TABLE OF CONTENTS 3
11.4 Adjusting the high-speed compression
damping of the shock absorber 42
11.5 Adjusting the rebound damping of the shock
absorber 42
11.6 Measuring the rear wheel dimension
unloaded 43
11.7 Checking the static sag of the shock absorber 44
11.8 Checking the riding sag of the shock absorber.... 44
11.9 Adjusting the spring preload of the shock
absorber ............................ 44
11.10 Adjusting the riding sag ............................. 45
11.11 Checking the basic setting of the fork ............... 46
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 (All
Six Days models) .................... 48
11.15 Handlebar position 48
11.16 Adjusting the handlebar position ................... 49
12 SERVICE WORK ON THE CHASSIS 51
12.1 Raising the motorcycle with a lift stand 51
12.2 Removing the motorcycle from the lift stand 51
12.3 Bleeding the fork legs 51
12.4 Cleaning the dust boots of the fork legs 51
12.5 Removing the fork protector ............................. 52
12.6 Installing the fork protector 52
12.7 Removing the fork legs .. 52
12.8 Installing the fork legs ................................. 53
12.9 Removing the lower triple clamp (All
standard EXC/XC-W models) 54
12.10 Removing the lower triple clamp (All
Six Days models) .................... 54
12.11 Installing the lower triple clamp (All
standard EXC/XC-W models) 55
12.12 Installing the lower triple clamp (All
Six Days models) .................... 57
12.13 Checking the play of the steering head
bearing ............................................. 58
12.14 Adjusting the steering head bearing play ........ 59
12.15 Lubricating the steering head bearing ............ 59
12.16 Removing the front fender ......................... 60
12.17 Installing the front fender ................................ 60
12.18 Removing the shock absorber ................ 60
12.19 Installing the shock absorber .................. 61
12.20 Removing the seat ................ 61
12.21 Mounting the seat 61
12.22 Removing the air filter box cover ...................... 62
12.23 Installing the air filter box cover ....................... 62
12.24 Removing the air filter ................................. 63
12.25 Installing the air filter .................................. 63
12.26 Cleaning the air filter and air filter box .......... 63
12.27 Securing the air filter box cover .................... 64
12.28 Sealing the air filter box ............................ 64
12.29 Removing the main silencer ............................. 65
12.30 Installing the main silencer 65
12.31 Changing the glass fiber yarn filling in the
main silencer .......................................... 65
12.32 Removing the fuel tank ............................... 66
12.33 Installing the fuel tank ................................. 67
12.34 Checking the chain for dirt............................... 68
12.35 Cleaning the chain ........................................ 68
12.36 Checking the chain tension .................. 69
12.37 Adjusting the chain tension.............................. 69
12.38 Checking the chain, rear sprocket, motor
sprocket, and chain guide 70
12.39 Checking the frame ..................................... 72
12.40 Checking the swingarm ................................ 72
12.41 Checking throttle cable routing 72
12.42 Checking the rubber grip .......................... 73
12.43 Adjusting the basic position of the clutch
lever ............................... 73
12.44 Checking/correcti the fluid level of the
hydraulic clutch 73
12.45 Changing the hydraulic clutch fluid ............... 74
12.46 Removing the engine guard (All Six Days
models, EXC AU) .................................... 75
12.47 Installing the engine guard (All Six Days
models, EXC AU) .................................... 75
13 BRAKE SYSTEM .................................. 76
13.1 Checking the free travel of the hand brake
lever ............................... 76
13.2 Adjusting free travel of hand brake lever (All
EXC/EXC Six Days models, 125 XC‑ W EU) 76
13.3 Adjusting the basic position of the hand brake
lever (XC‑ W US, XC‑ W Six Days US) 76
13.4 Checking the brake discs ................................. 77
13.5 Checking the front brake fluid level .................. 77
13.6 Adding front brake fluid ............................ 78
13.7 Checking the front brake linings ....................... 79
13.8 Changing the front brake linings ............. 79
13.9 Checking the free travel of foot brake lever ........ 81
13.10 Adjusting the basic position of the foot brake
lever ........ 81
13.11 Checking the rear brake fluid level 82
13.12 Adding rear brake fluid ........ 82
13.13 Checking the rear brake linings ........................ 83
13.14 Changing the rear brake linings ..................... 83
14 WHEELS, TIRES .................................... 85
14.1 Removing the front wheel ............................. 85
14.2 Installing the front wheel ............................. 85
14.3 Removing the rear wheel ............................. 86
14.4 Installing the rear wheel ............................... 87
14.5 Checking the tire condition .............................. 88
14.6 Checking the tire air pressure 88
14.7 Checking spoke tension .............................. 89
15 ELECTRICAL SYSTEM ............................ 90
15.1 Removing the battery (All 250/300 models,
XC‑ W US, XC‑ W Six Days US) 90
15.2 Installing the battery (All 250/300 models,
XC‑ W US, XC‑ W Six Days US) 91
15.3 Recharging the battery (All 250/300
models, XC‑ W US, XC‑ W Six Days US) .............. 91
15.4 Changing the main fuse (All 250/300 models,
XC‑ W US, XC‑ W Six Days US) 93
15.5 Removing the headlight mask with the
headlight......................... 94
15.6 Installing the headlight mask with the
headlight......................... 95
15.7 Changing the headlight bulb ............................ 95
15.8 Changing the turn signal bulb (All
EXC/EXC Six Days models) 96
15.9 Checking the headlight setting ......................... 97
15.10 Adjusting the headlight range 97
15.11 Changing the speedomete battery .................... 97
16 COOLING SYSTEM ...................................... 99
16.1 Cooling system ..................................... 99
