KTM 60/65/125/200/350/390 Repair Service Manual 1998-2014
Complete service repair manual with Electrical Wiring Diagrams for 1998-2014 KTM 60, 65, 125, 200, 350, 390, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
KTM 60/65/125/200/350/390 1998-2014 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
3206091en - KTM REPAIR MANUAL 2011 350 SX-F EU, 350 SX-F USA.pdf
3206110en - KTM REPAIR MANUAL 2011 125 Duke EU, 125 Duke DE.pdf
3206111 - KTM Repair Manual 2012 (350 EXC‐F EU, 350 EXC‐F AUS, 350 EXC‐F SIX DAYS EU, 350 XCF‐W USA, 350 EXC‐F USA).pdf
3206127en - KTM REPAIR MANUAL 2012 125 Duke EU, 125 Duke DE, 200 Duke EU, 200 Duke 2013 COL.pdf
3206162en - KTM REPAIR MANUAL 2013 125 Duke EU, 200 Duke EU, 200 Duke MAL, 200 Duke 2014 COL.pdf
3206167en - KTM 390 Duke EU, 390 Duke AUS, 390 Duke MAL, 390 Duke 2014 COL 2013.pdf
KTM 60SX, 65SX Repair Manual - Engine.pdf
KTM REPAIR MANUAL 125-200 1999-2006.pdf
KTM Repair Manual Engine 125-200.pdf
PRODUCT DETAILS:
Total Pages: 613 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
MAKE: KTM
MODEL: 60 SX, 65 SX, 125 EGS, 125 EXE, 125 EXC, 125 EXC Six Days, 125 MXC, 125 SX, 125 SXS, 125 Supermoto, 200 EGS, 200 EXC, 200 EXC Six Days, 200 MXC, 200 SX, 200 SXS, 200 XC, 200 XC-W, 125 Duke EU, 125 Duke DE, 200 Duke EU, 200 Duke MAL, 200 Duke 2013 COL, 200 Duke 2014 COL, 350 EXC‑F EU, 350 EXC‑F AUS, 350 EXC‑F SIX DAYS EU, 350 SX-F EU, 350 SX-F USA, 350 XCF‑W USA, 350 EXC‑F USA, 390 Duke EU, 390 Duke AUS, 390 Duke MAL, 390 Duke 2014 COL
YEAR: 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014
"'13-'14 125-200 Duke.pdf"
288 pages; Repair Manual 2013-2014 for 125 Duke EU, 200 Duke EU, 200 Duke MAL, 200 Duke 2014 COL
"'13-'14 390 Duke.pdf"
204 pages; Repair Manual 2013-2014 for 390 Duke EU, 390 Duke AUS, 390 Duke MAL, 390 Duke 2014 COL
"'12-'13 125-200 Duke.pdf"
267 pages; Repair Manual 2012-2013 for 125 Duke EU, 125 Duke DE, 200 Duke EU, 200 Duke 2013 COL
"'12 350 EXC-F, XCF-W"
~1,500 pages, 68 pages PDF, EN/DE/ES/FR/IT; REPAIR MANUAL 2012 for 350 EXC‑F EU, 350 EXC‑F AUS, 350 EXC‑F SIX DAYS EU, 350 XCF‑W USA, 350 EXC‑F USA
"'11 125 Duke.pdf"
195 pages; REPAIR MANUAL 2011 for 125 Duke EU, 125 Duke DE
"'11 350 SX-F (EU_USA).pdf"
220 pages; REPAIR MANUAL 2011 for 350 SX-F EU, 350 SX-F USA
"'99-'06 125-200.pdf"
213 pages; Repair Manual 1999-2006 for 125 SX, 125 SXS, 125 Supermoto, 125 MXC, 125 EXE, 125 EXC, 125 EXC Six Days, 125 EGS, 200 SX, 200 SXS, 200 MXC, 200 EXC, 200 EGS, 200 EXC Six Days, 200 XC, 200 XC-W
"'99-'03 125-200.pdf"
158 pages; Repair Manual Engine 1999-2003 for 125 SX, 125 MXC, 125 EXC, 125 EXE, 125 EGS, 125 SUPERMOTO, 200 SX, 200 MXC, 200 EXC, 200 EGS
"'98-'03 60SX, 65SX.pdf"
92 pages; Repair Manual Engine 1998-2003 for 60 SX, 65 SX
TABLE OF CONTENTS
1 MEANS OF REPRESENTATION...7
1.1 Symbols used...7
1.2 Formats used...7
2 SAFETY ADVICE...8
2.1 Repair Manual...8
2.2 Safety advice...8
2.3 Degrees of risk and symbols...8
2.4 Work rules...8
3 IMPORTANT NOTES...9
3.1 Guarantee, warranty...9
3.2 Operating and auxiliary substances...9
3.3 Spare parts, accessories...9
3.4 Figures...9
4 SERIAL NUMBERS...10
4.1 Chassis number/type label...10
4.2 Key number...10
4.3 Engine number...10
5 MOTORCYCLE...11
5.1 Raising the motorcycle with the rear wheel stand...11
5.2 Taking the motorcycle off of the rear wheel stand...11
5.3 Raising the motorcycle with the front wheel stand...11
5.4 Taking the motorcycle off of the front wheel stand...12
5.5 Raising the motorcycle with the work stand...12
5.6 Removing the motorcycle from the work stand...13
5.7 Starting...13
5.8 Starting the motorcycle to make checks...14
6 FORK, TRIPLE CLAMP...15
6.1 Cleaning the dust boots of the fork legs...15
6.2 Removing fork legs...15
6.3 Installing the fork legs...16
6.4 Disassembling the fork legs...17
6.5 Checking the fork legs...19
6.6 Assembling the fork legs...20
6.7 Removing the lower triple clamp...22
6.8 Installing the lower triple clamp...24
6.9 Checking the steering head bearing play...26
6.10 Adjusting the steering head bearing play...27
7 HANDLEBAR, CONTROLS...28
7.1 Checking the play in the throttle cable...28
7.2 Adjusting the play in the throttle cable...28
7.3 Checking the clutch lever play...28
7.4 Adjusting the clutch cable play...29
8 SHOCK ABSORBER, SWINGARM...30
8.1 Adjusting the spring preload of the shock absorber...30
8.2 Removing the shock absorber...30
8.3 Installing the shock absorber...30
8.4 Removing the spring...31
8.5 Installing the spring...31
9 EXHAUST...33
9.1 Removing the exhaust manifold...33
9.2 Installing the exhaust manifold...34
9.3 Removing the main silencer...35
9.4 Installing the main silencer...36
10 AIR FILTER...37
10.1 Removing the air filter...37
10.2 Installing the air filter...37
11 FUEL TANK, SEAT, TRIM...38
11.1 Opening the filler cap...38
11.2 Closing the filler cap...38
11.3 Removing the seat...38
11.4 Mounting the seat...39
11.5 Removing the passenger seat...39
11.6 Mounting the passenger seat...39
11.7 Removing the fuel tank cover...39
11.8 Installing the fuel tank cover...42
11.9 Removing the fuel tank...44
11.10 Installing the fuel tank...46
11.11 Removing the front spoiler...47
11.12 Fitting front spoiler...47
11.13 Dismounting the front fender...48
11.14 Installing the front fender...48
11.15 Checking the fuel pressure...48
11.16 Changing the fuel filter...50
11.17 Replacing the fuel pump...51
12 WHEELS...53
12.1 Checking the tire air pressure...53
12.2 Checking the tire condition...53
12.3 Checking the brake discs...54
12.4 Front wheel...54
12.4.1 Removing the front wheel...54
12.4.2 Installing the front wheel...54
12.4.3 Removing the brake disc of the front brake...55
12.4.4 Installing the brake disc of the front brake...55
12.5 Rear wheel...56
12.5.1 Removing the rear wheel...56
12.5.2 Installing the rear wheel...56
12.5.3 Removing the brake disc of the rear brake...57
12.5.4 Installing the brake disc of the rear brake...57
13 WIRING HARNESS, BATTERY...62
13.1 Removing the battery...62
13.2 Installing the battery...62
13.3 Disconnecting the negative cable of the battery...63
13.4 Reconnecting the negative cable of the battery...63
13.5 Recharging the battery...63
13.6 Checking the charging voltage...64
13.7 Changing the fuses of individual power consumers...65
14 BRAKE SYSTEM...66
14.1 Checking the front brake linings...66
14.2 Changing the front brake linings...66
14.3 Checking the brake fluid level of the front brake...68
14.4 Adding front brake fluid...68
14.5 Changing the front brake fluid...69
14.6 Checking the rear brake linings...70
14.7 Changing the rear brake linings...71
14.8 Checking the free travel of foot brake lever...72
14.9 Adjusting the free travel of the foot brake lever...73
14.10 Checking the rear brake fluid level...73
14.11 Adding rear brake fluid...74
14.12 Changing the rear brake fluid...74
15 LIGHTING SYSTEM, INSTRUMENTS...76
15.1 Setting kilometers or miles...76
15.2 Adjusting the shift speed RPM 1...76
15.3 Adjusting the shift speed RPM 2...76
15.4 Setting the time...77
15.5 Resetting the service interval display...77
15.6 Checking the headlight setting...77
15.7 Adjusting the headlight range...78
15.8 Changing the parking light bulb...79
15.9 Changing the headlight bulb...80
16 ENGINE...82
16.1 Removing the engine...82
16.2 Installing the engine...85
16.3 Disassembling the engine...90
16.3.1 Preparations...90
16.3.2 Draining the engine oil...90
16.3.3 Removing the chain securing guide...91
16.3.4 Removing the valve cover...91
16.3.5 Removing the spark plug...91
16.3.6 Removing the clutch cover...91
16.3.7 Setting the engine to ignition top dead center...92
16.3.8 Removing the starter motor...92
16.3.9 Removing the timing chain tensioner...93
16.3.10 Removing the camshaft...93
16.3.11 Removing the cylinder head...94
16.3.12 Removing the piston...94
16.3.13 Removing the water pump wheel...95
16.3.14 Removing the alternator cover...96
16.3.15 Removing the rotor...96
16.3.16 Removing the starter drive...97
16.3.17 Removing the balancer shaft drive wheel...97
16.3.18 Removing the gear position sensor...98
16.3.19 Removing the spacer...99
16.3.20 Removing the clutch basket...99
16.3.21 Removing the primary gear...100
16.3.22 Removing the oil pump...100
16.3.23 Removing the shift shaft...101
16.3.24 Removing the shift drum locating...101
16.3.25 Removing the locking lever...101
16.3.26 Removing the oil filter...101
16.3.27 Removing the left engine case...102
16.3.28 Removing the shift rails...103
16.3.29 Removing the shift drum...103
16.3.30 Removing the shift forks...103
16.3.31 Removing the transmission shafts...103
16.3.32 Removing the balancer shaft...104
16.3.33 Removing the crankshaft...104
16.4 Work on individual parts...104
16.4.1 Work on the left section of the engine case...104
16.4.2 Work on the right section of the engine case...105
16.4.3 Changing the shaft seal ring of the water pump...105
16.4.4 Removing the main bearing...106
16.4.5 Checking the radial play of the lower conrod bearing...107
16.4.6 Changing the conrod bearing...108
16.4.7 Changing the balancer shaft bearing...109
16.4.8 Changing the camshaft bearing...109
16.4.9 Work on the cylinder head...110
16.4.10 Checking the cylinder head...111
16.4.11 Checking/measuring the cylinder...111
16.4.12 Checking the piston ring...112
16.4.13 Checking/measuring the piston...112
16.4.14 Checking the piston/cylinder mounting clearance...113
16.4.15 Checking the oil pump...113
16.4.16 Checking the oil pressure regulator valve...113
16.4.17 Checking the clutch...114
16.4.18 Preassembling the clutch...115
16.4.19 Checking the shift mechanism...116
16.4.20 Preassembling the shift shaft...117
16.4.21 Disassembling the main shaft...117
16.4.22 Dismantling the countershaft...118
16.4.23 Checking the transmission...118
16.4.24 Assembling the main shaft...120
16.4.25 Assembling the countershaft...120
16.4.26 Checking the timing assembly...122
16.4.27 Changing the stator...122
16.4.28 Checking the electric starter drive...123
16.4.29 Checking the freewheel...124
16.5 Assembling the engine...124
16.5.1 Installing the crankshaft...124
16.5.2 Installing the balancer shaft...124
16.5.3 Installing the transmission shafts...125
16.5.4 Installing the shift forks...125
16.5.5 Installing the shift drum...125
16.5.6 Installing the shift rails...126
16.5.7 Installing the left engine case...126
16.5.8 Installing the oil filter...127
16.5.9 Installing the locking lever...127
16.5.10 Installing the shift drum locating...127
16.5.11 Installing the shift shaft...128
16.5.12 Installing the oil pump...128
16.5.13 Installing the primary gear...129
16.5.14 Installing the clutch basket...129
16.5.15 Installing the spacer...130
16.5.16 Installing the gear position sensor...130
16.5.17 Installing the balancer shaft drive wheel...131
16.5.18 Installing the starter drive...132
16.5.19 Installing the rotor...133
16.5.20 Installing the alternator cover...133
16.5.21 Installing the water pump cover...133
16.5.22 Installing the piston...134
16.5.23 Installing the cylinder head...135
16.5.24 Installing the camshafts...136
16.5.25 Installing the timing chain tensioner...137
16.5.26 Checking the valve clearance...138
16.5.27 Adjusting the valve clearance...138
16.5.28 Installing the starter motor...138
16.5.29 Installing the clutch cover...139
16.5.30 Installing the spark plug...139
16.5.31 Installing the valve cover...140
16.5.32 Installing the chain securing guide...140
16.5.33 Installing the oil screen...140
16.5.34 Removing the engine from the engine assembly stand...141
17 SHIFT MECHANISM...142
17.1 Adjusting the shift lever...142
18 WATER PUMP, COOLING SYSTEM...143
18.1 Draining the coolant...143
18.2 Filling/bleeding the cooling system...143
18.3 Checking the antifreeze and coolant level...144
18.4 Checking the coolant level...145
19 LUBRICATION SYSTEM...147
19.1 Oil circuit...147
19.2 Checking the engine oil level...147
19.3 Checking the engine oil pressure...147
19.4 Changing the engine oil and oil filter, cleaning the oil screen...149
19.5 Adding engine oil...150
20 IGNITION SYSTEM...151
20.1 Alternator - checking the stator winding...151
21 TECHNICAL DATA...152
21.1 Engine...152
21.2 Engine tolerance, wear limits...152
21.3 Engine tightening torques...153
21.4 Capacities...154
21.4.1 Engine oil...154
21.4.2 Coolant...154
21.4.3 Fuel...154
21.5 Chassis...154
21.6 Electrical system...155
21.7 Tires...155
21.8 Fork...155
21.9 Shock absorber...156
21.10 Chassis tightening torques...156
22 CLEANING/PROTECTIVE TREATMENT...158
22.1 Cleaning the motorcycle...158
22.2 Checks and maintenance steps for winter operation...159
23 STORAGE...160
23.1 Storage...160
24 SERVICE SCHEDULE...161
24.1 Service schedule...161
25 WIRING DIAGRAM...162
25.1 Page 1 of 8...162
25.2 Page 2 of 8...164
25.3 Page 3 of 8...166
25.4 Page 4 of 8...168
25.5 Page 5 of 8...170
25.6 Page 6 of 8...172
25.7 Page 7 of 8...174
25.8 Page 8 of 8...176
26 SUBSTANCES...178
27 AUXILIARY SUBSTANCES...180
28 SPECIAL TOOLS...182
29 STANDARDS...191
INDEX...192
A...192
B...192
C...192
D...192
E...193
F...193
H...193
K...193
L...194
M...194
O...194
P...194
R...194
S...194
T...194
W...194
...
DE...2
DARSTELLUNGSMITTEL...9
WICHTIGE HINWEISE...10
SERIENNUMMERN...12
Fahrgestellnummer...12
Typenschild...12
Schlüsselnummer (alle EXC‑F Modelle)...12
Motornummer...13
Gabelartikelnummer...13
Federbeinartikelnummer...13
MOTORRAD...14
Motorrad mit Hubständer aufheben...14
Motorrad vom Hubständer nehmen...14
Startvorgang...14
Motorrad starten für Kontrolltätigkeit...15
01/GABEL, GABELBRÜCKE...16
Druckstufendämpfung der Gabel einstellen...16
Zugstufendämpfung der Gabel einstellen...16
Federvorspannung der Gabel einstellen...16
Gabelbeine entlüften...17
Staubmanschetten der Gabelbeine reinigen...17
Gabelschutz lösen...18
Gabelschutz positionieren...18
Gabelbeine ausbauen...18
Gabelbeine einbauen...19
Gabelschutz ausbauen...20
Gabelschutz einbauen...20
Gabelservice durchführen...20
Gabelbeine zerlegen...21
Patrone zerlegen...24
Druckstufenaufnahme zerlegen...25
Gabelbeine kontrollieren...26
Druckstufenaufnahme zusammenbauen...27
Patrone zusammenbauen...28
Gabelbeine zusammenbauen...30
Steuerkopflager schmieren...34
Untere Gabelbrücke ausbauen (EXC-F SIX DAYS)...34
Untere Gabelbrücke einbauen (EXC-F SIX DAYS)...35
Untere Gabelbrücke ausbauen (EXC‑F EU/AUS/USA, XCF‑W)...36
Untere Gabelbrücke einbauen (EXC‑F EU/AUS/USA, XCF‑W)...37
Steuerkopflagerspiel kontrollieren...39
Steuerkopflagerspiel einstellen (EXC-F SIX DAYS)...39
Steuerkopflagerspiel einstellen (EXC‑F EU/AUS/USA, XCF‑W)...40
02/LENKER, ARMATUREN...41
Lenkerposition...41
Lenkerposition einstellen...41
Grundstellung des Kupplungshebels einstellen...41
Gasbowdenzugverlegung kontrollieren...42
Gasbowdenzugspiel kontrollieren...42
Gasbowdenzugspiel einstellen...43
03/RAHMEN...44
Motorschutz ausbauen (EXC‑F AUS, EXC-F SIX DAYS)...44
Motorschutz einbauen (EXC‑F AUS, EXC-F SIX DAYS)...44
04/FEDERBEIN, SCHWINGARM...45
Druckstufendämpfung High Speed des Federbeins einstellen...45
Druckstufendämpfung Low Speed des Federbeins einstellen...45
Zugstufendämpfung des Federbeins einstellen...46
Maß Hinterrad entlastet ermitteln...46
Statischen Durchhang des Federbeins kontrollieren...46
Fahrtdurchhang des Federbeins kontrollieren...47
Federvorspannung des Federbeins einstellen...47
Fahrtdurchhang einstellen...48
Federbein ausbauen...48
Federbein einbauen...48
Federbeinservice durchführen...49
Feder ausbauen...49
Stoßdämpfer zerlegen...50
Kolbenstange zerlegen...51
Dichtringträger zerlegen...52
Führungsbuchse wechseln...53
Stoßdämpfer kontrollieren...54
Zugstufeneinstellung zerlegen...54
Schwenklager ausbauen...55
Schwenklager einbauen...56
Zugstufeneinstellung zusammenbauen...57
Dichtringträger zusammenbauen...57
Kolbenstange zusammenbauen...58
Stoßdämpfer zusammenbauen...59
Stoßdämpfer entlüften und füllen...62
Stoßdämpfer mit Stickstoff füllen...64
Feder einbauen...65
Schwenklager wechseln...66
05/AUSPUFF...68
Krümmer ausbauen...68
Krümmer einbauen...68
Enddämpfer ausbauen...69
Enddämpfer einbauen...69
Glasfasergarnfüllung des Enddämpfers wechseln...69
06/LUFTFILTER...71
Luftfilterkastendeckel ausbauen...71
Luftfilterkastendeckel einbauen...71
Luftfilter ausbauen...71
Luftfilter einbauen...71
Luftfilter und Luftfilterkasten reinigen...72
07/KRAFTSTOFFTANK, SITZBANK, VERKLEIDUNG...73
Tankverschluss öffnen...73
Tankverschluss schließen...73
Sitzbank abnehmen...73
Sitzbank montieren...74
Kraftstofftank ausbauen...74
Kraftstofftank einbauen...75
Kraftstoffsieb wechseln...76
Kraftstofffilter wechseln...77
Kraftstoffpumpe wechseln...79
Kraftstoffdruck kontrollieren...80
08/MASKE, KOTFLÜGEL...82
Kotflügel vorne ausbauen...82
Kotflügel vorne einbauen...82
Scheinwerfermaske mit Scheinwerfer ausbauen...82
Scheinwerfermaske mit Scheinwerfer einbauen...82
09/VORDERRAD...84
Vorderrad ausbauen...84
Vorderrad einbauen...84
Bremsscheiben kontrollieren...85
Bremsscheibe der Vorderradbremse ausbauen...85
Bremsscheibe der Vorderradbremse einbauen...86
Reifenzustand kontrollieren...86
Reifenluftdruck kontrollieren...86
Speichenspannung kontrollieren...87
10/HINTERRAD...88
Hinterrad ausbauen...88
Hinterrad einbauen...88
Bremsscheibe der Hinterradbremse ausbauen...89
Bremsscheibe der Hinterradbremse einbauen...89
Kettenspannung kontrollieren...89
Kettenspannung einstellen...90
Kettenführung einstellen...91
Kette, Kettenrad, Kettenritzel und Kettenführung kontrollieren...91
Kettenverschmutzung kontrollieren...93
Kette reinigen...93
11/KABELSTRANG, BATTERIE...94
Hauptsicherung ausbauen...94
Hauptsicherung einbauen...94
Sicherungen der einzelnen Stromverbraucher wechseln...94
Sicherung des Kühlerlüfters wechseln (EXC-F SIX DAYS)...95
Batterie ausbauen...96
Batterie einbauen...96
Batterie laden...96
13/BREMSANLAGE...98
Bremsbeläge der Vorderradbremse kontrollieren...98
Bremsbeläge der Vorderradbremse wechseln...98
Leerweg am Handbremshebel kontrollieren...100
Grundstellung des Handbremshebels einstellen (XCF‑W)...100
Leerweg des Handbremshebels einstellen (alle EXC‑F Modelle)...100
Bremsflüssigkeitsstand der Vorderradbremse kontrollieren...101
Bremsflüssigkeit der Vorderradbremse nachfüllen...101
Bremsflüssigkeit der Vorderradbremse wechseln...102
Bremsbeläge der Hinterradbremse kontrollieren...103
Bremsbeläge der Hinterradbremse wechseln...103
Leerweg am Fußbremshebel kontrollieren...105
Grundstellung des Fußbremshebels einstellen...105
Bremsflüssigkeitsstand der Hinterradbremse kontrollieren...106
Bremsflüssigkeit der Hinterradbremse nachfüllen...106
Bremsflüssigkeit der Hinterradbremse wechseln...107
14/LICHTANLAGE, INSTRUMENTE...109
Tachofunktionen einstellen...109
Kilometer oder Meilen einstellen...109
Zusatzfunktionen aktivieren...110
Radumfang einstellen...110
Uhrzeit einstellen...111
Scheinwerfereinstellung kontrollieren...111
Leuchtweite des Scheinwerfers einstellen...112
30/MOTOR...113
Motor ausbauen...113
Motor einbauen...117
30/MOTOR ZERLEGEN...122
Vorbereitung...122
Kupplungsdruckstange ausbauen...122
Distanzbuchse ausbauen...122
Motoröl ablassen...122
Ölfilter ausbauen...123
Zündkerze ausbauen...123
Ventildeckel ausbauen...123
Kickstarter ausbauen...124
Generatordeckel ausbauen...124
Drehmomentbegrenzer ausbauen...124
Motor auf Zünd-OT stellen...125
Steuerkettenspanner ausbauen...125
Nockenwelle ausbauen...125
Zylinderkopf ausbauen...126
Kolben ausbauen...126
Startertrieb ausbauen...127
Saugpumpe ausbauen...128
Wasserpumpenrad ausbauen...129
Kupplungsdeckel ausbauen...129
Kupplungslamellen ausbauen...129
Kupplungskorb ausbauen...130
Kickstarterwelle ausbauen...131
Kickstarterzwischenrad ausbauen...131
Schaltwelle ausbauen...131
Schaltarretierung ausbauen...131
Arretierhebel ausbauen...131
Druckpumpe ausbauen...132
Primärrad ausbauen...132
Steuerkette ausbauen...133
Distanzbuchse ausbauen...133
Motorgehäuse links ausbauen...133
Schaltschienen ausbauen...134
Schaltwalze ausbauen...134
Schaltgabeln ausbauen...134
Getriebewellen ausbauen...134
Kurbelwelle ausbauen...135
30/MOTOR - ARBEITEN AN DEN EINZELNEN TEILEN...136
Arbeiten an der rechten Motorgehäusehälfte...136
Arbeiten an der linken Motorgehäusehälfte...137
Arbeiten am Kupplungsdeckel...138
Öldruckregelventil kontrollieren...139
Schmiersystem kontrollieren...140
Kurbelwellenlager-Innenring ausbauen...140
Kurbelwellenlager-Innenring einbauen...140
Pleuel, Pleuellager und Hubzapfen wechseln...141
Kurbelwellenschlag am Lagerzapfen kontrollieren...142
Antriebsrad der Ausgleichswelle ausbauen...142
Antriebsrad der Ausgleichswelle einbauen...142
Zylinder - Nikasil®-beschichtung...143
Zylinder kontrollieren/vermessen...143
Kolben kontrollieren/vermessen...143
Kolben/Zylinder - Einbauspiel ermitteln...144
Kolbenring-Stoßspiel kontrollieren...144
Nockenwellenlager wechseln...145
Nockenwellen kontrollieren...145
Lagerstellen der Nockenwellen kontrollieren...145
Ventile ausbauen...146
Ventile kontrollieren...147
Ventilfedern kontrollieren...148
Ventilfederauflage kontrollieren...148
Schlepphebel kontrollieren...148
Zylinderkopf kontrollieren...148
Ventile einbauen...149
Freilauf kontrollieren...150
Kickstarterwelle vormontieren...150
E-Startertrieb kontrollieren...152
Steuertrieb kontrollieren...153
Steuerkettenspanner für den Einbau vorbereiten...153
Kupplung kontrollieren...154
Schaltung kontrollieren...155
Schaltwelle vormontieren...156
Antriebswelle zerlegen...157
Abtriebswelle zerlegen...157
Getriebe kontrollieren...158
Antriebswelle zusammenbauen...159
Abtriebswelle zusammenbauen...160
30/MOTOR ZUSAMMENBAUEN...161
Kurbelwelle einbauen...161
Getriebewellen einbauen...161
Schaltgabeln einbauen...161
Schaltwalze einbauen...162
Schaltschienen einbauen...162
Motorgehäuse links einbauen...162
Distanzbuchse einbauen...163
Steuerkette einbauen...163
Primärrad einbauen...164
Druckpumpe einbauen...164
Saugpumpe einbauen...165
Arretierhebel einbauen...166
Schaltarretierung einbauen...166
Schaltwelle einbauen...166
Kickstarterzwischenrad einbauen...166
Kickstarterwelle einbauen...166
Kupplungskorb einbauen...167
Kupplungslamellen einbauen...168
Kupplungsdeckel einbauen...169
Wasserpumpendeckel einbauen...169
Startertrieb einbauen...170
Kolben einbauen...171
Zylinderkopf einbauen...172
Nockenwellen einbauen...173
Steuerzeit kontrollieren...174
Steuerzeit einstellen...174
Steuerkettenspanner einbauen...175
Ventilspiel kontrollieren...176
Ventilspiel einstellen...177
Drehmomentbegrenzer einbauen...177
Generatordeckel einbauen...177
Kickstarter einbauen...178
Ventildeckel einbauen...178
Zündkerze einbauen...179
Ölfilter einbauen...179
Ölsieb einbauen...179
Distanzbuchse einbauen...180
Kupplungsdruckstange einbauen...180
Motor vom Montagebock nehmen...180
32/KUPPLUNG...181
Flüssigkeitsstand der hydraulischen Kupplung kontrollieren...181
Flüssigkeit der hydraulischen Kupplung wechseln...181
35/WASSERPUMPE, KÜHLSYSTEM...183
Kühlsystem...183
Frostschutz und Kühlflüssigkeitsstand kontrollieren...183
Kühlflüssigkeitsstand kontrollieren...184
Kühlflüssigkeit ablassen...184
Kühlflüssigkeit einfüllen...185
38/SCHMIERSYSTEM...186
Ölkreislauf...186
Motorölstand kontrollieren...186
Motoröl und Ölfilter wechseln, Ölsieb reinigen...187
Motoröl nachfüllen...189
Motoröldruck kontrollieren...189
39/ZÜNDANLAGE...191
Zündspule - Sekundärwicklung kontrollieren...191
Zündkerzenstecker kontrollieren...191
Generator - Statorwicklung kontrollieren...191
Stator und Impulsgeber ausbauen...192
Stator und Impulsgeber einbauen...193
40/ELEKTROSTARTER...194
Startermotor kontrollieren...194
41/DROSSELKLAPPENKÖRPER...195
Drosselklappensensor Kreis A - Grundeinstellung kontrollieren...195
Drosselklappensensor - Grundeinstellung einstellen...195
TECHNISCHE DATEN - MOTOR...197
Füllmenge - Motoröl...197
Füllmenge - Kühlflüssigkeit...197
TECHNISCHE DATEN - TOLERANZ, VERSCHLEIßGRENZEN MOTOR...198
TECHNISCHE DATEN - ANZUGSDREHMOMENTE MOTOR...199
TECHNISCHE DATEN - FAHRGESTELL...201
Lampenbestückung...202
Reifen...202
Füllmenge - Kraftstoff...202
TECHNISCHE DATEN - GABEL...203
TECHNISCHE DATEN - FEDERBEIN...204
TECHNISCHE DATEN - ANZUGSDREHMOMENTE FAHRGESTELL...205
REINIGUNG, PFLEGE...206
Motorrad reinigen...206
Kontroll- und Pflegearbeiten für den Winterbetrieb...207
LAGERUNG...208
Lagerung...208
Inbetriebnahme nach der Lagerung...208
SERVICEPLAN...209
Serviceplan...209
Servicearbeiten (als Zusatzauftrag)...210
SCHALTPLAN...211
Seite 1 von 8 (EXC‑F EU, EXC-F SIX DAYS)...211
Seite 2 von 8 (EXC‑F EU, EXC-F SIX DAYS)...213
Seite 3 von 8 (EXC‑F EU, EXC-F SIX DAYS)...215
Seite 4 von 8 (EXC‑F EU, EXC-F SIX DAYS)...217
Seite 5 von 8 (EXC‑F EU, EXC-F SIX DAYS)...219
Seite 6 von 8 (EXC‑F EU, EXC-F SIX DAYS)...221
Seite 7 von 8 (EXC‑F EU, EXC-F SIX DAYS)...223
Seite 8 von 8 (EXC‑F EU, EXC-F SIX DAYS)...225
Seite 1 von 8 (EXC‑F AUS)...227
Seite 2 von 8 (EXC‑F AUS)...229
Seite 3 von 8 (EXC‑F AUS)...231
Seite 4 von 8 (EXC‑F AUS)...233
Seite 5 von 8 (EXC‑F AUS)...235
Seite 6 von 8 (EXC‑F AUS)...237
Seite 7 von 8 (EXC‑F AUS)...239
Seite 8 von 8 (EXC‑F AUS)...241
Seite 1 von 8 (EXC-F USA)...243
Seite 2 von 8 (EXC-F USA)...245
Seite 3 von 8 (EXC-F USA)...247
Seite 4 von 8 (EXC-F USA)...249
Seite 5 von 8 (EXC-F USA)...251
Seite 6 von 8 (EXC-F USA)...253
Seite 7 von 8 (EXC-F USA)...255
Seite 8 von 8 (EXC-F USA)...257
Seite 1 von 7 (XCF‑W)...259
Seite 2 von 7 (XCF‑W)...261
Seite 3 von 7 (XCF‑W)...263
Seite 4 von 7 (XCF‑W)...265
Seite 5 von 7 (XCF‑W)...267
Seite 6 von 7 (XCF‑W)...269
Seite 7 von 7 (XCF‑W)...271
BETRIEBSSTOFFE...273
HILFSSTOFFE...275
SPEZIALWERKZEUGE...277
NORMEN...290
INDEXVERZEICHNIS...291
A...291
B...291
D...291
E...291
F...291
G...291
H...291
I...292
K...292
L...292
M...292
O...293
P...293
R...293
S...293
T...294
U...294
V...294
W...294
Z...294
EN...296
MEANS OF REPRESENTATION...303
IMPORTANT NOTES...304
SERIAL NUMBERS...305
Chassis number...305
Type label...305
Key number (All EXC‑F models)...305
Engine number...306
Fork part number...306
Shock absorber part number...306
MOTORCYCLE...307
Raising the motorcycle with the lift stand...307
Removing the motorcycle from the lift stand...307
Starting...307
Starting the motorcycle for a check...308
01/FORK, TRIPLE CLAMP...309
Adjusting the compression damping of the fork...309
Adjusting the rebound damping of the fork...309
Adjusting the spring preload of the fork...309
Bleeding fork legs...310
Cleaning the dust boots of the fork legs...310
Loosening the fork protector...311
Positioning the fork protection...311
Removing the fork legs...311
Installing the fork legs...312
Removing the fork protector...313
Installing the fork protector...313
Performing a fork service...313
Disassembling the fork legs...314
Cartridge disassembly...317
Disassembling the compression damping fitting...318
Checking the fork legs...319
Assembling the compression damping fitting...320
Assembling the cartridge...321
Assembling the fork legs...323
Greasing the steering head bearing...327
Removing the lower triple clamp (EXC-F SIX DAYS)...327
Installing the lower triple clamp (EXC-F SIX DAYS)...328
Removing the lower triple clamp (EXC‑F EU/AUS/USA, XCF‑W)...329
Installing the lower triple clamp (EXC‑F EU/AUS/USA, XCF‑W)...330
Checking the steering head bearing play...332
Adjusting the play of the steering head bearing (EXC-F SIX DAYS)...332
Adjusting the play of the steering head bearing (EXC‑F EU/AUS/USA, XCF‑W)...333
02/HANDLEBAR, INSTRUMENTS...334
Handlebar position...334
Adjusting handlebar position...334
Adjusting the basic position of the clutch lever...334
Checking the throttle cable routing...335
Checking the play in the throttle cable...335
Adjusting the play in the throttle cable...336
03/FRAME...337
Removing the engine guard (EXC‑F AUS, EXC-F SIX DAYS)...337
Installing the engine guard (EXC‑F AUS, EXC-F SIX DAYS)...337
04/SHOCK ABSORBER, SWINGARM...338
Adjusting the high-speed compression damping of the shock absorber...338
Adjusting the low-speed compression damping of the shock absorber...338
Adjusting the rebound damping of the shock absorber...339
Measuring rear wheel sag unloaded...339
Checking the static sag of the shock absorber...339
Checking the riding sag of the shock absorber...340
Adjusting the spring preload of the shock absorber...340
Adjusting the riding sag...341
Removing the shock absorber...341
Installing the shock absorber...341
Servicing the shock absorber...342
Removing the spring...342
Disassembling the damper...343
Disassembling the piston rod...344
Disassembling the seal ring retainer...345
Replacing the pilot bushing...346
Checking the damper...347
Disassembling the rebound adjuster...347
Removing the heim joint...348
Installing the heim joint...349
Assembling the rebound adjuster...350
Assembling the seal ring retainer...350
Assembling the piston rod...351
Assembling the damper...352
Bleeding and filling the damper...355
Filling the damper with nitrogen...357
Installing the spring...358
Changing the heim joint...359
05/EXHAUST...361
Removing the manifold...361
Installing the manifold...361
Removing main silencer...362
Installing the main silencer...362
Changing the glass fiber yarn filling of the main silencer...362
06/AIR FILTER...364
Removing the air filter box lid...364
Installing the air filter box lid...364
Removing the air filter...364
Installing the air filter...364
Cleaning the air filter and air filter box...365
07/FUEL TANK, SEAT, TRIM...366
Opening filler cap...366
Closing filler cap...366
Removing the seat...366
Mounting the seat...367
Removing the fuel tank...367
Installing the fuel tank...368
Changing the fuel screen...369
Changing the fuel filter...370
Changing the fuel pump...372
Checking the fuel pressure...373
08/MASK, FENDER...375
Removing the front fender...375
Installing the front fender...375
Removing headlight mask with headlight...375
Refitting the headlight mask with the headlight...375
09/FRONT WHEEL...377
Removing the front wheel...377
Installing the front wheel...377
Checking the brake discs...378
Removing the front brake disc...378
Installing the front brake disc...379
Checking the tire condition...379
Checking tire air pressure...379
Checking spoke tension...380
10/REAR WHEEL...381
Removing the rear wheel...381
Installing the rear wheel...381
Removing the rear brake disc...382
Installing the rear brake disc...382
Checking the chain tension...382
Adjusting the chain tension...383
Adjusting the chain guide...384
Checking the chain, rear sprocket, engine sprocket and chain guide...384
Checking for chain dirt accumulation...386
Cleaning the chain...386
11/WIRING HARNESS, BATTERY...387
Removing the main fuse...387
Installing the main fuse...387
Changing the fuses of individual power consumers...387
Changing the fuse of the radiator fan (EXC-F SIX DAYS)...388
Removing the battery...389
Installing the battery...389
Charging the battery...389
13/BRAKE SYSTEM...391
Checking the front brake linings...391
Changing the front brake linings...391
Checking free travel of hand brake lever...393
Adjusting the basic position of the hand brake lever (XCF‑W)...393
Adjusting free travel of hand brake lever (All EXC‑F models)...393
Checking the front brake fluid level...394
Adding front brake fluid...394
Changing the front brake fluid...395
Checking the rear brake linings...396
Changing the rear brake linings...396
Checking the free travel of foot brake lever...398
Adjusting the basic position of the foot brake lever...398
Checking the rear brake fluid level...399
Adding brake fluid to the rear brake circuit...399
Changing the rear brake fluid...400
14/LIGHTING SYSTEM, INSTRUMENTS...402
Adjusting the speedometer functions...402
Setting kilometers or miles...402
Activating the additional functions...403
Setting the wheel circumference...403
Setting the clock...404
Checking the headlight setting...404
Adjusting the headlight range...405
30/ENGINE...406
Removing the engine...406
Installing the engine...410
30/DISASSEMBLING THE ENGINE...415
Preparations...415
Removing the clutch push rod...415
Removing the spacer...415
Draining the engine oil...415
Removing the oil filter...416
Removing the spark plug...416
Removing the valve cover...416
Removing the kick starter...417
Removing the alternator cover...417
Removing the torque limiter...417
Positioning the engine at ignition top dead center...418
Removing the timing chain tensioner...418
Removing the camshaft...418
Removing the cylinder head...419
Removing the piston...419
Removing the starter drive...420
Removing the suction pump...421
Removing the water pump wheel...422
Removing the clutch cover...422
Removing the clutch discs...422
Removing the outer clutch hub...423
Removing the intermediate kick starter gear...424
Removing the intermediate kick starter gear...424
Removing the shift shaft...424
Removing the shift drum locating unit...424
Removing the locking lever...424
Removing the force pump...425
Removing the primary gear...425
Removing the timing chain...426
Removing the spacer...426
Removing the left section of the engine case...426
Removing the shift rails...427
Removing the shift drum...427
Removing the shift forks...427
Removing the transmission shafts...427
Removing the crankshaft...428
30/ENGINE - WORK ON THE INDIVIDUAL PARTS...429
Work on the right section of the engine case...429
Working on the left section of the engine case...430
Work on the clutch cover...431
Checking the oil pressure regulator valve...432
Checking the lubrication system...433
Removing the crankshaft bearing inner race...433
Installing the crankshaft bearing inner race...433
Changing the connecting rod, conrod bearing and crank pin...434
Checking the crankshaft run-out at the bearing pin...435
Removing the drive wheel of the balancer shaft...435
Installing the drive wheel of the balancer shaft...435
Cylinder - Nikasil® coating...436
Checking/measuring the cylinder...436
Checking/measuring the piston...436
Measuring the piston/cylinder mounting clearance...437
Checking the piston ring...437
Changing the camshaft bearing...438
Checking the camshafts...438
Checking the pivot points of the camshafts...438
Removing the valves...439
Checking the valves...440
Checking the valve springs...441
Checking the valve spring seat...441
Checking the cam levers...441
Checking the cylinder head...441
Installing the valves...442
Checking the freewheel...443
Preassembling the kick starter shaft...443
Checking the electric starter drive...444
Checking the timing assembly...445
Preparing the timing chain tensioner for installation...446
Checking the clutch...446
Checking the shift mechanism...448
Preassembling the shift shaft...449
Disassembling the main shaft...449
Disassembling the countershaft...450
Checking the transmission...450
Assembling the main shaft...452
Assembling the countershaft...452
30/ENGINE ASSEMBLY...454
Installing the crankshaft...454
Installing the transmission shafts...454
Installing the shift forks...454
Installing the shift drum...455
Installing the shift rails...455
Installing the left engine case...455
Installing the spacer...456
Installing the timing chain...456
Installing the primary gear...457
Installing the force pump...457
Installing the suction pump...458
Installing the locking lever...459
Installing the shift drum locating unit...459
Installing the shift shaft...459
Installing the intermediate kick starter gear...459
Installing the kick starter shaft...459
Installing the outer clutch hub...460
Installing the clutch discs...461
Installing the clutch cover...462
Installing the water pump cover...462
Installing the starter drive...463
Installing the piston...464
Installing the cylinder head...465
Installing the camshafts...466
Checking the valve timing...467
Adjusting the valve timing...467
Installing the timing chain tensioner...468
Checking the valve clearance...469
Adjusting the valve clearance...470
Installing the torque limiter...470
Installing the alternator cover...470
Installing the kick starter...471
Installing the valve cover...471
Installing the spark plug...472
Installing the oil filter...472
Installing the oil screen...472
Installing the spacer...473
Installing the clutch push rod...473
Removing the engine from the work stand...473
32/CLUTCH...474
Checking the fluid level of the hydraulic clutch...474
Changing the hydraulic clutch fluid...474
35/WATER PUMP, COOLING SYSTEM...475
Cooling system...475
Checking the antifreeze and coolant level...475
Checking the coolant level...476
Draining the coolant...476
Refilling coolant...477
38/LUBRICATION SYSTEM...478
Oil circuit...478
Checking the engine oil level...478
Changing the engine oil and oil filter, cleaning the oil screen...479
Adding engine oil...481
Checking the engine oil pressure...481
39/IGNITION SYSTEM...483
Ignition coil - checking the secondary winding...483
Checking the spark plug connector...483
Alternator - checking the stator winding...483
Removing the stator and ignition pulse generator...484
Installing the stator and ignition pulse generator...485
40/ELECTRIC STARTER...486
Checking the starter motor...486
41/THROTTLE VALVE BODY...487
Throttle position sensor circuit A - checking the basic settings...487
Throttle position sensor - adjusting the basic settings...487
TECHNICAL DATA - ENGINE...489
Capacity - engine oil...489
Capacity - coolant...489
TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE...490
TECHNICAL DATA - ENGINE TIGHTENING TORQUES...491
TECHNICAL DATA - CHASSIS...493
Lighting equipment...494
Tires...494
Capacity - fuel...494
TECHNICAL DATA - FORK...495
TECHNICAL DATA - SHOCK ABSORBER...496
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES...497
CLEANING, CARE...498
Cleaning the motorcycle...498
Checks and maintenance steps for winter operation...499
STORAGE...500
Storage...500
Preparing for use after storage...500
SERVICE SCHEDULE...501
Service schedule...501
Service work (as additional order)...502
WIRING DIAGRAM...503
Page 1 of 8 (EXC‑F EU, EXC-F SIX DAYS)...503
Page 2 of 8 (EXC‑F EU, EXC-F SIX DAYS)...505
Page 3 of 8 (EXC‑F EU, EXC-F SIX DAYS)...507
Page 4 of 8 (EXC‑F EU, EXC-F SIX DAYS)...509
Page 5 of 8 (EXC‑F EU, EXC-F SIX DAYS)...511
Page 6 of 8 (EXC‑F EU, EXC-F SIX DAYS)...513
Page 7 of 8 (EXC‑F EU, EXC-F SIX DAYS)...515
Page 8 of 8 (EXC‑F EU, EXC-F SIX DAYS)...517
Page 1 of 8 (EXC‑F AUS)...519
Page 2 of 8 (EXC‑F AUS)...521
Page 3 of 8 (EXC‑F AUS)...523
Page 4 of 8 (EXC‑F AUS)...525
Page 5 of 8 (EXC‑F AUS)...527
Page 6 of 8 (EXC‑F AUS)...529
Page 7 of 8 (EXC‑F AUS)...531
Page 8 of 8 (EXC‑F AUS)...533
Page 1 of 8 (EXC-F USA)...535
Page 2 of 8 (EXC-F USA)...537
Page 3 of 8 (EXC-F USA)...539
Page 4 of 8 (EXC-F USA)...541
Page 5 of 8 (EXC-F USA)...543
Page 6 of 8 (EXC-F USA)...545
Page 7 of 8 (EXC-F USA)...547
Page 8 of 8 (EXC-F USA)...549
Page 1 of 7 (XCF‑W)...551
Page 2 of 7 (XCF‑W)...553
Page 3 of 7 (XCF‑W)...555
Page 4 of 7 (XCF‑W)...557
Page 5 of 7 (XCF‑W)...559
Page 6 of 7 (XCF‑W)...561
Page 7 of 7 (XCF‑W)...563
SUBSTANCES...565
AUXILIARY SUBSTANCES...567
SPECIAL TOOLS...569
STANDARDS...582
INDEX...583
A...583
B...583
C...583
E...583
F...584
H...585
I...585
K...585
L...585
M...585
O...585
P...585
R...585
S...585
T...586
W...586
ES...588
MEDIOS DE REPRESENTACIÓN...595
ADVERTENCIAS IMPORTANTES...596
NÚMEROS DE SERIE...598
Número de chasis...598
Placa de características...598
Número de la llave (Todos los modelos EXC-F)...598
Número del motor...599
Referencia de la horquilla...599
Referencia del amortiguador...599
MOTOCICLETA...600
Levantar la motocicleta con un caballete elevador...600
Bajar la motocicleta del caballete elevador...600
Arrancar el motor...600
Arrancar la motocicleta para controlarla...601
01/HORQUILLA, TIJA HORQUILLA...602
Ajustar la amortiguación de la compresión de la horquilla...602
Ajustar la amortiguación de la extensión de la horquilla...602
Ajustar el pretensado del muelle de la horquilla...603
Purgar el aire de las botellas de la horquilla...603
Limpiar los manguitos guardapolvo de las botellas de la horquilla...603
Soltar el protector de la horquilla...604
Colocar el protector de la horquilla en su posición...604
Desmontar las botellas de la horquilla...604
Montar las botellas de la horquilla...605
Desmontar el protector de la horquilla...606
Montar el protector de la horquilla...606
Realizar el mantenimiento de la horquilla...606
Desarmar las botellas de la horquilla...607
Desarmar el cartucho...610
Desarmar el asiento del nivel de compresión...611
Controlar las botellas de la horquilla...612
Ensamblar el asiento del nivel de compresión...613
Ensamblar el cartucho...614
Ensamblar las botellas de la horquilla...616
Engrasar el cojinete de la pipa de la dirección...620
Desmontar la tija inferior de la horquilla (EXC-F SIX DAYS)...620
Montar la tija inferior de la horquilla (EXC-F SIX DAYS)...621
Desmontar la tija inferior de la horquilla (EXC‑F EU/AUS/USA, XCF‑W)...622
Montar la tija inferior de la horquilla (EXC‑F EU/AUS/USA, XCF‑W)...623
Controlar la holgura del cojinete de la pipa de la dirección...625
Ajustar la holgura del cojinete de la pipa de la dirección (EXC-F SIX DAYS)...625
Ajustar la holgura del cojinete de la pipa de la dirección (EXC‑F EU/AUS/USA, XCF‑W)...626
02/MANILLAR, VÁLVULAS...627
Posición del manillar...627
Ajustar la posición del manillar...627
Ajustar la posición básica de la maneta del embrague...628
Controlar el tendido del cable bowden del acelerador...628
Controlar la holgura del cable bowden del acelerador...629
Ajustar la holgura del cable bowden del acelerador...629
03/CHASIS...630
Desmontar el protector del motor (EXC‑F AUS, EXC-F SIX DAYS)...630
Montar el protector del motor (EXC‑F AUS, EXC-F SIX DAYS)...630
04/AMORTIGUADOR, BASCULANTE...631
Ajustar la amortiguación de la compresión High Speed del amortiguador...631
Ajustar la amortiguación de la compresión Low Speed del amortiguador...631
Ajustar la amortiguación de la extensión del amortiguador...632
Determinar la cota con la rueda trasera descargada...632
Controlar el recorrido estático de la suspensión...632
Controlar el recorrido de la suspensión con conductor...633
Ajustar el pretensado del muelle del amortiguador...633
Ajustar el recorrido de la suspensión con conductor...634
Desmontar el amortiguador...634
Montar el amortiguador...634
Realizar el mantenimiento del amortiguador...635
Desmontar el muelle...635
Desarmar el amortiguador...636
Desarmar el vástago del émbolo...637
Desarmar el soporte del anillo de hermetizado...638
Sustituir el casquillo guía...639
Controlar el amortiguador...640
Desarmar el reglaje del nivel de extensión...640
Desmontar el cojinete giratorio...641
Montar el cojinete giratorio...642
Ensamblar el reglaje del nivel de extensión...643
Ensamblar el soporte del anillo de hermetizado...643
Ensamblar el vástago del émbolo...644
Ensamblar el amortiguador...645
Purgar y llenar el amortiguador...648
Llenar el amortiguador con nitrógeno...650
Montar el muelle...651
Sustituir el cojinete giratorio...652
05/SISTEMA DE ESCAPE...654
Desmontaje del colector...654
Montar el colector...654
Desmontar el silenciador...655
Montar el silenciador...655
Sustituir el relleno de fibra de vidrio del silenciador...655
06/FILTRO DE AIRE...657
Desmontar la tapa de la caja del filtro de aire...657
Montar la tapa de la caja del filtro de aire...657
Desmontar el filtro de aire...657
Montar el filtro de aire...657
Limpiar el filtro de aire y la caja del filtro de aire...658
07/DEPÓSITO, ASIENTO, CARENADO...659
Abrir el tapón del depósito de combustible...659
Cerrar el tapón del depósito de combustible...659
Desmontar el asiento...659
Montar el asiento...660
Desmontar el depósito de combustible...660
Montar el depósito de combustible...661
Sustituir el tamiz de combustible...662
Cambio del filtro de combustible...663
Sustituir la bomba de combustible...665
Controlar la presión del combustible...666
08/SOPORTE FARO, GUARDABARROS...668
Desmontar el guardabarros delantero...668
Montar el guardabarros delantero...668
Desmontar la cubierta del faro con el faro...668
Montar la cubierta del faro con el faro...668
09/RUEDA DELANTERA...670
Desmontar la rueda delantera...670
Montar la rueda delantera...670
Controlar los discos de freno...671
Desmontar el disco de freno del freno delantero...671
Montar el disco de freno del freno delantero...672
Controlar el estado de los neumáticos...672
Controlar la presión de inflado de los neumáticos...672
Controlar la tensión de los radios...673
10/RUEDA TRASERA...674
Desmontar la rueda trasera...674
Montar la rueda trasera...674
Desmontar el disco de freno del freno trasero...675
Montar el disco de freno del freno trasero...675
Controlar la tensión de la cadena...675
Ajustar la tensión de la cadena...676
Ajustar la guía de la cadena...677
Controlar la cadena y la corona, el piñón y la guía de la cadena...677
Controlar la suciedad de la cadena...679
Limpiar la cadena...679
11/MAZO DE CABLES, BATERÍA...681
Desmontar el fusible principal...681
Montar el fusible principal...681
Sustituir los fusibles de los distintos consumidores eléctricos...681
Sustituir el fusible del ventilador del radiador (EXC-F SIX DAYS)...682
Desmontar la batería...683
Montar la batería...683
Recargar la batería...683
13/EQUIPO DE FRENOS...685
Controlar las pastillas del freno de la rueda delantera...685
Sustituir las pastillas del freno delantero...685
Controlar la carrera en vacío de la maneta del freno de mano...687
Ajustar la posición básica de la maneta del freno de mano (XCF‑W)...687
Ajustar la carrera en vacío de la maneta del freno de mano (Todos los modelos EXC-F)...687
Comprobar el nivel de líquido de frenos en el freno delantero...688
Completar el líquido de frenos de la rueda delantera...688
Sustituir el líquido de frenos del freno delantero...689
Controlar las pastillas del freno de la rueda trasera...690
Sustituir las pastillas del freno trasero...690
Controlar la carrera en vacío del pedal del freno...692
Ajustar la posición básica del pedal del freno...692
Controlar el nivel de líquido de frenos en el freno trasero...693
Completar el líquido de frenos en el freno de la rueda trasera...693
Sustituir el líquido del freno trasero...694
14/EQUIPO DE LUCES, INSTRUMENTOS...696
Ajustar las funciones del velocímetro...696
Ajuste de kilómetros o millas...696
Activar las funciones adicionales...697
Ajustar el perímetro de la rueda...697
Ajustar la hora...698
Controlar el ajuste del faro...698
Ajustar la distancia de alumbrado del faro...699
30/MOTOR...700
Desmontar el motor...700
Montar el motor...704
30/DESARMAR EL MOTOR...709
Preparativos...709
Desmontar el vástago de presión del embrague...709
Desmontar el casquillo distanciador...709
Vaciar el aceite del motor...709
Desmontar el filtro de aceite...710
Desmontar la bujía...710
Desmontar la tapa de las válvulas...710
Desmontar el pedal de arranque...711
Desmontar la tapa del alternador...711
Desmontar el limitador de par...711
Colocar el motor en el PMS de encendido...712
Desmontar el tensor de la cadena de distribución...712
Desmontar el árbol de levas...712
Desmontar la culata...713
Desmontar el pistón...713
Desmontar el mecanismo de arranque...714
Desmontar la bomba de aspiración...715
Desmontar el rodete de la bomba de agua...716
Desmontar la tapa del embrague...716
Desmontar los discos del embrague...716
Desmontar la jaula del embrague...717
Desmontar el árbol del pedal de arranque...718
Desmontar el piñón intermedio del pedal de arranque...718
Desmontar el árbol de mando del cambio...718
Desmontar el dispositivo de bloqueo del cambio...718
Desmontar la palanca de enclavamiento...718
Desmontar la bomba de presión...719
Desmontar la corona primaria...719
Desmontar la cadena de distribución...720
Desmontar el casquillo distanciador...720
Desmontar la carcasa izquierda del motor...720
Desmontar las barras de cambio...721
Desmontar el barrilete selector...721
Desmontar las horquillas del cambio...721
Desmontar el árbol del cambio...721
Desmontar el cigüeñal...722
30/MOTOR - TRAB. EN COMPONENTES...723
Trabajos en la semicarcasa derecha del motor...723
Trabajos en la semicarcasa izquierda del motor...724
Trabajos en la tapa del embrague...725
Controlar la válvula de regulación de la presión del aceite...726
Controlar el sistema de lubricación...727
Desmontar el aro interior del cojinete del cigüeñal...727
Montar el aro interior del cojinete del cigüeñal...728
Sustituir la biela, el cojinete de la biela y el gorrón elevador...728
Controlar el alabeo en el gorrón del cigüeñal...729
Desmontar el piñón de accionamiento del árbol de compensación...730
Montar el piñón de accionamiento del árbol de compensación...730
Cilindro - Recubrimiento de Nikasil®...730
Controlar/medir el cilindro...730
Controlar/medir el pistón...731
Pistón/cilindro - Determinar el juego inicial...732
Controlar la holgura de la junta del segmento del pistón...732
Sustituir el cojinete del árbol de levas...732
Controlar los árboles de levas...733
Controlar los puntos de apoyo de los árboles de levas...733
Desmontar las válvulas...734
Controlar las válvulas...735
Controlar los muelles de las válvulas...735
Controlar el platillo de los muelles de las válvulas...735
Controlar el balancín de un solo brazo...736
Controlar la culata...736
Montar las válvulas...736
Controlar el piñón libre...737
Premontaje del árbol del pedal de arranque...738
Controlar el mecanismo del motor de arranque...739
Controlar el mando de las válvulas...740
Preparar el tensor de la cadena de distribución para el montaje...740
Controlar el embrague...741
Controlar el cambio...742
Premontar el árbol de mando del cambio...743
Desarmar el árbol primario...744
Desarmar el árbol secundario...744
Controlar la caja de cambios...745
Ensamblar el árbol primario...746
Ensamblar el árbol secundario...747
30/ENSAMBLAR EL MOTOR...748
Montar el cigüeñal...748
Montar el árbol del cambio...748
Montar las horquillas del cambio...748
Montar el barrilete selector...749
Montar las barras de cambio...749
Montar la carcasa izquierda del motor...749
Montar el casquillo distanciador...750
Montar la cadena de distribución...750
Montar la corona primaria...751
Montar la bomba de presión...751
Montar la bomba de aspiración...752
Montar la palanca de enclavamiento...753
Montar el dispositivo de bloqueo del cambio...753
Montar el árbol de mando del cambio...753
Montar el piñón intermedio del pedal de arranque...753
Montar el árbol del pedal de arranque...753
Montar la jaula del embrague...754
Montar los discos del embrague...755
Montar la tapa del embrague...756
Montar la tapa de la bomba de agua...756
Montar el mecanismo de arranque...757
Montar el pistón...758
Montar la culata...759
Montar los árboles de levas...760
Controlar el tiempo de mando...761
Ajustar el tiempo de mando...761
Montar el tensor de la cadena de distribución...762
Controlar el juego de las válvulas...763
Ajustar el juego de las válvulas...764
Montar el limitador de par...764
Montar la tapa del alternador...764
Montar el pedal de arranque...765
Montar la tapa de las válvulas...765
Montar la bujía...766
Montar el filtro de aceite...766
Montar el tamiz de aceite...766
Montar el casquillo distanciador...767
Montar el vástago de presión del embrague...767
Extraer el motor del caballete de montaje...767
32/EMBRAGUE...768
Controlar el nivel de líquido del embrague hidráulico...768
Cambiar el líquido del embrague hidráulico...768
35/BOMBA DE AGUA, REFRIGERACIÓN...770
Sistema de refrigeración...770
Controlar el nivel de líquido refrigerante y la protección anticongelante...770
Controlar el nivel de líquido refrigerante...771
Vaciar el líquido refrigerante...771
Llenar el líquido refrigerante...772
38/SISTEMA DE LUBRICACIÓN...773
Circuito de aceite...773
Controlar el nivel del aceite del motor...773
Cambiar el aceite del motor y el filtro de aceite, limpiar el tamiz de aceite...774
Completar el aceite del motor...776
Controlar la presión del aceite del motor...776
39/EQUIPO DE ENCENDIDO...778
Bobina de encendido - Controlar el devanado secundario...778
Controlar la pipa de la bujía...778
Controlar el devanado del estátor del alternador...778
Desmontar el estátor y el transmisor de impulsos...779
Montar el estátor y el transmisor de impulsos...780
40/ARRANCADOR ELÉCTRICO...781
Controlar el motor de arranque...781
41/CUERPO DE LA VÁLVULA DE MARIPOSA...782
Sensor de la válvula de mariposa circuito A - Controlar el reglaje básico...782
Sensor de la válvula de mariposa - Ajustar el reglaje básico...782
DATOS TÉCNICOS - MOTOR...784
Cantidad de llenado - Aceite del motor...784
Cantidad de llenado - Líquido refrigerante...785
DATOS TÉCNICOS - TOLERANCIAS, LÍMITES DESGASTE MOTOR...786
PARES DE APRIETE DEL MOTOR...787
DATOS TÉCNICOS - CHASIS...789
Bombillas...790
Neumáticos...790
Cantidad de llenado - Combustible...790
DATOS TÉCNICOS - HORQUILLA...791
DATOS TÉCNICOS - AMORTIGUADOR...792
PARES DE APRIETE DEL CHASIS...793
LIMPIEZA, MANTENIMIENTO...795
Limpiar la motocicleta...795
Trabajos de inspección y cuidado para el invierno...796
ALMACENAMIENTO...797
Almacenamiento...797
Puesta en servicio después de un periodo de inmovilización...797
PROGRAMA DE SERVICIO...798
Programa de servicio...798
Mantenimiento (con una orden de taller adicional)...799
ESQUEMA DE CONEXIONES...801
Página 1 de 8 (EXC‑F EU, EXC-F SIX DAYS)...801
Página 2 de 8 (EXC‑F EU, EXC-F SIX DAYS)...803
Página 3 de 8 (EXC‑F EU, EXC-F SIX DAYS)...805
Página 4 de 8 (EXC‑F EU, EXC-F SIX DAYS)...807
Página 5 de 8 (EXC‑F EU, EXC-F SIX DAYS)...809
Página 6 de 8 (EXC‑F EU, EXC-F SIX DAYS)...811
Página 7 de 8 (EXC‑F EU, EXC-F SIX DAYS)...813
Página 8 de 8 (EXC‑F EU, EXC-F SIX DAYS)...815
Página 1 de 8 (EXC‑F AUS)...817
Página 2 de 8 (EXC‑F AUS)...819
Página 3 de 8 (EXC‑F AUS)...821
Página 4 de 8 (EXC‑F AUS)...823
Página 5 de 8 (EXC‑F AUS)...825
Página 6 de 8 (EXC‑F AUS)...827
Página 7 de 8 (EXC‑F AUS)...829
Página 8 de 8 (EXC‑F AUS)...831
Página 1 de 8 (EXC-F USA)...833
Página 2 de 8 (EXC-F USA)...835
Página 3 de 8 (EXC-F USA)...837
Página 4 de 8 (EXC-F USA)...839
Página 5 de 8 (EXC-F USA)...841
Página 6 de 8 (EXC-F USA)...843
Página 7 de 8 (EXC-F USA)...845
Página 8 de 8 (EXC-F USA)...847
Página 1 de 7 (XCF‑W)...849
Página 2 de 7 (XCF‑W)...851
Página 3 de 7 (XCF‑W)...853
Página 4 de 7 (XCF‑W)...855
Página 5 de 7 (XCF‑W)...857
Página 6 de 7 (XCF‑W)...859
Página 7 de 7 (XCF‑W)...861
AGENTES DE SERVICIO...863
AGENTES AUXILIARES...865
HERRAMIENTAS ESPECIALES...867
NORMAS...880
ÍNDICES...881
A...881
B...881
C...881
D...881
E...882
F...882
G...883
H...883
L...883
M...883
N...883
P...883
R...884
S...884
T...884
V...884
FR...886
MODE DE REPRÉSENTATION...893
REMARQUES IMPORTANTES...894
NUMÉROS DE SÉRIE...896
Numéro de châssis...896
Plaque signalétique...896
Numéro de clé (toutes les EXC-F)...896
Numéro de moteur...897
Référence de la fourche...897
Référence de l'amortisseur...897
MOTO...898
Surélever la moto sur un socle réglable...898
Retirer la moto du socle réglable...898
Démarrage...898
Démarrer la moto à des fins de contrôle...899
01/FOURCHE, TÉ DE FOURCHE...900
Régler l'amortissement en compression de la fourche...900
Régler sur la fourche...900
Régler la prétension du ressort de la fourche...901
Purger les bras de fourche...901
Nettoyer les cache-poussières des bras de fourche...901
Démonter la protection de fourche...902
Positionner les protections de fourche...902
Déposer les bras de fourche...902
Monter les bras de fourche...903
Déposer la protection de fourche...904
Monter la protection de fourche...904
Exécuter l'entretien de la fourche...904
Démonter les bras de fourche...905
Désassembler la cartouche...908
Désassembler la douille de compression...909
Contrôler les bras de fourche...910
Assembler la douille de compression...911
Assembler la cartouche...912
Assembler les bras de fourche...914
Graisser le palier de la tête de direction...918
Déposer le té de fourche inférieur (EXC-F SIX DAYS)...918
Monter le té de fourche inférieur (EXC-F SIX DAYS)...919
Déposer le té de fourche inférieur (EXC‑F EU/AUS/USA, XCF‑W)...920
Monter le té de fourche inférieur (EXC‑F EU/AUS/USA, XCF‑W)...921
Contrôler le jeu de roulement de la tête de direction...923
Régler le jeu du palier de la tête de direction (EXC-F SIX DAYS)...923
Régler le jeu du palier de la tête de direction (EXC‑F EU/AUS/USA, XCF‑W)...924
02/GUIDON, INSTRUMENTS...925
Position du guidon...925
Régler la position du guidon...925
Régler la position de base du levier d'embrayage...925
Contrôler la pose du câble d'accélérateur...926
Contrôler le jeu du câble d'accélérateur...926
Régler le jeu du câble d'accélérateur...927
03/CADRE...928
Déposer la protection moteur (EXC‑F AUS, EXC-F SIX DAYS)...928
Poser la protection moteur (EXC‑F AUS, EXC-F SIX DAYS)...928
04/AMORTISSEUR, BRAS OSCILLANT...929
Régler l'amortissement en compression Grande Vitesse de l'amortisseur...929
Régler l'amortissement en compression Petite Vitesse de l'amortisseur...929
Régler l'amortissement de détente de l'amortisseur...930
Déterminer l'enfoncement à vide de la roue arrière...930
Vérifier l'enfoncement statique de l'amortisseur...931
Contrôler l'enfoncement en charge de l'amortisseur...931
Régler la prétension du ressort de l'amortisseur...931
Régler l'enfoncement en charge...932
Déposer l'amortisseur...933
Monter l'amortisseur...933
Procéder à l'entretien de l'amortisseur...933
Déposer le ressort...934
Démonter l'amortisseur...934
Démonter la tige de piston...936
Désassembler le support de joints...937
Remplacer la bague de guidage...938
Contrôler l'amortisseur...938
Désassembler le réglage à la détente...939
Déposer le palier de pivot...940
Poser le palier de pivot...940
Assembler le réglage à la détente...941
Assembler le support de joints...942
Remonter la tige de piston...942
Assembler l'amortisseur...944
Purger et remplir l'amortisseur...946
Remplir l'amortisseur d'azote...948
Poser le ressort...949
Remplacer le palier de pivot...950
05/ÉCHAPPEMENT...952
Déposer le collecteur...952
Poser le collecteur...952
Déposer le silencieux arrière...953
Monter le silencieux arrière...953
Remplacer la laine de roche du silencieux arrière...953
06/FILTRE À AIR...955
Déposer le couvercle de boîtier de filtre à air...955
Installer le couvercle de boîtier de filtre à air...955
Déposer le filtre à air...955
Remonter le filtre à air...955
Nettoyer le filtre à air et le boîtier du filtre à air...956
07/RÉSERVOIR, SELLE, HABILLAGE...957
Ouvrir le bouchon du réservoir...957
Fermer le bouchon du réservoir...957
Retirer la selle...957
Remonter la selle...958
Déposer le réservoir de carburant...958
Monter le réservoir de carburant...959
Remplacer la crépine à essence...960
Remplacer le filtre à carburant...961
Remplacer la pompe à carburant...963
Contrôler la pression de carburant...964
08/MASQUE, GARDE-BOUE...966
Déposer le garde-boue avant...966
Monter le garde-boue avant...966
Déposer la plaque-phare et le phare...966
Poser la plaque-phare et le phare...966
09/ROUE AVANT...968
Déposer la roue avant...968
Monter la roue avant...968
Contrôler les disques de frein...969
Déposer le disque de frein avant...969
Monter le disque de frein avant...970
Contrôler l'état des pneus...970
Contrôler la pression de l'air des pneus...970
Vérifier la tension des rayons...971
10/ROUE ARRIÈRE...972
Démonter la roue arrière...972
Monter la roue arrière...972
Déposer le disque de frein arrière...973
Poser le disque de frein arrière...973
Contrôler la tension de la chaîne...973
Régler la tension de chaîne...974
Régler le guide-chaîne...975
Inspecter la chaîne, la couronne, le pignon et le guide-chaîne...975
Vérifier l'état d'encrassement de la chaîne...977
Nettoyer la chaîne...977
11/FAISCEAU DE CÂBLES, BATTERIE...979
Enlever le fusible général...979
Monter le fusible général...979
Remplacer les fusibles des divers consommateurs...979
Remplacer le fusible du ventilateur du radiateur (EXC-F SIX DAYS)...980
Déposer la batterie...981
Poser la batterie...981
Charger la batterie...982
13/SYSTÈME DE FREINAGE...983
Contrôler les plaquettes de frein avant...983
Remplacer les plaquettes de frein avant...983
Vérifier la course libre du levier de frein à main...985
Régler la position de base du levier de frein à main (XCF-W)...985
Régler la course libre du levier de frein à main (toutes les EXC-F)...985
Contrôler le niveau de liquide de frein avant...986
Faire l'appoint de liquide de frein à l'avant...986
Vidanger le liquide de frein à l'avant...987
Contrôler les plaquettes de frein arrière...988
Remplacer les plaquettes de frein arrière...988
Vérifier la course libre de la pédale de frein arrière...990
Régler la position de base de la pédale de frein arrière...990
Contrôler le niveau de liquide de frein arrière...991
Faire l'appoint de liquide de frein à l'arrière...991
Vidanger le liquide de frein arrière...992
14/ÉCLAIRAGE, INSTRUMENTS...995
Régler les fonctions de tachymètre...995
Régler sur kilomètres ou sur miles...995
Activer les fonctions additionnelles...996
Régler la circonférence de la roue...996
Régler l'heure...997
Contrôler le réglage du phare...997
Régler la portée du phare...998
30/MOTEUR...999
Déposer le moteur...999
Poser le moteur...1003
30/DÉMONTER LE MOTEUR...1008
Opérations préalables...1008
Déposer la biellette d'embrayage...1008
Déposer l'entretoise...1008
Vidanger l'huile moteur...1008
Déposer le filtre à huile...1009
Déposer la bougie...1009
Déposer le couvre-culasse...1009
Déposer le kick...1010
Déposer le couvre-alternateur...1010
Déposer le limiteur de couple...1010
Régler le moteur sur le point mort haut d'allumage...1011
Déposer le tendeur de chaîne de distribution...1011
Déposer l'arbre à cames...1011
Déposer la culasse...1012
Déposer le piston...1012
Déposer l'entraînement du démarreur...1013
Déposer la pompe aspirante...1014
Déposer la turbine de pompe à eau...1015
Déposer le carter d'embrayage...1015
Déposer les lamelles d'embrayage...1015
Déposer la cloche d'embrayage...1016
Déposer l'arbre de kick...1017
Déposer le pignon intermédiaire du kick...1017
Déposer l'arbre de sélection...1017
Déposer le verrouillage...1017
Déposer le levier de verrouillage...1017
Déposer la pompe de refoulement...1018
Déposer le pignon de distribution...1018
Déposer la chaîne de distribution...1019
Déposer l'entretoise...1019
Déposer le carter moteur gauche...1019
Déposer les tiges de fourchettes...1020
Déposer le tambour de sélection...1020
Déposer les fourchettes de sélection...1020
Déposer les arbres de boîte...1020
Déposer le vilebrequin...1021
30/MOTEUR - TRAVAUX SUR LES DIFF. PIÈCES...1022
Travaux sur le demi-carter moteur droit...1022
Travaux sur le demi-carter moteur gauche...1023
Travaux sur le carter d'embrayage...1024
Contrôler la soupape de réglage de la pression d'huile...1025
Contrôler le système de graissage...1026
Déposer la bague intérieure du palier de vilebrequin...1026
Poser la bague intérieure du palier de vilebrequin...1027
Remplacer la bielle, les paliers de bielle et les manetons...1027
Contrôler l'excentricité du vilebrequin au niveau du maneton...1028
Déposer le pignon de commande de l'arbre d'équilibrage...1029
Poser le pignon de commande de l'arbre d'équilibrage...1029
Cylindre - revêtement Nikasil®...1029
Contrôler/mesurer le cylindre...1029
Contrôler/mesurer le piston...1030
Déterminer le jeu de montage du piston/cylindre...1031
Contrôler le jeu à la coupe du segment...1031
Remplacer les paliers d'arbre à cames...1031
Contrôler l'arbre à cames...1032
Contrôler les paliers de l'arbre à cames...1032
Déposer les soupapes...1033
Contrôler les soupapes...1034
Contrôler les ressorts de soupapes...1034
Contrôler les sièges de soupapes...1034
Contrôler le culbuteur...1035
Contrôler la culasse...1035
Poser les soupapes...1035
Contrôler la roue libre...1036
Effectuer le prémontage de l'arbre de kick...1037
Contrôler le moteur de démarreur électrique...1038
Contrôler la commande de distribution...1039
Préparer les tendeurs de chaîne au montage...1039
Contrôler l'embrayage...1040
Contrôler la sélection...1041
Prémonter l'arbre de sélection...1042
Démonter l'arbre primaire...1043
Démonter l'arbre de sortie...1043
Contrôler la boîte de vitesses...1044
Monter l'arbre primaire...1045
Monter l'arbre de sortie...1046
30/REMONTER LE MOTEUR...1047
Poser le vilebrequin...1047
Poser les arbres de boîte...1047
Poser les fourchettes de sélection...1047
Poser le tambour de sélection...1048
Poser les tiges de fourchettes...1048
Poser le carter moteur gauche...1048
Monter l'entretoise...1049
Poser la chaîne de distribution...1049
Poser le pignon de distribution...1050
Poser la pompe de refoulement...1050
Poser la pompe aspirante...1051
Poser le levier de verrouillage...1052
Poser le dispositif de verrouillage de sélection...1052
Poser l'arbre de sélection...1052
Monter le pignon intermédiaire du kick...1052
Poser l'arbre de kick...1052
Poser la cloche d'embrayage...1053
Monter les lamelles d'embrayage...1054
Poser le carter d'embrayage...1055
Monter le couvercle de pompe à eau...1055
Poser l'entraînement du démarreur...1056
Poser le piston...1057
Poser la culasse...1058
Poser les arbres à cames...1059
Contrôler le diagramme de distribution...1060
Régler le diagramme de distribution...1060
Poser le tendeur de chaîne de distribution...1061
Contrôler le jeu aux soupapes...1062
Régler le jeu aux soupapes...1063
Monter le limiteur de couple...1063
Poser le couvre-alternateur...1063
Poser le kick...1064
Poser le couvre-culasse...1064
Poser la bougie...1065
Poser le filtre à huile...1065
Monter la crépine...1065
Monter l'entretoise...1066
Monter la biellette d'embrayage...1066
Enlever le moteur du chevalet de montage...1066
32/EMBRAYAGE...1067
Contrôler le niveau de liquide de l'embrayage hydraulique...1067
Vidanger le liquide d'embrayage hydraulique...1067
35/POMPE À EAU, REFROIDISSEMENT...1069
Système de refroidissement...1069
Contrôler l'antigel et le niveau de liquide de refroidissement...1069
Contrôler le niveau de liquide de refroidissement...1070
Vidanger le circuit de refroidissement...1070
Remplir de liquide de refroidissement...1071
38/SYSTÈME DE GRAISSAGE...1072
Circuit d'huile...1072
Contrôler le niveau d'huile moteur...1072
Vidanger l'huile de moteur et remplacer le filtre à huile, nettoyer le tamis d'huile...1073
Faire l'appoint d'huile moteur...1075
Contrôler la pression moteur...1075
39/ALLUMAGE...1077
Bobine d'allumage - contrôler l'enroulement secondaire...1077
Contrôler les cosses de bougie d'allumage...1077
Alternateur - vérifier l'enroulement du stator...1077
Démonter le stator et le générateur d'impulsions...1078
Monter le stator et le générateur d'impulsions...1079
40/DÉMARREUR ÉLECTRIQUE...1080
Contrôler le démarreur électrique...1080
41/CORPS DU CLAPET D'ÉTRANGLEMENT...1081
Capteur de position de clapet d'étranglement circuit A - vérifier le réglage de base...1081
Capteur de position de clapet d'étranglement - régler la position de base...1081
DONNÉES TECHNIQUES - MOTEUR...1083
Quantité de remplissage - huile moteur...1083
Quantité de remplissage - liquide de refroidissement...1083
DONNÉES TECHNIQUES - TOLÉRANCE/USURE MOTEUR...1084
DONNÉES TECHNIQUES - COUPLES SERRAGE MOTEUR...1085
DONNÉES TECHNIQUES - PARTIE-CYCLE...1087
Ampoules utilisées...1088
Pneus...1088
Quantité de remplissage - carburant...1088
DONNÉES TECHNIQUES - FOURCHE...1089
DONNÉES TECHNIQUES - AMORTISSEUR...1090
DONNÉES TECHNIQUES - COUPLES PARTIE-CYCLE...1091
NETTOYAGE, SUIVI...1093
Nettoyer la moto...1093
Opérations de contrôle et d'entretien en prévention de l'usure d'hiver...1094
STOCKAGE...1095
Stockage...1095
Mise en service après le stockage...1095
PLAN D'ENTRETIEN...1096
Plan d'entretien...1096
Travaux d'entretien (en sus)...1097
SCHÉMA DE CÂBLAGE...1099
Page 1 sur 8 (EXC‑F EU, EXC-F SIX DAYS)...1099
Page 2 sur 8 (EXC‑F EU, EXC-F SIX DAYS)...1101
Page 3 sur 8 (EXC‑F EU, EXC-F SIX DAYS)...1103
Page 4 sur 8 (EXC‑F EU, EXC-F SIX DAYS)...1105
Page 5 sur 8 (EXC‑F EU, EXC-F SIX DAYS)...1107
Page 6 sur 8 (EXC‑F EU, EXC-F SIX DAYS)...1109
Page 7 sur 8 (EXC‑F EU, EXC-F SIX DAYS)...1111
Page 8 sur 8 (EXC‑F EU, EXC-F SIX DAYS)...1113
Page 1 sur 8 (EXC‑F AUS)...1115
Page 2 sur 8 (EXC‑F AUS)...1117
Page 3 sur 8 (EXC‑F AUS)...1119
Page 4 sur 8 (EXC‑F AUS)...1121
Page 5 sur 8 (EXC‑F AUS)...1123
Page 6 sur 8 (EXC‑F AUS)...1125
Page 7 sur 8 (EXC‑F AUS)...1127
Page 8 sur 8 (EXC‑F AUS)...1129
Page 1 sur 8 (EXC-F USA)...1131
Page 2 sur 8 (EXC-F USA)...1133
Page 3 sur 8 (EXC-F USA)...1135
Page 4 sur 8 (EXC-F USA)...1137
Page 5 sur 8 (EXC-F USA)...1139
Page 6 sur 8 (EXC-F USA)...1141
Page 7 sur 8 (EXC-F USA)...1143
Page 8 sur 8 (EXC-F USA)...1145
Page 1 sur 7 (XCF-W)...1147
Page 2 sur 7 (XCF-W)...1149
Page 3 sur 7 (XCF-W)...1151
Page 4 sur 7 (XCF-W)...1153
Page 5 sur 7 (XCF-W)...1155
Page 6 sur 7 (XCF-W)...1157
Page 7 sur 7 (XCF-W)...1159
MATIÈRES CONSOMMABLES...1161
PRODUITS AUXILIAIRES...1163
OUTILLAGE SPÉCIAL...1165
NORMES...1178
INDEX...1179
A...1179
B...1179
C...1179
D...1179
E...1180
É...1180
F...1180
G...1180
H...1180
J...1180
L...1180
M...1180
N...1181
P...1181
R...1181
S...1182
T...1182
U...1182
IT...1184
LEGENDA...1191
NOTE IMPORTANTI...1192
NUMERI DI SERIE...1193
Numero di telaio...1193
Targhetta di identificazione...1193
Numero chiave (tutti i modelli EXC-F)...1193
Numero del motore...1194
Codice articolo della forcella...1194
Codice articolo dell'ammortizzatore...1194
MOTOCICLETTA...1195
Sollevamento della motocicletta tramite cavalletto di sollevamento...1195
Rimozione della motocicletta dal cavalletto di sollevamento...1195
Procedura di avviamento...1195
Avvio della motocicletta per le operazioni di controllo...1196
01/FORCELLA, PIASTRA FORCELLA...1197
Regolazione dello smorzamento in compressione della forcella...1197
Regolazione dello smorzamento in estensione della forcella...1197
Regolazione del precarico molla della forcella...1198
Sfiato degli steli della forcella...1198
Pulizia delle cuffie parapolvere degli steli della forcella...1198
Allentamento del copristelo...1199
Posizionamento del copristelo...1199
Smontaggio degli steli della forcella...1199
Montaggio degli steli della forcella...1200
Smontaggio del copristelo...1201
Montaggio del copristelo...1201
Manutenzione della forcella...1201
Scomposizione degli steli della forcella...1202
Scomposizione della cartuccia...1205
Scomposizione dell'attacco del registro di compressione...1206
Controllo degli steli della forcella...1207
Riassemblaggio dell'attacco del registro di compressione...1208
Riassemblaggio della cartuccia...1209
Riassemblaggio degli steli della forcella...1211
Lubrificazione del cuscinetto del cannotto di sterzo...1215
Smontaggio della piastra inferiore della forcella (EXC-F SIX DAYS)...1215
Montaggio della piastra inferiore della forcella (EXC-F SIX DAYS)...1216
Smontaggio della piastra inferiore della forcella (EXC‑F EU/AUS/USA, XCF‑W)...1217
Montaggio della piastra inferiore della forcella (EXC‑F EU/AUS/USA, XCF‑W)...1218
Controllo del gioco del cuscinetto del cannotto di sterzo...1220
Regolazione del gioco del cuscinetto del cannotto di sterzo (EXC-F SIX DAYS)...1220
Regolazione del gioco del cuscinetto del cannotto di sterzo (EXC‑F EU/AUS/USA, XCF‑W)...1221
02/MANUBRIO, COMANDI...1222
Posizione del manubrio...1222
Regolazione della posizione del manubrio...1222
Regolazione della posizione a riposo della leva della frizione...1222
Controllo della posa dei cavi flessibili del gas...1223
Controllo del gioco dei cavi flessibili del gas...1223
Regolazione del gioco dei cavi flessibili del gas...1224
03/TELAIO...1225
Smontaggio del paramotore (EXC‑F AUS, EXC-F SIX DAYS)...1225
Montaggio del paramotore (EXC‑F AUS, EXC-F SIX DAYS)...1225
04/AMMORTIZZATORE, FORCELLONE...1226
Regolazione dello smorzamento in compressione High Speed dell'ammortizzatore...1226
Regolazione dello smorzamento in compressione Low Speed dell'ammortizzatore...1226
Regolazione dello smorzamento in estensione dell'ammortizzatore...1227
Determinazione della misura della ruota posteriore senza carico...1227
Controllo della compressione statica dell'ammortizzatore...1227
Controllo della compressione in ordine di marcia dell'ammortizzatore...1228
Regolazione del precarico molla dell'ammortizzatore...1228
Regolazione della compressione in ordine di marcia...1229
Smontaggio dell'ammortizzatore...1229
Montaggio dell'ammortizzatore...1229
Manutenzione dell'ammortizzatore...1230
Smontaggio della molla...1230
Scomposizione dell'ammortizzatore...1231
Smontaggio dell'asta...1232
Scomposizione del supporto dell'anello di tenuta...1233
Sostituzione della bussola di guida...1234
Controllo dell'ammortizzatore...1235
Scomposizione del registro di estensione...1235
Smontaggio del supporto oscillante...1236
Montaggio del supporto oscillante...1237
Riassemblaggio del registro di estensione...1238
Riassemblaggio del supporto dell'anello di tenuta...1238
Riassemblaggio dell'asta...1239
Riassemblaggio dell'ammortizzatore...1240
Sfiato e riempimento dell'ammortizzatore...1243
Riempimento dell'ammortizzatore con azoto...1245
Montaggio della molla...1246
Sostituzione del supporto oscillante...1247
05/SCARICO...1249
Smontaggio del collettore...1249
Montaggio del collettore...1249
Smontaggio del silenziatore...1250
Montaggio del silenziatore...1250
Sostituzione del materiale fonoassorbente del silenziatore...1250
06/FILTRO DELL'ARIA...1252
Smontaggio del coperchio della cassa del filtro...1252
Montaggio del coperchio della cassa del filtro...1252
Smontaggio del filtro dell'aria...1252
Montaggio del filtro dell'aria...1252
Pulizia del filtro dell'aria e dell'airbox...1253
07/SERBATOIO CARBURANTE, SELLA, CARENA...1254
Apertura del tappo del serbatoio...1254
Chiusura del tappo del serbatoio...1254
Smontaggio della sella...1254
Montaggio della sella...1255
Smontaggio del serbatoio carburante...1255
Montaggio del serbatoio carburante...1256
Sostituzione del filtro a reticella...1257
Sostituzione del filtro carburante...1258
Sostituzione della pompa del carburante...1260
Controllo della pressione del carburante...1261
08/MASCHERINA, PARAFANGO...1263
Smontaggio del parafango anteriore...1263
Montaggio del parafango anteriore...1263
Smontaggio della mascherina portafaro con il faro...1263
Montaggio della mascherina portafaro con il faro...1263
09/RUOTA ANTERIORE...1265
Smontaggio della ruota anteriore...1265
Montaggio della ruota anteriore...1265
Controllo dei dischi del freno...1266
Smontaggio del disco del freno della ruota anteriore...1266
Montaggio del disco del freno della ruota anteriore...1267
Controllo dello stato dei pneumatici...1267
Controllo della pressione dei pneumatici...1267
Controllo della tensione dei raggi...1268
10/RUOTA POSTERIORE...1269
Smontaggio della ruota posteriore...1269
Montaggio della ruota posteriore...1269
Smontaggio del disco del freno della ruota posteriore...1270
Montaggio del disco del freno della ruota posteriore...1270
Controllo della tensione della catena...1270
Regolazione della tensione della catena...1271
Regolazione del guidacatena...1272
Controllo di catena, corona dentata, pignone e guidacatena...1272
Controllo dell'imbrattamento della catena...1274
Pulizia della catena...1274
11/CABLAGGIO, BATTERIA...1275
Smontaggio del fusibile principale...1275
Montaggio del fusibile principale...1275
Sostituzione dei fusibili delle singole utenze...1275
Sostituzione del fusibile della ventola del radiatore (EXC-F SIX DAYS)...1276
Smontaggio della batteria...1277
Montaggio della batteria...1277
Caricamento della batteria...1277
13/IMPIANTO FRENANTE...1279
Controllo delle pastiglie del freno della ruota anteriore...1279
Sostituzione delle pastiglie del freno della ruota anteriore...1279
Controllo della corsa a vuoto della leva del freno anteriore...1281
Regolazione della posizione base della leva del freno anteriore (XCF‑W)...1281
Regolazione della corsa a vuoto della leva del freno anteriore (tutti i modelli EXC-F)...1281
Controllo del livello del fluido freni della ruota anteriore...1282
Rabbocco del fluido freni della ruota anteriore...1282
Sostituzione del fluido freni della ruota anteriore...1283
Controllo delle pastiglie del freno della ruota posteriore...1284
Sostituzione delle pastiglie del freno della ruota posteriore...1284
Controllo della corsa a vuoto del pedale del freno...1286
Regolazione della posizione a riposo del pedale del freno...1286
Controllo del livello del fluido freni della ruota posteriore...1287
Rabbocco del fluido freni della ruota posteriore...1287
Sostituzione del liquido freni del freno della ruota posteriore...1288
14/IMPIANTO LUCI, STRUMENTAZIONE...1290
Impostazione funzioni tachimetro...1290
Impostazione di chilometri o miglia...1290
Attivazione delle funzioni supplementari...1291
Impostazione della circonferenza ruota...1291
Impostazione dell'ora...1292
Controllo dell'orientamento del faro...1292
Regolazione della profondità del fascio luminoso del faro...1293
30/MOTORE...1294
Smontaggio del motore...1294
Montaggio del motore...1298
30/SCOMPOSIZIONE DEL MOTORE...1303
Preparazione...1303
Smontaggio dell'asta di spinta della frizione...1303
Smontaggio della bussola distanziale...1303
Scarico dell'olio motore...1303
Smontaggio del filtro dell'olio...1304
Smontaggio della candela...1304
Smontaggio del coperchio valvole...1304
Smontaggio del pedale di avviamento...1305
Smontaggio del coperchio del generatore...1305
Smontaggio del limitatore di coppia...1305
Posizionamento del motore sul punto morto superiore di accensione...1306
Smontaggio del tenditore della catena di distribuzione...1306
Smontaggio dell'albero a camme...1306
Smontaggio della testa del cilindro...1307
Smontaggio del pistone...1307
Smontaggio dell'ingranaggio dell'avviamento...1308
Smontaggio della pompa di aspirazione...1309
Smontaggio della girante della pompa dell'acqua...1310
Smontaggio del coperchio della frizione...1310
Smontaggio dei dischi della frizione...1310
Smontaggio della campana della frizione...1311
Smontaggio dell'albero del pedale di avviamento...1312
Smontaggio dell'ingranaggio intermedio del pedale di avviamento...1312
Smontaggio dell'albero di comando del cambio...1312
Smontaggio del dispositivo selettore marce...1312
Smontaggio della leva selettore...1312
Smontaggio della pompa a pressione...1313
Smontaggio dell'ingranaggio primario...1313
Smontaggio della catena di distribuzione...1314
Smontaggio della bussola distanziale...1314
Smontaggio del carter motore sinistro...1314
Smontaggio delle aste di guida della forcella...1315
Smontaggio del desmodromico del cambio...1315
Smontaggio delle forcelle del cambio...1315
Smontaggio degli alberi di trasmissione...1315
Smontaggio dell'albero motore...1316
30/MOTORE - LAVORI SULLE PARTI...1317
Lavori sul semicarter destro del motore...1317
Lavori sul semicarter sinistro del motore...1318
Lavori sul coperchio della frizione...1319
Controllo della valvola di regolazione della pressione dell'olio...1320
Controllo del sistema di lubrificazione...1321
Smontaggio dell'anello interno del cuscinetto dell'albero motore...1321
Montaggio dell'anello interno del cuscinetto dell'albero motore...1321
Sostituzione di biella, cuscinetto di biella e asse di accoppiamento...1322
Controllo della rotazione eccentrica dell'albero motore sul perno di banco...1323
Smontaggio della ruota motrice dell'albero di equilibratura...1323
Montaggio della ruota motrice dell'albero di equilibratura...1323
Cilindro - rivestimento Nikasil®...1324
Controllo/misurazione del cilindro...1324
Controllo/misurazione del pistone...1324
Determinazione del gioco di montaggio di pistone/cilindro...1325
Controllo della luce del segmento pistone...1325
Sostituzione del cuscinetto dell'albero a camme...1326
Controllo degli alberi a camme...1326
Controllo delle sedi di supporto degli alberi a camme...1326
Smontaggio delle valvole...1327
Controllo delle valvole...1328
Controllo delle molle delle valvole...1329
Controllo del supporto molla della valvola...1329
Controllo dei bilancieri a dito...1329
Controllo della testa del cilindro...1329
Montaggio delle valvole...1330
Controllo della ruota libera...1331
Premontaggio dell'albero del pedale di avviamento...1331
Controllo dell'ingranaggio dell'avviamento elettrico...1332
Controllo della catena di distribuzione...1333
Preparazione del montaggio del tenditore della catena di distribuzione...1334
Controllo della frizione...1334
Controllo del cambio...1336
Premontaggio dell'albero di comando del cambio...1337
Scomposizione dell'albero primario...1337
Scomposizione dell'albero secondario...1338
Controllo del cambio...1338
Riassemblaggio dell'albero primario...1340
Riassemblaggio dell'albero secondario...1340
30/RIASSEMBLAGGIO DEL MOTORE...1342
Montaggio dell'albero motore...1342
Montaggio degli alberi di trasmissione...1342
Montaggio delle forcelle del cambio...1342
Montaggio del desmodromico del cambio...1343
Montaggio delle aste di guida della forcella...1343
Montaggio del carter sinistro del motore...1343
Montaggio della bussola distanziale...1344
Montaggio della catena di distribuzione...1344
Montaggio dell'ingranaggio primario...1345
Montaggio della pompa a pressione...1345
Montaggio della pompa di aspirazione...1346
Montaggio della leva selettore...1347
Montaggio del dispositivo selettore marce...1347
Montaggio dell'albero di comando del cambio...1347
Montaggio dell'ingranaggio intermedio del pedale di avviamento...1347
Montaggio dell'albero del pedale di avviamento...1347
Montaggio della campana della frizione...1348
Montaggio dei dischi della frizione...1349
Montaggio del coperchio della frizione...1350
Montaggio del coperchio della pompa dell'acqua...1350
Montaggio dell'ingranaggio dell'avviamento...1351
Montaggio del pistone...1352
Montaggio della testa del cilindro...1353
Montaggio degli alberi a camme...1354
Controllo del diagramma della distribuzione...1355
Regolazione del diagramma della distribuzione...1355
Montaggio del tenditore della catena di distribuzione...1356
Controllo del gioco valvole...1357
Regolazione del gioco valvole...1358
Montaggio del limitatore di coppia...1358
Montaggio del coperchio del generatore...1358
Montaggio del pedale di avviamento...1359
Montaggio del coperchio valvole...1359
Montaggio della candela...1360
Montaggio del filtro dell'olio...1360
Montaggio dell'unità filtrante...1360
Montaggio della bussola distanziale...1361
Montaggio dell'asta di spinta della frizione...1361
Rimozione del motore dal cavalletto di montaggio...1361
32/FRIZIONE...1362
Controllo del livello dell'olio della frizione idraulica...1362
Sostituzione del fluido della frizione idraulica...1362
35/POMPA ACQUA, SISTEMA RAFFREDDAMENTO...1363
Sistema di raffreddamento...1363
Controllo dell'antigelo e del livello del liquido di raffreddamento...1363
Controllo del livello del liquido di raffreddamento...1364
Scarico del liquido di raffreddamento...1364
Immissione del liquido di raffreddamento...1365
38/SISTEMA DI LUBRIFICAZIONE...1366
Circuito dell'olio...1366
Controllo del livello dell'olio motore...1366
Sostituzione dell'olio motore e del filtro dell'olio, pulizia dell'unità filtrante...1367
Rabbocco dell'olio motore...1369
Controllo della pressione dell'olio motore...1369
39/IMPIANTO D'ACCENSIONE...1371
Bobina di accensione - Controllo dell'avvolgimento secondario...1371
Controllo del cappuccio della candela...1371
Controllo dell'avvolgimento dello statore del generatore...1371
Smontaggio dello statore e del trasduttore d'impulsi...1372
Montaggio dello statore e del trasduttore d'impulsi...1373
40/STARTER ELETTRICO...1374
Controllo del motorino d'avviamento elettrico...1374
41/VALVOLA A FARFALLA...1375
Sensore posizione farfalla circuito A - Controllo della taratura base...1375
Sensore posizione farfalla - Regolazione della taratura base...1375
DATI TECNICI - MOTORE...1377
Quantitativo - olio motore...1377
Quantitativo - liquido di raffreddamento...1377
DATI TECNICI - TOLLERANZE, LIMITI DI USURA MOTORE...1378
DATI TECNICI - COPPIE DI SERRAGGIO MOTORE...1379
DATI TECNICI - CICLISTICA...1381
Lampadine...1382
Pneumatici...1382
Quantitativo - carburante...1382
DATI TECNICI - FORCELLA...1383
DATI TECNICI - AMMORTIZZATORE...1384
DATI TECNICI - COPPIE DI SERRAGGIO CICLISTICA...1385
PULIZIA, CURA...1387
Pulizia della motocicletta...1387
Interventi di controllo e manutenzione ordinaria per l'uso invernale...1388
STOCCAGGIO PER MESSA A RIPOSO...1389
Stoccaggio per messa a riposo...1389
Messa in funzione dopo un periodo di magazzinaggio...1389
PROGRAMMA DI MANUTENZIONE...1390
Programma di manutenzione...1390
Manutenzione (con ordine supplementare)...1391
SCHEMA ELETTRICO...1393
Pagina 1 di 8 (EXC‑F EU, EXC-F SIX DAYS)...1393
Pagina 2 di 8 (EXC‑F EU, EXC-F SIX DAYS)...1395
Pagina 3 di 8 (EXC‑F EU, EXC-F SIX DAYS)...1397
Pagina 4 di 8 (EXC‑F EU, EXC-F SIX DAYS)...1399
Pagina 5 di 8 (EXC‑F EU, EXC-F SIX DAYS)...1401
Pagina 6 di 8 (EXC‑F EU, EXC-F SIX DAYS)...1403
Pagina 7 di 8 (EXC‑F EU, EXC-F SIX DAYS)...1405
Pagina 8 di 8 (EXC‑F EU, EXC-F SIX DAYS)...1407
Pagina 1 di 8 (EXC‑F AUS)...1409
Pagina 2 di 8 (EXC‑F AUS)...1411
Pagina 3 di 8 (EXC‑F AUS)...1413
Pagina 4 di 8 (EXC‑F AUS)...1415
Pagina 5 di 8 (EXC‑F AUS)...1417
Pagina 6 di 8 (EXC‑F AUS)...1419
Pagina 7 di 8 (EXC‑F AUS)...1421
Pagina 8 di 8 (EXC‑F AUS)...1423
Pagina 1 di 8 (EXC-F USA)...1425
Pagina 2 di 8 (EXC-F USA)...1427
Pagina 3 di 8 (EXC-F USA)...1429
Pagina 4 di 8 (EXC-F USA)...1431
Pagina 5 di 8 (EXC-F USA)...1433
Pagina 6 di 8 (EXC-F USA)...1435
Pagina 7 di 8 (EXC-F USA)...1437
Pagina 8 di 8 (EXC-F USA)...1439
Pagina 1 di 7 (XCF‑W)...1441
Pagina 2 di 7 (XCF‑W)...1443
Pagina 3 di 7 (XCF‑W)...1445
Pagina 4 di 7 (XCF‑W)...1447
Pagina 5 di 7 (XCF‑W)...1449
Pagina 6 di 7 (XCF‑W)...1451
Pagina 7 di 7 (XCF‑W)...1453
MATERIALI DI CONSUMO...1455
MATERIALI AUSILIARI...1457
UTENSILI SPECIALI...1459
NORME...1472
INDICE...1473
...
1 MEANS OF REPRESENTATION...8
1.1 Symbols used...8
1.2 Formats used...8
2 SAFETY ADVICE...9
2.1 Repair Manual...9
2.2 Safety advice...9
2.3 Degrees of risk and symbols...9
2.4 Work rules...9
3 IMPORTANT NOTES...10
3.1 Guarantee, warranty...10
3.2 Operating and auxiliary substances...10
3.3 Spare parts, accessories...10
3.4 Figures...10
4 SERIAL NUMBERS...11
4.1 Chassis number/type label...11
4.2 Key number...11
4.3 Engine number...11
5 MOTORCYCLE...12
5.1 Raising the motorcycle with the rear wheel stand...12
5.2 Taking the motorcycle off of the rear wheel stand...12
5.3 Raising the motorcycle with the front wheel stand...12
5.4 Taking the motorcycle off of the front wheel stand...13
5.5 Raising the motorcycle with the work stand...13
5.6 Removing the motorcycle from the work stand...14
5.7 Starting...15
5.8 Starting the motorcycle to make checks...16
6 FORK, TRIPLE CLAMP...17
6.1 Cleaning the dust boots of the fork legs...17
6.2 Removing fork legs...17
6.3 Installing the fork legs...18
6.4 Disassembling the fork legs...19
6.5 Checking the fork legs...21
6.6 Assembling the fork legs...22
6.7 Removing the lower triple clamp...24
6.8 Installing the lower triple clamp...26
6.9 Checking the steering head bearing play...28
6.10 Adjusting the steering head bearing play...29
7 HANDLEBAR, CONTROLS...30
7.1 Checking the play in the throttle cable...30
7.2 Adjusting the play in the throttle cable...30
7.3 Checking the clutch lever play...30
7.4 Adjusting the clutch cable play...31
8 SHOCK ABSORBER, SWINGARM...32
8.1 Adjusting the spring preload of the shock absorber...32
8.2 Removing the shock absorber...32
8.3 Installing the shock absorber...32
8.4 Removing the spring...33
8.5 Installing the spring...33
9 EXHAUST...35
9.1 Removing the exhaust manifold...35
9.2 Installing the exhaust manifold...36
9.3 Removing the main silencer...37
9.4 Installing the main silencer...38
10 AIR FILTER...39
10.1 Removing the air filter...39
10.2 Installing the air filter...39
11 FUEL TANK, SEAT, TRIM...40
11.1 Opening the filler cap...40
11.2 Closing the filler cap...40
11.3 Removing the seat...40
11.4 Mounting the seat...41
11.5 Removing the passenger seat...41
11.6 Mounting the passenger seat...41
11.7 Removing the fuel tank cover...41
11.8 Installing the fuel tank cover...44
11.9 Removing the fuel tank...46
11.10 Installing the fuel tank...48
11.11 Removing the front spoiler...49
11.12 Fitting front spoiler...49
11.13 Dismounting the front fender...50
11.14 Installing the front fender...50
11.15 Checking the fuel pressure...50
11.16 Changing the fuel filter...52
11.17 Replacing the fuel pump...53
12 WHEELS...55
12.1 Checking the tire air pressure...55
12.2 Checking the tire condition...55
12.3 Checking the brake discs...56
12.4 Front wheel...56
12.4.1 Removing the front wheel...56
12.4.2 Installing the front wheel...56
12.4.3 Removing the brake disc of the front brake...57
12.4.4 Installing the brake disc of the front brake...57
12.5 Rear wheel...58
12.5.1 Removing the rear wheel...58
12.5.2 Installing the rear wheel...58
12.5.3 Removing the brake disc of the rear brake...59
12.5.4 Installing the brake disc of the rear brake...59
12.5.5 Checking the chain tension...60
12.5.6 Adjusting the chain tension...60
12.5.7 Checking the chain, rear sprocket, and engine sprocket...61
12.5.8 Cleaning the chain...62
12.5.9 Checking the rear hub rubber dampers...63
13 WIRING HARNESS, BATTERY...64
13.1 Removing the battery...64
13.2 Installing the battery...64
13.3 Disconnecting the negative cable of the battery...65
13.4 Reconnecting the negative cable of the battery...65
13.5 Recharging the battery...65
13.6 Checking the charging voltage...66
13.7 Changing the fuses of individual power consumers...67
14 BRAKE SYSTEM...68
14.1 Checking the front brake linings...68
14.2 Changing the front brake linings...68
14.3 Checking the brake fluid level of the front brake...70
14.4 Adding front brake fluid...70
14.5 Changing the front brake fluid...71
14.6 Checking the rear brake linings...72
14.7 Changing the rear brake linings...73
14.8 Checking the free travel of foot brake lever...74
14.9 Adjusting the free travel of the foot brake lever...75
14.10 Checking the rear brake fluid level...75
14.11 Adding rear brake fluid...76
14.12 Changing the rear brake fluid...76
15 LIGHTING SYSTEM, INSTRUMENTS...78
15.1 Setting kilometers or miles...78
15.2 Adjusting the shift speed RPM 1...78
15.3 Adjusting the shift speed RPM 2...78
15.4 Setting the time...79
15.5 Resetting the service interval display...79
15.6 Checking the headlight setting...79
15.7 Adjusting the headlight range...80
15.8 Changing the parking light bulb...81
15.9 Changing the headlight bulb...82
16 ENGINE...84
16.1 Removing the engine...84
16.2 Installing the engine...87
16.3 Disassembling the engine...92
16.3.1 Preparations (125 Duke)...92
16.3.2 Draining the engine oil (125 Duke)...92
16.3.3 Removing the chain securing guide (125 Duke)...93
16.3.4 Removing the valve cover (125 Duke)...93
16.3.5 Removing the spark plug (125 Duke)...93
16.3.6 Removing the clutch cover (125 Duke)...93
16.3.7 Setting the engine to ignition top dead center (125 Duke)...94
16.3.8 Removing the starter motor (125 Duke)...94
16.3.9 Removing the timing chain tensioner (125 Duke)...95
16.3.10 Removing the camshaft (125 Duke)...95
16.3.11 Removing the cylinder head (125 Duke)...96
16.3.12 Removing the piston (125 Duke)...96
16.3.13 Removing the water pump wheel (125 Duke)...97
16.3.14 Removing the alternator cover (125 Duke)...98
16.3.15 Removing the rotor (125 Duke)...98
16.3.16 Removing the starter drive (125 Duke)...99
16.3.17 Removing the balancer shaft drive wheel (125 Duke)...99
16.3.18 Removing the gear position sensor (125 Duke)...100
16.3.19 Removing the spacer (125 Duke)...101
16.3.20 Removing the clutch basket (125 Duke)...101
16.3.21 Removing the primary gear (125 Duke)...102
16.3.22 Removing the oil pump (125 Duke)...102
16.3.23 Removing the shift shaft (125 Duke)...103
16.3.24 Removing the shift drum locating (125 Duke)...103
16.3.25 Removing the locking lever (125 Duke)...103
16.3.26 Removing the oil filter (125 Duke)...103
16.3.27 Removing the left engine case (125 Duke)...104
16.3.28 Removing the shift rails (125 Duke)...105
16.3.29 Removing the shift drum (125 Duke)...105
16.3.30 Removing the shift forks (125 Duke)...105
16.3.31 Removing the transmission shafts (125 Duke)...105
16.3.32 Removing the balancer shaft (125 Duke)...106
16.3.33 Removing the crankshaft (125 Duke)...106
16.3.34 Preparations (200 Duke)...106
16.3.35 Draining the engine oil (200 Duke)...106
16.3.36 Removing the chain securing guide (200 Duke)...107
16.3.37 Removing the valve cover (200 Duke)...107
16.3.38 Removing the spark plug (200 Duke)...107
16.3.39 Removing the clutch cover (200 Duke)...107
16.3.40 Setting the engine to ignition top dead center (200 Duke)...108
16.3.41 Removing the starter motor (200 Duke)...108
16.3.42 Removing the timing chain tensioner (200 Duke)...109
16.3.43 Removing the camshaft (200 Duke)...109
16.3.44 Removing the cylinder head (200 Duke)...110
16.3.45 Removing the piston (200 Duke)...110
16.3.46 Removing the water pump wheel (200 Duke)...111
16.3.47 Removing the alternator cover (200 Duke)...112
16.3.48 Removing the rotor (200 Duke)...112
16.3.49 Removing the starter drive (200 Duke)...113
16.3.50 Removing the balancer shaft drive wheel (200 Duke)...113
16.3.51 Removing the gear position sensor (200 Duke)...114
16.3.52 Removing the spacer (200 Duke)...115
16.3.53 Removing the clutch basket (200 Duke)...115
16.3.54 Removing the primary gear (200 Duke)...116
16.3.55 Removing the oil pump (200 Duke)...116
16.3.56 Removing the shift shaft (200 Duke)...117
16.3.57 Removing the shift drum locating (200 Duke)...117
16.3.58 Removing the locking lever (200 Duke)...117
16.3.59 Removing the oil filter (200 Duke)...117
16.3.60 Removing the left engine case (200 Duke)...118
16.3.61 Removing the shift rails (200 Duke)...119
16.3.62 Removing the shift drum (200 Duke)...119
16.3.63 Removing the shift forks (200 Duke)...119
16.3.64 Removing the transmission shafts (200 Duke)...119
16.3.65 Removing the balancer shaft (200 Duke)...120
16.3.66 Removing the crankshaft (200 Duke)...120
16.4 Work on individual parts...120
16.4.1 Work on the left section of the engine case (125 Duke)...120
16.4.2 Work on the right section of the engine case (125 Duke)...121
16.4.3 Changing the shaft seal ring of the water pump (125 Duke)...121
16.4.4 Removing the main bearing (125 Duke)...122
16.4.5 Checking the radial play of the lower conrod bearing (125 Duke)...123
16.4.6 Changing the conrod bearing (125 Duke)...124
16.4.7 Changing the balancer shaft bearing (125 Duke)...125
16.4.8 Changing the camshaft bearing (125 Duke)...125
16.4.9 Work on the cylinder head (125 Duke)...126
16.4.10 Checking the cylinder head (125 Duke)...127
16.4.11 Checking/measuring the cylinder (125 Duke)...127
16.4.12 Checking the piston ring...128
16.4.13 Checking/measuring the piston (125 Duke)...128
16.4.14 Checking the piston/cylinder mounting clearance (125 Duke)...129
16.4.15 Checking the oil pump (125 Duke)...129
16.4.16 Checking the oil pressure regulator valve (125 Duke)...129
16.5 Assembling the engine...160
16.5.1 Installing the crankshaft (125 Duke)...160
16.5.2 Installing the balancer shaft (125 Duke)...160
16.5.3 Installing the transmission shafts (125 Duke)...161
16.5.4 Installing the shift forks (125 Duke)...161
16.5.5 Installing the shift drum (125 Duke)...161
16.5.6 Installing the shift rails (125 Duke)...162
16.5.7 Installing the left engine case (125 Duke)...162
16.5.8 Installing the oil filter (125 Duke)...163
16.5.9 Installing the locking lever (125 Duke)...163
16.5.10 Installing the shift drum locating (125 Duke)...163
16.5.11 Installing the shift shaft (125 Duke)...164
16.5.12 Installing the oil pump (125 Duke)...164
16.5.13 Installing the primary gear (125 Duke)...165
16.5.14 Installing the clutch basket (125 Duke)...165
16.5.15 Installing the spacer (125 Duke)...166
16.5.16 Installing the gear position sensor (125 Duke)...166
16.5.17 Installing the balancer shaft drive wheel (125 Duke)...167
16.5.18 Installing the starter drive (125 Duke)...168
16.5.19 Installing the rotor (125 Duke)...169
16.5.20 Installing the alternator cover (125 Duke)...169
16.5.21 Installing the water pump cover (125 Duke)...169
16.5.22 Installing the piston (125 Duke)...170
16.5.23 Installing the cylinder head (125 Duke)...171
16.5.24 Installing the camshafts (125 Duke)...172
16.5.25 Installing the timing chain tensioner (125 Duke)...173
16.5.26 Checking the valve clearance (125 Duke)...174
16.5.27 Adjusting the valve clearance (125 Duke)...174
16.5.28 Installing the starter motor (125 Duke)...174
16.5.29 Installing the clutch cover (125 Duke)...175
16.5.30 Installing the spark plug (125 Duke)...175
16.5.31 Installing the valve cover (125 Duke)...176
16.5.32 Installing the chain securing guide (125 Duke)...176
16.5.33 Installing the oil screen (125 Duke)...176
16.5.34 Removing the engine from the engine assembly stand (125 Duke)...177
16.5.35 Installing the crankshaft (200 Duke)...177
16.5.36 Installing the balancer shaft (200 Duke)...177
16.5.37 Installing the transmission shafts (200 Duke)...178
16.5.38 Installing the shift forks (200 Duke)...178
16.5.39 Installing the shift drum (200 Duke)...178
16.5.40 Installing the shift rails (200 Duke)...179
16.5.41 Installing the left engine case (200 Duke)...179
16.5.42 Installing the oil filter (200 Duke)...180
16.5.43 Installing the locking lever (200 Duke)...180
16.5.44 Installing the shift drum locating (200 Duke)...180
16.5.45 Installing the shift shaft (200 Duke)...181
16.5.46 Installing the oil pump (200 Duke)...181
16.5.47 Installing the primary gear (200 Duke)...182
16.5.48 Installing the clutch basket (200 Duke)...182
16.5.49 Installing the spacer (200 Duke)...183
16.5.50 Installing the gear position sensor (200 Duke)...183
16.5.51 Installing the balancer shaft drive wheel (200 Duke)...184
16.5.52 Installing the starter drive (200 Duke)...185
16.5.53 Installing the rotor (200 Duke)...186
16.5.54 Installing the alternator cover (200 Duke)...186
16.5.55 Installing the water pump cover (200 Duke)...186
16.5.56 Installing the piston (200 Duke)...187
16.5.57 Installing the cylinder head (200 Duke)...188
16.5.58 Installing the camshafts (200 Duke)...189
16.5.59 Installing the timing chain tensioner (200 Duke)...190
16.5.60 Checking the valve clearance (200 Duke)...191
16.5.61 Adjusting the valve clearance (200 Duke)...191
16.5.62 Installing the starter motor (200 Duke)...191
16.5.63 Installing the clutch cover (200 Duke)...192
16.5.64 Installing the spark plug (200 Duke)...192
16.5.65 Installing the valve cover (200 Duke)...193
16.5.66 Installing the chain securing guide (200 Duke)...193
16.5.67 Installing the oil screen (200 Duke)...193
16.5.68 Removing the engine from the engine assembly stand (200 Duke)...194
17 SHIFT MECHANISM...195
17.1 Adjusting the shift lever...195
18 WATER PUMP, COOLING SYSTEM...196
18.1 Draining the coolant...196
18.2 Filling/bleeding the cooling system...196
18.3 Checking the antifreeze and coolant level...197
18.4 Checking the coolant level...198
19 LUBRICATION SYSTEM...200
19.1 Oil circuit...200
19.2 Checking the engine oil level...200
19.3 Checking the engine oil pressure...200
19.4 Changing the engine oil and oil filter, cleaning the oil screen...202
19.5 Adding engine oil...203
20 IGNITION SYSTEM...204
20.1 Alternator - checking the stator winding...204
21 TECHNICAL DATA...205
21.1 Engine...205
21.1.1 125 Duke...205
21.1.2 200 Duke...205
21.2 Engine tolerance, wear limits...206
21.2.1 125 Duke...206
21.2.2 200 Duke...207
21.3 Engine tightening torques...207
21.4 Capacities...208
21.4.1 Engine oil...208
21.4.2 Coolant...208
21.4.3 Fuel...208
21.5 Chassis...209
21.6 Electrical system...209
21.7 Tires...210
21.8 Fork...210
21.9 Shock absorber...210
21.10 Chassis tightening torques...210
22 CLEANING/PROTECTIVE TREATMENT...213
22.1 Cleaning the motorcycle...213
22.2 Checks and maintenance steps for winter operation...214
23 STORAGE...215
23.1 Storage...215
23.2 Preparing for use after storage...215
24 SERVICE SCHEDULE...216
24.1 Service schedule...216
25 WIRING DIAGRAM...218
25.1 Page 1 of 8 (125 Duke, 200 Duke EU)...218
25.2 Page 2 of 8 (125 Duke, 200 Duke EU)...220
25.3 Page 3 of 8 (125 Duke, 200 Duke EU)...222
25.4 Page 4 of 8 (125 Duke, 200 Duke EU)...224
25.5 Page 5 of 8 (125 Duke, 200 Duke EU)...226
25.6 Page 6 of 8 (125 Duke, 200 Duke EU)...228
25.7 Page 7 of 8 (125 Duke, 200 Duke EU)...230
25.8 Page 8 of 8 (125 Duke, 200 Duke EU)...232
25.9 Page 1 of 8 (200 Duke 2013 COL)...234
25.10 Page 2 of 8 (200 Duke 2013 COL)...236
25.11 Page 3 of 8 (200 Duke 2013 COL)...238
25.12 Page 4 of 8 (200 Duke 2013 COL)...240
25.13 Page 5 of 8 (200 Duke 2013 COL)...242
25.14 Page 6 of 8 (200 Duke 2013 COL)...244
25.15 page 7 of 8 (200 Duke 2013 COL)...246
25.16 Page 8 of 8 (200 Duke 2013 COL)...248
26 SUBSTANCES...250
27 AUXILIARY SUBSTANCES...252
28 SPECIAL TOOLS...254
29 STANDARDS...263
INDEX...264
A...264
B...264
C...264
D...264
E...265
F...265
H...265
K...265
L...266
M...266
O...266
P...266
R...266
S...266
T...266
W...266
...
HOME...0
NOTES AND PREFACE...1
Title page and file spine...1
Important information...7
Updating instructions...7
Explanation update...9
Introduction...11
Reply fax for repair manuals...13
TABLE OF CONTENTS...5
SERVICE-INFORMATIONS...0
GENERAL INFORMATION...15
CARBURETOR ADJUSTMENT...16
BLEEDING OF THE HYDRAULIC CLUTCH...17
SPECIAL TOOLS...18
CLEANING...20
STORAGE...20
REMOVING AND REFITTING ENGINE...21
REMOVING ENGINE...23
REFITTING ENGINE...26
DISASSEMBLING ENGINE...29
CLAMP THE ENGINE INTO THE MOUNTING RACK,...31
DRAINING GEAR OIL...31
DISMOUNT OF CYLINDER HEAD, CYLINDER AND PISTON...31
DISMANTLE THE WATER PUMP...32
REMOVE THE CLUTCH COVER...32
DISMANTLE CLUTCH...33
PRIMARY DRIVE...33
REMOVE KICKSTARTER SHAFT...34
REMOVE SHIFT SHAFT AND SHIFTING MECHANISM...34
REMOVE INTAKE FLANGE AND REED VALVE HOUSING...35
REMOVE IGNITION SYSTEM UP TO MODEL 2002...35
REMOVE IGNITION SYSTEM FROM MODEL 2003...36
REMOVING THE ENGINE SPROCKET...37
SEPARATING THE HOUSING HALVES...37
REMOVING THE TRANSMISSION SHAFTS...37
REMOVING THE CRANKSHAFT OF THE ENGINE HOUSING...38
SERVICING INDIVIDUAL COMPONENTS...39
WORKS ON THE LEFT HOUSING HALF...41
WORKS ON THE RIGHT HOUSING HALF...42
MEASURING THE CRANKSHAFT...43
WORKS ON THE CLUTCH COVER...43
DISMANTLING AND CHECKING THE WATER PUMP...44
CHECKING THE PISTON...45
PISTON RING END GAP...45
MEASURING PISTON AND CYLINDER, PISTON FITTING CLEARANCE...45
REED VALVE HOUSING, INTAKE FLANGE...46
DISASSEMBLING THE SHIFTING SHAFT...47
SHIFTING MECHANISM - CHECKING PARTS FOR WEAR...47
PREASSEMBLING THE SHIFTING SHAFT...47
CLUTCH - CHECKING PARTS FOR WEAR...48
PREASSEMBLING THE DISC PACKAGE...48
PREASSEMBLE AND ASSEMBLE THE CLUTCH RELEASE...49
PREASSEMBLING THE KICKSTARTER SHAFT...49
TRANSMISSION - CHECKING PARTS FOR WEAR...50
ASSEMBLING THE MAIN SHAFT...50
ASSEMBLING THE COUNTER SHAFT...50
ASSEMBLING ENGINE...51
INSERTING THE CRANKSHAFT...53
MOUNT TRANSMISSION AND SHIFT MECHANISM...53
ASSEMBLING THE ENGINE HOUSING...54
MOUNT KICKSTARTER SHAFT...54
MOUNT SHIFT MECHANISM AND SHIFT SHAFT...55
ASSEMBLE CLUTCH...55
MOUNT PRIMARY DRIVE...56
MOUNT RATCHET GEAR, PRELOAD THE KICKSTARTER SHAFT...56
MOUNT CLUTCH COVER...56
MOUNT THE ENGINE SPROCKET...57
MOUNT REED VALVE HOUSING AND INKTAKE FLANGE...57
MOUNT PISTON AND CYLINDER...58
ADJUSTING DIMENSION „X“...58
IGNITION, ADJUSTING THE IGNITION UP TO MODEL 2002...59
IGNITION, ADJUSTING THE IGNITION FROM MODEL 2003...60
MOUNT CYLINDER HEAD...61
MOUNT KICKSTARTER...61
MOUNT IGNITION COVER...61
FILLING GEAR OIL...61
TROUBLE SHOOTING...63
TROUBLE SHOOTING...65
RESISTOR VALUES OF THE IGNITION SYSTEM...67
MEASUREMENT WITH PEAK VOLTAGE ADAPTER...68
TECHNICAL SPECIFICATIONS...69
MODEL 1998/99 - ENGINE...71
MODEL 1998/99 - CHASSIS...72
MODEL 2000 - ENGINE...73
MODEL 2000 - CHASSIS...74
MODEL 2001 - ENGINE...75
MODEL 2001 - CHASSIS...76
MODEL 2002 - ENGINE...77
MODEL 2002 - CHASSIS...78
MODEL 2003 - ENGINE...79
MODEL 2003 - CHASSIS...80
TOLERANCES AND FITTING CLEARANCES...81
TIGHTENING TORQUES - ENGINE...81
TIGHTENING TORQUES - CHASSIS...81
PERIODIC MAINTENANCE SCHEDULE...83
MODEL 1998...85
MODEL 2001...86
MODEL 2002...88
MODEL 2003...90
...
HOME...0
NOTES AND PREFACE...0
Important information...3
Updating instructions...3
Explanation updating...5
Introduction...7
Reply fax for repair manuals...9
TABLE OF CONTENTS...1
GENERAL INFORMATION...11
BLEEDING THE HYDRAULIC CLUTCH...13
ADJUSTING THE OIL PUMP (ONLY WITH SEPARATE LUBRICATION)...14
CHECKING THE EXHAUST CONTROL...15
CHANGING THE FRONT BRAKE FLUID...16
CHANGING THE REAR BRAKE FLUID...17
CHECKING BRAKE PADS AND BRAKE DISCS...17
REMOVING AND REFITTING ENGINE...19
REMOVING THE ENGINE...21
INSTALLING THE ENGINE...22
DISASSEMBLING THE ENGINE...25
SPECIAL TOOLS - ENGINE 125/200...27
DRAINING THE GEAR OIL...28
DISMOUNTING THE CLUTCH SLAVE CYLINDER...28
CYLINDER HEAD, CYLINDER AND PISTON...28
IGNITION...29
ENGINE SPROCKET...29
REED VALVE HOUSING, INTAKE FLANGE AND CLUTCH COVER...30
REED VALVE HOUSING, INTAKE FLANGE AND OIL PUMP- MODELS WITH SEPARATE LUBRICATION...31
REMOVING THE CLUTCH AND PRIMARY DRIVE...31
SHIFT DRUM LOCATING, KICKSTARTER...32
DIVIDING THE ENGINE HOUSING...33
REMOVING THE SHIFT MECHANISM AND TRANSMISSION...34
REMOVING THE CRANKSHAFT...34
SERVICING INDIVIDUAL COMPONENTS...35
RIGHT HOUSING HALF...37
LEFT HOUSING HALF...38
CRANKSHAFT...39
CRANKSHAFT WEBS - MEASURE OUTER DIMENSION...39
PISTON...39
PISTON RING END GAP...39
CHECKING THE CYLINDER FOR WEAR...40
NIKASIL COATING OF CYLINDER...40
DISMOUNTING AND CHECKING THE EXHAUST CONTROL SYSTEM IN THE CYLINDER...41
PREASSEMBLING THE CYLINDER...42
DISMOUNTING THE EXHAUST CONTROL SYSTEM IN THE CLUTCH COVER AND CHECKING PARTS FOR WEAR...45
PREASSEMBLING THE CLUTCH COVER...45
DISASSEMBLING AND CHECKING THE WATER PUMP...46
PREASSEMBLING THE WATER PUMP...46
CHECKING THE CLUTCH FOR WEAR...47
REED VALVE HOUSING, INTAKE FLANGE...48
KICKSTARTER...49
PREASSEMBLING THE KICKSTARTER SHAFT...49
SHIFTING MECHANISM...51
PREASSEMBLING THE SHIFTING SHAFT...51
TRANSMISSION...52
ASSEMBLING THE MAIN SHAFT...52
ASSEMBLING THE COUNTERSHAFT...53
IGNITION, SPARK PLUG...54
CHECK STATOR AND PULSE GENERATOR...54
ASSEMBLING THE ENGINE...55
MOUNTING THE CRANKSHAFT...57
TRANSMISSION AND SHIFT MECHANISM...57
ASSEMBLING THE ENGINE HOUSING...58
ENGINE SPROCKET...58
IGNITION SYSTEM...58
SHIFT DRUM LOCATING DEVICE...59
KICKSTARTER...60
PRIMARY DRIVE AND CLUTCH...60
CLUTCH DISCS AND PRESSURE CAP...61
OIL PUMP, REED VALVE HOUSING AND INTAKE FLANGE (SEPARATE LUBRICATION)...62
CLUTCH COVER...63
REED VALVE HOUSING AND INTAKE FLANGE...63
PISTON AND CYLINDER...64
ADJUSTING DIMENSION “X“...64
ADJUSTING THE CONTROL FLAP (DIMENSION “Z“)...65
CYLINDER HEAD...65
IGNITION COVER...66
MEASURING DIMENSION “Y“...66
MOUNTING THE CLUTCH SLAVE CYLINDER...67
REFILLING THE GEAR OIL...67
ELECTRICAL...69
CHECKING THE VOLTAGE REGULATOR-RECTIFIER (SHINDENGEN)...70
CHECKING THE VOLTAGE REGULATOR (KOKUSAN)...70
CHECKING THE CAPACITOR...70
IGNITION COIL...70
CDI UNIT...71
MEASUREMENTS WITH PEAK VOLTAGE ADAPTER...0
UP TO MODEL 2004...0
STATIC IGNITION VALUES 125-200 SX, MXC, EXC...72
STATIC GENERATOR VALUES 125-200 EXC...74
STATIC IGNITION VALUES / GENERATOR VALUES 125-200 MXC, EXC USA...76
STATIC IGNITION VALUES 125 EXE, SUPERMOTO...78
STATIC GENERATOR VALUES 125 EXE, SUPERMOTO...80
AS OF MODEL 2005...0
STATIC IGNITION VALUES 125/200 SX, SXS, EXC, EXC SIXDAYS...82
STATIC GENERATOR VALUES 125/200 EXC, EXC SIXDAYS...84
STATIC IGNITION AND GENERATOR VALUES 125/200 EXC USA, 200 XC / XC-W...86
FUEL SYSTEM...89
OPERATING RANGES OF THE CARBURETOR...91
CARBURETOR ADJUSTMENT...92
DISMOUNTING AND INSTALLING THE CARBURETOR...95
DISASSEMBLING THE CARBURETOR...97
CHECKING THE JET NEEDLE AND THROTTLE SLIDE...98
CHECKING THE STARTING PISTON...98
CHECKING THE FLOAT NEEDLE VALVE...98
CHECKING THE CARBURETOR JETS AND GASKETS...99
ASSEMBLING THE CARBURETOR...99
DRAINING THE CARBURETOR FLOAT CHAMBER...100
CHECKING THE FLOAT LEVEL...100
TROUBLE SHOOTING...101
TROUBLE SHOOTING 125 / 200...103
TECHNICAL SPECIFICATIONS 1999-2005...105
MODEL 1999...0
ENGINE 125/200...109
CHASSIS 125/200...111
ENGINE 200 ONLY SINGAPORE...112
MODEL 2000...0
ENGINE 125 EXE, SUPERMOTO...113
CHASSIS 125 EXE, SUPERMOTO...114
ENGINE 125/200 SX, MXC, EXC ...115
CHASSIS 125/200 SX, MXC, EXC...117
MODEL 2001...0
ENGINE 125 EXE, SUPERMOTO...113
CHASSIS 125 EXE, SUPERMOTO...114
ENGINE 125/200 SX, MXC, EXC...118
CHASSIS 125/200 SX, MXC, EXC...120
MODEL 2002...0
ENGINE 125/200...121
CHASSIS 125/200...123
MODEL 2003...0
ENGINE 125/200...124
CHASSIS 125/200...126
MODEL 2004...0
ENGINE 125/200...128
CHASSIS 125/200...130
MODEL 2005...0
ENGINE 125/200...132
CHASSIS 125/200...134
TECHNICAL SPECIFICATIONS 2006 / CARBURATOR SPECIFICATION...107
MODEL 2006...0
ENGINE 125...136
ENGINE 200...137
CHASSIS 125...139
CHASSIS 200...140
CARBURATOR SPECIFICATION...0
MODEL 1999...142
MODEL 2000...145
MODEL 2001...148
MODEL 2002...151
MODEL 2003...154
MODEL 2004...158
MODEL 2005...162
MODEL 2006...165
PERIODIC MAINTENANCE SCHEDULE...169
125 / 200 UP TO 2000...171
125 / 200 SX, MXC, EXC 2001/2002...172
125 EXE / SUPERMOTO 2000/2001...174
125 / 200 2003...176
125 / 200 2004...178
125 / 200 2005...180
125 / 200 2006...183
WIRING DIAGRAMS...185
MODEL 1999...0
125/200 EXC (EUROPA)...187
125/200 EGS (EUROPA)...188
125 EXC (USA)...190
200 EXC (USA)...191
MODEL 2000...0
125/200 EXC (USA)...193
125/200 EXC (EUROPA)...194
125 EXE, SUPERMOTO...196
MODEL 2001...0
125/200 EXC (EUROPA)...198
125/200 EXC (USA)...201
125 EXE, SUPERMOTO...196
MODEL 2002...0
125/200 EXC (EUROPA)...198
125/200 EXC (USA)...201
MODEL 2003...0
125/200 EXC (EUROPA/AUS)...202
125/200 EXC (USA)...204
MODEL 2004...0
125/200 EXC (EUROPA)...205
125/200 EXC (USA)...206
125/200 SX...207
TERMS/TRANSLATIONS, CABLE COLOURS...213
MODEL 2005...0
125/200 EXC (EUROPA)...208
125/200 EXC (USA)...209
125 SX...210
TERMS/TRANSLATIONS, CABLE COLOURS...213
MODEL 2006...0
125/200 EXC/EXC SIX DAYS...211
125 SX/SXS...210
200 XC...210
200 XC-W...212
TERMS/TRANSLATIONS, CABLE COLOURS...213
...
HOME...0
NOTES AND PREFACE...1
Title page and file spine...1
Important information...7
Updating instruction...7
Explanation update...9
Introduction...11
Reply fax for repair manuals...13
TABLE OF CONTENTS...5
SERVICE-INFORMATIONS...1
DERESTRICTION...0
INTERMEDIATE FLANGE...0
SHIFT SPRING...0
CHAIN TENSION...0
CONTROL FLAP AXLE...0
OILPUMP ADJUSTMENT...0
CRANKSHAFT MAIN BEARING...0
MASTER CYLINDER...0
GENERAL INFORMATION...15
OPERATING RANGES OF THE CARBURETOR...17
CARBURETOR ADJUSTMENT...18
BLEEDING OF THE HYDRAULIC CLUTCH...19
OIL PUMP ADJUSTING -...20
CHECK OF EXHAUST CONTROL...21
REMOVING AND REFITTING ENGINE...23
REMOVING THE ENGINE...25
REFITTING THE ENGINE...26
DISASSEMBLING THE ENGINE...29
SPECIAL TOOLS – ENGINE 125/200...31
DRAINING THE GEAR OIL...32
DISMOUNTING THE CLUTCH SLAVE CYLINDER...32
CYLINDER HEAD, CYLINDER, PISTON...32
IGNITION...33
ENGINE SPROCKET...33
REED VALVE HOUSING, INTAKE FLANGE AND CLUTCH COVER...34
REED VALVE HOUSING, INTAKE FLANGE AND OIL PUMP...35
REMOVING CLUTCH AND PRIMARY DRIVE...35
SHIFT DRUM LOCATING, KICKSTARTER...36
DIVIDING THE ENGINE HOUSING...37
REMOVING SHIFT MECHANISM AND TRANSMISSION...38
REMOVING CRANKSHAFT...38
SERVICING INDIVIDUAL COMPONENTS...39
RIGHT HOUSING HALF...41
LEFT HOUSING HALF...42
CRANKSHAFT...43
CRANKSHAFT WEBS – MEASURE OUTER DIMENSION...43
PISTON...43
PISTON RING END GAP...43
CHECKING CYLINDER FOR WEAR...44
NIKASIL COATING OF CYLINDER...44
DISMOUNTING AND CHECKING THE EXHAUST CONTROL...45
PREASSEMBLING THE CYLINDER...46
CLUTCH COVER...49
PREASSEMBLING THE CLUTCH COVER...49
WATER PUMP...50
PREASSEMBLING THE WATER PUMP...50
CHECKING CLUTCH FOR WEAR...51
REED VALVE HOUSING, INTAKE FLANGE...52
KICKSTARTER...53
PREASSEMBLING THE KICKSTARTER SHAFT...53
SHIFT MECHANISM...55
PREASSEMBLING THE SHIFT SHAFT...55
TRANSMISSION...56
ASSEMBLING THE MAIN SHAFT...56
ASSEMBLING THE COUNTERSHAFT...57
IGNITION...58
CHECK STATOR AND PULSE GENERATOR...58
ASSEMBLING THE ENGINE...59
MOUNTING THE CRANKSHAFT...61
TRANSMISSION SHAFT, SHIFT MECHANISM...61
ASSEMBLING THE ENGINE HOUSING...62
ENGINE SPROCKET...62
IGNITION SYSTEM...62
SHIFT DRUM LOCATING DEVICE...63
KICKSTARTER...64
PRIMARY DRIVE, CLUTCH...64
CLUTCH DISCS, PRESSURE CAP...65
OIL PUMP, REED VALVE HOUSING, INTAKE FLANGE...66
REED VALVE HOUSING, INTAKE FLANGE...67
CLUTCH COVER...67
PISTON, CYLINDER...68
ADJUSTING DIMENSION „X“...68
ADJUSTING THE CONTROL FLAP (DIMENSION „Z“)...69
CYLINDER HEAD...69
IGNITION COVER...70
MEASURING DIMENSION „Y“...70
MOUNTING THE CLUTCH SLAVE CYLINDER...71
FILLING IN THE GEAR OIL...71
ELECTRICAL...73
CHECKING THE VOLTAGE REGULATOR-RECTIFIER (SHINDENGEN)...74
CHECKING THE VOLTAGE REGULATOR (KOKUSAN)...74
CHECKING THE CAPACITOR...74
IGNITION COIL (KOKUSAN)...74
CDI UNIT...75
MEASUREMENTS WITH PEAK VOLTAGE ADAPTER...73
STATIC IGNITION VALUES 125-200 SX, MXC, EXC...76
STATIC GENERATOR VALUES 125-200 EXC...78
STATIC IGNITION VALUES/GENERATOR VALUES 125-200 MXC, EXC USA...80
STATIC IGNITION VALUES 125 EXE, SUPERMOTO...82
STATIC GENERATOR VALUES 125 EXE, SUPERMOTO...84
TROUBLE SHOOTING...87
TECHNICAL SPECIFICATIONS...91
MODEL 1999...91
TECHNICAL SPECIFICATIONS – ENGINE 125/200...93
TECHNICAL SPECIFICATIONS – CHASSIS 125/200...95
TECHNICAL SPECIFICATIONS – ENGINE 200 ONLY SINGAPORE...96
BASIC CARBURETOR SETTING – 200 ONLY SINGAPORE...96
MODEL 2000...91
TECHNICAL SPECIFICATIONS – ENGINE 125 EXE, SUPERMOTO...97
TECHNICAL SPECIFICATIONS – CHASSIS 125 EXE, SUPERMOTO...98
TECHNICAL SPECIFICATIONS – ENGINE 125/200 SX, MXC, EXC...99
TECHNICAL SPECIFICATIONS – CHASSIS 125/200 SX, MXC, EXC...101
MODEL 2001...91
TECHNICAL SPECIFICATIONS – ENGINE 125 EXE, SUPERMOTO...97
TECHNICAL SPECIFICATIONS – CHASSIS 125 EXE, SUPERMOTO...98
TECHNICAL SPECIFICATIONS – ENGINE 125/200...102
TECHNICAL SPECIFICATIONS – CHASSIS 125/200...104
MODEL 2002...91
TECHNICAL SPECIFICATIONS – ENGINE 125/200...105
TECHNICAL SPECIFICATIONS – CHASSIS 125/200...107
MODEL 2003...91
TECHNICAL SPECIFICATIONS – ENGINE 125/200...108
TECHNICAL SPECIFICATIONS – CHASSIS 125/200...110
CARBURATOR SPECIFICATION...91
MODEL 1999...112
MODEL 2000...115
MODEL 2001...118
MODEL 2002...121
MODEL 2003...124
PERIODIC MAINTENANCE SCHEDULE...129
125 / 200 UP TO 2000...131
125 / 200 SX, MXC, EXC 2001 / 2002...132
125 EXE, SUPERMOTO...134
125 / 200 SX, MXC, EXC 2003...136
WIRING DIAGRAMS...139
WIRING DIAGRAMS 1999...139
125/200 EXC (EUROPE)...141
125/200 EGS...142
125 EXC (USA)...144
200 EXC (USA)...145
WIRING DIAGRAMS 2000...139
125/200 EXC (USA)...147
125/200 EXC (EUROPA)...148
125 EXE, SUPERMOTO...150
WIRING DIAGRAMS 2001...139
125/200 EXC (EUROPA)...152
125/200 EXC (USA)...155
125 EXE, SUPERMOTO...150
WIRING DIAGRAMS 2002...139
125/200 EXC (EUROPA)...152
125/200 EXC (USA)...155
WIRING DIAGRAMS 2003...139
125/200 EXC (EUROPA)...156
125/200 EXC (USA)...158
KTM 60/65/125/200/350/390 Repair Service Manual 1998-2014
