TABLE OF CONTENTS 3
Removing the seat......................................................... 55
Mounting the seat ......................................................... 55
Removing the air filter box lid......................................... 56
Installing the air filter box lid.......................................... 56
Removing the air filter x............................................... 56
Installing the air filter x ............................................... 56
Cleaning the air filter and air filter box x........................ 57
Removing the main silencer............................................ 57
Installing the main silencer ............................................ 58
Changing the glass fiber yarn filling of the main
silencer x ................................................................... 58
Removing the fuel tank x ............................................. 58
Installing the fuel tank x.............................................. 59
Checking the chain for dirt ............................................. 60
Cleaning the chain......................................................... 60
Checking the chain tension ............................................ 61
Checking the chain, rear sprocket, engine sprocket and
chain guide................................................................... 61
Adjusting the chain tension ............................................ 63
Adjusting the chain guide x.......................................... 64
Checking the frame x................................................... 65
Checking the swingarm x ............................................. 65
Checking the throttle cable routing.................................. 65
Checking the rubber grip................................................ 66
Additionally securing the rubber grip ............................... 66
Adjusting the basic position of the clutch lever................. 66
Checking the fluid level of the hydraulic clutch ................ 67
Changing the hydraulic clutch fluid x............................ 67
BRAKES........................................................................... 69
Checking free travel of hand brake lever........................... 69
Adjusting the basic position of the hand brake lever
(XC-W).......................................................................... 69
Adjusting free travel of hand brake lever (All EXC
models) ........................................................................ 69
Checking the brake discs................................................ 70
Checking the front brake fluid level ................................. 70
Adding front brake fluid x ............................................ 70
Checking the front brake linings...................................... 71
Changing the front brake linings x................................. 72
Checking the free travel of foot brake lever....................... 73
Adjusting the basic position of the foot brake lever x ...... 73
Checking the rear brake fluid level .................................. 74
Adding brake fluid for the rear brake x .......................... 74
Checking the rear brake linings ....................................... 75
Removing the rear brake linings x ................................. 75
Installing the rear brake linings x.................................. 76
Changing the rear brake linings x.................................. 76
WHEELS, TIRES ............................................................... 78
Removing the front wheel x.......................................... 78
Installing the front wheel x........................................... 78
Removing the rear wheel x ........................................... 79
Installing the rear wheel x............................................ 79
Checking the tire condition............................................. 80
Checking the tire air pressure ......................................... 81
Checking the spoke tension ............................................ 81
ELECTRICAL SYSTEM ....................................................... 83
Removing the battery x (All 250/300 models) ................ 83
Installing the battery x (All 250/300 models)................. 83
Recharging the battery x (All 250/300 models) .............. 83
Changing the main fuse (All 250/300 models) ................. 84
Removing the headlight mask with the headlight (All EXC
models) ........................................................................ 85
Refitting the headlight mask with the headlight (All EXC
models) ........................................................................ 86
Changing the headlight bulb (All EXC models).................. 86
Checking the headlight setting (All EXC models)............... 87
Adjusting the headlight range (All EXC models) ................ 87
Changing the speedometer battery .................................. 87
COOLING SYSTEM ............................................................ 89
Cooling system .............................................................. 89
Checking the antifreeze and coolant level ........................ 89
Checking the coolant level.............................................. 90
Draining the coolant x.................................................. 90
Refilling with coolant x................................................ 91
TUNING THE ENGINE ....................................................... 93
Checking the play in the throttle cable............................. 93
Adjusting the play in the throttle cable x ....................... 93
Carburetor .................................................................... 93
Carburetor - adjusting the idle speed x .......................... 94
Emptying the carburetor float chamber x ....................... 95
Checking the basic position of the shift lever.................... 96
Adjusting the basic position of the shift lever x .............. 96
Engine characteristic - auxiliary spring
(All 250/300 models) .................................................... 96
Engine characteristic - adjusting the auxiliary spring x
(All 250/300 models) .................................................... 96
SERVICE WORK ON THE ENGINE ...................................... 98
Checking the gear oil level.............................................. 98
Changing the gear oil x ................................................ 98
Draining the gear oil x ................................................. 99
Refilling with gear oil x................................................ 99
Adding gear oil x....................................................... 100
CLEANING, CARE ........................................................... 101
Cleaning the motorcycle............................................... 101
Checks and maintenance steps for winter operation ........ 102
STORAGE ....................................................................... 103
Storage....................................................................... 103
Preparing for use after storage ...................................... 103
TROUBLESHOOTING....................................................... 104
TECHNICAL DATA - ENGINE............................................ 106
125 EXC EU, 125 EXC SIX DAYS EU ............................ 106
All 200 models ........................................................... 106
All 250 models ........................................................... 107
All 300 models ........................................................... 107
Capacity - transmission oil............................................ 108
Capacity - coolant........................................................ 108
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........ 109
All 125/200 models .................................................... 109
All 250/300 models .................................................... 110
TECHNICAL DATA - CARBURETOR................................... 111
125 EXC EU, 125 EXC SIX DAYS EU ............................ 111
200 EXC EU ............................................................... 111
200 EXC AUS ............................................................. 111
200 XC‑W USA ........................................................... 111
250 EXC EU, 250 EXC SIX DAYS EU ............................ 112
250 EXC AUS ............................................................. 112
250 XC‑W USA ........................................................... 112
300 EXC EU, 300 EXC SIX DAYS EU ............................ 112
300 EXC AUS ............................................................. 113
300 XC‑W USA ........................................................... 113
Carburetor configuration (125 EXC EU,
125 EXC SIX DAYS EU) x .......................................... 113
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