Operation Manual

TABLE OF CONTENTS 4
16.2 Checking the antifreeze and coolant level.......... 99
16.3 Checking the coolant level ............................. 100
16.4 Draining the coolant .................................. 100
16.5 Refilling with coolant ................................. 101
17 TUNING THE ENGINE.............................................. 103
17.1 Checking the play in the throttle cable ............ 103
17.2 Adjusting the play in the throttle cable ........ 103
17.3 Carburetor setting ......................................... 104
17.4 Carburetor - idle............................................ 106
17.5 Carburetor – adjusting the idle speed .......... 106
17.6 Ignition curve plug-in connector ..................... 107
17.7 Changing the ignition curve............................ 107
17.8 Checking the basic position of the shift lever ... 107
17.9 Adjusting the basic position of the shift
lever ......................................................... 107
17.10 Engine characteristic – auxiliary spring ........... 108
17.11 Engine characteristic – setting the auxiliary
spring ....................................................... 108
18 SERVICE WORK ON THE ENGINE ............................. 111
18.1 Emptying the carburetor float chamber ........ 111
18.2 Checking the gear oil level ............................. 111
18.3 Changing the gear oil ................................. 112
18.4 Adding gear oil .......................................... 114
19 CLEANING, CARE .................................................... 115
19.1 Cleaning the motorcycle ................................ 115
19.2 Checks and maintenance steps for winter
operation...................................................... 116
20 STORAGE................................................................ 117
20.1 Storage ........................................................ 117
20.2 Preparing for use after storage........................ 118
21 TROUBLESHOOTING ............................................... 119
22 TECHNICAL DATA.................................................... 121
22.1 Engine ......................................................... 121
22.1.1 125 XC‑W EU........................................... 121
22.1.2 150 XC‑W US........................................... 121
22.1.3 All 250 models......................................... 122
22.1.4 All 300 models......................................... 122
22.2 Engine tightening torques .............................. 123
22.2.1 125 XC‑W EU........................................... 123
22.2.2 150 XC‑W US........................................... 124
22.2.3 All 250/300 models.................................. 125
22.3 Capacities .................................................... 126
22.3.1 Gear oil.................................................... 126
22.3.2 Coolant.................................................... 126
22.3.3 Fuel ........................................................ 126
22.4 Chassis ........................................................ 126
22.5 Electrical system........................................... 127
22.6 Tires............................................................ 127
22.7 Fork............................................................. 128
22.7.1 All 125/150 models.................................. 128
22.7.2 All standard 250/300 EXC/XC-W models ..... 128
22.7.3 All Six Days models................................... 128
22.8 Shock absorber............................................. 129
22.8.1 All 125/150 models.................................. 129
22.8.2 All 250/300 models.................................. 129
22.9 Chassis tightening torques ............................. 130
22.10 Carburetor.................................................... 132
22.10.1 125 XC‑W EU........................................... 132
22.10.2 150 XC‑W US........................................... 132
22.10.3 250 EXC EU, 250 EXC AU,
250 EXC Six Days EU ............................... 132
22.10.4 250 XC‑W US........................................... 132
22.10.5 300 EXC EU, 300 EXC AU,
300 EXC Six Days EU ............................... 133
22.10.6 300 XC‑W US, 300 XC‑W Six Days US........ 133
22.10.7 300 EXC BR ............................................ 133
23 CARBURETOR TUNING............................................ 134
23.1 Carburetor tuning (125 XC‑W EU) ............... 134
23.2 Carburetor tuning (150 XC‑W US) ............... 135
23.3 Carburetor tuning (250 EXC EU,
250 EXC AU, 250 EXC Six Days EU) ........... 136
23.4 Carburetor tuning (250 XC‑W US) ............... 137
23.5 Carburetor tuning (300 EXC EU,
300 EXC AU, 300 EXC Six Days EU) ........... 138
23.6 Carburetor tuning (300 XC‑W US,
300 XC‑W Six Days US) ............................. 139
23.7 Carburetor tuning (300 EXC BR) ................. 140
24 SUBSTANCES ......................................................... 141
25 AUXILIARY SUBSTANCES ........................................ 143
26 STANDARDS ........................................................... 144
27 LIST OF ABBREVIATIONS......................................... 145
28 LIST OF SYMBOLS................................................... 146
28.1 Yellow and orange symbols............................. 146
28.2 Green and blue symbols................................. 146
INDEX ............................................................................ 147