TABLE OF CONTENTS 3
11.12 Adjusting the compression damping of the
fork ............................................................... 44
11.13 Adjusting the rebound damping of the fork ........ 45
11.14 Adjusting the spring preload of the fork
(EXC EU/AU, XC‑W)......................................... 46
11.15 Handlebar position.......................................... 47
11.16 Adjusting handlebar position ........................ 48
12 SERVICE WORK ON THE CHASSIS.............................. 50
12.1 Raising the motorcycle with the lift stand.......... 50
12.2 Removing the motorcycle from the lift stand...... 50
12.3 Bleeding the fork legs...................................... 50
12.4 Cleaning the dust boots of the fork legs............. 51
12.5 Removing the fork legs ................................. 51
12.6 Installing the fork legs ................................. 52
12.7 Removing the fork protector ............................. 54
12.8 Installing the fork protector.............................. 54
12.9 Removing the lower triple clamp (All EXC
models).......................................................... 54
12.10 Removing the lower triple clamp (XC‑W) ........ 55
12.11 Installing the lower triple clamp (All EXC
models).......................................................... 56
12.12 Installing the lower triple clamp (XC‑W)......... 59
12.13 Checking the steering head bearing play............ 60
12.14 Adjusting the play of the steering head
bearing (All EXC models).............................. 61
12.15 Adjusting the play of the steering head
bearing (XC‑W)............................................ 62
12.16 Greasing the steering head bearing ................ 62
12.17 Removing the front fender ............................... 62
12.18 Installing the front fender ................................ 63
12.19 Removing the shock absorber ....................... 63
12.20 Installing the shock absorber ........................ 63
12.21 Removing the seat .......................................... 64
12.22 Mounting the seat........................................... 64
12.23 Removing the air filter box cover ...................... 64
12.24 Installing the air filter box cover ....................... 64
12.25 Removing the air filter ................................. 65
12.26 Installing the air filter .................................. 65
12.27 Cleaning the air filter and air filter box .......... 65
12.28 Sealing the air filter box ............................... 66
12.29 Removing main silencer................................... 66
12.30 Installing the main silencer.............................. 66
12.31 Cleaning spark arrestor (XC‑W)...................... 67
12.32 Changing glass fiber yarn filling in the main
silencer ...................................................... 68
12.33 Removing the fuel tank ................................ 69
12.34 Installing the fuel tank ................................. 70
12.35 Checking for chain dirt accumulation................ 72
12.36 Cleaning the chain .......................................... 72
12.37 Checking the chain tension .............................. 73
12.38 Adjusting the chain tension.............................. 73
12.39 Checking the chain, rear sprocket, engine
sprocket and chain guide................................. 74
12.40 Checking the frame ..................................... 76
12.41 Checking the swingarm ................................ 76
12.42 Checking throttle cable routing......................... 76
12.43 Checking the rubber grip ................................. 77
12.44 Additionally securing the rubber grip................. 77
12.45 Adjusting the basic position of the clutch
lever .............................................................. 77
12.46 Checking/correcting the fluid level of the
hydraulic clutch.............................................. 77
12.47 Changing the hydraulic clutch fluid ............... 78
12.48 Removing the engine guard (All EXC models)..... 78
12.49 Installing the engine guard (All EXC models) ..... 78
13 BRAKE SYSTEM ........................................................ 79
13.1 Checking free travel of hand brake lever ............ 79
13.2 Adjusting free travel of hand brake lever (All
EXC models)................................................... 79
13.3 Adjusting the basic position of the hand brake
lever (XC‑W) ................................................... 79
13.4 Checking the brake discs ................................. 80
13.5 Checking the brake fluid level of the front
brake ............................................................. 80
13.6 Adding front brake fluid ............................... 80
13.7 Checking the front brake linings ....................... 81
13.8 Changing the front brake linings ................... 82
13.9 Checking the free travel of foot brake lever ........ 83
13.10 Adjusting the basic position of the foot brake
lever ........................................................... 83
13.11 Checking the rear brake fluid level.................... 84
13.12 Adding rear brake fluid ................................ 84
13.13 Checking the rear brake linings ........................ 85
13.14 Changing the rear brake linings ..................... 86
14 WHEELS, TIRES ........................................................ 88
14.1 Removing the front wheel ............................. 88
14.2 Installing the front wheel ............................. 88
14.3 Removing the rear wheel .............................. 89
14.4 Installing the rear wheel ............................... 90
14.5 Checking the tire condition .............................. 90
14.6 Checking the tire air pressure........................... 91
14.7 Checking spoke tension ................................... 91
15 ELECTRICAL SYSTEM ................................................ 93
15.1 Removing the battery ................................... 93
15.2 Installing the battery .................................... 93
15.3 Charging the battery .................................... 94
15.4 Changing the main fuse................................... 95
15.5 Changing the fuses of individual power
consumers...................................................... 96
15.6 Removing headlight mask with headlight........... 96
15.7 Refitting the headlight mask with the
headlight........................................................ 97
15.8 Changing the headlight bulb ............................ 98
15.9 Changing the turn signal bulb (All EXC
models).......................................................... 98
15.10 Checking the headlight setting ......................... 99
15.11 Adjusting the headlight range........................... 99
15.12 Changing the speedometer battery .................. 100
16 COOLING SYSTEM ................................................... 101
16.1 Cooling system ............................................. 101
16.2 Checking the antifreeze and coolant level........ 101
16.3 Checking the coolant level ............................. 101
16.4 Draining the coolant .................................. 102
16.5 Refilling coolant ........................................ 102
17 TUNING THE ENGINE.............................................. 104
17.1 Checking the play in the throttle cable ............ 104
17.2 Adjusting the play in the throttle cable ........ 104
17.3 Adjusting the idle speed ............................. 105
17.4 Checking the basic position of the shift lever ... 105
17.5 Adjusting the basic position of the shift
lever ......................................................... 105
18 SERVICE WORK ON THE ENGINE ............................. 107
18.1 Changing the fuel screen ............................ 107
18.2 Checking the engine oil level.......................... 107
18.3 Changing the engine oil and oil filter,
cleaning the oil screens ............................. 108
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