TABLE OF CONTENTS 3
11 SERVICE WORK ON THE CHASSIS.............................. 44
11.1 Raising the motorcycle with the lift stand.......... 44
11.2 Removing the motorcycle from the lift stand...... 44
11.3 Bleeding the fork legs...................................... 44
11.4 Cleaning the dust boots of the fork legs............. 45
11.5 Loosening the fork protection ........................... 45
11.6 Positioning the fork protection.......................... 45
11.7 Removing the fork legs x ............................... 46
11.8 Installing the fork legs x................................ 46
11.9 Removing the fork protector x ........................ 47
11.10 Installing the fork protector x......................... 47
11.11 Removing the lower triple clamp x.................. 47
11.12 Installing the lower triple clamp x .................. 48
11.13 Checking the play of the steering head
bearing .......................................................... 49
11.14 Adjusting the play of the steering head
bearing x ..................................................... 50
11.15 Greasing the steering head bearing x .............. 50
11.16 Removing the front fender ............................... 51
11.17 Installing the front fender ................................ 51
11.18 Removing the shock absorber x...................... 51
11.19 Installing the shock absorber x....................... 52
11.20 Removing the seat .......................................... 53
11.21 Mounting the seat........................................... 53
11.22 Removing the air filter box lid .......................... 53
11.23 Installing the air filter box lid ........................... 53
11.24 Removing the air filter x................................ 53
11.25 Installing the air filter x................................. 54
11.26 Cleaning the air filter and air filter box x ......... 54
11.27 Sealing the air filter box x.............................. 55
11.28 Removing the main silencer ............................. 55
11.29 Installing the main silencer.............................. 55
11.30 Changing the glass fiber yarn filling of the
main silencer x............................................. 56
11.31 Removing the right side cover .......................... 56
11.32 Installing the right side cover ........................... 57
11.33 Removing the fuel tank x............................... 57
11.34 Installing the fuel tank x................................ 58
11.35 Checking the chain for dirt............................... 59
11.36 Cleaning the chain .......................................... 59
11.37 Checking the chain tension .............................. 59
11.38 Adjusting the chain tension.............................. 60
11.39 Checking the chain, rear sprocket, engine
sprocket, and chain guide................................ 61
11.40 Adjusting the chain guide x ........................... 63
11.41 Checking the frame x .................................... 63
11.42 Checking the swingarm x............................... 63
11.43 Checking the throttle cable routing ................... 64
11.44 Checking the rubber grip ................................. 64
11.45 Additionally securing the rubber grip................. 65
11.46 Adjusting the basic position of the clutch
lever .............................................................. 65
11.47 Checking/rectifying the fluid level of the
hydraulic clutch.............................................. 65
11.48 Changing the hydraulic clutch fluid x.............. 66
11.49 Removing the engine guard.............................. 67
11.50 Installing the engine guard .............................. 67
12 BRAKE SYSTEM ........................................................ 69
12.1 Checking the free travel of the hand brake
lever .............................................................. 69
12.2 Adjusting free travel of hand brake lever
(TE EU/AUS) .................................................. 69
12.3 Adjusting the basic position of the hand brake
lever (TE USA)................................................ 69
12.4 Checking the brake discs ................................. 70
12.5 Checking the front brake fluid level .................. 70
12.6 Adding front brake fluid x.............................. 70
12.7 Checking the front brake linings ....................... 71
12.8 Changing the front brake linings x.................. 72
12.9 Checking the free travel of the foot brake
lever .............................................................. 73
12.10 Adjusting the basic position of the foot brake
lever x ......................................................... 73
12.11 Checking the rear brake fluid level.................... 74
12.12 Adding rear brake fluid x ............................... 74
12.13 Checking the rear brake linings ........................ 75
12.14 Changing the rear brake linings x ................... 75
13 WHEELS, TIRES ........................................................ 77
13.1 Removing the front wheel x ........................... 77
13.2 Installing the front wheel x ............................ 77
13.3 Removing the rear wheel x............................. 78
13.4 Installing the rear wheel x.............................. 78
13.5 Checking the tire condition .............................. 79
13.6 Checking the tire air pressure........................... 80
13.7 Checking the spoke tension.............................. 80
14 ELECTRICAL SYSTEM ................................................ 82
14.1 Removing the battery x (TE 250/300)............. 82
14.2 Installing the battery x (TE 250/300) ............. 82
14.3 Recharging the battery x (TE 250/300)........... 82
14.4 Changing the main fuse (TE 250/300).............. 83
14.5 Removing the headlight mask with the
headlight........................................................ 84
14.6 Installing the headlight mask with the
headlight........................................................ 84
14.7 Changing the headlight bulb ............................ 85
14.8 Changing the turn signal bulb (TE EU/AUS)....... 85
14.9 Checking the headlight setting ......................... 86
14.10 Adjusting the headlight range........................... 86
14.11 Changing the speedometer battery .................... 86
15 COOLING SYSTEM ..................................................... 88
15.1 Cooling system ............................................... 88
15.2 Checking the antifreeze and coolant level.......... 88
15.3 Checking the coolant level ............................... 89
15.4 Draining the coolant x................................... 89
15.5 Refilling with coolant x.................................. 90
16 TUNING THE ENGINE................................................ 92
16.1 Checking the play in the throttle cable .............. 92
16.2 Adjusting the play in the throttle cable x......... 92
16.3 Carburetor...................................................... 92
16.4 Carburetor - adjusting the idle speed x............ 93
16.5 Emptying the carburetor float chamber x......... 94
16.6 Checking the basic position of the shift lever ..... 95
16.7 Adjusting the basic position of the shift
lever x ......................................................... 95
16.8 Engine characteristic - auxiliary spring
(TE 250/300)................................................. 95
16.9 Engine characteristic - setting the auxiliary
spring x (TE 250/300) .................................. 95
17 SERVICE WORK ON THE ENGINE ............................... 97
17.1 Checking the gear oil level ............................... 97
17.2 Changing the gear oil x.................................. 97
17.3 Draining the gear oil x................................... 98
17.4 Refilling with gear oil x.................................. 98
17.5 Adding gear oil x........................................... 99
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