Husqvarna FC 350 2014 Repair Manual
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Husqvarna FC 350 2014 Repair Manual

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PIONEERING SINCE 1903
REPAIR MANUAL2014
FC 350 EU
®
Husqvarna
Art. no. 3403006en
MOTORCYCLES

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Summary of Contents for Husqvarna FC 350 2014

  • Page 1 PIONEERING SINCE 1903 REPAIR MANUAL2014 FC 350 EU ® Husqvarna Art. no. 3403006en MOTORCYCLES...
  • Page 3 Husqvarna accepts no lia­ bility for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 6.32 Changing the steering head bearing ....40 MEANS OF REPRESENTATION ........6 6.33 Adjusting the steering head bearing play ... 41 Symbols used ............6 HANDLEBAR, CONTROLS ..........42 1 .2 Formats used ............6 Handlebar position ..........
  • Page 5 TABLE OF CONTENTS 11.4 Installing the air filter ........... 77 16.4 Adjusting the basic position of the hand brake lever ............111 11.5 Cleaning the air filter and air filter box ....

  • Page 6: Installing The Manifold

    TABLE OF CONTENTS 17.4.5 Checking the lubrication system ....14 7 17.5.15 Installing the outer clutch hub ...... 17.4.6 Removing the crankshaft bearing inner 17.5.16 Installing the clutch discs ......race .............. 148 17.5.17 Installing the clutch cover ......17.4.7 Changing the connecting rod, conrod 17.5.18 Installing the water pump cover ....
  • Page 7 TABLE OF CONTENTS 23.4.3 Fuel ............... 204 23.5 Chassis ............. 205 23.6 Electrical system ..........205 23. 7 Tires ..............205 23.8 Fork ..............

  • Page 8: Means Of Representation

    MEANS OF REPRESENTATION S mbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). Indicates a page reference (more information is provided on the specified page). Indicates information with more details or tips .

  • Page 9: Safety Advice

    Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you repair and maintain your vehicle. This manual assumes that the necessary special Husqvarna tools and Husqvarna workplace and workshop equipment are avail­ able.

  • Page 10: Important Notes

    IMPORTANT NOTES Manufacturer and im lied warran The work prescribed in the service schedule must be carried out by an authorized Husqvarna Motorcycles workshop only and con­ firmed both in the customer's Service & Warranty Booklet and in the Husqvarna Motorcycles Dealer.net;...

  • Page 11: Serial Numbers

    SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. 401945-10 The type label is fixed to the front of the steering head. 401946-10 The engine number is stamped on the left side of the engine under the engine sprocket.

  • Page 12: Motorcycle

    MOTORCYCLE Raising the motorc cle with the lift stand Note Danger of damage The parked vehicle may roll away or fall over. Always place the vehicle on a firm and even surface. Raise the motorcycle at the frame underneath the engine. ✓...

  • Page 13: Starting The Motorcycle For A Check

    MOTORCYCLE Press the electric starter button CD. • Info Press the electric starter button for at most 5 seconds. Wait for a least 5 seconds before trying again. Fl warning lamp lights up briefly as a functional control when starting. 400733-01 Starting the motorc cle for a check Danger...

  • Page 14: Fork, Triple Clamp

    FORK, TRIPLE CLAMP Ad"ustin in of the fork Info The hydraulic compression damping determines the fork suspension behavior. Turn adjusting screws clockwise all the way. • Info Adjusting screws are located at the top end of the fork legs. Make the same adjustment on both fork legs. Turn counterclockwise by the number of clicks corresponding to the fork type.

  • Page 15: Cleaning The Dust Boots Of The Fork Legs

    FORK, TRIPLE CLAMP Main work Release bleeder screws ✓ Any excess pressure escapes from the interior of the fork. Tighten the bleeder screws. Finishing work Remove the motorcycle from the lift stand. ( p. 10) Cleaning the dust boots of the fork legs Preparatory work Raise the motorcycle with the lift stand.

  • Page 16: Positioning The Fork Protection

    FORK, TRIPLE CLAMP Position the fork protection on the left fork leg. Mount and tighten screws Guideline Remaining screws, chassis 110 Nm (7.4 lbf ft) Position the brake line and clamp. Mount and tighten screws Position the fork protection on the right fork leg. Mount and tighten the screws. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft)

  • Page 17: Removing The Fork Protector

    FORK, TRIPLE CLAMP Position the brake caliper. Mount and tighten screws Guideline 25 Nm Screw, front brake caliper Loctite ® ™ (18.4 lbf ft) Position the brake line and clamp. Mount and tighten screws Finishing work Install the front wheel. (,... p. 93) Removing the fork rotector Preparatory work Raise the motorcycle with the lift stand.

  • Page 18: Conducting Minor Fork Service

    FORK, TRIPLE CLAMP Disassemble the fork legs. (or p. 16) Disassemble the cartridge. (or p. 19) Disassemble the piston rod. (or p. 21) Disassemble the screw cap with the membrane holder. (or p. 22) Disassemble the screw sleeve. (or p. 23) Check the fork legs.
  • Page 19 FORK, TRIPLE CLAMP Remove protection cap 6). Note down the present state of rebound damping and compression damp­ ing@. Fully open the adjusters of the rebound and compression damping. Clamp the fork leg in the area of the lower triple clamp. Clamping stand (T1403S) (- p.
  • Page 20 FORK, TRIPLE CLAMP Press the cartridge against the spring and mount special tool (D on the piston rod. Support tool (T14020) (,... p. 231) Hold nut @ and remove the rebound adjuster. Press the cartridge against the spring and remove special tool (D. Remove the cartridge from the fork leg.

  • Page 21: Disassembling The Cartridge

    FORK, TRIPLE CLAMP 48 . Remove upper sliding bushing Info Without using a tool, carefully pull the stack apart by hand. Take off the lower sliding bushing Ci). Take off support ring Take off seal ring Cl). Take off lock ring Take off dust boot Unclamp the fork leg.
  • Page 22 FORK, TRIPLE CLAMP Pierce the membrane with the needle of the special tool. Nitrogen charging tool (T14019) (- p. 231) ✓ The pressurized nitrogen is bled off. 200838-10 Loosen and remove screw cap with the membrane holder. Pin wrench (T103) (- p. 228) Unclamp the cartridge.

  • Page 23: Disassembling The Piston Rod

    FORK, TRIPLE CLAMP C&. Remove filling screw and O-ring 200845-10 Press check valve against the spring and remove it. 200846-10 Disassemblin iston rod Info The steps are identical for both fork legs. Preparatory work Disassemble the fork legs. (,... p. 16) Disassemble the cartridge.

  • Page 24: Disassembling The Screw Cap With The Membrane Holder

    FORK, TRIPLE CLAMP Remove the piston ring from the piston. 200859-10 Remove compression shim stack Remove spring@. Remove tap rebound @. Remove spring with the sleeve. Remove the valve with the spring from tap rebound Remove the 0-rings. 200862-10 Disassembling the screw ca� with the membrane holder Info The steps are identical for both fork legs.

  • Page 25: Disassembling The Screw Sleeve

    FORK, TRIPLE CLAMP Remove membrane Unclamp the special tool. Remove O-ring Clamp the open end wrench in a vise. Position compression holder Remove nut Remove spring Remove rebound washer Remove compression piston@. Remove O-ring @. Remove compression shim stack@). Remove O-ring 41). Disassembling the screw sleeve Info The steps are identical for both fork legs.

  • Page 26: Checking The Fork Legs

    FORK, TRIPLE CLAMP Screw the special tool onto the screw sleeve. Threaded bushing (T14023) (- p. 232) ✓ The special tool must have an overhang to protect the thread. I Overhang 11 mm (0.04 in) Pry out seal ring being sure only to brace the lever against the special tool. 200867-10 6.18 Checking the fork legs...

  • Page 27: Service

    FORK, TRIPLE CLAMP Check the surface of the sliding bushing. If the bronze-colored layer under the sliding layer is visible or the sur­ face is rough: Replace the sliding bushing. � 200665-10 Check the spring length. Guideline Spring length with preload spacer(s) 490 mm (19.29 in) If the measured value is greater than the specified value: Reduce the thickness of the preload spacers.

  • Page 28: Changing The Pilot Bushing

    FORK, TRIPLE CLAMP Measure the outside diameter of the inner tube at several locations. Outside diameter of the inner tube 47.975 ... 48.005 mm (1.88878 ... 1.88996 in) If the measured value is less than the specified value: Change the inner tube. Measure the run-out of the inner tube.

  • Page 29: Assembling The Screw Sleeve

    FORK, TRIPLE CLAMP Main work Press the pilot bushing out of screw sleeve using the special tool. Mounting tool (T14022) ( p. 232) Slide the new pilot bushing fj onto the special tool. Mounting tool (T14022) ( p. 232) Ensure that special tool is mounted and that there is an overhang to protect the thread.

  • Page 30: Assembling The Screw Cap With The Membrane Holder

    FORK, TRIPLE CLAMP Assembling the screw ca with the membrane holder Info The steps are identical for both fork legs. Preparatory work Check the fork legs. ( p. 24) ,... Main work Lubricate and mount O-ring Lubricant (T158) ( ,... p.

  • Page 31: Assembling The Piston Rod

    FORK, TRIPLE CLAMP Assembling the iston rod Info The steps are identical for both fork legs. Mount and grease the O-rings of tap rebound and the valve. Lubricant (T158) ( p. 219) Position the valve with the spring in the tap rebound. 200862-11 Degrease the piston rod.

  • Page 32: Assembling The Cartridge

    FORK, TRIPLE CLAMP Mount rebound shim stack (3. Info Align triangular plates exactly with the openings of the rebound piston. Mount and tighten new nut @ with the collar facing downward. Guideline Rebound nut M6x0.5 I 5 Nm (3.7 lbf ft} •...
  • Page 33 FORK, TRIPLE CLAMP Place the special tool onto the piston rod. Mounting sleeve (T14029) (r p. 232) Grease seal ring @ and slide onto the piston rod with the open side forward. Remove the special tool. Lubricant (T511) (r p. 219) Slide screw sleeve onto the piston rod.

  • Page 34: Assembling The Fork Legs

    FORK, TRIPLE CLAMP Assembling the fork le s Info The steps are identical for both fork legs. Preparatory work Check the fork legs. ( p. 24) ,... Assemble the screw cap with the membrane holder. ( ,... p. 28) Assemble the piston rod. ( p.
  • Page 35 FORK, TRIPLE CLAMP Slide on the outer tube. Warm up the outer tube in area of the lower sliding bushing. Guideline 50 °c (122 °F) Hold the lower sliding bushing with the longer shoulder of the special tool. Mounting tool (T14040S) ('r p. 233) Press the outer tube all the way in.
  • Page 36 FORK, TRIPLE CLAMP Hold onto nut and tighten the rebound adjuster. Guideline Rebound adjuster on the piston rod M12x1 30 Nm (22.1 lbf ft) Press the cartridge against the spring and remove special tool @. Tighten the rebound adjuster. Guideline Rebound adjuster on the axle clamp M20x1 30 Nm (22.1 lbf ft)

  • Page 37: Bleeding And Filling The Cartridge

    FORK, TRIPLE CLAMP Alternative 2 Warning Danger of accident Modifications to the suspension setting may seriously alter the handling characteristic. Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components. Only make adjustments within the recommended range. Ride slowly to start with after making adjustments to get the feel of the new handling characteristic.

  • Page 38: Filling The Cartridge With Nitrogen

    FORK, TRIPLE CLAMP When the vacuum gauge reaches the required value, turn control lever Oil reser­ voir Equalize pressure. Guideline 10 mbar ✓ The pressure gauge increases to the required value. 0 bar When the pressure gauge reaches the required value, turn control lever Damper Pressure.

  • Page 39: Greasing The Steering Head Bearing

    FORK, TRIPLE CLAMP Fill the cartridge for at least 15 seconds. Guideline Gas pressure 1 .2 bar (1 7 psi) Info Watch the pressure regulator dial. Ensure that the cartridge is filled to the specified pressure. Close the valve. Close the nitrogen bottle. Remove the special tool.

  • Page 40: Installing The Lower Triple Clamp

    FORK, TRIPLE CLAMP 6.30 Installing the lower tri Main work Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease (,r p. 219) Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

  • Page 41: Checking The Steering Head Bearing Play

    FORK, TRIPLE CLAMP Mount and tighten screw@. Guideline Screw, top steering stem 17 Nm Loctite ® ™ (12.5 lbf ft) Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains. Tighten screws Guideline Screw, top triple clamp 17 Nm (12.5 lbf ft) Secure the wiring harness with cable holder@).

  • Page 42: Changing The Steering Head Bearing

    FORK, TRIPLE CLAMP Move the handlebar to and fro over the entire steering range. The handlebar must be able to move easily over the entire steering range. No resting locations should be noticeable. If click positions are noticeable: Adjust the steering head bearing play. ('r p. 41) Check the steering head bearing and change if necessary.

  • Page 43: Adjusting The Steering Head Bearing Play

    FORK, TRIPLE CLAMP Pull off bearing Remove seal ring retainer. Remove O-ring. Grease the new O-ring and mount with seal ring retainer. Press on the new bearing with a suitable tube as far as it will go. G01808-10 Finishing work Install the lower triple clamp.

  • Page 44: Handlebar,Controls

    HANDLEBAR,CONTROLS Handlebar osition On the upper triple clamp, there are two holes at a distance of to each other. I Hole distance A 15 mm (0.59 in) The holes on the handlebar support are placed at a distance of from the center. I Hole distance B I 3.5 mm (0.138 in) The handlebar can be mounted in four different positions.

  • Page 45: Checking The Throttle Cable Routing

    HANDLEBAR,CONTROLS Checkin the throttle cable routin Preparatory work Remove the seat. (.- p. 80) Remove the fuel tank. (.- p. 80) Main work Check the throttle cable routing. Both throttle cables must be routed to the throttle valve body side by side behind the handlebars and above the fuel tank bracket.

  • Page 46: Checking The Play In The Throttle Cable

    HANDLEBAR,CONTROLS in the throttle cable Preparatory work Remove the seat. (.- p. 80) Remove the fuel tank. (.- p. 80) Check the throttle cable routing. (.- p. 43) Main work Move the handlebar to the straight-ahead position. Push back sleeves Loosen nut @.

  • Page 47: Frame

    If the frame exhibits cracks or deformation due to a mechanical impact: Change the frame. • Info Always replace a frame that has been damaged due to a mechan­ ical impact. Repair of the frame is not authorized by Husqvarna Motorcycles.

  • Page 48: Shock Absorber, Swingarm

    SHOCK ABSORBER, SWINGARM Ad"ustin Caution Danger of accidents Disassembly of pressurized parts can lead to injury. The shock absorber is filled with high density nitrogen. Adhere to the description provided. Info The high-speed setting can be seen during the fast compression of the shock absorber. Turn adjusting screw all the way clockwise with a socket wrench.

  • Page 49: Adjusting The Rebound Damping Of The Shock Absorber

    SHOCK ABSORBER, SWINGARM Ad"ustin the rebound dam in of the shock absorber Caution Disassembly of pressurized parts can lead to injury. Danger of accidents The shock absorber is filled with high density nitrogen. Adhere to the description provided. Turn adjusting screw clockwise up to the last perceptible click.

  • Page 50: Checking The Riding Sag Of The Shock Absorber

    SHOCK ABSORBER, SWINGARM sag of the shock absorber Measure distance of rear wheel unloaded.( p. 47) With another person holding the motorcycle, the rider, wearing full protective clothing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down a few times.

  • Page 51: Adjusting The Riding Sag

    SHOCK ABSORBER, SWINGARM Finishing work Install the shock absorber. (.- p. 50) Install the main silencer. (.- p. 75) Install the right side cover. (.- p. 80) Mount the seat. (.- p. 80) Remove the motorcycle from the lift stand. (.- p. 10) Adjusting the riding sag Preparatory work Raise the motorcycle with the lift stand.

  • Page 52: Installing The Shock Absorber

    SHOCK ABSORBER, SWINGARM Press angle lever toward the rear. Press linkage lever downward. Detach springs Spring hook (50305017000) (- p. 221) Remove screw and take off the manifold. Remove screws @ on both sides. Loosen screws on both sides. Remove screw Raise the rear frame slightly and remove the shock absorber toward the top.

  • Page 53: Checking The Shock Absorber Linkage

    SHOCK ABSORBER, SWINGARM Position the rear frame. Mount and tighten screws on both sides. Guideline Screw, subframe 30 Nm Loctite ® 2701 (22.1 lbf ft) Remove screws on both sides. Mount and tighten screws on both sides. Guideline Screw, subframe 30 Nm Loctite 2701...

  • Page 54: Clearance

    SHOCK ABSORBER, SWINGARM Remove screw connection Take off the angle lever. 303096-10 Check needle bearing for damage and wear. If there is damage or wear: Change the needle bearing. Check spacers and @ for damage and wear. If there is damage or wear: Change the spacers.

  • Page 55: Servicing The Shock Absorber

    SHOCK ABSORBER, SWINGARM Mount screw but do not tighten yet. Guideline Screw, bottom shock 60 Nm Loctite 2701 ™ ® absorber (44.3 lbf ft) • Info Raise the wheel slightly to make it easier to mount the screw. Position the linkage lever. Mount and tighten fitting @.

  • Page 56: Removing The Spring

    SHOCK ABSORBER, SWINGARM 9.13 ring Condition The shock absorber has been removed. Clamp the shock absorber in the vise using soft jaws for protection. Measure and note spring length in its preloaded state. Loosen screw Turn adjusting ring until the spring is no longer under tension. Hook wrench (T106S) (- p.

  • Page 57: Disassembling The Piston Rod

    SHOCK ABSORBER, SWINGARM Press in seal ring retainer (3 using the special tool. Disassembly tool (T1216) (- p. 230) Remove lock ring @. Info Do not scratch the inner surface. Remove the piston rod. Remove adjusting ring (;) with the intermediate washer. Drain the oil.

  • Page 58: Disassembling The Seal Ring Retainer

    SHOCK ABSORBER, SWINGARM Main work Clamp the piston rod with the fork in a vise. Guideline Use soft jaws. Remove nut Remove washer Remove rebound shim stack • Info Place the rebound shim stack onto a screwdriver and set it down as a unit. Remove piston Remove compression shim stack •...

  • Page 59: Changing The Pilot Bushing

    SHOCK ABSORBER, SWINGARM Remove centering disk Remove seal ring 201406-10 Remove washer for seal ring Remove washer @. Remove dust boot. 201407-10 9.17 Chan ilot bushin Preparatory work Remove the spring. ( p. 54) Disassemble the damper. ( p. 54) Disassemble the piston rod.

  • Page 60: Checking The Damper

    SHOCK ABSORBER, SWINGARM 9.18 Condition The damper has been disassembled. Measure the inside diameter on both ends and in the middle of the damper car­ tridge. Damper cartridge Diameter s 50.08 mm (S 1.9716 in) If the measured value is greater than the specified value: Change the damper cartridge.

  • Page 61: Installing The Heim Joint

    SHOCK ABSORBER, SWINGARM Remove seal rings on both sides. Press the heim joint against a lock ring using the special tool. Pressing tool (T1207S) (- p. 230) Remove the second lock ring Place special tool underneath and press out heim joint with special tool@).

  • Page 62: Assembling The Seal Ring Retainer

    SHOCK ABSORBER, SWINGARM Position both collar bushings and press them in. 9.21 Mount dust boot using the special tool. Mounting sleeve (T1204) ( ,..p. 229) Lubricate the sealing lip of the dust boot. Lubricant (T625) ( p. 219) ,..Mount washer@}.

  • Page 63: Assembling The Piston Rod

    SHOCK ABSORBER, SWINGARM 9.22 Assembling the iston rod Preparatory work Assemble the seal ring retainer. ( p. 60) Main work Clamp the piston rod with the fork in a vise. Guideline Use soft jaws. Mount rubber buffer and locking cap Position special tool on the piston rod.

  • Page 64: Assembling The Damper

    SHOCK ABSORBER, SWINGARM Mount washer with the collar facing downward. Grease the thread of the piston rod. Lubricant (T152) ( p. 219) Mount and tighten nut Guideline Nut, piston rod M16x1 45 Nm (33.2 lbf ft) 9.23 Assemblin Preparatory work Assemble the seal ring retainer.
  • Page 65 SHOCK ABSORBER, SWINGARM Install the seal ring bearer and push it under the ring groove. Mount lock ring • Info Do not scratch the inner surface. Pull out the piston rod so that the seal ring retainer rests against the lock ring. Mount locking cap (3 of the damper cartridge.

  • Page 66: Bleeding And Filling The Damper

    SHOCK ABSORBER, SWINGARM Alternative 2 Warning Danger of accident Modifications to the suspension setting may seriously alter the handling characteristic. Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components. Only make adjustments within the recommended range. Ride slowly to start with after making adjustments to get the feel of the new handling characteristic.
  • Page 67 SHOCK ABSORBER, SWINGARM When the vacuum pressure gauge reaches the specified value, turn the Oil reser­ voir control lever to Equalize pressure. Guideline 4 mbar ✓ The pressure gauge increases to the specified value. 0 bar When the pressure gauge reaches the specified value, turn the Damper control lever...

  • Page 68: Filling The Damper With Nitrogen

    SHOCK ABSORBER, SWINGARM When the pressure gauge reaches the specified value, turn the con­ Damper trol lever to Vacuum. Guideline 3 bar ✓ The pressure gauge drops to the specified value. 0 bar When the pressure gauge reaches the specified value, operate the switch.

  • Page 69: Installing The Spring

    SHOCK ABSORBER, SWINGARM Open filler tap G). Fill the damper for at least 15 seconds. Guideline Gas pressure 11 0 bar (145 psi) • Info Watch the pressure regulator dial. Make sure that the damper is filled to the specified pressure. Close the filling port screw using tap handle f).

  • Page 70: Checking The Swingarm

    If the swingarm shows signs of damage, cracking, or deformation: Change the swingarm. • Info Always change a damaged swingarm. Repair of the swingarm is not authorized by Husqvarna M otorcycles. 500285-01 9.28 Removing the swingarm Preparatory work Raise the motorcycle with the lift stand. (- p. 10) Remove the rear wheel.

  • Page 71: Installing The Swingarm

    SHOCK ABSORBER, SWINGARM Remove connecting link of the chain. • Info Cover the components to protect them against damage. Take off the chain. Remove fitting Lower the swingarm. Remove nut Remove the swingarm pivot. Remove the swingarm. Main work Position the swingarm. Mount the swingarm pivot. Mount and tighten nut Guideline Nut, swingarm pivot...

  • Page 72: Changing The Swingarm Bearing

    SHOCK ABSORBER, SWINGARM Position the engine sprocket cover and mount in the holder. Mount and tighten screws Guideline Screw, clutch slave cylinder 10 Nm (7.4 lbf ft) Remaining screws, chassis 25 Nm (18.4 lbf ft) Position the brake caliper and pull it back. Position the brake line in the guide.
  • Page 73 SHOCK ABSORBER, SWINGARM Main work Remove the outer collar bushings G01813-10 Remove bushing G01814-10 Remove shaft seal rings using a suitable tool. Using a suitable tool, press the bearing out from the inside to the outside. Press in the new bearing until it is flush using a suitable tool.
  • Page 74 SHOCK ABSORBER, SWINGARM Press in shaft seal rings Mount bushing(!}. G01814-10 Grease the shaft seal rings. Long-life grease (- p. 219) •- Position collar bushings with the shoulder facing inward. G01819-10 Finishing work Install the swingarm. (- p. 69) Install the rear wheel. (- p. 96) Remove the motorcycle from the lift stand.

  • Page 75: Exhaust

    EXHAUST 10.1 Removin the manifold Preparatory work Raise the motorcycle with the lift stand. (,... p. 10) Remove the right side cover. (,... p. 79) Remove the main silencer. (,... p. 75) Main work Remove screw Remove fitting @. Press angle lever toward the rear.
  • Page 76 EXHAUST Remove screw Turn the shock absorber and lower it. Take off the manifold. Main work Slip in the manifold and position it. Position the shock absorber and mount and tighten screw Guideline Screw, top shock 60 Nm Loctite 2701 ®...

  • Page 77: Removing The Main Silencer

    EXHAUST Finishing work Install the main silencer. (,..p. 75) Install the right side cover. (,..p. 80) Remove the motorcycle from the lift stand. (,..p. 10) Removin the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. Allow the exhaust system to cool down.
  • Page 78 EXHAUST Main work Remove all screws on the main silencer. Take off silencer cap and O-ring @. Take off outer tube and O-ring Pull glass fiber yarn filling off of inner tube (D. Clean the parts that are to be reinstalled. Mount the new glass fiber yarn filling on the inner tube.

  • Page 79: Air Filter

    AIR FILTER Release catch pull off the air filter box lid sideways in areas f) and G) and remove toward the rear. Position the air filter box lid and tab Engage the air filter box lid in areas f) and G). Engage tab 11.3 Removin the air filter...

  • Page 80: Cleaning The Air Filter And Air Filter Box

    AIR FILTER Insert both parts together, position them, and fasten them using air filter holder in area ✓ The arrow of marking UP faces up. • Info If the air filter is not correctly mounted, dust and dirt can enter the engine and cause damage.

  • Page 81: Fuel Tank, Seat, Trim

    FUEL TANK, SEAT, TRIM 12.1 0 ening the filler ca Danger Fire hazard Fuel is highly flammable. Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. The fuel in the fuel tank expands when warm and may emerge if overfilled.

  • Page 82: Installing The Right Side Cover

    FUEL TANK, SEAT, TRIM Position the side cover and engage in area f). Mount and tighten screw Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) Remove screws in the recessed grips on the left and right. Lift up the seat at the rear, pull it back and then remove it from above. Mountin the seat Hook in the front of the seat at the collar bushing of the fuel tank, lower it at the rear and simultaneously it push forward.

  • Page 83: Installing The Fuel Tank

    FUEL TANK, SEAT, TRIM Main work Unplug connector of the fuel pump. Thoroughly clean plug-in connection of the fuel line using compressed air. Info • Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve. Disconnect the plug-in connection of the fuel line.

  • Page 84: Checking The Fuel Pressure

    FUEL TANK, SEAT, TRIM Warning Fuel is poisonous and a health hazard. Danger of poisoning Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water.

  • Page 85: Changing The Fuel Pump

    FUEL TANK, SEAT, TRIM Press on the small metal plate and disconnect fuel hose connection Info Remaining fuel may flow out of the fuel hose. Mount special tool @. Pressure tester (61029094000) (- p. 224) Mount special tool with nozzle label 0,60.
  • Page 86 FUEL TANK, SEAT, TRIM Warning Improper handling of fuel is a danger to the environment. Environmental hazard Do not allow fuel to get into the ground water, the ground, or the sewage system. Preparatory work Drain the fuel from the fuel tank into a suitable container. Remove the seat.

  • Page 87: Changing The Fuel Filter

    FUEL TANK, SEAT, TRIM Mount and tighten screws Guideline Screw, fuel pump EJOT I 3 Nm (2.2 lbf ft) Finishing work Install the fuel tank.(,... p. 81) Mount the seat. (,... p. 80) 12.11 Chan in the fuel filter Danger Fuel is highly flammable.
  • Page 88 FUEL TANK, SEAT, TRIM Pull out the fuel pump. Remove hose clamps Remove fuel filter 201990-10 Press lock (D. Pull back fuel pump housing Change fuel screen Mount the fuel pump housing. Mount fuel filter ✓ Arrow points away from the fuel pump. Mount hose clamps Hose clamp pliers (60029057000) (,...

  • Page 89: Changing The Fuel Screen

    FUEL TANK, SEAT, TRIM Position the fuel pump. Mount fuel connection fj with the gasket but do not tighten yet. Mount and tighten nut with the gasket. Guideline Nut, fuel pump fastener M12x1.75 15 Nm (11.1 lbf ft) Tighten fuel connection fj. Guideline Fuel port on fuel tank M8x1 .25...
  • Page 90 FUEL TANK, SEAT, TRIM Start the motor and check the response.

  • Page 91: Mask, Fender

    MASK, FENDER 13.1 Removin the front fender Preparatory work Remove the start number plate. (.- p. 89) Main work Remove screws and @. Remove the front fender. Main work Position the front fender. Mount and tighten screws and @. Guideline Remaining screws, chassis 110Nm(7.41bf ft) Finishing work...

  • Page 92: Installing The Start Number Plate

    MASK, FENDER Installing the start number late 13.4 Position the start number plate. Mount and tighten screw Guideline Remaining screws, chassis 110 Nm (7.4 lbf ft) ✓ The holding lugs engage. Position brake line in the brake line guide.

  • Page 93: Wheels

    Husqvarna Motorcycles recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear. If the tires are more than 5 years old: Change the tires.

  • Page 94: Checking The Spoke Tension

    WHEELS Check the thickness of the front and rear brake discs at several places on the disk to see if it conforms to measurement f). • Info Wear reduces the thickness of the brake disc around the area used by the brake linings.

  • Page 95: Installing The Front Wheel

    WHEELS Main work Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. • Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes. Loosen screw by several turns.

  • Page 96: Removing The Brake Disc Of The Front Brake

    WHEELS Mount and tighten screw Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) Activate the hand brake lever multiple times until the brake linings are in contact with the brake disc. Remove the motorcycle from the lift stand. ('r p. 10) Pull the front brake and compress the fork powerfully a few times.

  • Page 97: Rear Wheel

    WHEELS Press out bearing using a suitable tool. Info • Spacing tube can be pushed aside. Remove the spacing tube. Press out bearing using a suitable tool. Press in the new bearing all the way using a suitable tool. • Info Only press the bearing in via the outer ring;...

  • Page 98: Installing The Rear Wheel

    WHEELS Main work Press the brake caliper onto the brake disc by hand in order to push back the brake piston. • Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes. Remove nut Remove chain adjuster Withdraw wheel spindle...

  • Page 99: Removing The Brake Disc Of The Rear Brake

    WHEELS Position chain adjuster @). Mount nut but do not tighten it yet. Make sure that chain adjusters @) are fitted correctly on adjusting screws Check the chain tension. (,... p. 98) Tighten nut Guideline Nut, rear wheel spindle M20x1.5 I 80 Nm (59 lbf ft) Info •...

  • Page 100: Checking The Chain Tension

    WHEELS Checking the chain tension 14.6.5 Warning Danger caused by incorrect chain tension. Danger of accidents If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bearings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause the chain or the countershaft of the transmission to break in extreme cases.

  • Page 101: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    WHEELS Info The wide adjustment range of the chain adjusters (32 mm (1 .18 in)) enables different secondary ratios with the same chain length. Chain adjusters can be turned by 180 ° Finishing work Remove the motorcycle from the lift stand. (..- p. 10) Checking the chain, rear sprocket, engine sprocket, and chain guide 14.6.7 Preparatory work...

  • Page 102: Checking For Chain Dirt Accumulation

    WHEELS Check the chain sliding piece for wear. If the lower edge of the chain pin is at the level of or below the chain sliding piece: Change the chain sliding piece. Check that the chain sliding piece is firmly seated. If the chain sliding piece is loose: Tighten the chain sliding piece.

  • Page 103: Changing The Drivetrain Kit

    WHEELS Warning Reduced braking efficiency due to oil or grease on the brake discs. Danger of accidents Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Environmental hazard Hazardous substances cause environmental damage. Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

  • Page 104: Guideline

    WHEELS Remove engine sprocket Remove screw connections (D. Remove the rear sprocket. Position the new rear sprocket. Mount and tighten fittings. Guideline Nut, rear sprocket screw 35 Nm Loctite 2701 ® (25.8 lbf ft) Slide the new engine sprocket onto the countershaft. Mount the new chain.

  • Page 105: Changing The Rear Wheel Bearing

    WHEELS 14.6.11 Changing the rear wheel bearing Preparatory work Raise the motorcycle with the lift stand. (r p. 10) Remove the rear wheel. (r p. 95) Main work Remove shaft seal ring Remove lock ring Remove shaft seal ring Using a suitable tool, press bearing out from the inside to the outside.

  • Page 106: Finishing Work - Install The Rear Wheel

    WHEELS Clean, grease, and mount spacing tube Long-life grease (- p. 219) Press the new bearing all the way in from the outside to the inside. Info • Only press the bearing in via the outer ring; otherwise, the bearing will be damaged when it is pressed in.

  • Page 107: Wiring Harness, Battery

    WIRING HARNESS, BATTERY Changing the main fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. Use only fuses with the prescribed amperage. Never bypass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the air filter box lid. Preparatory work Switch off all power consumers and switch off the engine.
  • Page 108 WIRING HARNESS, BATTERY Main work Insert the battery into the battery compartment with the terminals facing to the front. Battery (YTXSL-BS) (,... p. 205) Reconnect rubber band • Info Contact disk must be mounted between screw and cable lug with the claws facing down. Position the positive cable and mount and tighten the screw.
  • Page 109 WIRING HARNESS, BATTERY 15.5 uiescent current Preparatory work Switch off all power consumers and switch off the engine. Remove the seat. (.- p. 80) Main work Disconnect the negative cable from the battery. Measure the current between battery ground (-) and the negative cable. •...

  • Page 110: Checking The Starter Relay

    WIRING HARNESS, BATTERY 15.7 Checkin the starter rela Preparatory work Switch off all power consumers and switch off the engine. Remove the seat. (.- p. 80) Remove the air filter box lid. (.- p. 77) Main work Disconnect the negative cable of the battery. Pull off connector Pull back the cover.

  • Page 111: Brake System

    BRAKE SYSTEM Checkin the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. Change worn brake linings immediately. Check the brake linings for minimum thickness 6). <'= 1 mm (<'= 0.04 in) Minimum thickness 6) If the minimum thickness is less than specified: Change the front brake linings.

  • Page 112: Checking The Free Travel Of The Hand Brake Lever

    BRAKE SYSTEM Manually press the brake caliper to the brake disc to push back the brake pistons. Ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suction if it does. Info • Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes.

  • Page 113: Brake Lever

    BRAKE SYSTEM Push the hand brake lever forward and check free travel Free travel of hand brake lever 2:: 3 mm (2:: 0.12 in) If the free travel does not meet specifications: Adjust the basic position of the hand brake lever. (r p. 111) 16.4 Adjusting the basic �osition of the hand brake lever Preparatory work...

  • Page 114: Adding Front Brake Fluid

    BRAKE SYSTEM Adding front brake fluid Warning Danger of accidents Brake system failure. If the brake fluid level drops below the specified marking or the specified value, this is an indication that the brake sys­ tem is leaking or that the brake linings are completely worn down. Check the brake system and do not continue riding. Warning Skin irritation Brake fluid can cause skin irritation on contact.

  • Page 115: Changing The Front Brake Fluid

    BRAKE SYSTEM Changing the front brake fluid Warning Skin irritation Brake fluid can cause skin irritation on contact. Avoid contact with skin and eyes, and keep out of the reach of children. Wear suitable protective clothing and goggles. If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 116: Checking The Rear Brake Linings

    BRAKE SYSTEM Open the bleeder screw again until brake fluid stops emerging. • Info This prevents overfilling of the brake fluid reservoir. Tighten the bleeder screw. Remove the hose of the bleeder bottle. Mount the pro­ tection cap. Disconnect the bleeding device. Remove the bleeder cover. Add brake fluid to level (9.
  • Page 117 BRAKE SYSTEM Info Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container.

  • Page 118: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM Checkin the free travel of foot brake lever Warning Danger of accidents Brake system failure. If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to overheating.

  • Page 119: Adding Rear Brake Fluid

    BRAKE SYSTEM Preparatory work Check the rear brake linings. (,..p. 114) Main work Stand the vehicle upright. Check the brake fluid level in the viewer lf the brake fluid level drops below marking f): Add rear brake fluid. (,..p. 117) Adding rear brake fluid Warning Brake system failure.

  • Page 120: Changing The Rear Brake Fluid

    BRAKE SYSTEM Changing the rear brake fluid Warning Skin irritation Brake fluid can cause skin irritation on contact. Avoid contact with skin and eyes, and keep out of the reach of children. Wear suitable protective clothing and goggles. If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 121 BRAKE SYSTEM Open the bleeder screw again until brake fluid stops emerging. • Info This prevents overfilling of the brake fluid reservoir. Tighten the bleeder screw. Remove the hose of the bleeder bottle. Mount the pro­ tection cap. Disconnect the bleeding device. Remove the bleeder cover. Stand the vehicle upright.

  • Page 122: Engine

    ENGINE 17.1 Removin the engine Preparatory work Raise the motorcycle with the lift stand. (,... p. 10) Drain the coolant. (,... p. 192) Remove the seat. (,... p. 80) Remove the fuel tank. (,... p. 80) Remove the right side cover. (,... p. 79) Remove the main silencer.
  • Page 123 ENGINE Unplug connector Remove the cable clamps and expose the cable. Remove screw (D. Loosen screw @. Repeat the operation on the opposite side. Swing up the subframe and secure it. Remove screw @. Swing the shock absorber to the rear and twist it slightly. Remove springs@).
  • Page 124 ENGINE C&. Remove screw Take off the manifold. Loosen hose clip Pull off the radiator hose. Loosen hose clip �. Pull off the radiator hose. Push back protection cap G). Unplug connector Pull off the spark plug connector Remove screw...
  • Page 125 ENGINE Remove screw 41). Take off the engine sprocket cover. Remove screws Qi). Remove the cable binders. Take off the clutch slave cylinder and hang it to the side. • Info Do not kink the clutch line. Do not activate the clutch lever if the clutch slave cylinder has been removed.
  • Page 126 ENGINE Loosen hose clip Pull the throttle valve body off of the cylinder head toward the rear and hang it to one side. Push back hose clamp � and remove the vent hose. Push back protection cap and remove the nut. Remove the positive cable and hang it to one side.

  • Page 127: Installing The Engine

    ENGINE Lift out the engine from the side. • Info You should have an assistant for this step. Make sure that the engine is sufficiently secured against falling over. Protect the frame and attachments from damage. Main work Position the engine in the frame. •...
  • Page 128 ENGINE Position the positive cable on the starter motor. Mount and tighten nut. Guideline Remaining nuts, chassis 10 Nm (7.4 lbf ft) Position protection cap Position the vent hose and mount the hose clamp (D. Position the throttle valve body. Tighten hose clip@.
  • Page 129 ENGINE Position the clutch slave cylinder with the gasket. Mount and tighten screws Guideline 10 Nm (7.4 lbf ft) Screw, clutch slave cylinder Mount the cable binders. Position the engine sprocket cover. Mount and tighten screw Guideline Screw, clutch slave cylinder 10 Nm (7.4 lbf ft) Mount and tighten screw Guideline...
  • Page 130 ENGINE Mount the radiator hose. Position and tighten hose clip Slip in the manifold. Mount screw Qi) but do not tighten yet. Guideline Screw, manifold holder 15 Nm (11.1 lbf ft) Mount springs 41). Spring hook (50305017000) ('r p. 221) Tighten screw Qi).
  • Page 131 ENGINE Route the cable without tension and secure with cable clamps. Plug in connector @) . Position and tighten hose clip � - Plug in connector � of the ignition pulse generator. Plug in connector � of the alternator. Route the cable without tension and secure it with cable binders. Mount EFI control unit �.

  • Page 132: Engine Disassembly

    Refill the coolant. (- p. 193) Execute the initialization run. (- p. 201) Take a short test ride. Read out the fault memory using the Husqvarna diagnostics tool. Check the engine for leakage. Check the engine oil level. (- p. 194) Check the coolant level.

  • Page 133: Removing The Clutch Push Rod

    ENGINE 17.3.2 Removing the clutch push rod Remove clutch push rod 17.3.3 Removing the spacer Remove spacer of the countershaft. Remove O-ring. 17.3.4 Draining the engine oil Remove plug with oil screen and the O-rings. Remove the oil drain plug @ with the magnet and seal ring. Remove oil drain plug with the O-ring.

  • Page 134: Removing The Oil Filter

    ENGINE 17.3.5 Removing the oil filter Remove screws Remove the oil filter cover@ with the O-ring. Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) (,... p. 222) 17.3.6 Removing the spark plug Remove the spark plug using special tool Spark plug wrench (77229172000) (,...

  • Page 135: Removing The Starter Motor

    ENGINE 17.3.8 Removing the starter motor Remove screws and take off cover @. Take off the gasket. Remove torque limiter (D. Remove screws Remove the alternator cover. Remove screws and take off the starter motor. 17.3.9 Positioning the engine at ignition top dead center Turn the crankshaft counterclockwise until markings on the cylinder head are located flush above the flat areas Ce) of the camshafts.

  • Page 136: Removing The Timing Chain Tensioner

    ENGINE Remove screw Info • Check through the hole whether the position notch of the crankshaft is visible. Mount and tighten screw without the washer. 17.3.10 Removing the timing chain tensioner Loosen screw Remove screw (!} with the seal ring. Pull out timing chain tensioner Remove O-ring 17.3.11...

  • Page 137: Removing The Cylinder Head

    ENGINE 17 .3.12 Removing the cylinder head Remove nut with the washer. G00485-10 Loosen nuts @ in a crisscross pattern and remove them with the washers. Remove the cylinder head. Remove cylinder head gasket 17 .3.13 Removing the piston Push the cylinder upward. •...

  • Page 138: Removing The Rotor

    ENGINE 17 .3.14 Removing the rotor Remove screw Insert special tool into the crankshaft. Protection cap (75029090000) (,... p. 225) Attach special tool to the rotor. Hold it tight using the special tool and pull off the rotor by turning the screw in. Extractor (58012009000) (,...

  • Page 139: Removing The Water Pump Wheel

    ENGINE Remove O-ring Take off suction pump Remove needle roller@). 17 .3.17 Removing the water pump wheel Remove screws Take off the water pump cover. Remove nut Take off the two-part water pump impeller...

  • Page 140: Removing The Clutch Cover

    ENGINE 17 .3.18 Removing the clutch cover Remove screws Take off the clutch cover. Remove the clutch cover seal. 17 .3.19 Removing the clutch discs Loosen screws and remove together with the washers and springs. Take off the pressure cap. Completely remove clutch discs Remove pressure piece Removing the outer clutch hub...

  • Page 141: Removing The Shift Shaft

    ENGINE Take off needle bearing and collar sleeve (D. 17 .3.21 Removing the shift shaft Push sliding plate away from the shift drum locating unit @. Remove shift shaft with the washer. 17.3.22 Removing the shift drum locating unit Remove screw Push away locking lever @ from shift drum locating unit and remove the shift drum locating unit.

  • Page 142: Removing The Primary Gear

    ENGINE Remove lock ring Take off washer@). Remove oil pump gear (D. Remove pin@. Remove screws Take off the oil pump cover. Remove pin@). Remove oil pump shaft G!) from below. 48 . Remove force pump 17 .3.25 Removing the primary gear Remove nut Info •...

  • Page 143: Removing The Spacer

    ENGINE Remove screw Take off balancer shaft with the timing chain and timing chain securing guide. Info If the timing chain is going to be used again, mark its direction of travel. 17 .3.27 Removing the spacer Remove spacer of the crankshaft. 17 .3.28 Removing the left section of the engine case Remove screws...

  • Page 144: Removing The Shift Rails

    ENGINE 17 .3.29 Removing the shift rails Remove shift rail together with upper spring Remove shift rail together with upper spring and the lower spring. 17 .3.30 Removing the shift drum Tilt shift forks to the side. • Info Do not misplace the shift rollers. Remove shift drum 17 .3.31 Removing the shift forks...

  • Page 145: Removing The Crankshaft

    ENGINE Pull both transmission shafts out of the bearing seats together. 17.3.33 Removing the crankshaft Take out crankshaft Take off the right section of the engine case. 17.4 Work on individual arts 17.4.1 Work on the right section of the engine case Remove all dowels.

  • Page 146: Work On The Left Section Of The Engine Case

    ENGINE After the engine case section has cooled, check that the bearings are firmly seated. • Info If the bearings are not firmly seated after cooling, it is likely that they will rotate in the engine case when warm. In this case, the engine case must be renewed.

  • Page 147: Work On The Clutch Cover

    ENGINE After the engine case section has cooled, check that the bearings are firmly seated. • Info If the bearings are not firmly seated after cooling, it is likely that they will rotate in the engine case when warm. In this case, the engine case must be renewed.

  • Page 148: Checking The Oil Pressure Regulator Valve

    ENGINE Press out bearing toward the inside. Mount lock ring @ . Press the shaft seal ring all the way in from the inside to the outside with the open side facing in. Press the new bearing all the way in from the inside to the outside using a suitable tool.

  • Page 149: Checking The Lubrication System

    ENGINE Measure the spring length of the oil pressure regulator valve. Oil pressure regulator valve Minimum length of pressure spring 23.5 mm (0.925 in) If the measured value does not meet specifications: Change the spring. Check ball and the sealing seat. If there is damage or wear: 306115-10 Change the ball and machine the sealing seat.

  • Page 150: Removing The Crankshaft Bearing Inner Race

    ENGINE 17.4.6 Removing the crankshaft bearing inner race Fix the crankshaft in the vise. • Info Use soft jaws. Warm up special tool Guideline 1150 °C (302 °F) Tool for inner bearing race (58429037037) ( p. 222) Push the warmed up special tool onto the crankshaft bearing inner race, press firmly together and pull jointly from the crankshaft.

  • Page 151: Checking The Crankshaft Run-Out At The Bearing Pin

    ENGINE Position special tool on the press. Pressing tool for crankshaft, complete (75029047000) ('r p. 225) Insert for crankshaft pressing tool (77229008000) (,..p. 226) Insert the crank web with connecting rod and bearing. Position the second crank web. Position special tool @ with the heel pointing down. Insert for crankshaft pressing tool (77229008000) (,..

  • Page 152: Measuring The Crankshaft End Play

    ENGINE Heat the crankshaft bearing inner race in special tool and mount together. Guideline 1120 °C (248 °F) Tool for inner bearing race (58429037037) (.- p. 222) Repeat the operation on the opposite side. Ensure that the new crankshaft bearing inner race is flush. •...

  • Page 153: Installing The Drive Wheel Of The Balancer Shaft

    ENGINE 17.4.12 Installing the drive wheel of the balancer shaft Ensure that woodruff key is seated properly. Warm drive wheel @ of the balancer shaft and push it onto the balancer shaft. Guideline 1100 °C (212 °F) 303077-10 17.4.13 Cylinder - Nikasil ®...

  • Page 154: Checking/Measuring The Piston

    ENGINE 17.4.15 Checking/measuring the piston Use the special tool to measure clearance of the piston rings in the piston ring groove. e -• ­ Guideline Piston ring - groove clearance $ 0.08 mm ($ 0.0031 in) Feeler gauge (590290411 00) (or p. 223) If play is larger than the specified value: Change the piston and piston rings.

  • Page 155: 17.4.17 Checking The Piston Ring End Gap

    ENGINE Guideline Piston/cylinder - mounting clearance Size I 0.035 ... 0.057 mm (0.00138 ... 0.00224 in) Size II 0.037 ... 0.060 mm (0.00146 ... 0.00236 in) Wear limit 0.070 mm (0.00276 in) 17.4.17 Checking the piston ring end gap Remove the piston ring from the piston. Place the piston ring in the cylinder and align with the piston.

  • Page 156: Checking The Camshafts

    ENGINE 17.4.19 Checking the camshafts Check the camshaft for damage and wear. If there is damage or wear: Change the camshaft. If the surface of the cams is damaged, check the oil supply to the camshaft and cam lever. Measure the cams of the camshaft. Camshaft - cam height Exhaust 36.15 ...

  • Page 157: Removing The Valves

    ENGINE Remove camshaft bearing bridge again. Compare the Plastigauge clearance gauge with the specifications on the packaging. Guideline Camshaft bearing - sleeve bearing Radial clearance 0.020 ... 0.054 mm (0.00079 ... 0.00213 in) Wear limit 0.065 mm (0.00256 in) Info •...

  • Page 158: Checking The Valves

    ENGINE •• Mark the valves corresponding to their installation position. • Info E"I// £ V 1)", Place the valves in a carton corresponding to their installation position and label them. 300117-10 17.4.22 Checking the valves Check the valve plate for run-out. Valve - run-out At the valve plate :,;...

  • Page 159: Checking The Cam Levers

    ENGINE Change the valve spring seat. 17.4.25 Checking the cam levers Check the cam levers and cam lever shafts for damage and wear. If there is damage or wear: Change the cam levers and/or cam lever shafts. 302718-10 17.4.26 Checking the cylinder head Check valve guides using the special tool.

  • Page 160: Checking The Freewheel

    ENGINE Pre-tension the valve spring using the special tool. Valve spring mounter (59029019000) (r p. 223) Insert for valve spring lever (77229060000) (r p. 228) Mount valve keys (D. • Info When mounting the valve keys, ensure that they are seated properly; it is recommended to adhere the valve keys to the valves with a small amount of grease.

  • Page 161: Removing The Freewheel

    ENGINE 17 .4.29 Removing the freewheel Remove lock ring � 1"],.! ,: , , · I · ' - ✓ "'' ► l'\, I ' ·, •-�� � I:•: Press expansion ring together with suitable pliers and take off. Take freewheel out of the primary gear.

  • Page 162: Checking The Electric Starter Drive

    ENGINE Ensure that all lugs of the expansion ring pass through slots of the freewheel and engage in groove of the primary gear. Mount lock ring 6) . 17.4.31 Checking the electric starter drive ·-• 305006-10 Check the gear mesh and bearing of starter idler gear for damage and wear.

  • Page 163: Checking The Timing Assembly

    ENGINE Change O-ring of the starter motor. Connect the negative cable of a 12 volt power supply to the housing of the starter motor. Connect the positive cable of the power supply briefly with the connector of the starter motor. If the starter motor does not turn when the circuit is closed: Change the starter motor.

  • Page 164: Preparing The Timing Chain Tensioner For Installation

    ENGINE 17.4.33 Preparing the timing chain tensioner for installation Press the timing chain tensioner together completely. • Info This requires some force, as the oil must be pressed out. Release the timing chain tensioner. ✓ Without pressure, the timing chain tensioner expands fully. Place two compensating disks or similar aids next to the timing chain tensioner piston.
  • Page 165 ENGINE If there is run-out: Change the push rod. Check the length of clutch springs I� Clutch spring - length 38.5 mm(� 1.516 in) If the clutch spring length is less than the specified value: Change all clutch springs. Check the thrust face of pressure cap Ci) for damage and wear. If there is damage or wear: Change the pressure cap.

  • Page 166: Checking The Shift Mechanism

    ENGINE 17.4.35 Checking the shift mechanism • � 306554-10 Check shift forks on disc for damage and wear (visual check). If there is damage or wear: Change the shift fork. Check shift grooves of shift drum @ for wear. If the shift groove is worn: Change the shift drum.

  • Page 167: Preassembling The Shift Shaft

    ENGINE Change the sliding plate. Preassemble the shift shaft. (,... p. 165) Check clearance between the sliding plate and the shift quadrant. Shift shaft - sliding plate/shift quad­ 0.40 ... 0.80 mm (0.0157 ... 0.0315 in) rant clearance If the measured value does not meet specifications: Change the sliding plate.

  • Page 168: Disassembling The Countershaft

    ENGINE Remove needle bearing 17.4.38 Disassembling the countershaft 306558-10 Fix the countershaft in the vise with the toothed end facing downward. Guideline Use soft jaws Remove stop disk and first-gear idler gear Remove needle bearing and stop disk Remove fifth-gear sliding gear Remove lock ring (D.

  • Page 169: Assembling The Main Shaft

    ENGINE 306561-10 Check needle bearings for damage and wear. If there is damage or wear: Change the needle bearings. Check the pivot points of main shaft and countershaft for damage and wear. If there is damage or wear: Change the main shaft and/or countershaft. Check the tooth profiles of main shaft and countershaft for damage and wear.

  • Page 170: Assembling The Countershaft

    ENGINE Preparatory work Check the transmission. (,..p. 166) Carefully lubricate all parts before assembling. Main work 306557-10 Secure the main shaft with the toothed end facing downward in the vise. Guideline Use soft jaws Mount needle bearing Mount fifth-gear idler gear@. Mount stop disk and lock ring Mount third-gear sliding gear...

  • Page 171: Engine Assembly

    ENGINE Main work 306559-10 Fix the countershaft in the vise with the toothed end facing downward. Guideline Use soft jaws Mount needle bearing and second-gear idler gear onto the countershaft with the protruding collar facing downward. Mount stop disk (D and lock ring Mount fourth-gear sliding gear with the shift groove facing upward.

  • Page 172: Installing The Transmission Shafts

    ENGINE 17.5.2 Installing the transmission shafts Oil the bearing. Slide both transmission shafts into the bearing seats together. Mount lock ring @ . 17.5.3 Installing the shift forks Shift fork has a smaller inside diameter; mount this in the shift groove of the main shaft.

  • Page 173: Installing The Shift Rails

    ENGINE 17.5.5 Installing the shift rails Install shift rail together with upper spring and the lower spring. Install shift rail (D together with upper spring 17.5.6 Installing the left engine case Mount the dowels. Degrease the sealing area. Apply the sealing compound to the left section of the engine case.

  • Page 174: Installing The Spacer

    ENGINE 17.5.7 Installing the spacer Grease the shaft seal ring. Mount spacer 17.5.8 Installing the timing chain Mount balancer shaft with the timing chain and timing chain securing guide. • Info If the timing chain was used before, ensure it is running in the correct direction.

  • Page 175: Installing The Force Pump

    ENGINE 17.5.10 Installing the force pump Oil the oil pump shaft, internal rotor and external rotor before assembly. Engine oil (SAE 1 0W/50) ('r p. 218) Position force pump ✓ The rounded side of the force pump faces the engine case. Mount the oil pump shaft from the ignition side.

  • Page 176: Installing The Locking Lever

    ENGINE Position suction pump Crank the oil pump gear wheel and ensure that it can move easily. Mount O-ring (D . Position oil pump cover Mount and tighten screws Guideline Screw, oil pump cover Loctite ® ™ (4.4 lbf ft) 17.5.12 Installing the locking lever Mount locking lever...

  • Page 177: Installing The Shift Shaft

    ENGINE 17 .5.14 Installing the shift shaft Slide shift shaft with the washer into the bearing seat. Push sliding plate away from the shift drum locating unit Insert the shift shaft all the way. Let the sliding plate engage in the shift drum locating unit. Shift through the transmission.

  • Page 178: Installing The Clutch Discs

    ENGINE 17.5.16 Installing the clutch discs Thoroughly oil the clutch facing discs. Engine oil (SAE 1 0W/50) ('r p. 218) Insert the intermediate clutch disc. Guideline Thickness mm (0.04 in) Place the clutch facing and intermediate discs into the outer clutch hub. Insert the intermediate clutch disc.

  • Page 179: Installing The Water Pump Cover

    ENGINE Mount screws b ut do not tighten yet. Guideline M6x25 Screw, clutch cover 110 Nm (7.4 lbfft) Mount screws b ut do not tighten yet. Guideline Screw, clutch cover M6x45 110 Nm (7.4 lbfft) Tighten all screws in a crisscross pattern. Guideline Screw, clutch cover 10 Nm (7.4 lbf ft)

  • Page 180: Installing The Rotor And Ignition Pulse Generator

    ENGINE Mount the starter idler gear with the washer. Mount lock ring 17.5.20 Installing the rotor and ignition pulse generator Ensure that the woodruff key is seated properly. Mount the rotor. • Info To simplify installation, turn the starter idler gear counterclockwise. Mount and tighten screw Guideline Rotor screw...
  • Page 181 ENGINE Apply a thin layer of sealing compound in area G). Loctite 5910 ® Place the cylinder base gasket on. Info Ensure that the dowel pins are seated properly. Cover the engine case opening with a cloth. Thread the timing chain through the chain shaft.

  • Page 182: Installing The Cylinder Head

    ENGINE 17.5.22 Installing the cylinder head Position cylinder head gasket • Info Ensure that the dowel pins are seated properly. Put the cylinder head in place. Mount nuts @ with the washers and tighten in a crisscross pattern. Guideline Nut, cylinder head M10x1 .25 Tightening Thread, oiled with...

  • Page 183: Installing The Camshafts

    ENGINE 17.5.23 Installing the camshafts Pull up the timing chain and insert intake camshaft Place the timing chain over the camshaft gear of the intake camshaft. ✓ Markings f) are aligned with the flat areas of the camshaft. ✓ Lock ring G) engages in groove (!). Ensure that bleeder@ are seated properly.
  • Page 184 ENGINE Mount special tool and tension the timing chain. Insert, timing chain tensioner (77229035000) ('r p. 227) Remove screws Position the special tool. Adjustment bush bridge (77229050044) (- p. 228) ✓ The valves are not activated. ✓ The special tool must be in full contact with the flat areas of the cam shafts. Mount and tighten screws (D .

  • Page 185: Installing The Timing Chain Tensioner

    ENGINE Remove special tool Insert, timing chain tensioner (77229035000) ('r p. 227) 17.5.26 Installing the timing chain tensioner Position timing chain tensioner and insert it with new O-ring @. Mount and tighten screw plug with the seal ring. Guideline Plug, timing chain tensioner M24x1.5 40 Nm (29.5 lbf ft) Remove screw...

  • Page 186: Adjusting The Valve Clearance

    ENGINE Position the engine at ignition top dead center. ✓ Markings on the cylinder head are flush above the flat areas of the camshafts. Check the valve clearance at all valves between the camshaft and cam levers. Guideline Valve clearance Intake at: 20 °c (68 °F) 0.10 ...

  • Page 187: Installing The Valve Cover

    ENGINE Position the gasket. • Info Ensure that the dowel pins are seated properly. Position the alternator cover. Mount and tighten screws Guideline Screw, alternator cover 10 Nm (7.4 lbf ft) Position torque limiter (D. Position the gasket. • Info Ensure that the dowel pins are seated properly.

  • Page 188: Installing The Spark Plug

    ENGINE Apply a thin layer of sealing compound in area 6). Loctite 5910 ® Position the valve cover with the gasket. Mount and tighten screws Guideline Screw, valve cover I 8 Nm (5.9 lbf ft) 17.5.31 Installing the spark plug Mount and tighten the spark plug with special tool Guideline Spark plug...

  • Page 189: Installing The Oil Screen

    ENGINE 17.5.33 Installing the oil screen Mount and tighten screw plug with the O-ring. Guideline M14x1.5 Oil drain plug 15 Nm (11.1 lbf ft) Mount and tighten the oil drain plug with the magnet and the new seal ring. Guideline Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft)

  • Page 190: Installing The Clutch Push Rod

    ENGINE 17.5.35 Installing the clutch push rod Mount clutch push rod 17.5.36 Removing the engine from the engine assembly stand Remove the screw connection from the special tool. Engine fixing arm (77229002000) (.- p. 226) Remove the engine from the engine assembly stand. Info Work with an assistant or a motorized hoist.

  • Page 191: Clutch

    CLUTCH Checkin /correctin the fluid level of the h draulic clutch Info The fluid level rises with increased wear of the clutch lining discs. Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. Remove screws Remove cover with membrane Check the fluid level.
  • Page 192 CLUTCH Position the cover with the membrane. Mount and tighten the screws.

  • Page 193: Water Pump, Cooling System

    WATER PUMP, COOLING SYSTEM Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 194: Checking The Coolant Level

    WATER PUMP, COOLING SYSTEM Checkin the coolant level Warning During motorcycle operation, the coolant gets very hot and is under pressure. Danger of scalding Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 195: Refilling Coolant

    WATER PUMP, COOLING SYSTEM Refilling coolant Warning Coolant is poisonous and a health hazard. Danger of poisoning Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swallowed, contact a physician immediately.

  • Page 196: Lubrication System

    LUBRICATION SYSTEM 20.1 Oil circuit 401052-60 Oil screen Force pump Oil pressure regulator valve Oil filter Oil nozzle for conrod bearing lubrication Oil nozzle for cam lever lubrication Oil nozzle, piston cooling Oil nozzle for alternator cooling Oil nozzle for clutch lubrication Suction pump Oil channel, transmission lubrication Timing chain tensioner...

  • Page 197: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen

    LUBRICATION SYSTEM If the engine oil does not reach the middle of the level viewer 6): Add engine oil. (- p. 196) Changing the engine oil and oil filter, cleaning the oil screen Warning Engine oil and gear oil get very hot when the motorcycle is ridden. Danger of scalding Wear appropriate protective clothing and safety gloves.

  • Page 198: Adding Engine Oil

    LUBRICATION SYSTEM Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) ('r p. 222) Completely drain the engine oil. Thoroughly clean the parts and sealing surface. Lay the motorcycle on its side and fill the oil filter housing to about ½ full with engine oil.

  • Page 199: Checking The Engine Oil Pressure

    LUBRICATION SYSTEM Danger Exhaust gases are toxic and inhaling them may Danger of poisoning result in unconsciousness and/or death. When running the engine, always make sure there is sufficient ventila­ tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.
  • Page 200 LUBRICATION SYSTEM Switch off the engine. Warning Danger of burns Some vehicle components get very hot when the machine is driven. Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Remove the special tools. Mount and tighten screw Guideline Screw, unlocking of timing chain ten­...

  • Page 201: Ignition System

    IGNITION SYSTEM 21.1 Ignition coil - checking the seconds winding Condition Ignition coil cylinder 1 is disconnected. Spark plug connector cylinder 1 has been removed. Ignition coil cylinder 1 - check the secondary winding resistance Measure the resistance between the specified points. Ignition coil cylinder 1 pin 2 (-) - Ignition coil cylinder 1 pin 3 Ignition coil Secondary winding resistance at:...

  • Page 202: Removing The Stator And Ignition Pulse Generator

    IGNITION SYSTEM 21.4 Removin ulse generator Condition The alternator cover has been removed. Remove screw Remove retaining bracket. Remove screw � " � Remove cable support sleeve from the alternator cover. _·., , Remove the stator and ignition pulse generator from the alternator cover. , ..

  • Page 203: Throttle Valve Body

    THROTTLE VALVE BODY Run the engine until warm. Set the desired idle speed by turning the idle speed adjusting screw Guideline Idle speed 2,250 ... 2,350 rpm • Info Turning counterclockwise lowers the idle speed. Turning clockwise raises the idle speed. 22.2 Executing the initialization run Condition...

  • Page 204: Technical Data

    TECHNICAL DATA 23.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 349. 7 cm (21.34 cu in) Stroke 57.5 mm (2.264 in) Bore 88 mm (3.46 in) Compression ratio 13,65:1 Idle speed 2,250 ... 2,350 rpm Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 36.3 mm (1.429 in)

  • Page 205: Engine Tightening Torques

    TECHNICAL DATA Cylinder/cylinder head - distortion of sealing area :5 0.10 mm (:5 0.0039 in) Piston - diameter Size I 87.955 ... 87.965 mm (3.46279 ... 3.46318 in) Size II 87.965 ... 87.975 mm (3.46318 ... 3.46358 in) Cylinder - drill hole diameter Size I 88.000 ...

  • Page 206: Capacities

    TECHNICAL DATA Screw, exhaust flange 10 Nm (7.4 lbfft) ® Loctite ™ Screw, oil filter cover 10 Nm (7.4 lbfft) Screw, shi f t drum locating 10 Nm (7.4 lbf ft) ® Loctite ™ 14 Nm (10.3 lbf ft) Screw, shi f t lever ®...

  • Page 207: Chassis

    Fuse 58011109110 10 A Fl warning lamp 23.7 Tires Front tires Rear tires 80/100 - 21 51M TT 110/90 - 19 57M TT Dunlop GEOMAX MX51 FA Dunlop GEOMAX MX51 Additional information is available in the Service section under: www.husqvarna-motorcycles.com...

  • Page 208: Fork

    TECHNICAL DATA 23.8 Fork Fork part number 14.18.7N.57 Fork Up Side Down 4860 MXMA CC WP Suspension Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Rebound damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Spring length with preload spacer(s) 490 mm (19.29 in) Spring rate Weight of rider: 65 ...

  • Page 209: Chassis Tightening Torques

    TECHNICAL DATA 23.10 Chassis tightening tor ues ® Screw, pressure regulator EJOT PT K60x25-Z 3 Nm (2.2 lbf ft) Spoke nipple, front wheel M4.5 5 ... 6 Nm (3.7 ... 4.4 lbf ft) Spoke nipple, rear wheel M4.5 5 ... 6 Nm (3.7 ... 4.4 lbf ft) Screw, battery terminal 2.5 Nm (1 .84 lbf ft) Screw, intake air temperature sensor...

  • Page 210: Cleaning

    CLEANING 24.1 Cleanin the motorc cle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts.

  • Page 211: Storage

    Store the vehicle in a dry location that is not subject to large fluctuations in tem­ perature. • Info Husqvarna Motorcycles recommends raising the motorcycle. Raise the motorcycle with the lift stand. (..- p. 10) Cover the vehicle with a tarp or similar cover that is permeable to air. Info •...

  • Page 212: Service Schedule

    Final check: Check the vehicle for safe operation and take a test ride. • • • • Read out the fault memory after the test ride using the Husqvarna Motorcycles diagnostics tool. • • • • Make the service entry in and in the service booklet.

  • Page 213: Service Work As Additional Order

    SERVICE SCHEDULE One-time interval • Periodic interval 26.2 Service work as additional order Annually Every 100 operating hours - corresponds to about 700 liters of fuel (185 US gal) Every 50 operating hours - corresponds to about 350 liters of fuel (92.5 US gal) •...
  • Page 214 --.. 1 � EB/4 r · - - FC/2 �BR/4 -X17 l"' -X19 -X18 .c o � 1 � � � < -X302 < ('I) ..�---------------------------------------------------------�-----+-------l>a /2.F1 �----------------------------------------------------------------__,.>-----l>b /2.F1 � ..FC 350 2014-2015 ..: � Hu � rna·...

  • Page 215: Wiring Diagram

    WIRING DIAGRAM Components: A 11 EFI control unit Capacitor Battery Alternator Starter relay with main fuse Power relay Starter motor Voltage regulator Electric starter button X295 Diagnostics connector...
  • Page 216 -X29 5 � -X301 � N E - 1 � AP/6 �- �- -CW/2 • -CX/2 < DD D � -X300 < ('I) "' � - /1.FB a. /1.FB b. � ® "' FC 350 2014-2015 "' � I 2/3 Hu5<Mlrna'...
  • Page 217 WIRING DIAGRAM Components: A 11 EFI control unit Fuel pump Injection valve (cylinder 1) warning lamp (MIL) CAN bus terminating resistor Kill switch X295 Diagnostics connector...
  • Page 218 LtiJ _ , ,, l+J { A M / 3 �DV/2 -X12 o � X1 3 { AP/6 {AX/2 {cM/2 · < _5::c _5::c < ..('I) ('I) 1· � ® FC 350 2014-2015 � r 3/3 ('I) Hu�rna' �...
  • Page 219 WIRING DIAGRAM Components: A 11 EFI control unit Throttle position sensor circuit A Intake air temperature sensor Engine coolant temperature sensor (cylinder 1) Rollover sensor Crankshaft position sensor Manifold absolute pressure sensor (cylinder 1) Ignition coil (cylinder 1) switch for ride mode (optional) Map-Select switch (optional) Cable colors:...

  • Page 220: Substances

    SUBSTANCES Brake fluid DOT 4 Standard/classification Guideline Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the cor- responding properties. Recommended supplier ® Bel-Ray Super DOT 4 Brake Fluid Coolant Guideline Only use high quality coolant with corrosion inhibitor for aluminum motors (even in countries with high temperatures).

  • Page 221: Auxiliary Substances

    AUXILIARY SUBSTANCES Air filter cleaning agent Recommended supplier ® Bel-Ray Foam Filter Cleaner & Degreaser Hi h viscosity rease Recommended supplier ® LGHB2 rease Recommended supplier ® Bel-Ray Waterproof Grease Lubricant (T158) Recommended supplier ® Lubcon ® Turmogrease PP 300 Lubricant (T511) Recommended supplier ®...
  • Page 222 AUXILIARY SUBSTANCES Preserving materials for aints, metal and rubber Recommended supplier ® Bel-Ray Silicone Detailer & Protectant Spray Universal oil s ray Recommended supplier ® Bel-Ray 6 in 1...

  • Page 223: Special Tools

    SPECIAL TOOLS Bleeder cover Art. no.: 00029013005 00029013005 H00504-01 Bleeder cover Art. no.: 00029013006 00029013006 H00505-01 Bleedin device Art. no.: 00029013100 00029013100 H00518-01 Extractor Art. no.: 46129021000 46129021000 H00539-01 S�ring hook Art. no.: 50305017000 50305017000 H00973-01...
  • Page 224 SPECIAL TOOLS Bleeds ringe Art. no.: 50329050000 50329050000 H00565-01 Circli liers reverse Art. no.: 51012011000 51012011000 H00572-01 Lift stand Art. no.: 54829055000 54829055000 H00974-01 Extractor Art. no.: 58012009000 58012009000 H00592-01 Tool for inner bearing race Art. no.: 58429037037 58429037037 H00596-01...
  • Page 225 SPECIAL TOOLS Tor ue wrench with various accessories in set Art. no.: 58429094000 ..fl.#'� �� 58429094000 H00606-01 Clutch holder Art. no.: 59029003100 � 59029003100 H00609-01 Valve sprin mounter Art. no.: 59029019000 2x£. 59029019000 H00610-01 Feeler gauge Art. no.: 59029041100 CJ::? 59029041100 H00616-01 Graduated disc...
  • Page 226 SPECIAL TOOLS Plastigauge clearance auge Art. no.: 60029012000 60029012000 H00627-01 tool Art. no.: 60029015000 60029015000 H00628-01 Hose clamp pliers Art. no.: 60029057000 60029057000 H00650-01 Testing hose Art. no.: 61029093000 61029093000 H00659-01 Pressure tester Art. no.: 61029094000 4x £ 61029094000 H00660-01...
  • Page 227 SPECIAL TOOLS Engine assembl stand Art. no.: 61229001000 61229001000 H00662-01 Release device for timin chain tensioner Art. no.: 61229021000 61229021000 H00675-01 Pressin tool for crankshaft, complete Art. no.: 75029047000 75029047000 H00714-01 Protection cap Art. no.: 75029090000 75029090000 H00726-01 Extractor, camshaft gear Art.
  • Page 228 SPECIAL TOOLS Engine fixing arm Art. no.: 77229002000 2x.&. 77229002000 H00748-01 Insert for crankshaft tool Art. no.: 77229008000 �J=� 77229008000 H00750-01 Extrude plate, base Art. no.: 77229009000 2x£ � 77229009000 H00751-01 Pliers for valve stem seals Art. no.: 77229010000 77229010000 H00752-01 Limit �lug gauge Art.
  • Page 229 SPECIAL TOOLS Insertion for iston ring lock Art. no.: 77229030000 77229030000 H00754-01 Protection ca Art. no.: 77229031000 77229031000 H00755-01 Separator plate Art. no.: 77229032000 77229032000 H00756-01 Insert, timing chain tensioner Art. no.: 77229035000 � 77229035000 H00757-01 Puller Art. no.: 77229048000 2x£...
  • Page 230 SPECIAL TOOLS Ad"ustment bush bridge Art. no.: 77229050044 77229050044 H00759-01 Insert for valve s Art. no.: 77229060000 77229060000 H00760-01 Spark plu wrench Art. no.: 77229172000 77229172000 H00761-01 Oil pressure adapter Art. no.: 77329006000 77329006000 H00764-01 Pin wrench Art. no.: T103 T103 H00838-01...
  • Page 231 SPECIAL TOOLS Hook wrench Art. no.: T106S T106S H00841-01 De th micrometer Art. no.: T107S T107S H00842-01 Art. no.: T120 T120 H00844-01 Mounting sleeve Art. no.: T1204 T1204 H00878-01 Calibration �in Art. no.: T1205 T1205 H00879-01...
  • Page 232 SPECIAL TOOLS Pressin tool Art. no.: T1206 T1206 H00880-01 Pressin tool Art. no.: T1207S T1207S H00881-01 Mountin sleeve Art. no.: T1215 T1215 H00886-01 Disassembly tool Art. no.: T1216 T1216 H00887-01 Vacuum �um� Art. no.: T1240S � T1240S H00890-01...
  • Page 233 SPECIAL TOOLS Protecting sleeve Art. no.: T1401 cs)) T1401 H00894-01 Clam in stand Art. no.: T14016S ill] T14016S H01036-01 Rin wrench Art. no.: T14017 T14017 H00904-01 Nitrogen charging tool Art. no.: T14019 .&2x.£ T14019 H00906-01 Su��ort tool Art. no.: T14020 T14020 H00907-01...
  • Page 234 SPECIAL TOOLS Calibrating unit Art. no.: T14021 T14021 H00908-01 Mountin tool Art. no.: T14022 T14022 H00909-01 Threaded bushin Art. no.: T14023 T14023 H00911-01 Mounting sleeve Art. no.: T14029 T14029 H00917-01 Filling ada�ter Art. no.: T14030 T14030 H00918-01...
  • Page 235 SPECIAL TOOLS Tweezers Art. no.: T14033 T14033 H00921-01 Clam in stand Art. no.: T1403S ❖ 2x£. T1403S H00896-01 Mountin tool Art. no.: T14040S � T14040S H00922-01 Press drift Art. no.: T1504 T1504 H00899-01 Assembl� tool Art. no.: T150S T150S H00852-01...
  • Page 236 SPECIAL TOOLS Nitro en filling tool Art. no.: T170S1 2x.&.3x.£. T170S1 H00855-01...

  • Page 237: Standards

    STANDARDS JASOT903MA Different technical development directions required a new specification for 4-stroke motorcycles - the JASO T903 MA Standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines.

  • Page 238: Index

    INDEX Chain tension adjusting ....... . . 98 'Accessories ....... . . 8 checking .
  • Page 239 INDEX ignition pulse generator, installing valve timing, adjusting ..... . 181 ignition pulse generator, removing valve timing, checking ..... . 181 left engine case section water pump cover, installing lubrication system, checking .
  • Page 240 INDEX cartridge, assembling ......30 cartridge, bleeding and filling ....35 Idle speed cartridge, disassembling .
  • Page 241 INDEX Rebound damping Starting ........1 O fork, adjusting .
  • Page 242 I 1 1 11 1 11 1 1 1 1 11 1 1 1 111 1 11 1 1 1 1 111 1 1 111 1 1 11 1 1 1 1 1 1 1 1 1 1 II I I II 3403006en 08/2015 ® Husqvarna Husqvarna Motorcycles GmbH StallhofnerstraBe 3 5230 Mattighofen Austria Photo: Mitterbauer, www.husqvarna-motorcycles.com MOTORCYCLES...

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