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TABLE OF CONTENTS
3
fork...................................................................... 42
11.13 Adjusting the rebound damping of the fork........ 42
11.14 Adjusting the spring preload of the fork ............. 43
11.15 Handlebar position.............................................. 44
11.16 Adjusting the handlebar position
12 SERVICE WORK ON THE CHASSIS ............................... 45
Raising the motorcycle with the lift stand........... 45
Removing the motorcycle from the lift stand...... 45
Bleeding the fork legs ......................................... 45
Cleaning the dust boots of the fork legs............. 45
Removing the fork legs ................................... 46
Installing the fork legs ..................................... 46
Removing the fork protector............................... 47
Installing the fork protector................................. 47
Removing the lower triple clamp
12.10 Installing the lower triple clamp
12.11 Checking the play of the steering head
bearing ................................................................ 50
12.12 Adjusting the play of the steering head
bearing ............................................................ 50
12.13 Greasing the steering head bearing ................ 51
12.14 Removing the front fender .................................. 51
12.15 Installing the front fender .................................... 51
12.16 Removing the shock absorber ........................ 52
12.17 Installing the shock absorber .......................... 53
12.18 Removing the seat .............................................. 54
12.19 Mounting the seat ............................................... 55
12.20 Removing the air filter box cover........................ 55
12.21 Installing the air filter box cover.......................... 56
12.22 Removing the air filter ..................................... 56
12.23 Cleaning the air filter and air filter box ............ 56
12.24 Installing the air filter ....................................... 57
12.25 Sealing the air filter box
.................................. 57
main silencer ................................................... 58
12.29 Removing the right side cover ............................ 59
12.30 Installing the right side cover.............................. 59
12.31 Removing the fuel tank
................................... 60
12.32 Installing the fuel tank ..................................... 61
12.33 Checking the chain for dirt.................................. 62
12.34 Cleaning the chain .............................................. 62
12.35 Checking the chain tension ................................ 62
12.36 Adjusting the chain tension................................. 63
12.37 Checking the chain, rear sprocket, engine
sprocket, and chain guide .................................. 64
12.38 Checking the frame ......................................... 65
12.39 Checking the swingarm
.................................. 66
12.40 Checking throttle cable routing .......................... 66
12.41 Checking the rubber grip .................................... 67
12.42 Adjusting the basic position of the clutch
lever .................................................................... 67
12.43 Checking/correcting the fluid level of the
hydraulic clutch................................................... 68
12.44 Changing the hydraulic clutch fluid
12.45 Removing the engine guard................................ 69
12.46 Installing the engine guard.................................. 70
13 BRAKE SYSTEM ............................................................. 71
Checking the free travel of the hand brake
lever .................................................................... 71
Adjusting free travel of hand brake lever
(TE 250/300 EU/AU, TX 125 EU)......................... 71
Adjusting the basic position of the hand brake
lever (TE US) ....................................................... 71
Checking the brake discs ................................... 72
Checking the front brake fluid level .................... 72
.................................. 73
Checking the front brake linings ......................... 74
Changing the front brake linings ..................... 74
Checking the free travel of the foot brake
lever .................................................................... 76
13.10 Adjusting the basic position of the foot brake
lever ................................................................. 76
13.11 Checking the rear brake fluid level ..................... 77
13.12 Adding rear brake fluid .................................... 77
13.13 Checking the rear brake linings .......................... 79
13.14 Changing the rear brake linings ...................... 79
14 WHEELS, TIRES.............................................................. 82
Removing the front wheel ............................... 82
Installing the front wheel ................................. 82
................................ 83
.................................. 84
Checking the tire condition................................. 85
Checking the tire air pressure............................. 85
Checking spoke tension ..................................... 86
15 ELECTRICAL SYSTEM.................................................... 87
(All 150/250/300 models) .................................... 87
(All 150/250/300 models) .................................... 87
(All 150/250/300 models) .................................... 88
(All 150/250/300 models) .................................... 89
Removing the headlight mask with the
headlight ............................................................. 90
Installing the headlight mask with the
headlight ............................................................. 91
Changing the headlight bulb............................... 91
Changing the turn signal bulb (TE 250/300
EU/AU) ................................................................ 92
Checking the headlight setting ........................... 93
16 COOLING SYSTEM......................................................... 95
Cooling system ................................................... 95
Checking the antifreeze and coolant level.......... 95
Checking the coolant level.................................. 96
Draining the coolant ........................................ 96
Refilling with coolant ....................................... 97
17 TUNING THE ENGINE..................................................... 99
Checking the play in the throttle cable ............... 99
Adjusting the play in the throttle cable
Carburetor setting............................................. 100
Carburetor - idle................................................ 102
adjusting the idle speed ........... 102