Husqvarna FE 350 2014 Repair Manual
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Husqvarna FE 350 2014 Repair Manual

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PIONEERING SINCE 1903
REPAIR MANUAL2014
leJ
FE 350 EU
FE 350 AU
FE 350 US
®
Husqvarna
Art. no. 3403001 en
MOTORCYCLES

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Summary of Contents for Husqvarna FE 350 2014

  • Page 1 PIONEERING SINCE 1903 REPAIR MANUAL2014 FE 350 EU FE 350 AU FE 350 US ® Husqvarna Art. no. 3403001 en 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 6.31 Adjusting the play of the steering head MEANS OF REPRESENTATION ........6 bearing ..............36 Symbols used ............6 HANDLEBAR, CONTROLS ..........38 1 .2 Formats used ............6 Handlebar position ..........
  • Page 5 TABLE OF CONTENTS 11.3 Removing the air filter ......... 73 16.3 Checking free travel of hand brake lever ..106 11.4 Installing the air filter ........... 73 16.4 Adjusting the basic position of the hand brake lever (FE 350 US) ........1 06 11.5 Cleaning the air filter and air filter box ....

  • Page 6: Installing The Clutch Discs

    TABLE OF CONTENTS 18.3.31 Removing the shift forks ......141 18.5.5 Installing the shift rails ........169 18.3.32 Removing the transmission shafts ....141 18.5.6 Installing the left engine case ....... 170 18.3.33 Removing the crankshaft ......141 18.5. 7 Installing the spacer ........
  • Page 7 TABLE OF CONTENTS ELECTRIC STARTER ............. 199 23.1 Checking the starter motor....... 199 THROTTLE VALVE BODY ..........200 24.1 Adjusting the idle speed ........200 24.2 Executing the initialization run ......200 TECHNICAL DATA ............201 25.1 Engine ............... 201 25.2 Engine tolerance, wear limits ......

  • 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 4. 1 Chassis number The chassis number is stamped on the steering head on the right. 401945-10 FE350 EU/AU The type label is fixed to the front of the steering head. 401946-10 4. 3 Key number {FE 350 EU/ AU) The key number for the steering lock is stamped onto the key connector.

  • Page 12: Shock Absorber Article Number

    SERIAL NUMBERS The shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side.

  • Page 13: Motorcycle

    MOTORCYCLE Raising the motorc cle with a 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. Lift stand (81329955000) (,...

  • Page 14: Starting The Motorcycle For A Check

    MOTORCYCLE Startin the motorc cle for a check Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 15: Fork, Triple Clamp

    FORK, TRIPLE CLAMP Ad"ustin in of the fork Info The hydraulic compression damping determines the fork suspension behavior. Turn the white adjusting screw all the way clockwise. • Info Adjusting screw is located at the upper end of the left fork leg. The compression damping is located in the left fork leg COMP (white...

  • Page 16: 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. 402556-10 Finishing work Remove the motorcycle from the lift stand.( p. 11) Cleaning the dust boots of the fork legs Preparatory work Raise the motorcycle with a lift stand.( p.

  • Page 17: Positioning The Fork Protector

    FORK, TRIPLE CLAMP rotector Position the fork protector on the left fork leg. Mount and tighten screws Guideline Remaining screws, chassis 1 10 Nm (7.4 lbf ft) Position the brake line, wiring harness, and clamp. Mount and tighten screws @. Position the fork protector on the right fork leg.

  • Page 18: Removing The Fork Protector

    FORK, TRIPLE CLAMP Position the brake caliper, and mount and tighten screws Guideline Screw, front brake caliper 25 Nm Loctite ® ™ (18.4 lbf ft) Mount the cable tie (s). Position the brake line, wiring harness, and clamp. Mount and tighten screws Finishing work Install the front wheel.

  • Page 19: Performing A Fork Service

    FORK, TRIPLE CLAMP 6.11 Performing a fork service Condition The fork legs have been removed. Disassemble the fork legs. (,... p. 17) Remove the spring. (,... p. 19) Disassemble the cartridge. (,... p. 20) Disassemble the piston rod.(,... p. 21) Disassemble the hydrostop unit.
  • Page 20 FORK, TRIPLE CLAMP Unclamp the fork leg. Push the outer tube down. Drain the fork oil. Clamp the fork leg with the axle clamp. Release hydrostop unit and remove it. • Info Do not use an impact wrench. Place a pan underneath since oil will run out. Remove the cartridge from the fork leg.

  • Page 21: Removing The Spring

    FORK, TRIPLE CLAMP Remove the upper sliding bushing Info Do not use a tool; pull the ends apart slightly by hand. Take off the lower sliding bushing Take off support ring Take off seal ring Take off lock ring @. Take off dust boot 0).

  • Page 22: Disassembling The Cartridge

    FORK, TRIPLE CLAMP Disassemblin the cartridge Info The steps are identical for both fork legs. Preparatory work Disassemble the fork legs. (- p. 17) Remove the spring. (- p. 19) Main work Degrease piston rod and clamp it in the vise. Clamping stand (T14049S) (- p.

  • Page 23: Disassembling The Piston Rod

    FORK, TRIPLE CLAMP Remove seal rings and O-ring Remove pilot bushings �. Disassembling the �iston rod Info The steps are identical for both fork legs, except for the hydrostop needle and valve. Preparatory work Disassemble the fork legs. (,..p. 17) Remove the spring.

  • Page 24: Disassembling The Hydrostop Unit

    FORK, TRIPLE CLAMP Remove valve needle from the piston rod. Info The adjusting tube can be used for this. Disassembling the h)'drosto unit Info The steps are identical for both fork legs. Preparatory work Disassemble the fork legs. (,..p. 17) Main work Mount the hydrostop unit on a fitting hexagon socket and clamp into a vice.

  • Page 25: Checking The Fork Legs

    FORK, TRIPLE CLAMP Main work Remove pilot bushing support Remove 0-ring and seal ring 6.18 Checking the fork legs Condition The fork legs have been disassembled. Check the inner tube and axle clamp for damage. If there is damage: Change the inner tube. 200728-10 Measure the outside diameter at multiple locations of the inner tube.

  • Page 26: Assembling The Seal Ring Retainer

    FORK, TRIPLE CLAMP Check the surface of the sliding bushings. If the bronze-colored layer under sliding layer is visible or the surface is rough: Change the sliding bushings. � 200665-10 Check the spring length. Guideline Spring length with preload spacer(s) 472 mm (18.58 in) If the measured value is larger than the specified value: Reduce the thickness of the preload spacers.

  • Page 27: Assembling The Piston Rod

    FORK, TRIPLE CLAMP Mount shim stack @ with the smaller washers facing downward. Mount and tighten sleeve Guideline Hydrostop unit sleeve M6x0.5 I 7 Nm (5.2 lbf ft) Check distance and total length G) of the hydrostop. Guideline ��'� Hydrostop distance ;;,: 1.5 mm (;;,: 0.059 in) Hydrostop length 108.5 ...

  • Page 28: Assembling The Cartridge

    FORK, TRIPLE CLAMP Grind the piston on both sides on a surfacing plate using 1200 grit sandpaper. Clean the piston. Lubricate the piston ring. Fork oil (SAE 4) (48601166S1) (or p. 256) Mount the piston with chamfer facing down. Mount the rebound shim stack with the smaller washers facing upward.

  • Page 29: Assembling The Fork Legs

    FORK, TRIPLE CLAMP Position sleeve in the reservoir. Clamp the tube of the cartridge into a vise. Clamping stand (T14049S) (- p. 269) Slide reservoir onto the tube. • Info Hold the sleeve in the reservoir to prevent it from sliding out. Mount lock ring Mount seal ring retainer @ with the washer and tighten.
  • Page 30 FORK, TRIPLE CLAMP Lubricate and mount dust boot Lubricant (T511) ( p. 257) Info Always change the dust boot, seal ring, lock ring and support ring. Mount the sealing lip with the spring expander facing downward. Slide on lock ring(!}. Lubricate and slide on seal ring (5).
  • Page 31 FORK, TRIPLE CLAMP Mount lock ring Info The lock ring must engage audibly. Mount dust boot Mount fork protection ring G). Lubricate the O-ring. Slide the cartridge all the way into the fork leg. Fork oil (SAE 4) (48601166S1) (.- p. 256) Turn the fork.
  • Page 32 FORK, TRIPLE CLAMP Pull out the piston rod and push it back in numerous times while pressing it to one side slightly. ✓ Air bubbles emerge and the cartridge is bled. Keep bleeding until no more air bubbles emerge. ✓ The piston rod moves out automatically to the middle of the total stroke distance.

  • Page 33: Lubricating The Steering Head Bearing

    FORK, TRIPLE CLAMP Guideline Rebound damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks Compression damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks Turn counterclockwise by the number of clicks corresponding to the fork type. Alternative 2 Warning Danger of accident Modifications to the suspension setting may...

  • Page 34: Installing The Lower Triple Clamp

    FORK, TRIPLE CLAMP Remove screw (D , take off the upper triple clamp with the Remove screw handlebar and set it aside. • Info Cover the components to protect them against damage. Do not kink the cables and lines. Remove O-ring Remove protective ring Take off the lower triple clamp with the steering stem.

  • Page 35: Guideline

    FORK, TRIPLE CLAMP Tighten screws (3. Guideline Screw, bottom triple clamp 15 Nm (11.1 lbf ft) Tighten screw •. Guideline Screw, top steering head M20x1.5 112 Nm (8.9 lbf ft) Mount and tighten screw@. Guideline Screw, top steering stem 17 Nm Loctite ®...

  • Page 36: Checking The Steering Head Bearing Play

    FORK, TRIPLE CLAMP Checkin the steerin head bearing Warning Unstable vehicle handling from incorrect steering head bearing play. Danger of accidents Adjust the steering head bearing play without delay. Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam­ aged over time.

  • Page 37: Checking The Steering Head Bearing Play

    FORK, TRIPLE CLAMP Checkin the steerin head bearing la Warning Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. Adjust the steering head bearing play without delay. Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam­ aged over time.

  • Page 38: Adjusting The Play Of The Steering Head Bearing

    FORK, TRIPLE CLAMP Remove the upper bearing race @ using a suitable tool. Press in the new bearing race all the way using a suitable tool. 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.
  • Page 39 FORK, TRIPLE CLAMP Finishing work Check the steering head bearing play. (.- p. 35) Remove the motorcycle from the lift stand.(.- p. 11)

  • Page 40: Handlebar,Controls

    HANDLEBAR,CONTROLS Handlebar osition On the upper triple clamp, there are two holes at a distance of to each other. 1 15 mm (0.59 in) I Hole distance The holes on the handlebar supports are placed at a distance of from the center. I 3.5 mm (0.138 in) I Hole distance The handlebar supports can be mounted in four different positions.

  • Page 41: Checking The Routing Of The Throttle Cable

    HANDLEBAR,CONTROLS Checkin the routing of the throttle cable Preparatory work Remove the seat. (.- p. 76) Remove the fuel tank. (.- p. 76) Main work Check the routing of the throttle cable. Both throttle cables must be routed to the throttle valve body side by side behind the handlebars and above the fuel tank bearing.

  • Page 42: Checking The Play In The Throttle Cable

    HANDLEBAR,CONTROLS in the throttle cable Preparatory work Remove the seat. (.- p. 76) Remove the fuel tank. (.- p. 76) Check the routing of the throttle cable. (.- p. 39) Main work Move the handlebar to the straight-ahead position. Push back sleeves Loosen nut @.

  • Page 43: 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 44: 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 effect of the high-speed setting can be seen in fast compression of the shock absorber. Turn adjusting screw all the way clockwise with a socket wrench.

  • Page 45: 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 46: Checking The Riding Sag Of The Shock Absorber

    SHOCK ABSORBER, SWINGARM sag of the shock absorber Measure distance of rear wheel unloaded. (.- p. 43) 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 47: Adjusting The Riding Sag

    SHOCK ABSORBER, SWINGARM Finishing work Install the shock absorber. (.- p. 46) Install the manifold. (.- p. 69) Mount the seat. (.- p. 76) Install the main silencer. (.- p. 71) Install the right side cover. (.- p. 76) Remove the motorcycle from the lift stand.(.- p. 11) Ad"usting the riding sag Preparatory work Raise the motorcycle with a lift stand.(.- p.

  • Page 48: Installing The Shock Absorber

    SHOCK ABSORBER, SWINGARM Main work Carefully take the shock absorber out of the vehicle toward the top. Main work Carefully position the shock absorber into the vehicle from above. Finishing work Install the manifold. (,r- p. 69) Mount the seat. (,r- p. 76) Install the main silencer.
  • Page 49 SHOCK ABSORBER, SWINGARM 303096-10 Check needle bearings for damage and wear. If there is damage or wear: Change the needle bearings. Check spacers and @ for damage and wear. If there is damage or wear: Change the spacers. Check the shaft seal rings for damage and wear. If there is damage or wear: Change the shaft seal rings.

  • Page 50: Servicing The Shock Absorber

    SHOCK ABSORBER, SWINGARM Position the linkage lever. Mount and tighten fitting Guideline Nut, linkage lever on angle lever M14x1.5 I 80 Nm (59 lbf ft) • Info Raise the wheel slightly to be able to mount the screw more easily. Tighten screws Guideline Screw, bottom shock...

  • Page 51: Disassembling The Damper

    SHOCK ABSORBER, SWINGARM Remove ring @ . Remove spring retainer and intermediate washer Remove the spring. 9.14 Disassembling the dam�er Preparatory work Remove the spring. (.- p. 48) Main work Note down the current state of rebound damping and compression damp­ ing @ .

  • Page 52: Disassembling The Piston Rod

    SHOCK ABSORBER, SWINGARM Remove lock ring Info Do not scratch the inner surface. Remove the piston rod. Remove adjusting ring with the intermediate washer. Drain the oil. Remove compression adjuster@). Remove the spring and piston. 9.15 Disassembling the �iston rod Preparatory work Remove the spring.

  • Page 53: Disassembling The Seal Ring Retainer

    SHOCK ABSORBER, SWINGARM 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@). • Info Place the compression shim stack onto a screwdriver and set it down as a unit.

  • Page 54: Changing The Pilot Bushing

    SHOCK ABSORBER, SWINGARM Remove washer for seal ring Remove washer Remove dust boot. 201407-10 9.17 Changing the ilot bushing Preparatory work Remove the spring. (.- p. 48) Disassemble the damper. (.- p. 49) Disassemble the piston rod. (.- p. 50) Disassemble the seal ring retainer.

  • Page 55: 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 56: 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. 267) Remove the second lock ring Place special tool underneath and press out heim joint with special tool@).

  • Page 57: 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. 267) Lubricate the sealing lip of the dust boot. Lubricant (T625) ( p. 257) ,..Mount washer@}.

  • Page 58: Assembling The Piston Rod

    SHOCK ABSORBER, SWINGARM 9.22 Assembling the iston rod Preparatory work Assemble the seal ring retainer. ( p. 55) 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 59: Assembling The Damper

    SHOCK ABSORBER, SWINGARM Mount washer with the collar facing downward. Grease the thread of the piston rod. Lubricant (T152) ( p. 257) 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 60 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 61: 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 62 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 63: 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 64: Installing The Spring

    SHOCK ABSORBER, SWINGARM Open filler tap G). Fill the damper for at least 15 seconds. Guideline Gas pressure 1 1 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 65: 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. 9.28 Removing the swingarm Preparatory work Raise the motorcycle with a lift stand. ('r p. 11) Remove the rear wheel.

  • Page 66: 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 67: 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) Mount and tighten screws Guideline Remaining screws, chassis 25 Nm (18.4 lbf ft) Position the brake caliper and pull it back.
  • Page 68 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 69 SHOCK ABSORBER, SWINGARM Press in shaft seal rings Mount bushing(!}. G01814-10 Grease the shaft seal rings. Long-life grease (- p. 257) •- Position collar bushings with the shoulder facing inward. G01819-10 Finishing work Install the swingarm. (- p. 64) Install the rear wheel. (- p. 91) Remove the motorcycle from the lift stand.

  • Page 70: Exhaust

    EXHAUST 10.1 Removin the manifold Preparatory work Raise the motorcycle with a lift stand.(.- p. 11) Remove the seat. (.- p. 76) Remove the right side cover. (.- p. 75) Remove the main silencer.(.- p. 71) Main work Remove fitting Remove screw Press angle lever toward the rear.

  • Page 71: Installing The Manifold

    EXHAUST Remove screw Raise the rear frame slightly and lower the shock absorber. (FE 350 EU) Remove the fuel tank. (.- p. 76) Disconnect plug-in connector of the lambda sensor and remove the cable binder. Remove springs@). Spring hook (50305017000) (.- p. 259) Remove screw �...
  • Page 72 EXHAUST Mount and tighten screw Guideline Remaining screws, chassis 25 Nm (18.4 lbf ft) (FE 350 EU) Connect plug-in connector of the lambda sensor, route the cable without tension, and secure with a new cable tie. Install the fuel tank. (,... p. 78) Lift the rear frame slightly and position the shock absorber.

  • Page 73: Removing The Main Silencer

    EXHAUST Install the right side cover. ( p. 76) Mount the seat. ( p. 76) Remove the motorcycle from the lift stand. ( p. 11) 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 74 EXHAUST Main work (FE 350 EU/ AU) Remove all screws on the main silencer. Take off silencer cap and 0-ring @. Take off outer tube (D and 0-ring Remove glass fiber yarn filling from inner tube (D. Clean the parts that need to be reinstalled and check for damage. Mount the new glass fiber yarn filling on the inner tube.

  • Page 75: 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 cover and catch Engage the air filter box cover in areas f) and G). Engage catch 11.3 Removin the air filter...

  • Page 76: Cleaning The Air Filter And Air Filter Box

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

  • Page 77: Fuel Tank, Seat, Trim

    FUEL TANK, SEAT, TRIM 12.1 0 ening 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 78: 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 the seat at the rear, pull it back, and take it off toward the top. Mountin the seat Mount the front of the seat on the collar bushing of the fuel tank, lower the seat at the rear, and simultaneously push the seat forward.
  • Page 79 FUEL TANK, SEAT, TRIM Main work Unplug connector of the fuel pump. Pull the hose off the fuel tank breather on the tank lid. Thoroughly clean the plug-in connection of the fuel line with an air line. • Info Dirt should not be allowed to get into the fuel line under any circumstances.

  • Page 80: Installing The Fuel Tank

    FUEL TANK, SEAT, TRIM 12.8 Installing the fuel tank 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 81: Changing The Fuel Screen

    FUEL TANK, SEAT, TRIM 12.9 Changing the fuel screen 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 FUEL TANK, SEAT, TRIM Preparatory work Drain the fuel from the fuel tank into a suitable container. Remove the seat. (� p. 76) Remove the fuel tank. (� p. 76) Main work Remove nut with the gasket. Remove fuel connection @ with the gasket. 305313-10 Remove screws Pull out the fuel pump.

  • Page 83: Changing The Fuel Pump

    FUEL TANK, SEAT, TRIM Mount fuel filter ✓ Arrow points away from the fuel pump. Mount hose clamps Hose clamp pliers (600290 5 7000) (or p. 261) 305316-10 Position the fuel pump. Mount fuel connection @ with the gasket but do not tighten yet. Guideline Fuel connection on fuel pump 10 Nm (7.4 lbf ft)

  • Page 84: Checking The Fuel Pressure

    FUEL TANK, SEAT, TRIM Main work Remove nut with the gasket. Remove fuel connection with the gasket. 305313-10 Remove screws Pull out the fuel pump. 305314-10 Position the fuel pump. Mount fuel connection @ with the gasket but do not tighten yet. Guideline Fuel connection on fuel pump 10 Nm (7.4 lbf ft)
  • Page 85 FUEL TANK, SEAT, TRIM Thoroughly clean the 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. Press on the small metal plate and disconnect fuel hose connection •...

  • Page 86: Mask, Fender

    MASK, FENDER 13.1 Removin the front fender Preparatory work Switch off all power consumers and switch off the engine. Remove the headlight mask with the headlight. (,... p. 85) Main work Disconnect plug-in connectors of the turn signals. Remove screws - Take the brake line and wiring harness out of the brake line guide.

  • Page 87: Removing The Headlight Mask With The Headlight

    MASK, FENDER 13.3 Removin the headlight mask with the headlight Preparatory work Switch off all power consumers and switch off the engine. Main work Open rubber bands on the fork legs. Tilt the headlight mask forward and detach at catch Disconnect connector Take off the headlight mask with headlight.

  • Page 88: Wheels

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

  • Page 89: Checking The Brake Discs

    WHEELS Checkin the brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc(s). Change the worn brake disc(s) without delay. Check the thickness of the front and rear brake discs at several places on the disk to see if it conforms to measurement t). •...

  • Page 90: Front Wheel

    WHEELS 14.5 Front wheel Removing the front wheel 14.5.1 Preparatory work Raise the motorcycle with a lift stand. (- p. 11) Main work Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. •...

  • Page 91: Removing The Front Brake Disc

    WHEELS Lift the front wheel into the fork, position it, and insert the wheel spindle. ✓ The brake linings are positioned. 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.

  • Page 92: 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 93: Installing The Rear Wheel

    WHEELS Main work Press the brake caliper by hand on to the brake disc in order to press 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 94: Removing The Rear Brake Disc

    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. 93) Tighten nut Guideline Nut, rear wheel spindle M20x1.5 I 80 Nm (59 lbf ft) Info •...

  • Page 95: 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 96: Checking The Chain, Rear Sprocket, Motor Sprocket, And Chain Guide

    WHEELS Info The wide adjustment range of the chain adjusters (32 mm (1 .26 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. 11) Checking the chain, rear sprocket, motor sprocket, and chain guide 14.6.7 Preparatory work...

  • Page 97: Checking For Chain Dirt Accumulation

    WHEELS Check the chain sliding piece for wear. If the lower edge of the chain pins is in line with 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 98: 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 99 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 100: Changing The Rear Wheel Bearing

    WHEELS 14.6.11 Changing the rear wheel bearing Preparatory work Raise the motorcycle with a lift stand. (r p. 11) Remove the rear wheel. (r p. 90) 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 101 WHEELS Clean, grease, and mount spacing tube Long-life grease (- p. 257) 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 102: 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 103: Checking The Starter Relay

    WIRING HARNESS, BATTERY Remove the defective fuse. Guideline Fuse - 10 A - EFI control unit Fuse 2 - 10 A- fuel pump Fuse - 10 A - high beam, low beam, parking light, tail light, license plate lamp Fuse - 10 A - horn, brake light, turn signal, radiator fan Fuses - 10 A - spare fuses...

  • Page 104: Removing The Battery

    WIRING HARNESS, BATTERY Removin the batte Warning Risk of injury Battery acid and battery gases cause serious chemical burns. Keep batteries out of the reach of children. Wear suitable protective clothing and goggles. Avoid contact with battery acid and battery gases. Keep sparks and open flames away from the battery.

  • Page 105: Checking The Charging Voltage

    WIRING HARNESS, BATTERY 15.6 Checkin the charging volta e Condition The battery must be fully functional and completely charged. Carry out the start procedure. (.- p. 11) Measure the voltage between the specified points. (+) - Measuring point Measuring point Plus Ground Charging voltage...

  • Page 106: Brake System

    Danger of accident Brake linings available in accessories stores often have not been tested and approved for use in Husqvarna motorcy­ cles. The structure and friction coefficient of the brake linings and thus their brake power may vary greatly from that of original Husqvarna Motorcycles bake linings.
  • Page 107 BRAKE SYSTEM Move the brake fluid reservoir mounted on the handlebar to a horizontal position. Remove screws Remove cover with membrane@). 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.

  • Page 108: Checking Free Travel Of Hand Brake Lever

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

  • Page 109: Checking The Front Brake Fluid Level

    BRAKE SYSTEM Checkin the front brake fluid level 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 Danger of accidents Reduced braking efficiency due to old brake fluid.

  • Page 110: Changing The Front Brake Fluid

    BRAKE SYSTEM Main work Move the brake fluid reservoir mounted on the handlebar to a horizontal position. Remove screws Remove cover with membrane Add brake fluid to level Guideline 5 mm (0.2 in) Level (brake fluid level below con- tainer rim) Brake fluid DOT 4 ( p.

  • Page 111: Checking The Rear Brake Linings

    BRAKE SYSTEM Open shut-off valve • Info Follow the operating instructions of the bleeding device. Ensure that the filling pressure is correctly set at pressure gauge 6) . If neces­ sary, adjust the filling pressure at pressure regulator Guideline Filling pressure 2 ...

  • Page 112: Changing The Rear Brake Linings

    Reduced braking efficiency due to the use of non-approved brake linings. Brake linings available in accessories stores often have not been tested and approved for use in Husqvarna motorcy­ cles. The structure and friction coefficient of the brake linings and thus their brake power may vary greatly from that of original Husqvarna Motorcycles bake linings.

  • Page 113: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated properly. ✓ The arrow on the leaf spring points in the rotation direction of the brake disc. Insert the new brake linings, insert pin and mount cotter pins (D.

  • Page 114: Adjusting The Basic Position Of The Foot Brake Lever

    BRAKE SYSTEM Ad"ustin the basic osition of the 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 115: Adding Rear Brake Fluid

    BRAKE SYSTEM Adding rear 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 116: 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 117 BRAKE SYSTEM Open the bleeder screw again until no more brake fluid emerges. • 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 118: Lighting System, Instruments

    LIGHTING SYSTEM, INSTRUMENTS 17.1 Setting the s eedometer Condition The motorcycle is stationary. Press both buttons for 3 - 5 seconds. ✓ The Setup menu is displayed. The display flashes. UNIT ____ ,�_ I _L, Press one of the buttons to select UNIT for the speed in kilometers KM/H...

  • Page 119: Setting The Kilometers Or Miles

    LIGHTING SYSTEM, INSTRUMENTS Setting the kilometers or miles Info If the unit is changed, the value ODO is retained and converted accordingly. Condition The motorcycle is stationary. Press both buttons for 3 - 5 seconds. ✓ The Setup menu is displayed. The UNIT display flashes.

  • Page 120: Setting The Service Display

    LIGHTING SYSTEM, INSTRUMENTS Wait for the menu TIRE to flash. Reducing the wheel circumference ----,�-1 - �-- Press the left button. -�: fE- ✓ The value decreases. ,,,,,, / I ' � ' "" Enlarging the wheel circumference Press the right button. ✓...

  • Page 121: Adjusting The Headlight Range

    LIGHTING SYSTEM, INSTRUMENTS If the light-dark border does not meet specifications: Adjust the headlight range. p. 119) 17.7 Ad"usting the headlight range Preparatory work Check the headlight setting. (or p. 118) Main work Adjust the headlight range of the headlight by turning adjusting screw Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with driver (instructions on how to apply the mark: Checking the...

  • Page 122: Engine

    ENGINE 18.1 Removin the engine Preparatory work Remove the engine guard.(,... p. 41) Drain the coolant. (,... p. 189) Raise the motorcycle with a lift stand.(,... p. 11) Remove the right side cover. (,... p. 75) Remove the main silencer.(,... p. 71) Remove the seat.
  • Page 123 ENGINE Remove screws Loosen screw (D. Repeat these steps on the opposite side. Swing up the subframe and secure it. Remove screw Swing back the shock absorber. Remove springs@). Spring hook (50305017000) (- p. 259) Remove screw Take off the manifold. Push back the cover.
  • Page 124 ENGINE G, . Loosen hose clip Pull off the radiator hose. 48 . Disconnect spring Remove screw Remove screw Take off the engine sprocket cover. Remove the connecting link of the chain. Take off the chain. Remove screws Take off the clutch slave cylinder and hang it to one side. •...
  • Page 125 ENGINE Loosen hose clip G). Pull off the throttle valve body toward the rear. Loosen hose clip�­ Pull off the radiator hose. Remove fittings Take off the engine braces. Remove nut�- Remove the swingarm pivot. Pull the swingarm toward the rear slightly. Remove screws Lift out the engine sideways.

  • Page 126: Installing The Engine

    ENGINE Main work Position the engine in the frame. Mount screws but do not tighten yet. Guideline Engine attachment bolt 60 Nm (44.3 lbf ft) Position the swingarm. Mount the swingarm pivot. Mount nut but do not tighten it yet. Guideline Nut, swingarm pivot M16x1.5...
  • Page 127 ENGINE Mount the throttle valve b ody. Position and tighten hose clip Ci) . Plug in connector (D . Position the protection cap. Plug in connector @ . Plug in connector @) . Mount the spark plug connector. Position the clutch slave cylinder with the gasket. Mount and tighten screws Guideline 1 10Nm(7.41bfft)
  • Page 128 ENGINE Mount the radiator hose. Position and tighten hose clip Position the cable. Mount and tighten nut Position the cover. Position the manifold and mount springs Spring hook (50305017000) ('r p. 259) Mount and tighten screw Guideline Remaining screws, chassis 25 Nm (18.4 lbf ft) Position the shock absorber.
  • Page 129 ENGINE Remove the fixation and position the subframe. • Info Watch out for the intake flange. Mount and tighten screws �. Guideline Screw, subframe 35 Nm Loctite 2701 ® (25.8 lbf ft) Remove screw �. Mount and tighten screw �. Guideline 35 Nm Screw, subframe...

  • Page 130: Engine Disassembly

    Execute the initialization run. (,... p. 200) Finishing work Take a test ride. Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. Check the engine for leakage. Check the engine oil level. (,... p. 191) Check the coolant level. (,... p. 189) Install the engine guard.

  • Page 131: Removing The Clutch Push Rod

    ENGINE 18.3.2 Removing the clutch push rod Remove clutch push rod 18.3.3 Removing the spacer Remove spacer of the countershaft. Remove O-ring. 18.3.4 Draining the engine oil Remove plug with oil screen and the O-rings. Remove oil drain plug @ with the magnet. Completely drain the engine oil.

  • Page 132: Removing The Spark Plug

    ENGINE Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) ('r p. 260) 18.3.6 Removing the spark plug Remove the spark plug using special tool Spark plug wrench (77229172000) (,... p. 265) 18.3.7 Removing the valve cover Remove screws Remove the valve cover with the valve cover seal.

  • Page 133: Removing The Torque Limiter

    ENGINE Take off the alternator cover gasket ✓ Dowels @ remain in the engine case. 18.3.9 Removing the torque limiter Remove torque limiter 18.3.10 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 G) of the camshafts.

  • Page 134: Removing The Camshaft

    ENGINE Pull out timing chain tensioner Remove O-ring 18.3.12 Removing the camshaft Loosen screws from the outside to the inside and remove. Take off guide rail fj . Take off the camshaft bearing bridge. Take the timing chain off the camshaft gear. Remove the camshafts.

  • Page 135: Removing The Piston

    ENGINE Remove cylinder head gasket 18.3.14 Removing the piston Push the cylinder upward. • Info Only push the cylinder as far up as necessary to take the piston pin out. Remove the piston pin retainer Remove the piston pin. Take off the cylinder and piston. Push the piston upward out of the cylinder.

  • Page 136: Removing The Suction Pump

    ENGINE Remove lock ring Take off the starter idler gear with the washer. Remove freewheel gear CD . Remove screws Remove the inside alternator cover. Take off gasket@. Remove screws @. Take off the starter motor. 18.3.16 Removing the suction pump Remove screws Take off oil pump cover...

  • Page 137: Removing The Water Pump Wheel

    ENGINE Remove O-ring Remove suction pump Remove needle roller@). 18.3.17 Removing the water pump wheel Remove screws Take off the water pump cover. Remove nut Take off the two-part water pump impeller...

  • Page 138: Removing The Clutch Cover

    ENGINE 18.3.18 Removing the clutch cover Remove screws Take off the clutch cover. Remove the clutch cover seal. 18.3.19 Removing the clutch discs Remove screws Take off spring retainer@. Take off spring washer@). Take off pretension ring Take off pressure cap...

  • Page 139: Removing The Clutch Basket

    ENGINE Completely remove clutch disc pack (D . Remove clutch pressure piece 18.3.20 Removing the clutch basket Bend open lock washer. Hold the inner clutch hub with the special tool. Loosen nut Clutch holder (51129003000) (- p. 260) Remove the nut with the lock washer. Dispose of the lock washer. Take off inner clutch hub and washer •...

  • Page 140: Removing The Shift Drum Locating Unit

    ENGINE 18.3.22 Removing the shift drum locating unit Remove screw Push away locking lever from shift drum locating unit and remove the shift drum locating unit. Relieve tension from the locking lever. 18.3.23 Removing the locking lever Unscrew and remove together with locking lever@, washer, sleeve and spring.

  • Page 141: Removing The Primary Gear

    ENGINE Remove pin@). Push oil pump shaft Gi) inward and take it out of the engine from the alternator side. Remove force pump 18.3.25 Removing the primary gear Remove nut • Info Left-handed thread! Take off primary gear(!}. 18.3.26 Removing the timing chain Remove screws Remove the timing chain tensioning rail(!}.

  • Page 142: Removing The Left Section Of The Engine Case

    ENGINE 18.3.28 Removing the left section of the engine case Remove screws Tilt the left section of the engine case upward and remove the screw connections of the engine fixing arm. Insert the special tool into the crankshaft. Protection cap (75029090000) ("" p. 263) Mount special tool with the appropriate screws.

  • Page 143: Removing The Shift Drum

    ENGINE 18.3.30 Removing the shift drum Tilt shift forks to the side. • Info Do not misplace the shift rollers. Remove shift drum@. 18.3.31 Removing the shift forks Remove shift forks Info Do not misplace shift rollers 18.3.32 Removing the transmission shafts Remove lock ring Pull both transmission shafts out of the bearing seats together.

  • Page 144: Work On Individual Parts

    ENGINE 18.4 Work on individual arts 18.4.1 Work on the right section of the engine case Remove all dowels. Remove shaft seal ring of the crankshaft. Remove nozzle Remove oil nozzle for conrod bearing lubrication. Remove screw Remove the oil nozzle for piston cooling. Remove screws@).

  • Page 145: Work On The Left Section Of The Engine Case

    ENGINE Guideline Screw, oil nozzle for pis­ Loctite ® ™ ton cooling (1 .5 lbf ft) Position all bearing locks. Mount and tighten screws Guideline Locking screw for bearing Loctite ® ™ (4.4 lbf ft) Blow out the oil channel with compressed air and check that it is clear. 18.4.2 Work on the left section of the engine case Remove all dowels.

  • Page 146: Work On The Clutch Cover

    ENGINE Press in shaft seal ring of the countershaft so it is flush with the open side facing in. Mount and tighten oil nozzle Guideline Oil nozzle for clutch lubri- Loctite ® ™ cation (4.4 lbf ft) Mount and tighten oil nozzle Guideline Oil nozzle, piston cooling 2 Nm...
  • Page 147 ENGINE 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 148: Checking The Oil Pressure Regulator Valve

    ENGINE 18.4.4 Checking the oil pressure regulator valve with sealing washer @ . Remove screw plug Remove pressure spring fs) and ball o- 8 305033-10 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.

  • Page 149: Removing The Crankshaft Bearing Inner Race

    ENGINE Change the oil pump shaft. Check the oil pump cover for damage and wear. If there is damage or wear: Change the oil pump cover. 18.4.6 Removing the crankshaft bearing inner race Fix the crankshaft in the vise. • Info Use soft jaws.
  • Page 150 ENGINE Press the crank pin out of the lower crank web. Press in the new crank pin as far as possible. ✓ Oil hole is aligned with oil hole@). X If the oil holes are not correctly aligned, the conrod bearing will not be sup­ plied with oil.

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

    ENGINE 18.4.9 Checking the crankshaft run-out at the bearing pin Position the crankshaft on a roller block. Turn the crankshaft slowly. Check the crankshaft run-out on both bearing pins. Crankshaft - run-out at bearing pin :5 0.03 mm (:5 0.0012 in) If the crankshaft run-out at the bearing pin is larger than the specification: Align the crankshaft.

  • Page 152: Installing The Drive Wheel Of The Balancer Shaft

    ENGINE 18.4.12 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 18.4.13 Cylinder - Nikasil ®...

  • Page 153: Checking/Measuring The Piston

    ENGINE 18.4.15 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. 261) If play is larger than the specified value: Change the piston and piston rings.

  • Page 154: Checking The Piston Ring End Gap

    ENGINE Guideline Piston/cylinder - mounting clearance Size I 0.025 ... 0.047 mm (0.00098 ... 0.00185 in) Size II 0.027 ... 0.049 mm (0.00106 ... 0.00193 in) Wear limit 0.070 mm (0.00276 in) 18.4.17 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 155: Checking The Camshafts

    ENGINE 18.4.19 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. Check the autodecompressor for damage and wear. If there is damage or wear: Change the exhaust camshaft.

  • Page 156: Removing The Valves

    ENGINE Take off the camshafts and clean the parts. 18.4.21 Removing the valves Remove screw plugs with the O-ring. Screw appropriate screw into the cam lever shaft. Hold cam levers and remove the cam lever shaft. • Info If the cam levers will continue to be used, note down their installation posi­ tion.

  • Page 157: Checking The Valves

    ENGINE 18.4.22 Checking the valves Check the valve plate for run-out. Valve - run-out At the valve plate s; 0.05 mm (s; 0.002 in) If the measured value does not meet specifications: Change the valve. 200193-10 Check sealing seat on the valve. Valve - sealing seat width Intake 1 .40 mm (0.0551 in)

  • Page 158: Checking The Cylinder Head

    ENGINE 18.4.26 Checking the cylinder head Check valve guides using the special tool. Limit plug gauge (77229026000) (or p. 264) If the special tool is easy to insert in the valve guide: Change the valve guide and valve. Check the sealing area of the spark plug thread and the valve seats from damage and cracking.

  • Page 159: Checking The Freewheel

    ENGINE Mount valve keys 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. Position cam levers in the positions they had before they were removed. Mount the cam lever shafts.

  • Page 160: Installing The Freewheel

    ENGINE Press expansion ring @ together with suitable pliers and take off. Take freewheel (D out of the primary gear. 18.4.30 Installing the freewheel Thoroughly oil all parts. Slide freewheel into the primary gear. Info Note the direction of rotation. Mount spreader ring@.

  • Page 161: Checking The Electric Starter Drive

    ENGINE 18.4.31 Checking the electric starter drive ·-• 305006-10 Check the gear mesh and bearing of starter idler gear for damage and wear. If there is damage or wear: Change the starter idler gear. Check the gear mesh and bearing of torque limiter for damage and wear.

  • Page 162: Checking The Timing Assembly

    ENGINE 18.4.32 Checking the timing assembly 305007-10 Check timing chain sprocket for damage and wear. If there is damage or wear: Change the timing chain sprocket. Check the timing chain tensioning rail for damage and wear. If there is damage or wear: Replace the timing chain tensioning rail.

  • Page 163: Checking The Clutch

    ENGINE Place two compensating disks or similar aids next to the timing chain tensioner piston. This ensures that, when pressed in, the piston cannot go in all the way. Guideline Thickness of the compensating disks 2 ... 2.5 mm (0.08 ... 0.098 in) Release the timing chain tensioner.

  • Page 164: Checking The Shift Mechanism

    ENGINE Change the pressure cap. Check clutch center @ for damage and wear. If there is damage or wear: Change the clutch center. Check damping rubber for damage and wear. If there is damage or wear: Change the damping rubbers. Check the inner clutch hub for damage and wear.

  • Page 165: Preassembling The Shift Shaft

    ENGINE Change the shift drum. Check the seating of the shift drum in the grooved ball bearings@). If the shift drum is not correctly seated: Change the shift drum and/or the grooved ball bearing. Check grooved ball bearing @) for smooth operation and wear. If the grooved ball bearings are stiff or worn: Change the grooved ball bearing.

  • Page 166: Disassembling The Main Shaft

    ENGINE 18.4.37 Disassembling the main shaft 305011-10 Secure the main shaft with the toothed end facing downward in the vise. Guideline Use soft jaws. Remove stop disk and 2nd-gear fixed gear Remove 5th-gear idler gear Ci) and needle bearing Remove stop disk Remove lock ring (3.

  • Page 167: Checking The Transmission

    ENGINE Guideline Use soft jaws Remove stop disk and 1st-gear idler gear @. Remove needle bearing (D. Remove stop disk Remove 6th-gear sliding gear Remove stop disk Cs). Remove lock ring @. Remove 3rd-gear idler gear@. Remove needle bearing Remove 4th-gear idler gear Gi). Remove needle bearing Remove stop disk and lock ring G).

  • Page 168: Assembling The Main Shaft

    ENGINE If there is damage or wear: Change the gear wheel pair. Check the shift dogs of idler gears and sliding gears @) for damage and wear. If there is damage or wear: Change the gear wheel pair. Check the tooth faces of idler gears sliding gears @), and fixed gear (3 for damage and wear.

  • Page 169: Assembling The Countershaft

    ENGINE Mount needle bearing Mount 6th-gear idler gear @. Mount stop disk and lock ring Mount 3rd/4th-gear sliding gear with the small gear wheel facing downward. Mount lock ring (3. Mount stop disk@. Mount needle bearing (D. Mount 5th-gear idler gear Mount 2nd-gear fixed gear and stop disk Finally, check all gear wheels for smooth operation.

  • Page 170: Engine Assembly

    ENGINE Mount 6th-gear sliding gear with the shift groove facing downward. Mount stop disk Gt). Mount needle bearing Ci}. Mount 1st-gear idler gear Mount stop disk Gi). Finally, check all gear wheels for smooth operation. 18.5 Engine assembl� 18.5.1 Installing the crankshaft Position the right section of the engine case in the engine work stand.

  • Page 171: Installing The Shift Forks

    ENGINE 18.5.3 Installing the shift forks Shift fork has a smaller inside diameter; mount this in the shift groove of the main shaft. •- Mount shift fork @ in the lower shift groove of the countershaft. Mount shift fork (D in the upper shift groove of the countershaft. Slide on shift rollers Fix the shift rollers in the shift forks with grease.

  • Page 172: Installing The Left Engine Case

    ENGINE 18.5.6 Installing the left engine case Mount the dowels. Degrease the sealing area. Apply sealing compound to the left section of the engine case. Loctite 591 O ® Mount the left section of the engine case. If necessary, strike it lightly with a rub­ ber mallet and turn the transmission shafts.

  • Page 173: Installing The Primary Gear

    ENGINE Position timing chain guide rail (D. Mount and tighten screw Guideline Screw, timing chain guide 10 Nm Loctite ® ™ rail (7.4 lbf ft) Position timing chain tensioning rail Mount and tighten screw 0). Guideline Screw, timing chain ten­ 15 Nm Loctite ®...

  • Page 174: Installing The Suction Pump

    ENGINE Position oil pump gear wheel (D. Mount washer@. Mount lock ring Crank the oil pump gear wheel and ensure that it can move easily. Mount oil pump idler gear with the washer. Mount washers 41). Mount lock ring 18.5.11 Installing the suction pump Insert needle roller Position suction pump...

  • Page 175: Installing The Locking Lever

    ENGINE 18.5.12 Installing the locking lever Mount locking lever with the washer, sleeve and spring. Mount and tighten screw Guideline Loctite Screw, locking lever ® ™ (4.4 lbf ft) 18.5.13 Installing the shift drum locating unit Push away locking lever from the shift drum locating unit and position the shift drum locating unit •...
  • Page 176 ENGINE Slide on washer and inner clutch hub Position the new lock washer and mount nut (s). Tighten the nut, holding the inner clutch hub with a special tool. Guideline Nut, inner clutch hub M18x1 .5 100 Nm Loctite ® ™...

  • Page 177: Installing The Clutch Cover

    ENGINE Position spring retainer with the I marking. Install the screws and tighten them diagonally. Guideline Screw, clutch spring I 6 Nm (4.4 lbf ft} Using a straightedge and the special tool, check the spring washer for distortion. Feeler gauge (590290411 00) ( p.

  • Page 178: Installing The Water Pump Cover

    ENGINE Position the clutch cover. • Info Ensure that the shaft seal rings of the water pump and the crankshaft are not damaged. Remove screw Mount screw @ with the washer but do not tighten yet. Guideline Screw, clutch cover M6x25 110 Nm (7.4 lbf ft) Mount screws...
  • Page 179 ENGINE Mount gasket Position the inside alternator cover. Mount and tighten screws (5). Guideline Screw, inside alternator cover I 6 Nm (4.4 lbf ft) Tighten screws Guideline Screw, starter motor 10 Nm (7.4 lbf ft) Position freewheel gear Mount the starter idler gear with the washer. Mount lock ring Position the rotor.

  • Page 180: Installing The Piston

    ENGINE 18.5.20 Installing the piston ° Shift the joint of the piston rings by 120 Place the special tool on the oiled piston. Compress the piston rings using the special tool. Piston ring mounting tool (60029015000) (,... p. 261) ✓ The piston rings are pushed together all the way. 302642-10 Position the piston on the cylinder using the special tool.

  • Page 181: Installing The Cylinder Head

    ENGINE Insert the special tool and press it forcefully to the piston. Turn the special tool clockwise, thereby pushing the piston pin retainer into the groove. Insertion for piston ring lock (77229030000) (or- p. 264) Ensure that the piston pin retainer is seated properly on both sides. Remove the cloth.

  • Page 182: Installing The Camshafts

    ENGINE Mount and tighten nut with the washer. Guideline Nut, cylinder head 10 Nm Lubricated with (7.4 lbf ft) engine oil 18.5.22 Installing the camshafts Pull up the timing chain and insert intake camshaft Place the timing chain over the camshaft gear of the intake camshaft. ✓...

  • Page 183: Adjusting The Valve Timing

    ENGINE Remove the special tool. Adjustment bush bridge (77229050044) ( p. 265) Insert, timing chain tensioner (77229035000) ( p. 265) 18.5.24 Adjusting the valve timing Condition Camshaft gears were loosened. Mount special tool and tension the timing chain. Insert, timing chain tensioner (77229035000) ( p.

  • Page 184: Installing The Timing Chain Tensioner

    ENGINE Mount and tighten screws Guideline Screw, camshaft bearing M7x1 14 Nm Lubricated with bridge (10.3 lbf ft) engine oil Remove special tool Insert, timing chain tensioner (77229035000) (- p. 265) 18.5.25 Installing the timing chain tensioner Preparatory work Prepare the timing chain tensioner for installation. (- p. 160) Main work Position timing chain tensioner and insert it with new O-ring...

  • Page 185: Checking The Valve Clearance

    ENGINE 18.5.26 Checking the valve clearance Remove screw Crank over the engine repeatedly. 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)

  • Page 186: Installing The Torque Limiter

    ENGINE Installing the torque limiter 18.5.28 Position torque limiter 18.5.29 Installing the alternator cover Position alternator cover gasket Position the alternator cover. Mount screws and tighten once all of the alter­ nator cover screws have been mounted. Guideline Screw, alternator cover M6x30 I 6 Nm (4.4 lbf ft) Mount screws...

  • Page 187: Installing The Spark Plug

    ENGINE Position the valve cover with the gasket. Mount and tighten screws Guideline Screw, valve cover I 8 Nm (5.9 lbf ft) 18.5.31 Installing the spark plug Mount and tighten the spark plug with special tool Guideline Spark plug M10x1 10 ...

  • Page 188: Installing The Spacer

    ENGINE Push the oil screen with O-rings onto a pin wrench. Push the pin wrench through the opening into the drill hole of the opposite engine case wall and push the oil screen as far as possible into the engine case. Mount and tighten screw plug with the O-ring.

  • Page 189: Clutch

    CLUTCH Checkin ing 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 190: Water Pump, Cooling System

    WATER PUMP, COOLING SYSTEM Water pump in the engine circulates the coolant. The water flow through the radiator is controlled as a function of the coolant temper­ ature. The cooling system is divided into two circuits. In the warming-up phase of the engine, the coolant flows through the small cooling circuit.

  • Page 191: 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 192: 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 193: Lubrication System

    LUBRICATION SYSTEM 21.1 Oil circuit 401362-60 Oil screen Force pump Oil pressure regulator valve Oil filter Oil nozzle, conrod lubrication Oil nozzle for cam follower 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 194: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen

    LUBRICATION SYSTEM 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. In case of burns, rinse immediately with lukewarm water. Warning Hazardous substances cause environmental damage.
  • Page 195 LUBRICATION SYSTEM Remove screws Take off the oil filter cover with the O-ring. Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) (- p. 260) Completely drain the engine oil. Thoroughly clean the parts and sealing area. Lay the motorcycle on its side and fill the oil filter housing to about ½...

  • Page 196: Adding Engine Oil

    LUBRICATION SYSTEM Adding engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. Main work Remove the oil filler plug with the O-ring from the clutch cover. Fill engine oil to the middle of the level viewer.
  • Page 197 LUBRICATION SYSTEM Check the oil pumps for wear. Check all oil holes for free flow. 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.

  • Page 198: Ignition System

    IGNITION SYSTEM 22.1 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 199: Removing The Stator And Ignition Pulse Generator

    IGNITION SYSTEM 601211-10 Stator winding - check for a short circuit to ground (terminal 31) Measure the resistance between the specified points. - Measuring point Stator, connector Ground Resistance If the value displayed does not meet specifications: Change the stator. Removin the stator and i nition pulse enerator 22.4 Condition...

  • Page 200: Generator

    IGNITION SYSTEM 22.5 Installing the stator and ignition enerator Blow out oil nozzle with compressed air and check that it is clear. Guideline Oil nozzle for alternator Loctite ® ™ cooling (1.5 lbf ft) 305322-10 Position the stator in the alternator cover. Mount and tighten screws Guideline Screw, stator...

  • Page 201: Electric Starter

    ELECTRIC ST ARTER 23.1 Checkin the starter motor Condition The starter motor has been removed. 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 to connector the starter motor.

  • Page 202: Throttle Valve Body

    THROTTLE VALVE BODY Ad"ustin the idle s eed Warning Danger of accidents The engine may go out spontaneously if the idle speed is set too low. Set the idle speed to the specified value. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.

  • Page 203: Technical Data

    TECHNICAL DATA 25.1 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 12.3:1 2,050 ... 2,150 rpm Idle speed Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 36.3 mm (1.429 in)

  • Page 204: Engine Tightening Torques

    TECHNICAL DATA 87.965 ... 87.975 mm (3.46318 ... 3.46358 in) Size I Size II 87.976 ... 87.985 mm (3.46362 ... 3.46397 in) Cylinder - drill hole diameter Size I 88.000 ... 88.012 mm (3.46456 ... 3.46503 in) Size II 88.012 ... 88.025 mm (3.46503 ... 3.46554 in) Piston/cylinder - mounting clearance Size I 0.025 ...

  • Page 205: Capacities

    TECHNICAL DATA Screw, timing chain guide rail 10 Nm (7.4 lbf ft) ® Loctite ™ Screw, timing chain securing guide 10 Nm (7.4 lbf ft) ® Loctite ™ Screw, valve cover 8 Nm (5.9 lbf ft) Screw, water pump cover 10 Nm (7.4 lbfft) Stud, cylinder head 10 Nm (7.4 lbfft)

  • Page 206: Chassis

    TECHNICAL DATA 25.5 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork WP Suspension Up Side Down 4860 4CS Suspension travel Front 300 mm (11.81 in) Suspension travel Rear 330 mm (12.99 in) Fork offset 20 mm (0. 79 in) Shock absorber WP Suspension 5018 BAVP DCC...

  • Page 207: Tires

    (FE 350 US) 80/100 - 21 M/C 51 M TT 110/100 - 18 M/C 64M TT Dunlop GEOMAX MX51 FA Dunlop GEOMAX MX51 Additional information is available in the Service section under: www.husqvarna-motorcycles.com Fork 25.8 Fork part number 24.18. 7N.67 Fork...

  • Page 208: Chassis Tightening Torques

    TECHNICAL DATA 2 06 Weight of rider: 85 ... 95 kg (187 ... 209 lb.) 57 N/mm (325 lb/in) Spring length 260 mm (10.24 in) Gas pressure 1 0 bar (145 psi) 30 mm (1.18 in) Static sag Riding sag 100 mm (3.94 in) Fitted length 490 mm (19.29 in)

  • Page 209: Cleaning, Care

    CLEANING, CARE 26.1 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 210: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE Checks and maintenance ste s for winter o eration Info If you use the vehicle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive road salt. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt.

  • Page 211: Storage

    • Info Husqvarna Motorcycles recommends raising the motorcycle. Raise the motorcycle with a lift stand.(..- p. 11) Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.

  • Page 212: Service Schedule

    • Final check: Check the vehicle for roadworthiness 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 the Husqvarna Motorcycles Dealer.net...

  • Page 213: Service Work As Additional Order

    SERVICE SCHEDULE One-time interval • Periodic interval 28.2 Service work as additional order Annually Every 135 operating hours Every 70 operating hours after sporting use Every 45 operating hours Once after 15 operating hours • Change the front brake fluid. (.- p. 108) •...

  • Page 215: Wiring Diagram

    WIRING DIAGRAM Components: Battery Starter relay with main fuse Starter motor Electric starter button...

  • Page 216: Fe 350 Eu)

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  • Page 217 WIRING DIAGRAM Components: A 11 EFI control unit Radiator fan temperature switch Fuse Fuse Fuse Alternator Light relay Power relay Radiator fan Voltage regulator X295 Diagnostics connector...

  • Page 218: Fe 350 Eu)

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  • Page 219 WIRING DIAGRAM Components: A 11 EFI control unit Low beam, high beam Speedometer Horn Parking light Light switch, horn button, kill switch...

  • Page 220: Fe 350 Eu)

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  • Page 221 WIRING DIAGRAM Components: Brake light switch, front Brake light switch, rear License plate lamp Brake/tail light...

  • Page 222: Fe 350 Eu)

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  • Page 223 WIRING DIAGRAM Components: Turn signal relay Turn signal indicator light Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right Turn signal switch...

  • Page 224: Fe 350 Eu)

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  • Page 225 WIRING DIAGRAM Components: A 11 EFI control unit Fuel level indicator Lambda sensor (cylinder 1) Fuse Speedometer...

  • Page 226: Fe 350 Eu)

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  • Page 227 WIRING DIAGRAM Components: A 11 EFI control unit Wheel speed sensor, front Fuel pump Injector (cylinder 1) CAN-bus terminating resistor 1 Speedometer X295 Diagnostics connector...

  • Page 228: Fe 350 Eu)

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  • Page 229 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 Ignition pulse generator Manifold absolute pressure sensor (cylinder 1) Ignition coil (cylinder 1) Map-Select switch for riding mode (optional) Map-Select switch for basic setting (optional) Cable colors:...
  • Page 231 WIRING DIAGRAM Components: Battery Starter relay with main fuse Starter motor Emergency OFF switch, electric starter button...

  • Page 232: Fe 350 Au)

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  • Page 233 WIRING DIAGRAM Components: A 11 EFI control unit Radiator fan temperature switch Fuse Fuse Fuse Alternator Light relay Power relay Radiator fan Voltage regulator X295 Diagnostics connector...

  • Page 234: Fe 350 Au)

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  • Page 235 WIRING DIAGRAM Components: A 11 EFI control unit Low beam, high beam Speedometer Horn Parking light Light switch, horn button, kill switch Emergency OFF switch, electric starter button...

  • Page 236: Fe 350 Au)

    � � l -� .., "' " � • _ /3.B8 f C>-- wh ·� "" "' � BY/4 -A H /2 -AH/2 f x1s -D1/2 ��" -AK/2 -AK/2 � -CV/4 CV/4 -X11 -B77 - ,... BY/4 -B76 - -P36 -X17 �...
  • Page 237 WIRING DIAGRAM Components: Brake light switch, front Brake light switch, rear License plate lamp Brake/tail light...

  • Page 238: Fe 350 Au)

    � /4.B8 bt>-----br � /4.B8 ,e>--ye-bu a.::o 5.:n -X 4 1 -X23 -X25 -X28 N M A J/3 -CX/2 -CX/2 -CX/2 -CX/2 - N F0/2 -AH/2 � � N MBG/3 -CW/2 -CW/2 -CW/2 -CW/2 -P4 6 � - -P42 - -P41 - -P45 �...
  • Page 239 WIRING DIAGRAM Components: Turn signal relay Turn signal indicator light Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right Turn signal switch...

  • Page 240: Fe 350 Au)

    � � " "- " -P13 /3.A6 -© /7.A4 /7.A2 ll� l""" � 1D"3S CY/3 CY/3 l°'"" -X15 -X15 -X15 -X15 CZ/3 CZ/3 -X51 -X51 :§l -�, � 7jlir }� " " _ , , , □ N F J /2 - GA/3 �...
  • Page 241 WIRING DIAGRAM Components: A 11 EFI control unit Fuel level indicator Fuse Speedometer...

  • Page 242: Fe 350 Au)

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  • Page 243 WIRING DIAGRAM Components: A 11 EFI control unit Wheel speed sensor, front Fuel pump Injector (cylinder 1) CAN-bus terminating resistor 1 Speedometer X295 Diagnostics connector...

  • Page 244: Fe 350 Au)

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  • Page 245 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 Ignition pulse generator Manifold absolute pressure sensor (cylinder 1) Ignition coil (cylinder 1) Map-Select switch for riding mode (optional) Map-Select switch for basic setting (optional) Cable colors:...
  • Page 247 WIRING DIAGRAM Components: Battery Starter relay with main fuse Starter motor Electric starter button...

  • Page 248: Fe 350 Us)

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  • Page 249 WIRING DIAGRAM Components: A 11 EFI control unit Radiator fan temperature switch (optional) Fuse Fuse Fuse Alternator Light relay Power relay Radiator fan (optional) Voltage regulator X295 Diagnostics connector...

  • Page 250: Fe 350 Us)

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  • Page 251 WIRING DIAGRAM Components: A 11 EFI control unit Low beam Parking light Tail light Kill switch Light switch...

  • Page 252: Fe 350 Us)

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  • Page 253 WIRING DIAGRAM Components: A 11 EFI control unit Fuel tank sensor Fuse Speedometer...

  • Page 254: Fe 350 Us)

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  • Page 255 WIRING DIAGRAM Components: A 11 EFI control unit Wheel speed sensor, front Fuel pump Injection valve (cylinder 1) Speedometer CAN bus terminating resistor 1 X295 Diagnostics connector...

  • Page 256: Fe 350 Us)

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  • Page 257 WIRING DIAGRAM Components: A 11 EFI control unit Throttle position sensor circuit A Intake air temperature sensor Coolant temperature sensor (cylinder 1) Rollover sensor Crankshaft position sensor Manifold absolute pressure sensor (cylinder 1) Ignition coil (cylinder 1) Map-Select switch for ride mode (optional) Map-Select switch for basic position (optional) Cable colors:...

  • Page 258: 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 259: 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 260 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 261: 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 Spring hook Art. no.: 50305017000 50305017000 H00973-01 Bleed s�ringe Art. no.: 50329050000 50329050000 H00565-01...
  • Page 262 SPECIAL TOOLS Circli liers reverse Art. no.: 51012011000 51012011000 H00572-01 Clutch holder Art. no.: 51129003000 51129003000 H00575-01 Extractor Art. no.: 58012009000 58012009000 H00592-01 Tool for inner bearing race Art. no.: 58429037037 58429037037 H00596-01 Torgue wrench with various accessories in set Art.
  • Page 263 SPECIAL TOOLS Valve s ring mounter Art. no.: 59029019000 2x.£. 59029019000 H00610-01 Feeler Art. no.: 59029041100 c:;?7 59029041100 H00616-01 Plasti e clearance Art. no.: 60029012000 60029012000 H00627-01 Piston ring mounting tool Art. no.: 60029015000 60029015000 H00628-01 Hose clam� �liers Art. no.: 60029057000 60029057000 H00650-01...
  • Page 264 SPECIAL TOOLS Testing hose Art. no.: 61029093000 61029093000 H00659-01 Pressure tester Art. no.: 61029094000 4x £ 61029094000 H00660-01 En ine assembly stand Art. no.: 61229001000 61229001000 H00662-01 Release device for timing chain tensioner Art. no.: 61229021000 61229021000 H00675-01 Pressing tool for crankshaft, com�lete Art.
  • Page 265 SPECIAL TOOLS Protection ca Art. no.: 75029090000 75029090000 H00726-01 Extractor, camshaft ear Art. no.: 77229001044 � 77229001044 H00747-01 Art. no.: 77229002000 2x£ � 77229002000 H00748-01 Insert for crankshaft pressing tool Art. no.: 77229008000 ®B 77229008000 H00750-01 Extrude �late, base Art. no.: 77229009000 2x.£...
  • Page 266 SPECIAL TOOLS Pliers for valve stem seals Art. no.: 77229010000 77229010000 H00752-01 Limit Art. no.: 77229026000 77229026000 H00753-01 Insertion for piston rin lock Art. no.: 77229030000 77229030000 H00754-01 Protection cap Art. no.: 77229031000 77229031000 H00755-01 Se�arator �late Art. no.: 77229032000 77229032000 H00756-01...
  • Page 267 SPECIAL TOOLS Insert, timin chain tensioner Art. no.: 77229035000 77229035000 H00757-01 Puller Art. no.: 77229048000 2x.£. 77229048000 H00758-01 Adjustment bush brid e Art. no.: 77229050044 2x&..£. 77229050044 H00759-01 Insert for valve spring lever Art. no.: 77229060000 77229060000 H00760-01 S�ark �lug wrench Art.
  • Page 268 SPECIAL TOOLS ressure ada ter Art. no.: 77329006000 77329006000 H00764-01 Lift stand Art. no.: 81329955000 81329955000 H01015-01 Hook wrench Art. no.: T106S T106S H00841-01 Depth micrometer Art. no.: T107S T107S H00842-01 Art. no.: T120 T120 H00844-01...
  • Page 269 SPECIAL TOOLS Mounting sleeve Art. no.: T1204 T1204 H00878-01 Calibration in Art. no.: T1205 T1205 H00879-01 Pressin tool Art. no.: T1206 � T1206 H00880-01 Pressing tool &..& Art. no.: T1207S <S))� T1207S H00881-01 Mounting sleeve Art. no.: T1215 T1215 H00886-01...
  • Page 270 SPECIAL TOOLS Disassembl tool Art. no.: T1216 T1216 H00887-01 Vacuum Art. no.: T1240S � T1240S H00890-01 Protectin sleeve Art. no.: T1401 cs)) T1401 H00894-01 Clamping stand Art. no.: T1403S ❖ 2x£ T1403S H00896-01 Mounting tool Art. no.: T14040S � T14040S H00922-01...
  • Page 271 SPECIAL TOOLS S ecial socket Art. no.: T14047 T14047 H00923-01 Clam in stand Art. no.: T14049S 2x£. T14049S H00924-01 Press-out tool Art. no.: T14051 T14051 H00926-01 Press drift Art. no.: T1504 T1504 H00899-01 Assembl� tool Art. no.: T150S T150S H00852-01...
  • Page 272 SPECIAL TOOLS Nitro en filling tool Art. no.: T170S1 2x.&.3x.£. T170S1 H00855-01...

  • Page 273: 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 274: Index

    INDEX Chain tension adjusting ....... . . 93 'Accessories ....... . . 8 checking .
  • Page 275 INDEX ignition pulse generator, removing ....197 valve timing, checking ..... . 180 left engine case section .
  • Page 276 INDEX cartridge, assembling ......26 Headlight mask with headlight cartridge, disassembling ..... . 20 installing .........
  • Page 277 INDEX setting ....... . . 116 wheel circumference, setting Rear sprocket Spoke tension checking .
  • Page 278 INDEX page 3 of 6 ......248 page 3 of 8 ......216,232 page 4 of 6 .
  • Page 279 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 11 1 1 11 1 1 1 1 1 1 1 II I I II 3403001en 08/2015 ® Husqvarna llmi Husqvarna Motorcycles GmbH StallhofnerstraBe 3 5230 Mattighofen Austria fiiiHiAv � LZZa" ·...

Table of Contents