TABLE OF CONTENTS
4
12.33 Installing the fuel tank .................. 82
12.34 Checking the chain for dirt................ 84
12.35 Cleaning the chain ........................... 84
12.36 Checking the chain tension ............... 85
12.37 Adjusting the chain tension............... 85
12.38 Checking the chain, rear sprocket,
motor sprocket, and chain guide........ 86
12.41 Checking throttle cable routing.......... 89
12.42 Checking the rubber grip .................. 90
12.43 Adjusting the basic position of the
clutch lever ..................................... 91
12.44 Checking/correcting the fluid level of
the hydraulic clutch ......................... 91
12.45 Changing the hydraulic clutch
fluid ............................................ 92
12.46 Removing the engine guard (All
Six Days models, EXC AU) ................ 93
12.47 Installing the engine guard (All
Six Days models, EXC AU) ................ 94
13 BRAKE SYSTEM ......................................... 95
Checking the free travel of the hand
brake lever ...................................... 95
Adjusting free travel of hand brake
lever (All EXC models) ...................... 95
Adjusting the basic position of the
hand brake lever (All XC
Checking the brake discs .................. 96
Checking the front brake fluid level ... 97
Checking the front brake linings ........ 98
Changing the front brake linings
Checking the free travel of foot
brake lever .................................... 101
13.10 Adjusting the basic position of the
.......................... 101
13.11 Checking the rear brake fluid
level ............................................. 102
13.13 Checking the brake linings of the
rear brake...................................... 104
13.14 Changing the rear brake linings .... 104
14 WHEELS, TIRES ....................................... 107
Removing the front wheel ............ 107
Installing the rear wheel .............. 109
Checking the tire condition ............. 111
Checking the tire air pressure.......... 111
Checking spoke tension .................. 112
15 ELECTRICAL SYSTEM ............................... 113
Installing the battery ................... 114
Changing the main fuse.................. 118
Removing the headlight mask with
the headlight ................................. 119
Installing the headlight mask with
the headlight ................................. 120
Changing the headlight bulb ........... 121
Changing the turn signal bulb (All
EXC models).................................. 121
Checking the headlight setting ........ 122
15.10 Adjusting the headlight range.......... 123
15.11 Changing the combination
instrument .................................... 123
16 COOLING SYSTEM .................................... 125
Cooling system .............................. 125
Checking the antifreeze and
coolant level .................................. 125
Checking the coolant level .............. 126
17 TUNING THE ENGINE............................... 129
Checking the play in the throttle
cable ............................................ 129
Adjusting the play in the throttle
cable ......................................... 129
Carburetor setting .......................... 131
Carburetor - idle............................. 133
........................................ 134
Ignition curve plug-in connector ...... 135
Changing the ignition timing map .... 135
Checking the basic position of the
shift lever...................................... 136
Adjusting the basic position of the
shift lever
.................................. 136
spring ........................................... 137
auxiliary spring ........................... 137
18 SERVICE WORK ON THE ENGINE .............. 139
Emptying the carburetor float
chamber
.................................... 139
Checking the gear oil level .............. 140
Adding gear oil ........................... 141