Conrod Bearing, and Crank Pin
148
Checking the Crankshaft Run-Out at the Bearing Pin
149
Checking/Measuring the Cylinder
149
Removing the Exhaust Control
150
Checking the Exhaust Control
152
Installing the Exhaust Control
152
Cylinder - Nikasil ® Coating
154
Checking/Measuring the Piston
155
Checking the Piston Ring End Gap
156
Piston/Cylinder - Measuring the Mounting Clearance
156
Checking the Reed Valve Housing, Reed Valve, and Intake Flange
157
Work on the Clutch Cover
157
Checking the Clutch
161
Preassembling the Shift Shaft
162
Checking the Shift Mechanism
163
Disassembling the Main Shaft
164
Disassembling the Countershaft
165
Checking the Transmission
165
Assembling the Main Shaft
166
Assembling the Countershaft
167
Checking the Kick Starter
169
Preassembling the Kick Starter Shaft
169
Checking the Electric Starter Drive
171
Engine Assembly
172
Installing the Crankshaft
172
Installing the Transmission Shafts
172
Installing the Shift Forks
173
Installing the Shift Drum
173
Installing the Shift Rails
173
Installing the Left Engine Case Section
173
Installing the Reed Valve Housing
174
Installing the Rotor
174
Installing the Locking Lever
175
Installing the Shift Drum Locating Unit
175
Installing the Shift Shaft
175
Installing the Intermediate Kick Starter Gear
175
Installing the Kick Starter Shaft
175
Installing the Clutch Basket
176
Installing the Clutch Discs
177
Installing the Clutch Cover
178
Installing the Water Pump Cover
179
Installing the Piston
179
Installing the Cylinder
180
Checking the X-Distance
181
Adjusting the X-Distance
182
Adjusting the Z-Distance
182
Installing the Cylinder Head
184
Installing the Kick Starter
184
Installing the Starter Motor
184
Installing the Spacer
186
Installing the Engine Sprocket
186
Installing the Shift Lever
186
Installing the Clutch Push Rod
187
Installing the Gear Oil Drain Plug
187
Removing the Engine from the Work Stand
187
19 Carburetor
188
Choke
188
Carburetor - Adjusting the Idle Speed
188
Emptying the Carburetor Float Chamber
189
Removing the Carburetor
189
Installing the Carburetor
190
Checking/Adjusting the Carburetor Components
191
Disassembling the Carburetor
192
Checking the Choke Slide
193
Checking the Jet Needle
193
Checking the Throttle Slide
193
Checking the Float Needle Valve
194
Assembling the Carburetor
194
Checking/Adjusting the Float Level
195
20 Clutch
196
Checking/Correcting the Fluid Level of the Hydraulic Clutch
196
Changing the Hydraulic Clutch Fluid
196
21 Water Pump, Cooling System
197
Cooling System
197
Checking the Antifreeze and Coolant Level
197
Checking the Coolant Level
197
Draining the Coolant
198
Refilling with Coolant
198
22 Exhaust Control
200
Engine Characteristic - Setting the Auxiliary Spring
200
23 Lubrication System
201
Changing the Gear Oil
201
Draining the Gear Oil
201
Refilling with Gear Oil
202
Checking the Gear Oil Level
202
Adding Gear Oil
202
24 Ignition System
204
Checking the Ignition System
204
Ignition Coil - Checking the Primary Winding
204
Ignition Coil - Checking the Secondary Winding
205
Checking the Spark Plug Connector
205
Alternator - Checking the Charging Coil of the Ignition
206
Alternator - Checking the Battery Winding
206
Alternator - Checking the Light Winding
207
Checking the Ignition Pulse Generator
207
Removing the Stator and Crankshaft Position Sensor
208
Installing the Stator and Crankshaft Position Sensor
208
25 Electric Starter
209
Checking the Starter Motor
209
26 Technical Data
210
Engine
210
All 250 Models
210
All 300 Models
210
Engine Tolerance, Wear Limits
211
Engine Tightening Torques
212
Capacities
212
Gear Oil
212
Coolant
212
Fuel
213
Chassis
213
Electrical System
214
Tires
214
Fork
214
Exc Eu/Aus, XC-W
214
250/300 Six Days
215
Shock Absorber
215
Chassis Tightening Torques
216
Carburetor
217
Exc Eu, 250 Exc Six Days Eu
217
Exc aus
217
XC-W Usa
217
Exc Eu, 300 Exc Six Days Eu
217
Exc aus
218
XC-W Usa, 300 XC-W Six Days Usa
218
Carburetor Tuning
219
Carburetor Tuning (All 250 Models)
219
Carburetor Tuning (All 300 Models)
220
General Carburetor Tuning
221
27 Cleaning, Care
222
Cleaning the Motorcycle
222
Checks and Maintenance Steps for Winter Operation
223
28 Storage
224
Preparing for Use after Storage
224
29 Service Schedule
225
Service Work (as Additional Order)
226
30 Wiring Diagram
228
250 Exc Eu, 300 Exc Eu)
228
250 Exc Eu, 300 Exc Eu)
230
250 Exc Eu, 300 Exc Eu)
232
250 Exc Eu, 300 Exc Eu)
234
250 Exc Eu, 300 Exc Eu)
236
250 Exc Six Days Eu, 300 Exc Six Days Eu)
238
250 Exc Six Days Eu, 300 Exc Six Days Eu)
240
250 Exc Six Days Eu, 300 Exc Six Days Eu)
242
250 Exc Six Days Eu, 300 Exc Six Days Eu)
244
250 Exc Six Days Eu, 300 Exc Six Days Eu)
246
250/300 Exc Aus)
248
250/300 Exc Aus)
250
250/300 Exc Aus)
252
250/300 Exc Aus)
254
250/300 Exc Aus)
256
250 XC-W Usa, 300 XC-W Usa)
258
250 XC-W Usa, 300 XC-W Usa)
260
250 XC-W Usa, 300 XC-W Usa)
262
300 XC-W Six Days Usa)
264
Page 1 of 3 (300 XC‑W SIX DAYS USA)
264
300 XC-W Six Days Usa)
266
Page 2 of 3 (300 XC‑W SIX DAYS USA)
266
300 XC-W Six Days Usa)
268
Page 3 of 3 (300 XC‑W SIX DAYS USA)
268
31 Substances
270
32 Auxiliary Substances
272
33 Special Tools
274
34 Standards
284
Index
285
Advertisement
KTM 300 XC-W SIX DAYS USA Owner's Manual (150 pages)
2014
Brand:
KTM
| Category:
Motorcycle
| Size: 3.99 MB
Table of Contents
Table of Contents
4
1 Means of Representation
7
Symbols Used
7
Formats Used
7
2 Safety Advice
8
Use Definition - Intended Use
8
Degrees of Risk and Symbols
8
Tampering Warning
8
Safe Operation
9
Protective Clothing
9
Work Rules
9
Environment
9
Owner's Manual
9
3 Important Notes
10
Guarantee, Warranty
10
Operating and Auxiliary Substances
10
Spare Parts, Accessories
10
Service
10
Figures
10
Customer Service
10
4 View of Vehicle
11
View of Vehicle, Front Left (Example)
11
View of Vehicle, Rear Right (Example)
12
5 Serial Numbers
13
Chassis Number
13
Type Label
13
Key Number (All EXC Models)
13
Engine Number
13
Fork Part Number
13
Shock Absorber Part Number
14
6 Controls
15
Clutch Lever
15
Hand Brake Lever
15
Throttle Grip
15
Kill Switch (All EXC Models)
15
Kill Switch (All XC-W Models)
16
Horn Button (All EXC Models)
16
Light Switch (All EXC Models)
16
Light Switch (All XC-W Models)
16
Turn Signal Switch (All EXC Models)
16
Emergency off Switch (EXC AUS)
17
Electric Starter Button (200/250/300 EXC EU, 250/300 SIX DAYS, XC-W)
17
Electric Starter Button (EXC AUS)
17
Overview of Indicator Lamps (EXC EU/AUS)
17
Overview of Indicator Lamps (SIX DAYS EU)
17
Overview of Indicator Lamps (300 XC-W SIX DAYS USA)
18
Opening the Filler Cap
18
Closing the Filler Cap
18
Fuel Tap
19
Choke
19
Shift Lever
19
Kick Starter
20
Foot Brake Lever
20
Side Stand
20
Steering Lock (All EXC Models)
20
Locking the Steering (All EXC Models)
21
Unlocking the Steering (All EXC Models)
21
7 Speedometer
22
Exc, XC-W
22
Speedometer Overview
22
Activation and Test
22
Setting Kilometers or Miles
22
Adjusting the Speedometer Functions
23
Setting the Clock
23
Querying Lap Time
23
Display Mode SPEED (Speed)
24
Display Mode SPEED/H (Service Hours)
24
Setup Menu
24
Unit of Measurement Menu
25
Display Mode SPEED/CLK (Time)
25
Setting the Clock
25
Display Mode SPEED/LAP (Lap Time)
26
Viewing the Lap Time
26
Display Mode SPEED/ODO (Odometer)
26
Display Mode SPEED/TR1 (Trip Master 1)
26
Display Mode SPEED/TR2 (Trip Master 2)
27
Setting TR2 (Trip Master 2)
27
Display Mode SPEED/A1 (Average Speed 1)
27
Display Mode SPEED/A2 (Average Speed 2)
28
Display Mode SPEED/S1 (Stop Watch 1)
28
Display Mode SPEED/S2 (Stop Watch 2)
28
Table of Functions
28
Table of Conditions and Menu Activation
29
Six Days
29
Speedometer Overview
29
Activation and Test
30
Setting Kilometers or Miles
30
Setting the Speedometer Functions
30
Setting the Clock
31
Viewing the Lap Time
31
Display Mode SPEED (Speed)
32
Display Mode SPEED/H (Service Hours)
32
Setup Menu
32
Setting the Unit of Measurement
33
Display Mode SPEED/CLK (Time)
33
Setting the Clock
33
Display Mode SPEED/LAP (Lap Time)
34
Viewing the Lap Time
34
Display Mode SPEED/ODO (Odometer)
34
Display Mode SPEED/TR1 (Trip Master 1)
34
Display Mode SPEED/TR2 (Trip Master 2)
35
Setting TR2 (Trip Master 2)
35
Display Mode SPEED/A1 (Average Speed 1)
35
Display Mode SPEED/A2 (Average Speed 2)
36
Display Mode SPEED/S1 (Stop Watch 1)
36
Display Mode SPEED/S2 (Stop Watch 2)
36
Table of Functions
37
Table of Conditions and Menu Activation
38
8 Preparing for Use
39
Advice on First Use
39
Running in the Engine
40
Preparing the Vehicle for Difficult Riding Conditions
40
Preparations for Riding on Dry Sand
41
Preparations for Riding on Wet Sand
41
Preparations for Riding on Wet and Muddy Surfaces
42
Preparations for Riding at High Temperatures and Low Speeds
42
Preparing for Riding at Low Temperatures or in Snow
43
9 Riding Instructions
44
Checks and Maintenance Work When Preparing for Use
44
Starting
44
Start off
45
Shifting, Riding
45
Braking
45
Stopping, Parking
46
Transport
46
Refueling
47
10 Service Schedule
48
Service Work (as Additional Order)
49
11 Tuning the Chassis
50
Checking the Basic Chassis Setting with the Rider's Weight
50
Compression Damping of Shock Absorber
50
Adjusting the Low-Speed Compression Damping of the Shock Absorber
50
Adjusting the High-Speed Compression Damping of the Shock Absorber
51
Adjusting the Rebound Damping of the Shock Absorber
51
Measuring the Sag of the Unloaded Rear Wheel
52
Checking the Static Sag of the Shock Absorber
52
Checking the Riding Sag of the Shock Absorber
53
Adjusting the Spring Preload of the Shock Absorber
53
Adjusting the Riding Sag
54
Checking the Basic Setting of the Fork
54
Adjusting the Compression Damping of the Fork
55
Adjusting the Rebound Damping of the Fork
56
Adjusting the Spring Preload of the Fork (EXC, XC-W)
57
Handlebar Position
57
Adjusting the Handlebar Position
58
12 Service Work on the Chassis
59
Raising the Motorcycle with the Lift Stand
59
Removing the Motorcycle from the Lift Stand
59
Bleeding the Fork Legs
59
Cleaning the Dust Boots of the Fork Legs
60
Loosening the Fork Protection
60
Positioning the Fork Protection
61
Removing the Fork Legs
61
Installing the Fork Legs
61
Removing the Fork Protector
62
Installing the Fork Protector
63
Removing the Lower Triple Clamp (EXC, XC-W)
63
Removing the Lower Triple Clamp (SIX DAYS)
64
Installing the Lower Triple Clamp (EXC, XC-W)
64
Installing the Lower Triple Clamp
66
Six Days)
66
Checking the Play of the Steering Head Bearing
68
Adjusting the Play of the Steering Head Bearing
68
Greasing the Steering Head Bearing
69
Removing the Front Fender
69
Installing the Front Fender
69
Removing the Shock Absorber
70
Installing the Shock Absorber
70
Removing the Seat
71
Mounting the Seat
71
Removing the Air Filter Box Lid
72
Installing the Air Filter Box Lid
72
Removing the Air Filter
72
Installing the Air Filter
72
Cleaning the Air Filter and Air Filter Box
73
Sealing the Air Filter Box
73
Removing the Main Silencer
74
Installing the Main Silencer
74
Changing the Glass Fiber Yarn Filling of the Main Silencer
74
Removing the Fuel Tank
75
Installing the Fuel Tank
76
Checking the Chain for Dirt
77
Cleaning the Chain
77
Checking the Chain Tension
77
Adjusting the Chain Tension
78
Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide
79
Checking the Frame
80
Checking the Swingarm
81
Checking the Routing of the Throttle Cable
81
Checking the Rubber Grip
82
Additionally Securing the Rubber Grip
82
Adjusting the Basic Position of the Clutch Lever
82
Checking/Correcting the Fluid Level of the Hydraulic Clutch
83
Changing the Hydraulic Clutch Fluid
83
Removing the Engine Guard (SIX DAYS)
84
Installing the Engine Guard (SIX DAYS)
85
13 Brake System
86
Checking the Free Travel of the Hand Brake Lever
86
Adjusting Free Travel of Hand Brake Lever (All EXC Models)
86
Adjusting the Basic Position of the Hand Brake Lever (All XC-W Models)
86
Checking the Brake Discs
87
Checking the Front Brake Fluid Level
87
Adding Front Brake Fluid
87
Checking the Front Brake Linings
88
Changing the Front Brake Linings
89
Checking the Free Travel of Foot Brake Lever
90
Adjusting the Basic Position of the Foot Brake Lever
90
Checking the Rear Brake Fluid Level
91
Adding Brake Fluid for the Rear Brake
91
Checking the Rear Brake Linings
92
Changing the Brake Linings of the Rear Brake
92
14 Wheels, Tires
95
Removing the Front Wheel
95
Installing the Front Wheel
95
Removing the Rear Wheel
96
Installing the Rear Wheel
96
Checking the Tire Condition
97
Checking the Tire Air Pressure
98
Checking the Spoke Tension
98
15 Electrical System
100
Removing the Battery (All 200/250/300 Models)
100
Installing the Battery (All 200/250/300 Models)
100
Recharging the Battery (All 200/250/300 Models)
101
Changing the Main Fuse (All 200/250/300 Models)
102
Removing the Headlight Mask with the Headlight
103
Refitting the Headlight Mask with the Headlight
103
Changing the Headlight Bulb
103
Changing the Turn Signal Bulb (All EXC Models)
104
Checking the Headlight Setting
105
Adjusting the Headlight Range
105
Changing the Speedometer Battery
105
16 Cooling System
107
Checking the Antifreeze and Coolant Level
107
Checking the Coolant Level
108
Draining the Coolant
108
Refilling with Coolant
109
17 Tuning the Engine
111
Checking the Play in the Throttle Cable
111
Adjusting the Play in the Throttle Cable
111
Carburetor - Idle
111
Carburetor - Adjusting the Idle Speed
112
Emptying the Carburetor Float Chamber
113
Checking the Basic Position of the Shift Lever
114
Adjusting the Basic Position of the Shift Lever
114
Engine Characteristic - Auxiliary Spring (All 250/300 Models)
114
Engine Characteristic - Setting the Auxiliary Spring X (All 250/300 Models)
114
18 Service Work on the Engine
116
Checking the Gear Oil Level
116
Changing the Gear Oil
116
Draining the Gear Oil
117
Refilling with Gear Oil
117
Adding Gear Oil
118
19 Cleaning, Care
120
Cleaning the Motorcycle
120
Checks and Maintenance Steps for Winter Operation
121
20 Storage
122
Preparing for Use after Storage
122
21 Troubleshooting
123
22 Technical Data
125
Engine
125
All 125 Models
125
All 200 Models
125
All 250 Models
126
All 300 Models
126
Engine Tightening Torques
127
All 125/200 Models
127
All 250/300 Models
128
Capacities
129
Gear Oil
129
Coolant
129
Fuel
129
Chassis
129
Electrical System
130
Tires
131
Fork
131
EXC EU, All 200 Models
131
250/300 Exc Eu/Aus, XC-W Usa
131
Exc Six Days Eu
132
250/300 Six Days
132
Shock Absorber
133
All 125/200 Models
133
All 250/300 Models
133
Chassis Tightening Torques
134
Carburetor
135
22.10.1 All 125 Models
135
22.10.2 200 Exc Eu
135
22.10.3 200 Exc aus
135
22.10.4 200 XC-W Usa
135
22.10.5 250 Exc Eu, 250 Exc Six Days Eu
136
22.10.6 250/300 Exc aus
136
22.10.7 250 XC-W Usa
136
22.10.8 300 Exc Eu, 300 Exc Six Days Eu
137
22.10.9 300 XC-W Usa, 300 XC-W Six Days Usa
137
Carburetor Tuning (All 125 Models)
137
Carburetor Tuning (All 200 Models)
138
Carburetor Tuning (All 250 Models)
139
Carburetor Tuning (All 300 Models)
140
General Carburetor Tuning
141
23 Substances
142
24 Auxiliary Substances
144
25 Standards
146
Index
147
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