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TABLE OF CONTENTS 3
Cleaning the chain......................................................... 52
Checking the chain tension ............................................ 52
Checking chain tension when fitting rear wheel ................ 53
Checking the rear sprocket/engine sprocket for wear ......... 53
Checking chain wear...................................................... 53
Adjusting chain tension.................................................. 54
Adjusting chain tension - after checking .......................... 55
Adjusting chain tension - fitting rear wheel ...................... 55
Adjusting chain guide x ............................................... 56
Checking brake discs ..................................................... 56
Checking free travel of hand brake lever........................... 56
Adjusting free travel of hand brake lever .......................... 57
Checking the brake fluid level of the front brake............... 57
Topping up the front brake fluid x................................. 57
Checking the front brake linings...................................... 58
Changing the front brake linings x................................. 59
Checking the free travel of the foot brake lever ................. 60
Adjusting the basic position of the foot brake lever x ...... 60
Checking rear brake fluid level........................................ 61
Adding brake fluid to the rear brake circuit x ................. 61
Checking rear brake linings ............................................ 62
Changing rear brake linings x ....................................... 62
Removing front wheel x................................................ 64
Installing the front wheel x........................................... 65
Removing the rear wheel x ........................................... 65
Installing the rear wheel x............................................ 66
Tire condition checking.................................................. 67
Checking tire air pressure............................................... 67
Checking spoke tension.................................................. 68
Removing the battery x ................................................ 68
Installing the battery x................................................. 69
Recharging the battery x.............................................. 69
Removing a fuse............................................................ 70
Installing the fuse ......................................................... 70
Checking the headlight adjustment ................................. 70
Adjusting the beam width of the headlight ....................... 71
Removing the seat......................................................... 71
Mounting the seat ......................................................... 71
Removing the fuel tank x ............................................. 71
Installing the fuel tank x.............................................. 72
Cooling system.............................................................. 73
Checking the anti-freeze and coolant level ....................... 73
Checking the coolant level.............................................. 74
Draining coolant x ....................................................... 74
Refilling coolant x ....................................................... 75
Glass fiber yarn filling of main silencer............................ 75
Removing main silencer ................................................. 75
Installing the main silencer ............................................ 76
Removing the air filter box lid......................................... 76
Installing the air filter box lid.......................................... 76
Removing the air filter x............................................... 76
Installing the air filter x ............................................... 77
Cleaning air filter x...................................................... 77
Adjusting basic position of clutch lever............................ 77
Checking the fluid level of hydraulic clutch...................... 78
Changing the hydraulic clutch fluid x............................ 78
Checking the basic position of the shift lever.................... 79
Adjusting the basic position of the shift lever x .............. 79
Carburetor - idle............................................................ 80
Carburetor - adjusting idle x ......................................... 80
Emptying the carburetor float chamber x ....................... 81
Checking engine oil level................................................ 81
Changing engine oil and oil filter, cleaning engine oil
screen x ..................................................................... 82
Draining engine oil, cleaning engine oil screen x ............ 82
Removing the oil filter x............................................... 82
Installing the oil filter x ............................................... 83
Filling up with engine oil x........................................... 83
Topping up engine oil .................................................... 84
Checking the gear oil level.............................................. 84
Changing gear oil, cleaning gear oil screen x.................. 84
Draining gear oil, cleaning gear oil screen x ................... 85
Filling up with gear oil x .............................................. 85
Adding gear oil x......................................................... 86
TROUBLESHOOTING......................................................... 87
CLEANING........................................................................ 89
Cleaning the motorcycle................................................. 89
STORAGE......................................................................... 90
Storage......................................................................... 90
Putting into operation after storage ................................. 90
TECHNICAL DATA - ENGINE.............................................. 91
Capacity - engine oil ...................................................... 91
Capacity - gear oil.......................................................... 91
Capacity - coolant.......................................................... 92
TECHNICAL DATA - ENGINE TIGHTENING TORQUES.......... 93
TECHNICAL DATA - CARBURETOR..................................... 95
450 EXC USA ............................................................... 95
530 EXC USA ............................................................... 95
TECHNICAL DATA - CHASSIS ............................................ 96
Lighting equipment ....................................................... 96
Tires ............................................................................ 97
Capacity - fuel............................................................... 97
TECHNICAL DATA - FORK.................................................. 98
TECHNICAL DATA - SHOCK ABSORBER ............................. 99
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 100
WIRING DIAGRAM .......................................................... 102
Wiring diagram............................................................ 102
SUBSTANCES................................................................. 105
AUXILIARY SUBSTANCES................................................ 107
STANDARDS................................................................... 109
INDEX............................................................................ 110