Husqvarna FC 350 2016 Repair Manual
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Husqvarna FC 350 2016 Repair Manual

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PIONEERING SINCE 1903
REPAIR MANUAL2016
FC350
®
Husqvarna
Art. no. 3403032en
MOTORCYCLES

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Summary of Contents for Husqvarna FC 350 2016

  • Page 1 PIONEERING SINCE 1903 REPAIR MANUAL2016 FC350 ® Husqvarna Art. no. 3403032en MOTORCYCLES...
  • Page 3 Husqvarna accepts no liability for delivery options, deviations from figures 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 6.15 Disassembling the seal ring MEANS OF REPRESENTATION ......7 retainer ..........24 Symbols used ........7 6.16 Checking the fork legs ......25 1 .2 Formats used ........7 6.17 Assembling the seal ring retainer ..26 SAFETY ADVICE ..........
  • Page 5 TABLE OF CONTENTS 12.4 Adjusting the spring preload of the Installing the right side cover ....94 shock absorber ........53 12.5 Removing the seat ......94 Adjusting the riding sag ...... 54 12.6 Mounting the seat ....... 95 Removing the shock absorber .... 55 12.7 Removing the fuel tank .......
  • Page 6 TABLE OF CONTENTS 15. 7 Checking the capacitor ..... 133 17.3.19 Removing the clutch discs ... 174 15.8 Checking the starter relay ....134 17.3.20 Removing the clutch basket ..175 17.3.21 Removing the primary gear ..176 BRAKE SYSTEM ........... 136 17.3.22 Removing the timing chain ...
  • Page 7 TABLE OF CONTENTS 17.4.20 17 .5.21 Checking the pivot points of the Installing the piston ...... 225 camshafts........196 17.5.22 Installing the cylinder head ... 226 17.4.21 Removing the valves ....197 17 .5.23 Installing the camshafts ....
  • Page 8 TABLE OF CONTENTS CYLINDER HEAD .......... 252 22.1 Checking the valve clearance ... 252 22.2 Adjusting the valve clearance ... 255 THROTTLE VALVE BODY ......256 23.1 Adjusting the idle speed ....256 23.2 Executing the initialization run ..256 TECHNICAL DATA ........

  • Page 9: Means Of Representation

    MEANS OF REPRESENTATION Symbols 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 10: 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 available.

  • Page 11: Important Notes

    3 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 confirmed both in the customer's Service & Warranty Booklet and in the Husqvarna Motor­...

  • Page 12: Serial Numbers

    4 SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steer­ ing head. 401945-10 e label The type label is fixed to the front of the steering head. 401946-10 En ine number Engine number is stamped onto the engine case at the top near the engine sprocket.

  • Page 13: Shock Absorber Article Number

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

  • Page 14: Motorcycle

    5 MOTORCYCLE Raising the motorcycle with a lift stand Note The parked vehicle can roll away or fall over. Danger of damage Park the vehicle on a firm and level surface. Raise the motorcycle at the frame underneath the engine. ✓...

  • Page 15: Starting The Motorcycle To Check The Function

    5 MOTORCYCLE Remove the plug-in stand Shift the transmission to idle. Condition Ambient temperature: < 20 °c (< 68 °F) Push the cold start button in all the way. 402001-10 Press the electric starter button CD. • Info Press the electric starter button for at most 5 sec­ onds.

  • Page 16: Fork, Triple Clamp

    6 FORK, TRIPLE CLAMP Adjusting the com�ression dam�ing of the fork Info The hydraulic compression damping determines the fork suspension behavior. Turn the white adjusting screw all the way clockwise. Info The adjusting screw is located at the upper end of the left fork leg.

  • Page 17: Bleeding The Fork Legs

    6 FORK, TRIPLE CLAMP Guideline Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks • Info Turn clockwise to increase damping; turn counter­ clockwise to reduce damping. Bleeding the fork legs Preparatory work Raise the motorcycle with a lift stand. p.

  • Page 18: Removing The Fork Legs

    6 FORK, TRIPLE CLAMP Clean and oil the dust boots and inner fork tubes of both fork legs. I Universal oil spray (llill p. 283) Press the dust boots back into their normal position. Remove excess oil. Finishing work Install the fork protector. (llill p.

  • Page 19: Removing The Fork Protector

    6 FORK, TRIPLE CLAMP Tighten screws Guideline Screw, top triple 17 Nm (12.5 lbf ft) clamp Tighten screws@). Guideline Screw, bottom triple 12 Nm (8.9 lbf ft) clamp Position the brake caliper. Mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft) ®...

  • Page 20: Performing A Fork Service

    6 FORK, TRIPLE CLAMP Performing a fork service Condition The fork legs have been removed. Disassemble the fork legs. (� p. 18) Remove the spring. (� p. 20) � Disassemble the cartridge.(� p. 21) Disassemble the piston rod. (ll!l p. 22) Disassemble the hydrostop unit.
  • Page 21 6 FORK, TRIPLE CLAMP Loosen the screw cover Mounting tool (T14047) (!!:,!Ip. 299) Info The cartridge cannot be taken off yet. 201701-10 Unclamp the fork leg. Slide the outer tube down. Drain the fork oil. Clamp the fork leg with the axle clamp. Release hydrostop unit and remove it.

  • Page 22: Removing The Spring

    6 FORK, TRIPLE CLAMP Remove lock ring@. Info The lock ring has a beveled end where a screwdriver can be applied. Warm up the outer tube in area of the lower sliding bush­ ing. Guideline (122 °F) Pull the outer tube from the inner tube with a jerk. Info Lower sliding bushing @ must be pulled from its 803528-13...

  • Page 23: Disassembling The Cartridge

    6 FORK, TRIPLE CLAMP Clamp the open end wrench in the vise. Release screw but do not remove it yet. Mounting tool (T14047) p. 299) Pull the spring downward. Remove the open end wrench. Remove the screw cap. Remove the spring with the preload spacer(s). Disassembling the cartridge Info The procedures are the same on both fork legs.

  • Page 24: Disassembling The Piston Rod

    6 FORK, TRIPLE CLAMP Degrease the cartridge and clamp it with the special tool. I Clamping stand (T14049S) (l!!l p. 299) Release seal ring retainer and remove with the washer. Remove lock ring (D. Pull reservoir @ out of the cartridge. Pull sleeve out of the reservoir.
  • Page 25 6 FORK, TRIPLE CLAMP Main work Degrease the piston rod. Clamp the piston rod with the special tool as far up as possi- ble. Clamping stand (T14049S) (� p. 299) Release hydrostop needle and remove it from the piston rod. ✓...

  • Page 26: Disassembling The Hydrostop Unit

    6 FORK, TRIPLE CLAMP Remove valve needle@) from the piston rod. Info The adjusting tube can be used for this. Disassemblin the hydrostop unit Info The procedures are the same on both fork legs. Preparatory work Disassemble the fork legs. (!!:,!I p.

  • Page 27: Checking The Fork Legs

    6 FORK, TRIPLE CLAMP Main work Remove pilot bushing support Remove 0-ring and seal ring (s). R00013-10 6.16 Checkin the fork le s Condition The fork legs have been disassembled. Check the inner tube and axle clamp for damage. If there is damage: Change the inner tube.

  • Page 28: Assembling The Seal Ring Retainer

    6 FORK, TRIPLE CLAMP Measure the inside diameter at multiple locations of the outer tube. Inside diameter of outer :s; 49.20 mm (s 1.937 in) tube If the measured value is larger than the specified value: Change the outer tube. Check the outer tube for damage.

  • Page 29: Assembling The Hydrostop Unit

    6 FORK, TRIPLE CLAMP Assembling the hydrostoR unit Info The procedures are the same on both fork legs. Mount and grease O-ring Lubricant (T158) (llill p. 282) Mount washer @. Mount shim stack @) with the smaller washers facing down- ward.
  • Page 30 6 FORK, TRIPLE CLAMP Position the spring. Mount compression shim stack with the smaller shims facing downward. Info Note the setting list. R00031-10 Grind the piston on both sides on a surfacing plate using 1200 grit sandpaper. Clean the piston. Lubricate the piston ring.

  • Page 31: Cartridge, Assembling

    6 FORK, TRIPLE CLAMP cartridge, assembling Info The procedures are the same on both fork legs. Preparatory work Assemble the seal ring retainer. (!,JI p. 26) Assemble the piston rod. (!,JI p. 27) Main work Mount and grease seal rings and O-ring Lubricant (T158) (!!:!

  • Page 32: Assembling The Fork Legs

    6 FORK, TRIPLE CLAMP Slide piston rod into the cartridge. • Info Check that the piston ring is correctly seated. Mount spring seat B04096-10 Clamp piston rod with the special tool. I Clamping stand (T14049S) (� p. 299) Screw spring guide � all the way on. Info The nut must be firmly tightened against the stop by hand.
  • Page 33 6 FORK, TRIPLE CLAMP Lubricant (T14034) (� p. 282) • Info Sealing lip downward, open side upward. Push on support ring Remove the special tool. Sand the edges of the sliding bushings with 600 grit sandpa- per; then clean and grease the bushings. Fork oil (SAE 4) (48601166S1) (�...
  • Page 34 6 FORK, TRIPLE CLAMP Mount lock ring Info The lock ring engages audibly. Mount dust boot Mount fork protector ring G). Grease O-ring. I Fork oil (SAE 4) (48601166S1) (� p. 280) Slide the cartridge all the way into the fork leg. Turn the fork.
  • Page 35 6 FORK, TRIPLE CLAMP Clamp the fork vertically. Add the remaining quantity of fork oil. 202091-10 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.
  • Page 36 6 FORK, TRIPLE CLAMP Mount the adjuster. Mount and tighten screw@). Guideline 2.5 Nm (1.84 lbf ft) I Screw, adjuster M4x0.5 Alternative 1 Turn the adjuster for rebound damping (mark REB) and the adjuster for compression damping (mark clockwise all the way. COMP) Turn counterclockwise by the number of clicks corre­...

  • Page 37: Lubricating The Steering Head Bearing

    6 FORK, TRIPLE CLAMP 6.22 Lubricating the steering head bearing Remove the lower triple clamp. (l!,JI p. 35) Install the lower triple clamp. (l!,JI p. 36) Info The steering head bearing is cleaned and lubricated in the course of removal and installation of the lower triple clamp.

  • Page 38: Installing The Lower Triple Clamp

    6 FORK, TRIPLE CLAMP 6.24 Installing the lower tri�le clam� Main work Clean the bearing and sealing elements, check for damage, and grease. I High viscosity grease (I!!:! p. 282) Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.
  • Page 39 6 FORK, TRIPLE CLAMP Tighten screws (D. Guideline Screw, bottom triple 12 Nm (8.9 lbf ft) clamp Tighten screw Guideline Screw, top steering M20x1 .5 12 Nm (8.9 lbf ft) head Mount and tighten screw @. Guideline Screw, top 20 Nm (14.8 lbf ft) ®...

  • Page 40: Checking The Steering Head Bearing Play

    6 FORK, TRIPLE CLAMP Position the brake caliper. Mount and tighten screws 41). Guideline Screw, front 25 Nm (18.4 lbf ft) ® Loctite brake caliper ™ Position the brake line and clamp. Mount and tighten screws Finishing work Install front fender. (�...

  • Page 41: Changing The Steering Head Bearing

    6 FORK, TRIPLE CLAMP Check the steering head bearing and change if neces­ sary. Finishing work Remove the motorcycle from the lift stand. (illJ p. 12) 6.26 Changing the steering head bearing Preparatory work Raise the motorcycle with a lift stand. (illJ p.

  • Page 42: Adjusting The Steering Head Bearing Play

    6 FORK, TRIPLE CLAMP Press the new bearing ring up to the stop with special tool @) . Tool bracket (58429089000) p. 287) Pressing tool (58429091000) p. 287) Remove lower steering head bearing Remove the seal ring. Grease and mount the new seal ring. Press on the new bearing with a suitable tube as far as it will D00075-10 Finishing work...
  • Page 43 6 FORK, TRIPLE CLAMP Tighten screws Guideline Screw, top triple 17 Nm (12.5 lbf ft) clamp Check the steering head bearing play. (!i.,!I p. 38) Finishing work Mount the handlebar cushion. Remove the motorcycle from the lift stand. (� p. 12)

  • Page 44: 7 Handlebar,Controls

    7 HANDLEBAR,CONTROLS Handlebar �osition The holes on the handlebar supports are placed at a distance from the center. Hole distance A 3.5 mm (0.138 in) The handlebar can be mounted in 2 different positions. In this way, the handlebar can be mounted in the most comfortable position for the rider.

  • Page 45: Adjusting The Basic Position Of The Clutch Lever

    7 HANDLEBAR,CONTROLS Adjusting the basic �osition of the clutch lever Adjust the basic position of the clutch lever to your hand size by turning adjusting screw • Info When the adjusting screw is turned counterclockwise, the clutch lever moves away from the handlebar. When the adjusting screw is turned clockwise, the clutch lever moves closer to the handlebar.

  • Page 46: Checking The Play In The Throttle Cable

    7 HANDLEBAR,CONTROLS Main work Check the throttle cable routing. Both throttle cables must be routed, side by side, behind the handlebars and above the fuel tank bracket, to the throttle valve body. Both throttle cables must be secured behind the fuel tank contact area rubber band. If the throttle cable is not routed as specified: Correct the throttle cable routing.

  • Page 47: Adjusting The Play In The Throttle Cable

    7 HANDLEBAR,CONTROLS Danger Exhaust gases are toxic and Danger of poisoning inhaling them may result in unconsciousness and death. Always make sure there is sufficient ventilation when running the engine. Use an effective exhaust extraction system when starting or running the engine in an enclosed space.

  • Page 48: Setting The Characteristic Map Of The Throttle Response

    7 HANDLEBAR,CONTROLS Install the right side cover. (� p. 94) Setting the characteristic map of the throttle response Info On the throttle grip, the characteristic map of the throttle response is changed by changing the guide plate. A guide plate with a different characteristic map is supplied. Main work Push back sleeve Remove screws @ and half-shells...
  • Page 49 7 HANDLEBAR,CONTROLS Position half-shells mount and tighten screws 4i}. Guideline Screw, throttle grip I 5 Nm (3.7 lbf ft) Slide on sleeve and check the throttle grip for ease of movement. Finishing work Check the play in the throttle cable. (�...

  • Page 50: Frame

    Change the frame. Info Always replace a frame that has been damaged due to a mechanical impact. Repair of the frame is not authorized by Husqvarna Motorcycles. Changing the footrests Info The procedures are the same on both footrests.
  • Page 51 8 FRAME Position spring as shown. ✓ Spring G) engages in area (!). ✓ Press the spring with special tool @. Footrest spring plier (79029083000) (l!!',!l p. 294) ✓ The special tool is applied to area on the footrest. Mount pin 6). 311720-10 Mount the washer and split pin 311719-10...

  • Page 52: Shock Absorber, Swingarm

    9 SHOCK ABSORBER, SWINGARM Adjusting the high-s�eed com�ression dam�ing of the shock absorber Caution Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incor- rectly. The shock absorber is filled with highly compressed nitrogen. Please follow the description provided.

  • Page 53: Adjusting The Rebound Damping Of The Shock Absorber

    9 SHOCK ABSORBER, SWINGARM Turn adjusting screw clockwise with a screwdriver up to the last perceptible click. Info Do not loosen fitting Turn counterclockwise by the number of clicks correspond­ ing to the shock absorber type. Guideline Compression damping, low-speed Comfort 17 clicks Standard...

  • Page 54: Measuring The Rear Wheel Dimension Unloaded

    9 SHOCK ABSORBER, SWINGARM Measuring the rear wheel dimension unloaded Preparatory work Raise the motorcycle with a lift stand. (� p. 12) Main work Position the sag gauge in the rear axle and measure the distance to marking SAG on the rear fender. Sag gauge (00029090500) Pin for sag gauge (0002999001 0) Note down the value as dimension 6) .

  • Page 55: Checking The Riding Sag Of The Shock Absorber

    9 SHOCK ABSORBER, SWINGARM Checking the riding sag of the shock absorber Measure dimension of rear wheel unloaded. (I!:! p. 52) With another person holding the motorcycle, the rider, wear­ ing full protective clothing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down a few times.

  • Page 56: Adjusting The Riding Sag

    9 SHOCK ABSORBER, SWINGARM Main work Loosen screw Turn adjusting ring until the spring is no longer under ten- sion. I Hook wrench (T1 06S) (ia:! p. 295) Measure the overall spring length while the spring is not under tension. Tighten the spring by turning adjusting ring to measure­...

  • Page 57: Removing The Shock Absorber

    9 SHOCK ABSORBER, SWINGARM Finishing work Install the shock absorber.(� p. 57) Check the free travel of the foot brake lever. (!!JJ p. 145) Check the static sag of the shock absorber. (!!JJ p. 52) Check the riding sag of the shock absorber. (�...
  • Page 58 9 SHOCK ABSORBER, SWINGARM Remove screws @. Pull off foot brake cylinder from the push rod. Remove the connecting link of the chain. Take off the chain. Info Cover the components to protect them against dam­ age. Remove nut and pull out the swingarm pivot. Push the swingarm back and secure it against falling over.

  • Page 59: Installing The Shock Absorber

    9 SHOCK ABSORBER, SWINGARM 9.10 Installing the shock absorber Main work Carefully position the shock absorber into the vehicle from the bottom. Mount and tighten screw Guideline Screw, top 60 Nm (44.3 lbf ft) ® Loctite 2701 shock absorber Position the swingarm and mount the swingarm pivot. Info Pay attention to flat area 6).

  • Page 60: Checking The Shock Absorber Linkage

    9 SHOCK ABSORBER, SWINGARM Mount and tighten screw@. Guideline Screw, bottom 60 Nm (44.3 lbf ft) shock absorber ® Loctite 2701 • Info Raise the wheel slightly to be able to mount the screw more easily. Position the frame protectors on the left and right. Mount and tighten screws Guideline Screw, frame pro­...
  • Page 61 9 SHOCK ABSORBER, SWINGARM •- -• 303096-10 Check needle bearings for damage and wear. If there is damage or wear: Change the needle bearings. Check spacers (3 and @ for damage and wear. If there is damage or wear: Change the spacers. Check the shaft seal rings for damage and wear.

  • Page 62: Servicing The Shock Absorber

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

  • Page 63: Removing The Spring

    9 SHOCK ABSORBER, SWINGARM Remove the spring. (ll!:! p. 61) Disassemble the damper. (ll!:! p. 62) Disassemble the piston rod. (� p. 63) Disassemble the seal ring retainer. (� p. 64) "oco, Check the damper. p. 66) l'.7� Remove the heim joint. p.

  • Page 64: Disassembling The Damper

    9 SHOCK ABSORBER, SWINGARM 9.14 Disassembling the dam�er Preparatory work Remove the spring.(� p. 61) Main work Make a note of the present state of rebound and com­ pression damping Open the adjusters of the rebound and compression damp­ ing completely. Slowly open screw ✓...

  • Page 65: Disassembling The Piston Rod

    9 SHOCK ABSORBER, SWINGARM Remove lock ring Info Check inner surface; do not scratch. Remove any burrs with sandpaper if needed. Remove the piston rod. Remove adjusting ring @ with the intermediate washer. Drain the oil. Remove compression adjuster @. Remove the spring and piston.

  • Page 66: Disassembling The Seal Ring Retainer

    9 SHOCK ABSORBER, SWINGARM Main work Clamp the piston rod with the fork in a vise. Guideline I 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.

  • Page 67: Changing The Pilot Bushing

    9 SHOCK ABSORBER, SWINGARM Main work Remove spring Remove O-ring @. Remove rebound rubber 201405-10 Remove centering disk Remove seal ring 201406-10 Remove washer for seal ring Remove washer @. Remove dust boot. 201407-10 9.17 Changing the pilot bushing Preparatory work Remove the spring.

  • Page 68: Checking The Damper

    9 SHOCK ABSORBER, SWINGARM Slide the new pilot bushing onto the special tool. I Pressing tool (T1504) p. 299) Position the pilot bushing in the seal ring retainer using the special tool. I Pressing tool (T1504) p. 299) Support seal ring retainer with sleeve of the special tool.

  • Page 69: Removing The Heim Joint

    9 SHOCK ABSORBER, SWINGARM Measure the diameter of the piston rod. Piston rod Diameter � 17.95 mm(� 0.7067 in) If the measured value is less than the specified value: Change the piston rod. Measure the run-out of the piston rod. Piston rod Run-out I �...

  • Page 70: Installing The Heim Joint

    9 SHOCK ABSORBER, SWINGARM Place special tool underneath and press out heim -� joint using special tool - --- I Pressing tool (T1207S) (l!lll p. 297) � � G02068-10 Position the new heim joint and the special tool in the bench vise.

  • Page 71: Assembling Seal Ring Retainer

    9 SHOCK ABSORBER, SWINGARM 9.21 Mount dust boot with the special tool. Mounting sleeve (T1204) p. 296) Grease the sealing lip of the dust boot. Lubricant (T625) (� p. 282) 201408-10 Mount washer Position washer on seal ring 201409-10 Grease seal ring and mount with the washer facing down­...
  • Page 72 9 SHOCK ABSORBER, SWINGARM Main work Clamp the piston rod with the fork in a vise. Guideline I Use soft jaws. Mount rubber buffer and locking cap Position special tool on the piston rod. I Mounting sleeve (T1215) (!!;!I p. 297) Grease the dust boot and push seal ring retainer onto the G02056-11...

  • Page 73: Assembling The Damper

    9 SHOCK ABSORBER, SWINGARM Mount the rebound shim stack @ with the smaller shims facing upward. G02058-10 Mount washer with the collar facing downward. Grease the thread of the piston rod. Lubricant (T152) (� p. 282) Mount and tighten nut Guideline Nut, piston rod I M16x1...
  • Page 74 9 SHOCK ABSORBER, SWINGARM Clamp the damper in a bench vise. Guideline I Use soft jaws. Mount adjusting ring with the intermediate washer. Info The adjusting ring cannot be mounted after the piston rod has been mounted. Fill the damper cartridge about half full. I Shock absorber fluid (SAE 2.5) (50180751 S1) (ll!:!l p.

  • Page 75: Bleeding And Filling The Damper

    9 SHOCK ABSORBER, SWINGARM Turn adjusting screw all the way clockwise with a socket wrench. Turn counterclockwise by the number of turns corre­ sponding to the shock absorber type. Guideline Compression damping, high-speed Comfort 2.5 turns Standard 2 turns Sport 1.5 turns Turn adjusting screw @) clockwise up to the last percep­...
  • Page 76 9 SHOCK ABSORBER, SWINGARM Remove the screw from the filling port. Mount adapter on the damper. • Info Hand-tighten only without using a tool. Connect adapter to connector @ of the vacuum pump. I Vacuum pump (T1240S) p. 298) Clamp the damper with soft jaws or hold it as shown in the figure.
  • Page 77 9 SHOCK ABSORBER, SWINGARM When the pressure gauge reaches the required value, turn control lever Damper to Pressure. Guideline 0 bar ✓ Oil is pumped into the damper. ✓ The pressure gauge increases to the required value. 3 bar When the pressure gauge reaches the required value, turn control lever Damper to Vacuum.
  • Page 78 9 SHOCK ABSORBER, SWINGARM When the pressure gauge reaches the required value, turn control lever Damper to Vacuum. Guideline 3 bar ✓ The pressure gauge drops to the required value. 0 bar When the pressure gauge reaches the required value, acti­ vate the On/Off switch.

  • Page 79: Filling The Damper With Nitrogen

    9 SHOCK ABSORBER, SWINGARM 9.25 Filling the dam�er with nitrogen Screw in screw by approx. 2 rotations but do not tighten. Info The piston rod is fully extended. Clamp the special tool in the vise. Filling tool (T170S1) (!!l p. 300) Connect the special tool to the pressure regulator of the filling cylinder.

  • Page 80: Installing The Spring

    9 SHOCK ABSORBER, SWINGARM 9.26 Installing the s ring Ensure that adjusting ring is screwed on with the interme­ diate washer. Measure the overall spring length while the spring is not under tension. Position the spring. Guideline Spring rate Weight of rider: 65 ... 45 N/mm (257 lb/in) 75 kg (143 ...

  • Page 81: Checking The Swingarm

    9 SHOCK ABSORBER, SWINGARM I Hook wrench (T106S) (l!!ll p. 295) Tighten screw Guideline Screw, shock 5 Nm (3.7 lbf ft} absorber adjusting ring G02091-10 9.27 Checking the swingarm Check the swingarm for damage, cracking, and deformation. If the swingarm shows signs of damage, cracking, or deformation: Change the swingarm.

  • Page 82: Removing The Swingarm

    9 SHOCK ABSORBER, SWINGARM Finishing work Remove the motorcycle from the lift stand. (� p. 12) 9.29 Removing the swingarm Preparatory work Raise the motorcycle with a lift stand. (� p. 12) Remove the rear wheel. (� p. 116) Remove the air filter box cover. (�...

  • Page 83: Installing The Swingarm

    9 SHOCK ABSORBER, SWINGARM Remove fitting Lower the swingarm. Remove the cable ties. Remove screws Remove screws with the washers. Remove the frame protectors on the left and right. Remove nut @. Remove the swingarm pivot. Remove the swingarm. Main work Position the swingarm.
  • Page 84 9 SHOCK ABSORBER, SWINGARM Lift the swingarm. &. Mount and tighten fitting Guideline Nut, linkage lever on M 14x1 .5 80 Nm (59 lbf ft) swingarm Mount the chain. Connect the chain with connecting link Guideline The closed side of the chain joint lock must face in the direction of travel.

  • Page 85: Changing The Swingarm Bearing

    9 SHOCK ABSORBER, SWINGARM Remove the motorcycle from the lift stand. (ll!;,! p. 12) 9.31 Changing the swingarm bearing Preparatory work Raise the motorcycle with a lift stand. (I!!;! p. 12) Remove the rear wheel. (I!!;! p. 116) Remove the air filter box cover. (I!!;! p.
  • Page 86 9 SHOCK ABSORBER, SWINGARM Mount bushing R02758-10 Grease the shaft seal rings. Long-life grease (� p. 282) Position collar bushings with the shoulder facing inward. R02763-10 Right swingarm bearing Remove collar bushings Q). R02760-10 Remove bushing@. R02761-10...
  • Page 87 9 SHOCK ABSORBER, SWINGARM Remove shaft seal rings using a suitable tool. Press out bearing @) using a suitable tool. Using a suitable tool, press in new bearing@). Press in shaft seal rings R02762-10 Mount bushing@ . R02761-10 Grease the shaft seal rings. I Long-life grease (ll!ll p.

  • Page 88: 10 Exhaust

    10 EXHAUST Removing the manifold 10.1 Preparatory work Raise the motorcycle with a lift stand. (� p. 12) Remove the right side cover. (� p. 94) Remove the main silencer. (� p. 88) Main work Remove screw Remove fitting Info Raise the link fork slightly to be able to remove the screws more easily.

  • Page 89: Installing The Manifold

    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 60 Nm (44.3 lbf ft) ®...

  • Page 90: Removing The Main Silencer

    10 EXHAUST Position the angle lever and linkage lever. &. Mount and tighten fitting Guideline Nut, linkage lever to M 14x1 .5 80 Nm (59 lbf ft) angle lever Info Raise the link fork slightly to be able to mount the screw more easily.

  • Page 91: Changing The Glass Fiber Yarn Filling Of The Main Silencer

    EXHAUST Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis Finishing work Install the right side cover. p. 94) Changing the glass fiber am filling of 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 before performing any work on the vehicle.

  • Page 92: 11 Air Filter

    11 AIR FILTER Removing the air filter box cover Pull off the air filter box cover sideways in areas and remove toward the front. Installing the air filter box cover Position air filter box cover on collar bushings and push toward the rear. Engage the air filter box cover in areas 11.3 Removin the air filter...

  • Page 93: Installing The Air Filter

    11 AIR FILTER Main work Detach retaining tab Remove air filter with air filter sup­ port. Take off air filter from air filter support. 11.4 lnstallin the air filter Main work Mount the clean air filter on the air filter support. Grease the air filter in area f).

  • Page 94: Sealing The Air Filter Box

    11 AIR FILTER Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. I Air filter cleaning agent (� p. 282) • Info Only press the air filter to dry it, never wring it out. Oil the dry air filter with a high quality filter oil.

  • Page 95: Fuel Tank, Seat, Trim

    FUEL TANK, SEAT, TRIM 12.1 O�ening the filler ca Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. Switch off the engine for refueling.

  • Page 96: Removing The Right Side Cover

    12 FUEL TANK, SEAT, TRIM Removing the right side cover Remove screw Pull off the side cover sideways in areas f) and remove toward the front. 12.4 Installing the right side cover Position the side cover on collar bushings push toward the rear. Engage the side cover in areas f) and Mount and tighten screw Guideline...

  • Page 97: Mounting The Seat

    FUEL TANK, SEAT, TRIM Main work Remove screw Pull seat back and lift it off. 12.6 Mounting the seat Main work Mount the front of the seat on the collar bushing of the fuel tank and the rear in the bracket. Push the seat forward.

  • Page 98: Removing The Fuel Tank

    12 FUEL TANK, SEAT, TRIM 12.7 Removing the fuel tank Danger Fuel is highly flammable. Fire hazard The fuel in the fuel tank expands when warm and can escape if overfilled. Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. Switch off the engine for refueling.

  • Page 99: Installing The Fuel Tank

    FUEL TANK, SEAT, TRIM Remove screws Remove screw with the rubber bushing. Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank. H00298-10 12.8 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled.
  • Page 100 12 FUEL TANK, SEAT, TRIM Main work Check the throttle cable routing. (llill p. 43) Position the fuel tank and fit the two spoilers to the sides of the radiator bracket. Make sure that no cables or throttle cables are trapped or damaged.

  • Page 101: Checking The Fuel Pressure

    FUEL TANK, SEAT, TRIM 12.9 Checking the fuel �ressure Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. Switch off the engine for refueling.

  • Page 102: Changing The Fuel Pump

    12 FUEL TANK, SEAT, TRIM Guideline Maximum duration of the 3 min actuator test Check the fuel pressure with the filler cap closed. Fuel pressure When the fuel pump is 3.3 ... 3. 7 bar (48 ... active 54 psi) If the specification is not reached: Open the filler cap.
  • Page 103 FUEL TANK, SEAT, TRIM Warning Environmental hazard Improper handling of fuel is a danger to the environment. Do not allow fuel to enter the groundwater, the soil, or the sewage system. Preparatory work Drain the fuel from the fuel tank into a suitable container. Remove the right side cover.

  • Page 104: Changing The Fuel Filter

    12 FUEL TANK, SEAT, TRIM Position the fuel pump. Mount fuel connection with the gasket but do not tighten yet. Mount and tighten nut with the gasket. Guideline Nut, fuel pump fas­ M12x1.75 15 Nm (11.1 lbf ft) tener Tighten fuel connection Guideline Fuel port on fuel M8x1 .25...
  • Page 105 FUEL TANK, SEAT, TRIM Warning Fuel is poisonous and a health hazard. Danger of poisoning Avoid skin, eye and clothing contact with fuel. Immediately consult a doctor if you swallow fuel. Do not inhale fuel vapors. In case of skin contact, rinse the affected area with plenty of water. Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
  • Page 106 12 FUEL TANK, SEAT, TRIM Pull out the fuel pump. Remove hose clamps Remove fuel filter D00571-10 Press lock (D. Pull back fuel pump housing@. 305317-10 Change fuel screen Mount the fuel pump housing.
  • Page 107 FUEL TANK, SEAT, TRIM Mount fuel filter ✓ Arrow points away from the fuel pump. Mount hose clamps Hose clamp plier (60029057000) p. 289) Position the fuel pump. Mount fuel connection with the gasket but do not tighten yet. Mount and tighten nut with the gasket.

  • Page 108: Changing The Fuel Screen

    12 FUEL TANK, SEAT, TRIM 12.12 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. Switch off the engine for refueling.
  • Page 109 FUEL TANK, SEAT, TRIM Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. Always make sure there is sufficient ventilation when running the engine. Use an effective exhaust extraction system when starting or running the engine in an enclosed space.

  • Page 110: 13 Mask, Fender

    13 MASK, FENDER 13.1 Removing front fender Preparatory work Remove the start number plate. p. 109) Main work Remove screws Remove front fender. Main work Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis Finishing work Install the start number plate.

  • Page 111: Removing The Start Number Plate

    13 MASK, FENDER Removing the start number �late Remove screw Swivel the start number plate to one side. Remove screw @ and take off the brake line guide and start number plate. Installing the start number �late Position the brake line and brake line guide on the start num­ ber plate.

  • Page 112: 14 Wheels

    Checking the tire condition Info Only mount tires approved and/or recommended by Husqvarna Motorcycles. Other tires could have a negative effect on handling characteristics. The type, condition, and air pressure of the tires all have a major impact on the handling of the motorcy­...

  • Page 113: Checking The Wheel Bearing For Play

    14 WHEELS If the tires are more than 5 years old: Change the tires. Checking the wheel bearing for Ria� 14.3 Preparatory work Raise the motorcycle with a lift stand. (l!!:!J p. 12) Place a load on the rear of the vehicle. ✓...

  • Page 114: Checking Spoke Tension

    14 WHEELS Check the front and rear brake discs for damage, cracking, and deformation. If the brake disc exhibits damage, cracking, or deforma­ tion: Change the front brake disc. p. 114) Change the rear brake disc. p. 118) Checking s�oke tension Warning Incorrectly tensioned spokes impair the handling characteristic and result in Danger of accidents...

  • Page 115: Installing The Front Wheel

    14 WHEELS Main work Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pis­ tons.

  • Page 116: Changing The Front Brake Disc

    14 WHEELS • Check the wheel bearing for damage and wear. If the wheel bearing is damaged or worn: Change front wheel bearing. p. 115) Clean and grease shaft seal rings and contact surfaces of the spacers. I Long-life grease p.

  • Page 117: Changing Front Wheel Bearing

    14 WHEELS 14.6.4 Changing front wheel bearing Preparatory work Raise the motorcycle with a lift stand. (� p. 12) Remove the front wheel. (� p. 112) Main work Remove shaft seal rings Press out bearing using a suitable tool. • Info Spacing tube can be pushed aside.

  • Page 118: Rear Wheel

    14 WHEELS Grease new shaft seal rings and press in until they are flush. Finishing work Install the front wheel. p. 113) 14.7 Rear wheel Removing the rear wheel 14.7.1 Preparatory work Raise the motorcycle with a lift stand. (� p.

  • Page 119: Installing The Rear Wheel

    14 WHEELS GO'? Remove spacers f� c::=C>� �◊) H00936-10 Installing the rear wheel 14.7.2 Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. Always keep the brake discs free of oil and grease. Clean the brake discs with brake cleaner when necessary. Main work Check the wheel bearing for damage and wear.

  • Page 120: Changing The Rear Brake Disc

    14 WHEELS Position chain adjuster (5) . Mount nut but do not tighten it yet. Make sure that chain adjusters (5) are fitted correctly on adjusting screws Check the chain tension. (� p. 119) Tighten nut Guideline M25x1.5 80 Nm (59 lbf ft) Info The wide adjustment range of the chain adjusters (32 mm (1.26 in)) enables different secondary ratios...

  • Page 121: Checking The Chain Tension

    14 WHEELS 14.7.4 Checking the chain tension Warning Incorrect chain tension damages components and results in accidents. Danger of accidents If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.

  • Page 122: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    14 WHEELS Main work Loosen nut Loosen nuts Adjust the chain tension by turning adjusting screws (D left and right. Guideline Chain tension 55 ... 58 mm (2.17 ... 2.28 in) Turn adjusting screws (D on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks f).
  • Page 123 14 WHEELS Pull at the top part of the chain with the specified weight f). Guideline 10 ... 15 kg (22 ... 33 lb.) Weight, chain wear mea­ surement Measure distance (;) of 18 chain rollers in the lower chain section.
  • Page 124 14 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 screw on the chain sliding piece.

  • Page 125: Checking For Chain Dirt Accumulation

    14 WHEELS 14.7.7 Checking for chain dirt accumulation Check the chain for coarse dirt accumulation. If the chain is very dirty: Clean the chain. (!!;!I p. 123) 400678-01 14. 7 .8 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces the road grip. Remove the lubricant from the tires using a suitable cleaning agent.
  • Page 126 14 WHEELS Main work Remove screws Remove the engine sprocket cover. Have an assistant operate the rear brake. Remove screw with washer. Remove the rear wheel. (!!;!I p. 116) Remove connecting link of the chain. Info Cover the components to protect them against dam­ age.

  • Page 127: Changing The Rear Wheel Bearing

    14 WHEELS Slide new engine sprocket onto the countershaft. Mount the new chain. Connect the chain with connecting link Guideline The closed side of the chain joint lock must face in the direction of travel. Install the rear wheel. (!ill p.
  • Page 128 14 WHEELS Main work Remove shaft seal ring Remove lock ring@. Remove shaft seal ring (D. Using a suitable tool, press bearing out from the inside to the outside. Remove spacing tube Using a suitable tool, press bearing (D out from the inside to the outside.
  • Page 129 14 WHEELS Clean, grease, and mount spacing tube Long-life grease (� p. 282) Press 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. Grease new shaft seal ring and press it in until it is flush.

  • Page 130: 15 Wiring Harness, Battery

    15 WIRING HARNESS, BATTERY Changing the main fuse Warning Incorrect fuses overload the electrical system. Fire hazard Only use fuses with the required ampere value. Do not 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 seat.

  • Page 131: Removing The Battery

    15 WIRING HARNESS, BATTERY Removing the batte� Warning Risk of injury Batteries contain harmful substances. Keep batteries out of the reach of children. Keep sparks and open flames away from the batteries. Only charge batteries in well-ventilated rooms. Maintain a minimum clearance from inflammable materials when charging batteries. 1 m (3 ft) Minimum clearance Do not charge deeply discharged batteries if charge is already below the minimum voltage.

  • Page 132: Installing The Battery

    15 WIRING HARNESS, BATTERY Installing the batte� Main work Insert the battery into the battery compartment with the ter­ minals facing forward and secure with holding bracket I Battery (C22S) p. 263) Mount and tighten screw Guideline Screw, battery sup­ 10 Nm (7.4 lbf ft) port bracket •...
  • Page 133 Warning Environmental hazard Batteries contain environmentally-hazardous materials. Do not dispose of batteries as household waste. Return batteries to your authorized Husqvarna Motorcycles dealer or dispose of them at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 134: Checking The Charging Voltage

    15 WIRING HARNESS, BATTERY Guideline The charging current, charging voltage, and charging time must not be exceeded. Charge the battery regularly 3 months when the motorcycle is not in use Finishing work Mount the seat. p. 95) Install the air filter box cover. p.

  • Page 135: Checking The Capacitor

    15 WIRING HARNESS, BATTERY Main work Disconnect the negative cable of the battery. Measure the current between battery ground (-) and the neg­ ative cable. • Info The value of the quiescent current applies only to vehicles in the original state, i.e. without additional power consumers.

  • Page 136: Checking The Starter Relay

    15 WIRING HARNESS, BATTERY » The lamp lights up for: > 2.0 s Change the capacitor. Install the capacitor. 15.8 Checking the starter rela� Preparatory work Press and hold the kill switch � while the engine is idling until the engine stops. Remove the air filter box cover.
  • Page 137 15 WIRING HARNESS, BATTERY Finishing work Mount the seat. (� p. 95) Install the air filter box cover. (!1ll p. 90)

  • Page 138: 16 Brake System

    16 BRAKE SYSTEM Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. Ensure that worn-out brake linings are replaced immediately. Check the brake linings for minimum thickness I � Minimum thickness 1 mm (� 0.04 in) If the minimum thickness is less than specified: Change the front brake linings.
  • Page 139 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 140: Checking The Free Travel Of The

    16 BRAKE SYSTEM Add brake fluid up to level f). Guideline 5 mm (0.2 in) Level f) (brake fluid level below reservoir rim) I Brake fluid DOT 4 (� p. 280) Position cover with membrane Mount and tighten screws Info Clean up overflowed or spilled brake fluid immediately with water.

  • Page 141: Checking The Brake Fluid Level Of

    BRAKE SYSTEM Main work Adjust the basic position of the hand brake lever to your hand size by turning adjusting screw Info Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the han­ dlebar. Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the handlebar.

  • Page 142: Adding Front Brake Fluid

    16 BRAKE SYSTEM Adding front brake fluid Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail. If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.

  • Page 143: 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 f). Guideline 5 mm (0.2 in) Level f) (brake fluid level below reservoir rim) Brake fluid DOT 4 (!ill p.
  • Page 144 16 BRAKE SYSTEM Move the brake fluid reservoir mounted on the handlebar to a horizontal position. Cover the painted parts. Remove screws Remove cover with membrane. Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid. Syringe (50329050000) (l!!;,!J p.

  • Page 145: Checking The Brake Linings Of The Rear Brake

    BRAKE SYSTEM Add brake fluid to level (!). Guideline 5 mm (0.2 in) Level (brake fluid level below container rim) Brake fluid DOT 4 (il!ll p. 280) Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilt brake fluid immediately with water.
  • Page 146 16 BRAKE SYSTEM Warning Danger of accidents Old brake fluid reduces the braking effect. Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. Warning Environmental hazard Hazardous substances cause environmental damage. Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.

  • Page 147: Brake Lever

    BRAKE SYSTEM Insert the new brake linings, insert pin and mount cotter pins@). Info Always change the brake linings in pairs. Make sure that decoupling plate @ is mounted on the piston side brake lining. Operate the foot brake lever repeatedly until the brake lin­ ings are in contact with the brake disc and there is a pressure point.

  • Page 148: Adjusting The Basic Position Of The Foot Brake Lever

    16 BRAKE SYSTEM Adjusting the basic �osition of the foot brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.

  • Page 149: Adding Rear Brake Fluid

    BRAKE SYSTEM Preparatory work Check the brake linings of the rear brake. (ilill p. 143) Main work Stand the vehicle upright. Check the brake fluid level in the viewer If the brake fluid level drops below marking Add rear brake fluid. (l!!',!l p.

  • Page 150: Changing The Rear Brake Fluid

    16 BRAKE SYSTEM Main work Stand the vehicle upright. Remove screw cap with membrane and the O-ring. Add brake fluid to level f). I Brake fluid DOT 4 (l!!ll p. 280) Mount and tighten the screw cap with the membrane and O­ ring.
  • Page 151 BRAKE SYSTEM Mount bleeder cover Bleeder cover (00029013006) (I!!;! p. 284) Connect the bleeding device. Bleeding device (00029013100) (IUJ p. 284) Open shut-off valve fi). • Info Follow the operating instructions of the bleeding device. Ensure that the filling pressure is correctly set at pressure gauge f).

  • Page 152: 17 Engine

    17 ENGINE 17.1 Removing the engine Preparatory work Raise the motorcycle with a lift stand. (� p. 12) Drain the coolant. (� p. 240) Remove the right side cover. (� p. 94) Remove the air filter box cover. (� p. 90) Remove the seat.
  • Page 153 17 ENGINE Push back protection cap Unplug the connector. Pull rollover sensor off of the holder and hang to one side. Remove screw (D. Loosen screw @. Repeat these steps on the opposite side. Pivot up the subframe and secure it. Remove screw Pivot the shock absorber toward the rear and twist it slightly.
  • Page 154 17 ENGINE Remove springs I Spring hook (50305017000) (� p. 286) Remove screw Gi) with the washer. Take off the manifold. Remove fittings Take off the engine braces. Disconnect plug-in connector Disconnect plug-in connectors 41).
  • Page 155 17 ENGINE Disconnect plug-in connector Remove the cable tie(s). Remove the cable clamps and expose the cable. Push back protection cap Unplug the connector. Gs). Loosen hose clip Pull off the radiator hose. Loosen hose clip Pull off the radiator hose.
  • Page 156 17 ENGINE Pull capacitor 4E) off of the holder and hang to one side. Pull off spark plug connector Qi). Remove screw fl!). Remove screw •. Take off the engine sprocket cover. Remove screws �. Take off the slave cylinder of the clutch and hang it to one side.
  • Page 157 17 ENGINE Remove the connecting link of the chain. Take off the chain. Remove screw Take off the engine sprocket. Remove screw .. with the washers. Take off the shift lever. Loosen hose clip Pull the throttle valve body off of the cylinder head toward the rear and hang it to one side.
  • Page 158 17 ENGINE Remove spring fl!). Remove fitting Remove screws Ci). Remove the foot brake cylinder and allow it to hang tension­ free to the side. Take the brake line out of the guide. Remove nut Remove the swingarm pivot. Carefully pull the swingarm back, and secure the swingarm.

  • Page 159: Installing The Engine

    17 ENGINE Remove screws Lift out the engine sideways. • Info The help of an assistant is useful in this step. Make sure that the engine is sufficiently secured against falling over. Protect the frame and attachments against damage. Main work Position the engine in the frame.
  • Page 160 17 ENGINE Position the brake line in the guide. Mount the foot brake cylinder on push rod and position it. • Info Ensure that the dust boot is correctly seated. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis Position the linkage lever.
  • Page 161 17 ENGINE Mount the vent hose and hose clamp Position the throttle valve body. Tighten hose clip Position the shift lever. Mount and tighten screw Ci) with washers. Guideline Screw, shift 14 Nm (10.3 lbf ft) Loctite ® ™ lever Slide on the engine sprocket with the collar facing the engine.
  • Page 162 17 ENGINE Position the clutch slave cylinder with the gasket. Mount and tighten screws 41). Guideline Screw, clutch slave 10 Nm (7.4 lbf ft) cylinder Position the engine sprocket cover. Mount and tighten screw Guideline Screw, clutch slave 10 Nm (7.4 lbf ft) cylinder Mount and tighten screw Guideline...
  • Page 163 17 ENGINE Mount the radiator hose. Position and tighten hose clip�- Plug in the connector. Position protection cap @i). Route the cable without tension and secure with cable clips and cable ties. Connect plug-in connector .. of the gear position sensor. Connect plug-in connector of the crankshaft position sensor.
  • Page 164 17 ENGINE Position the engine braces. Mount and tighten fittings Guideline Screw, engine 25 Nm (18.4 lbf ft) brace ® Loctite 2701 Tighten screws Guideline Engine carrying 60 Nm (44.3 lbf ft) screw Position the manifold. Mount screw � with washer but do not tighten yet. Guideline Remaining screws, 25 Nm (18.4 lbf ft)
  • Page 165 17 ENGINE Remove the locking piece and position the subframe. Info Watch out for the intake flange. Mount and tighten screw fl!). Guideline Screw, sub­ 30 Nm (22.1 lbf ft) Loctite ® 2701 frame Remove screw Ci). Mount and tighten screw Ci). Guideline Screw, sub­...
  • Page 166 17 ENGINE Connect negative cable@). Guideline Screw, battery termi- 2.5 Nm (1.84 lbf ft) • Info Contact disk must be mounted between screw and cable lug � with the claws facing downward. Install the air filter box cover. p. 90) Position the frame protectors on the left and right.

  • Page 167: Engine Disassembly

    (� p. 240) Execute the initialization run. p. 256) Go for a short test ride. Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. Check the engine for leak tightness. Check the engine oil level. (� p. 242) Check the coolant level.

  • Page 168: Removing The Oil Filter

    17 ENGINE Remove the oil drain plug with the magnet and seal ring. Remove oil drain plug with the O-ring. Completely drain the engine oil. 17.3.4 Removing the oil filter Remove screws Remove the oil filter cover with the O-ring. Pull oil filter out of the oil filter housing.

  • Page 169: Removing The Gear Position Sensor

    17 ENGINE 17.3.5 Removing the gear position sensor Remove screws Remove the protective plate and the gear position sensor . 17.3.6 Removing the spark plug Remove the spark plug with special tool Spark plug wrench with link (77229172000) (� p. 293) 17.3.7 Removing the valve cover Remove screws...

  • Page 170: Removing The Starter Motor

    17 ENGINE Remove spark plug shaft insert (D . 17.3.8 Removing the starter motor Remove screws Take off the alternator cover. Remove gasket Remove torque limiter (D . Remove screws and the starter motor.

  • Page 171: Positioning The Engine At Ignition Top Dead Center

    17 ENGINE 17.3.9 Positioning the engine at ignition top dead center Turn the crankshaft counterclockwise until markings flush with the edge of the cylinder head. Remove screw Info Look through the hole to check that the position notch of the crankshaft is visible. Mount and tighten screw without the washer.

  • Page 172: Removing The Camshafts

    17 ENGINE 17.3.11 Removing the camshafts Loosen and remove screws from the outside to the inside. Take off guide rail Take off the camshaft bearing bridge. Info Ensure that the dowel pins remain in place. Take the timing chain from the camshaft gear. Remove the camshafts.

  • Page 173: Removing The Piston

    17 ENGINE Remove cylinder head gasket (5). Remove dowels 17 .3.13 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.

  • Page 174: Removing The Starter Drive

    17 ENGINE Insert special tool into the crankshaft. I Protection cap (75029090000) (I!!;! p. 290) Attach special tool @) to the rotor. Hold it tight using the special tool and pull off the rotor by turning the screw in. I Extractor (79229032044) (I!!;! p.

  • Page 175: Removing The Water Pump Impeller

    17 ENGINE Remove O-ring (D. Take off suction pump Remove needle roller 17.3.17 Removing the water pump impeller Remove screws Take off the water pump cover. Remove gasket...

  • Page 176: Removing The Clutch Cover

    17 ENGINE Remove nut Take off two-part water pump impeller 17.3.18 Removing the clutch cover Remove screws Take off the clutch cover. Remove clutch cover gasket 17.3.19 Removing the clutch discs Loosen screws and remove together with the washers and springs. Take off the pressure cap.

  • Page 177: Removing The Clutch Basket

    17 ENGINE Completely remove clutch discs Remove pressure piece Removing the clutch basket 17 .3.20 Remove two opposing sleeves Bend up the lock washer. Hold the inner clutch hub with the special tool. Loosen Holding wrench (51129003000) (!ill p. 287) Remove the nut with the lock washer.

  • Page 178: Removing The Primary Gear

    17 ENGINE 17.3.21 Removing the primary gear Remove nut • Info Left-handed thread! Position the special tool in the crankshaft. I Protection cap (75029090000) p. 290) Pull off primary gear using the special tool. I Puller (46129021000) (� p. 286) 17.3.22 Removing the timing chain Remove screws...

  • Page 179: Removing The Locking Lever

    17 ENGINE Remove lock ring Take off washer Remove oil pump gear (D. Remove pin @. Remove screws @. Take off the oil pump cover. Remove pin Push oil pump shaft Ci) inward and take it out of the engine from the ignition side.

  • Page 180: Removing The Shift Drum Locating Unit

    17 ENGINE 17.3.25 Removing the shift drum locating unit Remove screw Push sliding plate away from shift drum locating unit Take off the shift drum locating unit. 17.3.26 Removing the shift shaft Remove shift shaft with the washer. 17.3.27 Removing the spacer Remove spacer of the crankshaft.

  • Page 181: Removing The Shift Rails

    17 ENGINE Insert the special tool into the crankshaft. Protection cap (75029090000) (� p. 290) Mount special tool with suitable screws. Puller (79229048000) (� p. 295) • Info Use the 792 drill hole. Pull off the section of the engine case. Info Do not tension the section of the engine case.

  • Page 182: Removing The Shift Forks

    17 ENGINE 17.3.31 Removing the shift forks Remove shift forks 17.3.32 Removing the transmission shafts Remove lock ring 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.

  • Page 183: Working On Individual Parts

    17 ENGINE Working on individual �arts 17.4 17.4.1 Working 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 Remove the bearing retainers.
  • Page 184 17 ENGINE Press in shaft seal ring of the crankshaft with the open side facing out so it is flush. Mount and tighten nozzle@. Guideline Nozzle, crank 2 Nm (1.5 lbf ft) Loctite ® ™ chamber venti- lation Mount and tighten oil nozzle Guideline Oil nozzle for 2 Nm (1.5 lbf ft)

  • Page 185: Work On The Left Section Of The Engine Case

    17 ENGINE 17.4.2 Work on the left section of the engine case Remove all dowels. Remove shaft seal ring of the crankshaft, shift shaft countershaft. Remove oil nozzle for clutch lubrication. Remove oil nozzle for piston cooling. Remove screws (D. Remove the bearing retainers. Remove any sealing mass remnants and clean the engine case section thoroughly.

  • Page 186: Work On The Clutch Cover

    17 ENGINE Guideline Oil nozzle for 2 Nm (1.5 lbf ft) ® Loctite ™ clutch lubrica- tion Mount and tighten oil nozzle Guideline Oil nozzle, pis­ 2 Nm (1.5 lbf ft) Loctite ® ™ ton cooling Position all bearing locks. Mount and tighten screws (D.
  • Page 187 17 ENGINE Press out bearing toward the inside. B03752-10 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 188: Checking The Oil Pressure Regulator Valve

    17 ENGINE Blow out the oil channel with compressed air and check that it is clear. 17.4.4 Checking the oil pressure regulator valve Remove screw plug with sealing washer Remove pressure spring and ball 310341-10 Measure the spring length of the oil pressure regulator valve. Oil pressure regulator valve Minimum length of 23.5 mm (0.925 in)

  • Page 189: Checking The Lubrication System

    17 ENGINE 17 .4.5 Checking the lubrication system 0� ✓ 310340-10 Check the internal rotor and external rotor of oil pumps for damage and wear. If there is damage or wear: Change the oil pumps. Check oil pump shaft for damage and wear. If there is damage or wear: Change the oil pump shaft.

  • Page 190: Changing The Connecting Rod, Conrod Bearing, And Crank Pin

    17 ENGINE 17.4.7 Changing the connecting rod, conrod bearing, and crank pin Main work Position crankshaft in the press using special tool I Separator plate (79229009000) (� p. 294) Press the crank pin out of the upper crankweb with the spe­ cial tool.
  • Page 191 17 ENGINE Position special tool on the press. Crankshaft pressing tool (75029047000) (l!!;!l p. 290) Crankshaft pressing tool insert (79029008000) (!,ll p. 293) Position special tool @ with the heel pointing down. Crankshaft pressing tool insert (79029008000) p. 293) Insert the crankweb with the connecting rod and bearing. Position the second crankweb.

  • Page 192: Checking The Crankshaft Run-Out At The Bearing Pin

    17 ENGINE 17.4.8 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 � 0.03 mm (� 0.0012 in) bearing pin If the crankshaft run-out at the bearing pin is larger than the specification:...

  • Page 193: Measuring The Crankshaft End Play

    17 ENGINE 17.4.10 Measuring the crankshaft end play Insert the crankshaft into the right section of the engine case. • Info Do not forget the fitted bushings. Mount the left section of the engine case. Mount and tighten screws. Guideline Screw, engine case 10 Nm (7.4 lbf ft) Mount the dial gauge support on the engine case and mea­...

  • Page 194: Installing The Drive Wheel Of The Balancer Shaft

    17 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 195: Checking/Measuring The Piston

    17 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 clear­ � 0.08 mm(� 0.0031 in) ance Feeler gauge (59029041100) (�...

  • Page 196: Measuring The Piston/Cylinder Mounting Clearance

    17 ENGINE Info Piston size is marked on the side of the piston. 17.4.16 Measuring the piston/cylinder mounting clearance Check/measure the cylinder. p. 192) Check/measure the piston. p. 193) The smallest piston/cylinder mounting clearance equals the smallest cylinder bore diameter minus the largest piston diameter.

  • Page 197: Changing The Camshaft

    17 ENGINE 17.4.18 Changing the camshaft bearing Clamp special tool into a vise. Adjustment bush bridge (77229050044) (� p. 292) Mount the camshaft on the special tool. Remove screw 306550-10 Pull camshaft gear (D off of the camshaft. Puller (77229001044) (�...

  • Page 198: Checking The Pivot Points Of The Camshafts

    17 ENGINE 17.4.20 Checking the pivot points of the camshafts Check the pivot points of the camshafts. If there is damage or wear: Change the cylinder head with the camshaft bearing bridge. 311625-10 Position the camshafts. ✓ The valves are not activated. Insert the clearance gauge in area f).

  • Page 199: Removing The Valves

    17 ENGINE 17 .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 position.

  • Page 200: Checking The Valves

    17 ENGINE 17.4.22 Checking the valves Check the valve plate for run-out. Valve - run-out At the valve plate :-;; 0.05 mm (:<;; 0.002 in) If the measured value does not meet specifications: Change the valve. 200193-10 Check sealing seat on valve for damage and wear.

  • Page 201: Checking The Valve Spring Seat

    17 ENGINE 17 .4.24 Checking the valve spring seat Check the valve spring seat for breakage and wear (visual check). If the valve spring seat is broken or worn: Change the valve spring seat. Measure the thickness of the valve spring seat. Valve spring seat - thick­...

  • Page 202: Installing The Valves

    17 ENGINE Check sealing seat of the valves. Valve - sealing seat width Intake 1 .40 mm (0.0551 in) Valve - sealing seat width Exhaust 1 .40 mm (0.0551 in) If the measured value does not meet specifications: Rework the valve seat. 302808-10 Blow compressed air through all oil holes and check that they are clear.

  • Page 203: Checking The Freewheel

    17 ENGINE Position cam levers in the positions they had before they were removed. Mount the cam lever shafts. Remove screw Mount and tighten screw plugs Cs). Guideline Screw plug, cam M10x1 10 Nm (7.4 lbf ft) lever axis Place the shims in the valve spring retainers corresponding to their installation position.

  • Page 204: Installing The Freewheel

    17 ENGINE Press expansion ring together with suitable pliers and take off. 310364-10 Take freewheel out of the primary gear. 310365-10 17.4.30 Installing the freewheel Thoroughly oil all parts. Slide freewheel into the primary gear. Info Note the direction of rotation. 310365-11 Mount spreader ring 310366-10...

  • Page 205: Checking The Electric Starter Drive

    17 ENGINE Mount lock ring 310363-11 17.4.31 Checking the electric starter drive •-• �- 310350-10 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 206: Checking The Timing Assembly

    17 ENGINE If the starter motor does not turn when the circuit is closed: Change the starter motor. 17.4.32 Checking the timing assembly 00• • .,.. • - 311615-10 Check timing chain sprocket for damage and wear. If there is damage or wear: Change the timing chain sprocket.

  • Page 207: Preparing The Timing Chain Tensioner For Installation

    17 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.

  • Page 208: Checking The Clutch

    17 ENGINE 17.4.34 Checking the clutch •- -• 310351-10 Check clutch throw-out for damage and wear. If there is damage or wear: Change the clutch throw-out. Check axial bearing for damage and wear. If there is damage or wear: Change the axial bearing. Place the clutch push rod on a flat surface and check for run-out.

  • Page 209: Checking The Shift Mechanism

    17 ENGINE If there is discoloration or scoring: Change all clutch facing discs. Check the thickness of clutch facing discs G}. I ;;:,: Clutch facing discs - thickness of total package 23.3 mm (<'= 0.917 in) If the clutch facing discs do not meet specifications: Change all clutch facing discs.

  • Page 210: Preassembling The Shift Shaft

    17 ENGINE If the bearings do not move freely or are worn: Change the bearings. Check the shift rollers for damage and wear. If there is damage or wear: Change the shift rollers. Check shift rails for run-out on a flat surface. If there is run-out: Change the shift rail.

  • Page 211: Disassembling The Main Shaft

    17 ENGINE 17.4.37 Disassembling the main shaft 306556-10 Secure the main shaft with the toothed end facing downward in the vise. Guideline I Use soft jaws. Remove stop disk and second-gear fixed gear Remove fourth-gear idler gear and needle bearing Remove stop disk Remove lock ring (D.

  • Page 212: Disassembling The Countershaft

    17 ENGINE 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 213 17 ENGINE 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 (D 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 (D for damage and wear.

  • Page 214: Assembling The Main Shaft

    17 ENGINE If there is damage or wear: Change the stop disks. Use new lock rings (D with every repair. 17.4.40 Assembling the main shaft Info Use new lock rings with every repair. Preparatory work Check the transmission. (� p. 210) Carefully lubricate all parts before assembling.

  • Page 215: Assembling The Countershaft

    17 ENGINE 17 .4.41 Assembling the countershaft Info Use new lock rings with every repair. Preparatory work Check the transmission.(� p. 210) Carefully lubricate all parts before assembling. Main work 306559-10 Fix the countershaft in the vise with the toothed end facing downward. Guideline I Use soft jaws Mount needle bearing...

  • Page 216: Engine Assembly

    17 ENGINE 17.5 Engine assembl� 17.5.1 Installing the crankshaft Position the right section of the engine case in the engine work stand. Oil the bearing. I Engine oil (SAE 1 0W/50) (� p. 280) Slide crankshaft into the bearing seat. 17.5.2 Installing the transmission shafts Oil the bearing.

  • Page 217: Installing The Shift Forks

    17 ENGINE 17.5.3 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 counter­ shaft. Mount shift fork in the upper shift groove of the counter­...

  • Page 218: Installing The Left Engine Case

    17 ENGINE 17.5.6 Installing the left engine case Mount the dowels. Degrease the sealing area. Apply sealing compound to the left section of the engine case. I Loctite 5910 ® Mount the left section of the engine case. If necessary, strike it lightly with a rubber mallet and turn the transmission shafts.

  • Page 219: Installing The Spacer

    17 ENGINE 17.5.7 Installing the spacer Grease the shaft seal ring. Long-life grease (� p. 282) Mount spacer Set the crankshaft to top dead center and lock it with screw 17.5.8 Installing the shift shaft Slide shift shaft with the washer into the bearing seat. 17.5.9 Installing the shift drum locating unit Push away sliding plate...

  • Page 220: Installing The Force Pump

    17 ENGINE 17 .5.11 Installing the force pump Oil the oil pump shaft, internal rotor, and external rotor before assembly. I Engine oil (SAE 1 0W/50) (!!:!I p. 280) Position force pump ✓ The rounded side of the force pump faces the engine case.

  • Page 221: Installing The Timing Chain

    17 ENGINE 17.5.12 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 run­ ning in the correct direction. Mount and tighten screw Guideline Screw, timing 10 Nm (7.4 lbf ft)

  • Page 222: Installing The Suction Pump

    17 ENGINE 17.5.14 Installing the suction pump Insert needle roller Position suction pump fj. ✓ The rounded sides of the external rotor face the engine case. Crank the oil pump gear wheel and ensure that it can move easily. Mount 0-ring Position the oil pump cover Mount and tighten screws Guideline...

  • Page 223: Installing The Clutch Basket

    17 ENGINE 17.5.15 Installing the clutch basket Mount collar sleeve and needle bearing Slide clutch basket onto the gearbox main shaft. Turn the oil pump gear until the gear teeth of the clutch basket mesh. Slide on washer and inner clutch hub Position the new lock washer and mount nut (3.

  • Page 224: Installing The Clutch Discs

    17 ENGINE 17.5.16 Installing the clutch discs Thoroughly oil the clutch facing discs. I Engine oil (SAE 1 0W/50) p. 280) Insert the intermediate clutch disc. Guideline I Thickness 11 mm (0.04 in) Place the clutch facing and intermediate discs into the clutch basket.

  • Page 225: Installing The Water Pump Cover

    17 ENGINE Guideline Screw, clutch cover M6x25 110 Nm (7.4 lbfft) Tighten all screws in a crisscross pattern. Guideline Screw, clutch cover 10 Nm (7.4 lbfft) 17.5.18 Installing the water pump cover Mount two-part water pump impeller Mount and tighten nut Guideline Nut, water­...

  • Page 226: Installing The Starter Drive

    17 ENGINE Guideline Screw, water pump M6x25 10 Nm (7.4 lbf ft) cover Installing the starter drive 17.5.19 Position freewheel gear Mount starter idler gear Mount and tighten screw with washer. Guideline Screw starter 10 Nm (7.4 lbf ft) ® Loctite idler gear ™...

  • Page 227: Installing The Piston

    17 ENGINE 17.5.21 Installing the piston ° Shift the joint of the piston rings by 120 Place the special tool on the oiled piston. Compress the pis- ton rings using the special tool. Piston ring mounting tool (60029015000) (� p. 289) ✓...

  • Page 228: Installing The Cylinder Head

    17 ENGINE Position the piston pin retainer. 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. I Insertion for piston ring lock (77229030000) (� p.

  • Page 229: Installing The Camshafts

    17 ENGINE Mount nuts (D with the washers and tighten in a crisscross pattern. Guideline Nut, cylinder M10x1 .25 Tightening sequence: Tighten diagonally. head 1st tightening stage 10 Nm (7.4 lbf ft) 2nd tightening stage 30 Nm (22.1 lbf ft) 3rd tightening stage 50 Nm (36.9 lbf ft) Thread, oiled with...

  • Page 230: Installing The Timing Chain Tensioner

    17 ENGINE Clean all oil nozzles thoroughly and blow out with compressed air. Position the camshaft bearing bridge. Info Ensure that the dowel pins are seated properly. Position guide rail Mount screws and tighten them from the inside to the outside.

  • Page 231: Checking The Valve Clearance

    17 ENGINE 17 .5.25 Checking the valve clearance Remove screw Crank the engine several times. Position the engine at ignition top dead center. ✓ Markings must line up with the edge of the cylinder head. Mount and tighten screw without the washer. Check the valve clearance at all valves between the camshaft and cam lever.

  • Page 232: 17.5.27 Installing The Starter Motor

    17 ENGINE Raise cam levers Correct the shims according to the findings from checking the valve clearance. Install the camshafts. (� p. 227) Install the timing chain tensioner. (� p. 228) Finishing work Check the valve clearance. (� p. 229) 17.5.27 Installing the starter motor Grease the O-ring.

  • Page 233: Installing The Valve Cover

    17 ENGINE Position the alternator cover. Mount and tighten screws Guideline Screw, alternator 10 Nm (7.4 lbf ft) cover 17.5.28 Installing the valve cover Grease the O-rings and mount spark plug shaft insert Position gasket Thinly apply sealing compound to area 6). Loctite ®...

  • Page 234: Installing The Spark Plug

    17 ENGINE 17.5.29 Installing the spark plug Mount and tighten the spark plug with special tool &. Guideline Spark plug M1 0x1 10 ... 12 Nm (7.4 ... 8.9 lbf ft) I Spark plug wrench with link (77229172000) (� p. 293) Installing the gear position sensor 17.5.30 Position gear position sensor.

  • Page 235: Installing The Oil Screen

    17 ENGINE 17.5.32 Installing the oil screen Mount and tighten oil drain plug with the O-ring. Guideline Oil drain plug I M14x1 .5 15 Nm (11.1 lbf ft) Mount and tighten oil drain plug with the magnet and a new seal ring. Guideline Oil drain plug with M12x1 .5...

  • Page 236: Installing The Clutch Push Rod

    17 ENGINE 17.5.33 Installing the clutch push rod Mount clutch push rod 17.5.34 Removing the engine from the engine assembly stand Remove the fitting from the special tool. I Holder and fitting for work stand (79229002000) (� p. 294) Remove the engine from the engine assembly stand. Info Work with an assistant or a motorized hoist.

  • Page 237: 18 Clutch

    18 CLUTCH Checking/correcting the fluid level of the h�draulic clutch Warning Brake fluid causes skin irritation. Skin irritation Keep brake fluid out of the reach of children. Wear suitable protective clothing and safety glasses. Do not allow brake fluid to come into contact with the skin, the eyes or clothing. Consult a doctor immediately if brake fluid has been swallowed.

  • Page 238: Changing The Hydraulic Clutch Fluid

    18 CLUTCH Changing the h}!draulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation. Keep brake fluid out of the reach of children. Wear suitable protective clothing and safety glasses. Do not allow brake fluid to come into contact with the skin, the eyes or clothing. Consult a doctor immediately if brake fluid has been swallowed.
  • Page 239 18 CLUTCH Inject the liquid into the system only until it emerges from drill hole of the master cylinder without bubbles. Now and then, extract fluid from the master cylinder reservoir to prevent overflow. Tighten the bleeder screw and remove the bleeding syringe with the hose.

  • Page 240: 19 Water Pump, Cooling System

    19 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 operat­ ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 241: Checking The Coolant Level

    19 WATER PUMP, COOLING SYSTEM Stand the motorcycle upright on a horizontal surface. Remove the radiator cap. Check the antifreeze in the coolant. I -25 ... -45 °C (-13 ... -49 °F) If the antifreeze in the coolant does not match the speci­ fied value: Correct the antifreeze in the coolant.

  • Page 242: Draining The Coolant

    19 WATER PUMP, COOLING SYSTEM Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
  • Page 243 19 WATER PUMP, COOLING SYSTEM Make sure that screw is tightened. Position the motorcycle upright. Pour coolant in up to measurement above the radiator fins. Guideline 10 mm (0.39 in) Dimension over the radi- ator fins 0.95 I (1 qt.) Coolant (ll!:! p.

  • Page 244: 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 �...

  • Page 245: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen

    20 LUBRICATION SYSTEM Condition The engine is cold. Check the engine oil level. The engine oil reaches the middle of level viewer If the engine oil does not reach the middle of the level viewer: Add engine oil. (I!!:! p. 246) Condition The engine is at operating temperature.
  • Page 246 LUBRICATION SYSTEM Main work Place a suitable container under the engine. Remove oil drain plug with the magnet and seal ring. Info Do not remove screws @ on both sides. Remove screw plug with oil screen Completely drain the engine oil. Thoroughly clean the parts and sealing surfaces.
  • Page 247 20 LUBRICATION SYSTEM Pull oil filter out of the oil filter housing. Lock ring plier (51012011000) (i!!,!l p. 286) Completely drain the engine oil. Thoroughly clean the parts and sealing surfaces. Lay the motorcycle on its side and fill the oil filter housing to about½...

  • Page 248: 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 oil filler plug with the O-ring from the clutch cover. Fill engine oil to the middle of the level viewer.
  • Page 249 20 LUBRICATION SYSTEM Main work Remove screw Position the special tool. Mount and tighten the banjo bolt. Guideline Banjo bolt I M10x1 I 8 Nm (5.9 lbf ft) Oil pressure adapter (77329006000) p. 293) Connect the pressure tester to the special tool without the T­ plate.
  • Page 250 LUBRICATION SYSTEM 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 M10x1...

  • Page 251: Ignition System

    IGNITION SYSTEM 21.1 Ignition coil - checking the seconda� 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 (-) - Ignition coil cylin­...

  • Page 252: Removing The Stator And Crankshaft Position Sensor

    IGNITION SYSTEM �6.3mm P00023-10 Stator winding - check the short circuit to ground (terminal 31) Measure the resistance between the specified points. Alternator, connector - Measuring point Ground, wiring harness/frame Resistance If the indicated value does not correspond to the required value: Change the stator.
  • Page 253 IGNITION SYSTEM Position the stator and ignition pulse generator in the alterna­ tor cover. Mount and tighten screws@. Guideline Screw, stator 6 Nm (4.4 lbf ft) ® Loctite ™ Position retaining bracket. Mount and tighten screws@). Guideline Screw, 6 Nm (4.4 lbf ft) Loctite ®...

  • Page 254: 22 Cylinder Head

    22 CYLINDER HEAD 22.1 Checking the valve clearance Preparatory work Remove the right side cover. p. 94) Remove the air filter box cover. p. 90) Remove the seat. p. 94 ) Remove the fuel tank. p. 96) Main work Pull capacitor away from the holder and hang to one side.
  • Page 255 22 CYLINDER HEAD Remove screw Turn the crankshaft counterclockwise until markings flush with the edge of the cylinder head. Remove screw @) . C&. Remove washer Look through the hole to check that the position notch of the crankshaft is visible. Mount and tighten screw @) without the washer.
  • Page 256 22 CYLINDER HEAD Mount and tighten screw@). Guideline Screw, alternator M24x1.5 18 Nm (13.3 lbf ft) cover Clean and degrease the sealing surface. Apply a thin layer of sealant to area G). I Loctite 5910 ® Mount gasket @. Position the valve cover with the gasket. Mount and tighten screws (D.

  • Page 257: Adjusting The Valve Clearance

    22 CYLINDER HEAD Mount capacitor Finishing work Install the fuel tank. (li!:,!l p. 97) Mount the seat. (!!,!I p. 95) Install the air filter box cover. (!!,!I p. 90) Install the right side cover. (!!:!I p. 94) Adjusting the valve clearance Info For purposes of illustration, the following operations are shown with the engine removed.

  • Page 258: 23 Throttle Valve Body

    23 THROTTLE VALVE BODY 23.1 Adjusting the idle s�eed Danger Exhaust gases are toxic and inhaling them may result in unconsciousness and Danger of poisoning death. Always make sure there is sufficient ventilation when running the engine. Use an effective exhaust extraction system when starting or running the engine in an enclosed space.
  • Page 259 23 THROTTLE VALVE BODY Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. Always make sure there is sufficient ventilation when running the engine. Use an effective exhaust extraction system when starting or running the engine in an enclosed space.

  • Page 260: 24 Technical Data

    24 TECHNICAL DATA Engine 24.1 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 14.0:1 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 261: Tolerance, Engine Wear Limits

    24 TECHNICAL DATA 24.2 Tolerance, engine wear limits Camshaft bearing - sleeve bearing Radial clearance 0.020 ... 0.054 mm (0.00079 ... 0.00213 in) Wear limit 0.065 mm (0.00256 in) Valve spring Minimum length, intake valve outer spring 42.40 mm (1.6693 in) Minimum length, intake valve inner spring 39.20 mm (1.5433 in) Minimum length, exhaust valve outer spring...

  • Page 262: Engine Tightening Torques

    24 TECHNICAL DATA 24.3 Engine tightening tor ues Nozzle, crank chamber ventilation 2 Nm (1 .5 lbf ft) ® Loctite ™ Oil nozzle for alternator cooling 2 Nm (1 .5 lbf ft) Loctite ® ™ Oil nozzle for balancer shaft lubri- 2 Nm (1 .5 lbf ft) ®...
  • Page 263 24 TECHNICAL DATA Screw, starter motor 10 Nm (7.4 lbf ft) Screw, timing chain guide rail 10 Nm (7.4 lbf ft) ® Loctite ™ Screw, timing chain securing 10 Nm (7.4 lbf ft) Loctite ® ™ guide Screw, valve cover 8 Nm (5.9 lbf ft) Screw, water pump cover 10 Nm (7.4 lbf ft)

  • Page 264: Capacities

    24 TECHNICAL DATA 24.4 Ca�acities 24.4.1 Engine oil I Engine oil 11.0 I (1.1 qt.) I Engine oil (SAE 1 0W/50) (� p. 280) 24.4.2 Coolant I Coolant (� p. 280) I 0.95 I (1 qt.) 24.4.3 Fuel I Super unleaded (ROZ 95/RON 95/PON 91) (lUI p.

  • Page 265: Electrical System

    80/100 - 21 51M TT 110/90 - 19 62M TT Dunlop Geomax MX52F Dunlop Geomax MX52 The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: www.husqvarna-motorcycles.com 24.8 Fork Fork part number 24.18.7P.57 Fork...

  • Page 266: Shock Absorber

    24 TECHNICAL DATA 24.9 Shock absorber Shock absorber article number 18.18.7P.57 Shock absorber WP Performance Systems 5018 DCC Link Compression damping, low-speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping, high-speed Comfort 2.5 turns Standard 2 turns Sport 1.5 turns Rebound damping...
  • Page 267 24 TECHNICAL DATA Screw, ball joint of push rod on 10 Nm (7.4 lbf ft) ® Loctite foot brake cylinder ™ Screw, chain sliding guard 6 Nm (4.4 lbf ft) Loctite ® ™ Screw, electric starter cable con- 4 Nm (3 lbf ft) nection Screw, front brake disc 14 Nm (10.3 lbf ft)
  • Page 268 24 TECHNICAL DATA Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft) Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) Screw-in nozzles, cooling system M20x1.5 12 Nm (8.9 lbf ft) ® Loctite ™...

  • Page 269: 25 Cleaning

    25 CLEANING 25.1 Cleaning the motorc}!cle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.
  • Page 270 25 CLEANING Preserving materials for paints, metal and rubber p . 28 3) (� Treat all plastic parts and powder-coated parts with a mild cleaning and care agent.

  • Page 271: 26 Storage

    O ... 35 °C (32 ... 95 °F) tery without direct sunshine Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info Husqvarna Motorcycles recommends raising the motorcycle. Raise the motorcycle with a lift stand. (� p. 12) Cover the vehicle with a tarp or similar cover that is perme- able to air.

  • Page 272: Preparing For Use After Storage

    26 STORAGE Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and the exhaust system to rust.

  • Page 273: 27 Service Schedule

    Every 30 operating hours Every 20 operating hours Every 10 operating hours/after every race Once after 1 operating hour • • • Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. • • • Check and charge the battery. • •...

  • Page 274: Recommended Work

    • • • • Final check: Check the vehicle for operating safety 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 275 27 SERVICE SCHEDULE...
  • Page 276 t : : 1 «! . · � 1 " 1 -" . R/ 4 NfC/2 l. x1 9 EB/ 4 • -C10 -M10 -G101 1+ � �K/4 ""ij -521 ,'!-, EB/ 4 r BR/ 4 FC/2 � � I -X1 9 ·...

  • Page 277: 28 Wiring Diagram

    28 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 278 � HY/33 HY/33 HY/33 HY/33 HY/33 �HY/33 HY/33 1 ·X16 1·X16 1·X16 1·X16 is� � ��i �I " ��; � - a .0.0 l.x 2 1 . x 1 . x s -BF/1 iCX/2 f 1 , 2 f r 1 2 -520 -P25 - X 295...
  • Page 279 28 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 280 -© -A11 " ' l " ' 1�, . l" 1 1 " l" l" 1 � m 1 1 � ru 1 � -X16 -X16 -X16 -X16 -X16 -X16 -X16 -X16 -X16 -X16 " 1""' "" • " � i �...
  • Page 281 28 WIRING DIAGRAM Components: A 11 EFI control unit Intake air temperature sensor Coolant temperature sensor (cylinder 1) Rollover sensor Gear position sensor Crankshaft position sensor Manifold absolute pressure sensor (cylinder 1) Throttle position sensor Ignition coil (cylinder 1) switch for ride mode (optional) switch (optional) Map-Select Cable colors:...

  • Page 282: 29 Substances

    29 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 corresponding properties. Recommended supplier ® Bel-Ray Super DOT 4 Brake Fluid Coolant Guideline Only use high-grade, silicate-free coolant with corrosion inhibitor additive for aluminum motors.
  • Page 283 29 SUBSTANCES Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification p. 301) (SAE 2.5) Guideline Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification DIN EN 228 (ROZ 95/RON 95/PON 91) Guideline...

  • Page 284: 30 Auxiliary Substances

    30 AUXILIARY SUBSTANCES Air filter cleaning agent Recommended supplier ® Bel-Ray Foam Filter Cleaner & Degreaser High viscosi't}f grease Recommended supplier ® LGHB 2 Long-life grease Recommended supplier ® Bel-Ray Waterproof Grease Lubricant (I158) Recommended supplier Lubcon ® ® Turmogrease PP 300 Lubricant 14034...
  • Page 285 30 AUXILIARY SUBSTANCES Oil for foam air filter Recommended supplier ® Bel-Ray Foam Filter Oil Preserving materials for �aints metal and rubber Recommended supplier ® Bel-Ray Silicone Detailer & Protectant Spray Universal oil s�ra}! Recommended supplier ® Bel-Ray 6 in 1...

  • Page 286: Special Tools

    SPECIAL TOOLS Bleeder cover Art. no.: 00029013005 00029013005 H00504-01 Bleeder cover Art. no.: 00029013006 00029013006 H00505-01 Bleeding device Art. no.: 00029013100 00029013100 H00518-01 EU batte charger XCharge- rofessional Art. no.: 00029095050 Feature EU safety plug Nominal voltage 230 V Mains fuse Power cable length 5 m (16 ft) approx.
  • Page 287 SPECIAL TOOLS US batterY charger XCharge-�rofessional Art. no.: 00029095051 Feature US plug Nominal voltage 120 V Mains fuse 32 A Power cable length 5 m (16 ft) approx. Charger cable 5 m (16 ft) H01065-01 length approx. e-professional Art. no.: 00029095052 Feature UK safety plug Nominal voltage...
  • Page 288 SPECIAL TOOLS Puller Art. no.: 46129021000 46129021000 H01519-01 S�ring hook Art. no.: 50305017000 50305017000 H00973-01 S}'ringe Art. no.: 50329050000 50329050000 H00565-01 Lock ring lier Art. no.: 51012011000 51012011000 H00572-01...
  • Page 289 SPECIAL TOOLS Holding wrench Art. no.: 51129003000 & 51129003000 H00575-01 Puller Art. no.: 58429037037 & Feature Inside diameter 37.5 mm (1.476 in) � 58429037037 H00596-01 Tool bracket Art. no.: 58429089000 2x£ 58429089000 H00603-01 Pressing tool Art. no.: 58429091000 58429091000 H00604-01...
  • Page 290 SPECIAL TOOLS Pressing tool Art. no.: 58429092000 58429092000 H00605-01 Torgue wrench set Art. no.: 58429094000 Feature Torque 3 ... 15 Nm (2.2 ... 11 .1 lbf ft) Open ended bit 3.9 mm (0.154 in) ..)P.,P� Open ended bit 4.9 mm (0.193 in) ��...
  • Page 291 SPECIAL TOOLS Plastigauge clearance gauge Art. no.: 60029012000 Feature 0.025 ... 0.175 mm (0.00098 ... 0.00689 in) 60029012000 H00627-01 Piston ring mounting tool Art. no.: 60029015000 Feature Height 80 mm (3.15 in) Diameter 57 ... 125 mm (2.24 ... 4.92 in) 60029015000 H00628-01 Hose clam�...
  • Page 292 SPECIAL TOOLS Pressure testing tool Art. no.: 61029094000 4x £ 61029094000 H00660-01 Release device for timing chain tensioner Art. no.: 61229021000 61229021000 H00675-01 Crankshaft �ressing tool Art. no.: 75029047000 � � 75029047000 H00714-01 Protection ca Art. no.: 75029090000 75029090000 H00726-01...
  • Page 293 SPECIAL TOOLS Puller Art. no.: 77229001044 77229001044 H00747-01 Crankshaft �ressing tool insert Art. no.: 77229008000 77229008000 H00750-01 Valve stem seals lier Art. no.: 77229010000 77229010000 H00752-01 Limit auge Art. no.: 77229026000 Feature Diameter I 5.55 mm (0.2185 in) 77229026000 H00753-01...
  • Page 294 SPECIAL TOOLS Insertion for �iston ring lock Art. no.: 77229030000 77229030000 H00754-01 Protection ca� Art. no.: 77229031000 77229031000 H00755-01 Se�arator �late Art. no.: 77229032000 77229032000 H00756-01 Ad"ustment bush bridge Art. no.: 77229050044 77229050044 H00759-01...
  • Page 295 SPECIAL TOOLS S�ark �lug wrench with link Art. no.: 77229172000 Feature Drive 3/8 in Hexagonal part 14 mm (0.55 in) Length 130 mm (5.12 in) 77229172000 H00761-01 Oil Qressure ada�ter Art. no.: 77329006000 77329006000 H00764-01 Crankshaft ressing tool insert Art. no.: 79029008000 79029008000 H00801-01 Insert for valve s ring lever...
  • Page 296 SPECIAL TOOLS Footrest s�ring �lier Art. no.: 79029083000 79029083000 H00804-01 Holder and fitting for work stand Art. no.: 79229002000 2x&& 79229002000 H01127-01 Se�arator �late Art. no.: 79229009000 79229009000 H00807-01 Extractor Art. no.: 79229032044 79229032044 H00808-01...
  • Page 297 SPECIAL TOOLS Puller Art. no.: 79229048000 79229048000 H00809-01 Engine work stand Art. no.: 80329001000 80329001000 H01047-01 Lift stand Art. no.: 81329955100 Feature Height 315 ... 425 mm (12.4 ... 16.73 in) Load s; 150 kg (:5 331 lb.) 81329955100 H00985-01 Hook wrench Art.
  • Page 298 SPECIAL TOOLS De th micrometer Art. no.: T107S T107S H00842-01 Drift Art. no.: T120 Feature I Diameter 8 mm (0.31 in) T120 H00844-01 Mounting sleeve Art. no.: T1204 Feature I Diameter 25.5 ... 30.5 mm (1 .004 ... 1 .201 in) T1204 H00878-01 Calibrating unit...
  • Page 299 SPECIAL TOOLS Pressing tool Art. no.: T1206 & Feature Diameter 1 15 ... 30 mm (0.59 ... 1 .18 in) � T1206 H00880-01 Pressing tool Art. no.: T1207S &.&. �� T1207S H00881-01 Mounting sleeve Art. no.: T1215 Feature Diameter 1 18 mm (0.71 in) T1215 H00886-01 Pressing tool...
  • Page 300 SPECIAL TOOLS Vacuum �um� Art. no.: T1240S � T1240S H00890-01 Protecting sleeve Art. no.: T1401 Feature I Diameter I 48 mm (1.89 in) T1401 H00894-01 Clam�ing stand Art. no.: T1403S £. Feature Diameter 48 mm (1.89 in) Diameter 60 mm (2.36 in) ��...
  • Page 301 SPECIAL TOOLS Mounting tool Art. no.: T14047 Feature Drive 1/2 in Narrow diameter 34 mm (1 .34 in) Wide diameter 42.7 mm (1.681 in) T14047 H00923-01 Clam�ing stand Art. no.: T14049S Feature Diameter 8 mm (0.31 in) Diameter 24.8 mm (0.976 in) T14049S H00924-01 Pressing tool...
  • Page 302 SPECIAL TOOLS Mounting tool Art. no.: T150S T150S H00852-01 Filling tool Art. no.: T170S1 £ £ T170S1 H00855-01...

  • Page 303: 32 Standards

    32 STANDARDS JASOT903MA Different technical development directions required a separate specification for motorcycles - the JASO T903 MA standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 304: 33 List Of Abbreviations

    33 LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 305: Index

    INDEX Cartridge of fork legs, assembling ....29 ......9 Accessories of fork legs, disassembling .
  • Page 306 INDEX countershaft, assembling ... . . 213 clutch cover, installing ....222 countershaft, disassembly ... . 210 clutch discs, installing crankshaft bearing inner race, installing clutch push rod, installing .
  • Page 307 INDEX piston rod, assembling ....27 primary gear, removing rotor, removing ....171 piston rod, disassembling .
  • Page 308 INDEX Ignition coil removing secondary winding, checking ..249 Rebound damping Implied warranty ..... . . 9 fork, adjusting .
  • Page 309 INDEX Spark plug connector Type label ......1 0 checking ......249 Spoke tension Valve clearance checking .
  • Page 310 I 1 1 11 1 11 1 1 1 1 11 1 1 1 111 1 11 1 1 1 1 111 1 11 1 1 1 1 1 1 1 11 1 I I I I I I II I I II 3403032en 05/2017 ® Husqvarna llmi Husqvarna Motorcycles GmbH StallhofnerstraBe 3 5230 Mattighofen Austria fiiiHiAv � LZZa" ·...

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