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CONTENTS 3
Removing the lower triple clampbx (EXC-RbEU,
EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA) ......................... 44
Installing the lower triple clampb
x (EXC-RbSIXbDAYS,
XCR-WbUSA) ................................................................. 44
Installing the lower triple clampb
x (EXC-RbEU,
EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA) ......................... 45
Greasing the steering head bearingb
x............................. 46
Dismounting the front fender.......................................... 46
Installing the front fender............................................... 46
Removing headlight mask with headlight (EXC-RbEU,
EXC-RbAUS/UK, EXC-RbSIXbDAYS, EXC-RbUSA,
XCR-WbZA).................................................................... 46
Refitting the headlight mask with the headlight
(EXC-RbEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS,
EXC-RbUSA, XCR-WbZA) ................................................. 47
Dismount the start number plate (XCR-WbUSA) ................ 47
Fitting the start number plate (XCR-WbUSA)..................... 47
Handlebar position ........................................................ 47
Adjusting handlebar positionb
x...................................... 48
Checking gas Bowden cable route ................................... 49
Checking play in the gas Bowden cable ........................... 50
Adjusting the gas Bowden cable playb
x.......................... 50
Checking chain dirt ....................................................... 50
Cleaning the chain......................................................... 50
Checking the chain tension ............................................ 51
Checking the chain tension when fitting rear wheel........... 51
Checking the rear sprocket / engine sprocket for wear ....... 52
Checking chain wear...................................................... 52
Adjusting the chain tension ............................................ 52
Adjusting chain tension - after checking .......................... 53
Adjusting chain tension - fitting rear wheel ...................... 54
Adjusting chain guideb
x ............................................... 54
Brake fluid reservoir....................................................... 54
Brake calipers............................................................... 55
Checking brake discs..................................................... 55
Checking free play of hand brake lever............................. 55
Adjusting basic position of handbrake lever (Every XCR-W
models)........................................................................ 56
Adjusting free travel of handbrake lever (Every EXC-R
models)........................................................................ 56
Checking the front brake fluid level................................. 56
Topping up the front brake fluidb
x................................. 56
Checking the front brake linings...................................... 57
Removing front brake liningsb
x...................................... 58
Installing the front brake liningsb
x................................. 58
Changing the front brake liningsb
x................................. 59
Checking free play of foot brake lever .............................. 59
Adjusting basic position of footbrake leverb
x................... 60
Checking the rear brake fluid level .................................. 60
Adding rear brake fluidb
x.............................................. 61
Checking rear brake linings ............................................ 61
Removing rear brake liningsb
x....................................... 62
Installing the rear brake liningsb
x.................................. 62
Changing the rear brake liningsb
x.................................. 63
Removing front wheelb
x................................................ 63
Fitting front wheelb
x .................................................... 64
Removing rear wheelb
x................................................. 65
Fitting rear wheelb
x...................................................... 65
Tire condition checking.................................................. 66
Checking tire air pressure............................................... 66
Checking spoke tension.................................................. 67
Removing the batteryb
x ................................................ 67
Installing the batteryb
x................................................. 67
Recharging the batteryb
x .............................................. 68
Removing a fuse............................................................ 69
Replacing the fuse......................................................... 69
Removing the seat......................................................... 69
Mounting the seat ......................................................... 69
Dismounting the fuel tankb
x ......................................... 70
Installing the fuel tankb
x .............................................. 70
Cooling system.............................................................. 71
Checking antifreeze and coolant level.............................. 71
Checking the coolant level.............................................. 72
Draining coolantb
x ....................................................... 72
Refilling coolantb
x ....................................................... 73
Glass fiber yarn filling of main silencer............................ 73
Removing main silencer................................................. 73
Fitting the main silencer ................................................ 74
Dismounting the air filter box lid..................................... 74
Installing the air filter box lid.......................................... 74
Removing the air filterb
x............................................... 74
Installing the air filterb
x ............................................... 75
Cleaning air filterb
x...................................................... 75
Adjusting basic position of clutch lever............................ 75
Checking fluid level of hydraulic clutch ........................... 75
Changing fluid level of hydraulic clutchb
x ...................... 76
Carburetor - idle............................................................ 77
Carburetor - adjusting idleb
x ......................................... 77
Emptying the carburetor float chamberb
x ....................... 78
Checking engine oil level................................................ 79
Changing engine oil and oil filter, cleaning engine oil
screenb
x ..................................................................... 79
Draining engine oil, cleaning engine oil screenb
x ............ 79
Removing the oil filterb
x............................................... 80
Mounting oil filterb
x..................................................... 80
Filling up with engine oilb
x ........................................... 81
Topping up engine oil .................................................... 81
Checking gear oil level ................................................... 81
Changing gear oil, cleaning gear oil screenb
x.................. 82
Draining gear oil, cleaning gear oil screenb
x ................... 82
Filling up with gear oilb
x............................................... 83
Topping up with gear oilb
x............................................ 83
TROUBLESHOOTING......................................................... 84
CLEANING........................................................................ 86
Cleaning motorcycle ...................................................... 86
STORAGE ......................................................................... 87
Storage......................................................................... 87
Putting into operation after storage ................................. 87
TECHNICAL DATA - ENGINE.............................................. 88
Capacity - engine oil...................................................... 88
Capacity - gear oil.......................................................... 88
Capacity - coolant.......................................................... 89
TECHNICAL DATA - ENGINE TIGHTENING TORQUES.......... 90
TECHNICAL DATA - CARBURETOR..................................... 92
450bEXC-RbEU, 450bEXC-RbAUS/UK (3900I)................... 92
450bEXC-RbSIXbDAYS, 450bEXC-RbUSA, 450bXCR-W
(3900L) ....................................................................... 92
530bEXC-RbEU, 530bEXC-RbAUS/UK (3900J)................... 93
530bEXC-RbSIXbDAYS,
530bEXC-RbUSA, 530bXCR-W
(3900M) ...................................................................... 93
TECHNICAL DATA - CHASSIS ............................................ 94
Lighting equipment ....................................................... 95
Tires ............................................................................ 95