TABLE OF CONTENTS 3
11.23 Installing the air filter box cover ....................... 58
11.24 Removing the air filter ................................. 59
11.25 Cleaning the air filter and air filter box .......... 59
11.26 Installing the air filter .................................. 60
11.27 Securing the air filter box cover .................... 60
11.28 Sealing the air filter box ............................... 61
11.29 Disassembling the main silencer ...................... 61
11.30 Installing the main silencer.............................. 62
11.31 Changing the glass fiber yarn filling in the
main silencer .............................................. 62
11.32 Removing the fuel tank ................................ 63
11.33 Installing the fuel tank ................................. 64
11.34 Checking the chain for dirt............................... 66
11.35 Cleaning the chain .......................................... 66
11.36 Checking the chain tension .............................. 67
11.37 Adjusting the chain tension.............................. 67
11.38 Checking the chain, rear sprocket, engine
sprocket, and chain guide................................ 68
11.39 Checking the frame ..................................... 71
11.40 Checking the swingarm ................................ 71
11.41 Checking the routing of the throttle cable.......... 71
11.42 Checking the rubber grip ................................. 72
11.43 Additionally securing the rubber grip................. 73
11.44 Adjusting basic position of clutch lever ............. 73
11.45 Checking/correcting the fluid level of the
hydraulic clutch.............................................. 73
11.46 Changing the hydraulic clutch fluid ............... 73
12 BRAKE SYSTEM ........................................................ 75
12.1 Checking the free travel of the hand brake
lever .............................................................. 75
12.2 Adjusting the basic position of the hand brake
lever .............................................................. 75
12.3 Checking the brake discs ................................. 75
12.4 Checking the front brake fluid level .................. 76
12.5 Adding front brake fluid ............................... 76
12.6 Checking the front brake linings ....................... 77
12.7 Changing the front brake linings ................... 77
12.8 Checking the free travel of foot brake lever ........ 79
12.9 Adjusting the basic position of the foot brake
lever ........................................................... 79
12.10 Checking the rear brake fluid level.................... 80
12.11 Adding rear brake fluid ................................ 81
12.12 Checking the rear brake linings ........................ 82
12.13 Changing the rear brake linings ..................... 82
13 WHEELS, TIRES ........................................................ 84
13.1 Removing the front wheel ............................. 84
13.2 Installing the front wheel ............................. 84
13.3 Removing the rear wheel .............................. 85
13.4 Installing the rear wheel ............................... 86
13.5 Checking the tire condition .............................. 86
13.6 Checking the tire air pressure........................... 87
13.7 Checking the spoke tension.............................. 87
14 ELECTRICAL SYSTEM ................................................ 89
14.1 Removing the battery (All XC models)............ 89
14.2 Installing the battery (All XC models)............. 89
14.3 Recharging the battery (All XC models).......... 90
14.4 Change the main fuse (All XC models)............... 91
15 COOLING SYSTEM ..................................................... 92
15.1 Cooling system ............................................... 92
15.2 Radiator cover (All 125/150 models) ................ 92
15.3 Installing the radiator cover (All 125/150
models).......................................................... 92
15.4 Removing the radiator cover (All 125/150
models).......................................................... 93
15.5 Checking the antifreeze and coolant level.......... 93
15.6 Checking the coolant level ............................... 94
15.7 Draining the coolant .................................... 94
15.8 Refilling with coolant ................................... 95
16 TUNING THE ENGINE................................................ 97
16.1 Checking the play in the throttle cable .............. 97
16.2 Adjusting the play in the throttle cable .......... 97
16.3 Carburetor – idle............................................. 98
16.4 Carburetor – adjusting the idle speed ............ 98
16.5 Ignition curve plug-in connector ....................... 99
16.6 Changing the ignition timing map ................... 100
16.7 Checking the basic position of the shift lever ... 100
16.8 Adjusting the basic position of the shift
lever ......................................................... 101
16.9 Engine characteristic – auxiliary spring (All
250/300 models).......................................... 101
16.10 Engine characteristic – setting the auxiliary
spring (All 250/300 models) ...................... 101
17 SERVICE WORK ON THE ENGINE ............................. 103
17.1 Emptying the carburetor float chamber ........ 103
17.2 Checking the gear oil level ............................. 103
17.3 Changing the gear oil ................................. 104
17.4 Draining the gear oil .................................. 104
17.5 Refilling with gear oil ................................. 105
17.6 Adding gear oil .......................................... 106
18 CLEANING, CARE .................................................... 107
18.1 Cleaning the motorcycle ................................ 107
19 STORAGE................................................................ 108
19.1 Storage ........................................................ 108
19.2 Preparing for use after storage........................ 108
20 TROUBLESHOOTING ............................................... 109
21 TECHNICAL DATA.................................................... 111
21.1 Engine ......................................................... 111
21.1.1 All 125 models......................................... 111
21.1.2 All 150 models......................................... 111
21.1.3 250 SX.................................................... 112
21.1.4 250 XC.................................................... 112
21.1.5 300 XC.................................................... 113
21.2 Engine tightening torques .............................. 114
21.2.1 All 125/150 models.................................. 114
21.2.2 250 SX.................................................... 114
21.2.3 All XC models........................................... 115
21.3 Carburetor.................................................... 117
21.3.1 All 125 models......................................... 117
21.3.2 Carburetor - basic setting for sandy
surfaces (All 125 models).......................... 117
21.3.3 Carburetor tuning (All 125 models) ............ 118
21.3.4 All 150 models......................................... 119
21.3.5 Carburetor - basic setting for sandy
surfaces (All 150 models).......................... 119
21.3.6 Carburetor tuning (All 150 models) ............ 120
21.3.7 250 SX.................................................... 121
21.3.8 Carburetor - basic setting for sandy
surfaces (250 SX)..................................... 121
21.3.9 Carburetor tuning (250 SX)........................ 122
21.3.10 250 XC.................................................... 123
21.3.11 Carburetor tuning (250 XC)........................ 123
21.3.12 300 XC.................................................... 125
21.3.13 Carburetor tuning (300 XC) .................... 125
21.3.14 General carburetor tuning ...................... 126
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