TABLE OF CONTENTS 3
11.10 Adjusting the riding sag ............................. 45
11.11 Checking the basic setting of the fork ............... 45
11.12 Adjusting the compressio damping of the
fork ................................................ 46
11.13 Adjusting the rebound damping of the fork ........ 47
11.14 Adjusting the spring preload of the fork (EXC,
XC‑ W) ................................. 48
11.15 Handlebar position 49
11.16 Adjusting the handlebar position ................... 50
12 SERVICE WORK ON THE CHASSIS 52
12.1 Raising the motorcycle with the lift stand 52
12.2 Removing the motorcycle from the lift stand 52
12.3 Bleeding the fork legs 52
12.4 Cleaning the dust boots of the fork legs 53
12.5 Removing the fork protector ............................. 53
12.6 Installing the fork protector 54
12.7 Removing the fork legs .. 54
12.8 Installing the fork legs ................................. 55
12.9 Removing the lower triple clamp
(200 XC‑ W US, 250 XC‑ W US, 300 EXC BR,
300 XC‑ W US) 56
12.10 Removing the lower triple clamp (EXC EU,
EXC Six Days, EXC EU/AU, Six Days) ................ 57
12.11 Installing the lower triple clamp
(200 XC‑ W US, 250 XC‑ W US, 300 EXC BR,
300 XC‑ W US) 57
12.12 Installing the lower triple clamp (EXC EU,
EXC Six Days, EXC EU/AU, Six Days) ................ 59
12.13 Checking the play of the steering head
bearing .......................................... 62
12.14 Adjusting the play of the steering head
bearing ......................... 63
12.15 Greasing the steering head bearing ................ 64
12.16 Removing the front fender ......................... 64
12.17 Installing the front fender ................................ 65
12.18 Removing the shock absorber ................ 65
12.19 Installing the shock absorber .................. 65
12.20 Removing the seat .......................................... 66
12.21 Mounting the seat 66
12.22 Removing the air filter box lid .......................... 67
12.23 Installing the air filter box lid ........................... 67
12.24 Removing the air filter ................................. 67
12.25 Installing the air filter .................................. 68
12.26 Cleaning the air filter and air filter box .......... 68
12.27 Sealing the air filter box ............................ 69
12.28 Removing the main silencer ............................. 69
12.29 Installing the main silencer 69
12.30 Changing the glass fiber yarn filling of the
main silencer .......................................... 69
12.31 Removing the fuel tank ............................... 70
12.32 Installing the fuel tank ................................. 71
12.33 Checking the chain for dirt............................... 72
12.34 Cleaning the chain .......................................... 72
12.35 Checking the chain tension 72
12.36 Adjusting the chain tension.............................. 73
12.37 Checking the chain, rear sprocket, engine
sprocket and chain guide 74
12.38 Checking the frame ..................................... 75
12.39 Checking the swingarm ................................ 76
12.40 Checking the routing of the throttle cable 76
12.41 Checking the rubber grip .......................... 77
12.42 Additionally securing the rubber grip................. 77
12.43 Adjusting the basic position of the clutch
lever ................................... 77
12.44 Checking/correcti the fluid level of the
hydraulic clutch 78
12.45 Changing the hydraulic clutch fluid ............... 78
12.46 Removing the engine guard 80
12.47 Installing the engine guard .............................. 80
13 BRAKE SYSTEM ............................ 81
13.1 Checking the free travel of the hand brake
lever ................................... 81
13.2 Adjusting free travel of hand brake lever (All
EXC models) 81
13.3 Adjusting the basic position of the hand brake
lever (All XC-W models) ................................... 81
13.4 Checking the brake discs ......................... 82
13.5 Checking the front brake fluid level .................. 82
13.6 Adding front brake fluid ............................ 82
13.7 Checking the front brake linings ...................... 83
13.8 Changing the front brake linings ........... 84
13.9 Checking the free travel of foot brake lever ........ 85
13.10 Adjusting the basic position of the foot brake
lever ......... 85
13.11 Checking the rear brake fluid level 86
13.12 Adding brake fluid for the rear brake ............. 87
13.13 Checking the rear brake linings ........................ 87
13.14 Changing the brake linings of the rear
brake ........... 88
14 WHEELS, TIRES ................................. 90
14.1 Removing the front wheel ............................. 90
14.2 Installing the front wheel ............................. 90
14.3 Removing the rear wheel ............................. 91
14.4 Installing the rear wheel ............................... 92
14.5 Checking the tire condition .............................. 92
14.6 Checking the tire air pressure 93
14.7 Checking the spoke tension.............................. 93
15 ELECTRICAL SYSTEM ................................ 95
15.1 Removing the battery
(All 200/250/300 models) 95
15.2 Installing the battery
(All 200/250/300 models) 95
15.3 Recharging the battery
(All 200/250/300 models) 96
15.4 Changing the main fuse
(All 200/250/300 models) 97
15.5 Removing the headlight mask with the
headlight......................... 98
15.6 Refitting the headlight mask with the
headlight......................... 98
15.7 Changing the headlight bulb ........................ 99
15.8 Changing the turn signal bulb (All EXC
models).............................. 99
15.9 Checking the headlight setting ....................... 100
15.10 Adjusting the headlight range 100
15.11 Changing the speedomete battery .................. 101
16 COOLING SYSTEM .......................................... 102
16.1 Cooling system ..................................... 102
16.2 Checking the antifreeze and coolant level 102
16.3 Checking the coolant level ............................. 103
16.4 Draining the coolant ........... 103
16.5 Refilling with coolant ................... 104
17 TUNING THE ENGINE 106
17.1 Checking the play in the throttle cable ............ 106
17.2 Adjusting the play in the throttle cable ........ 106
