Husqvarna FC 450 2018 Repair Manual
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Husqvarna FC 450 2018 Repair Manual

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PIONEERING SINCE 1903
REPAIR MANUAL2018
FC 450 Rockstar Edition
®
Husqvarna
Art. no. 3403072en
MOTORCYCLES

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Summary of Contents for Husqvarna FC 450 2018

  • Page 1 PIONEERING SINCE 1903 REPAIR MANUAL2018 FC 450 Rockstar Edition ® Husqvarna Art. no. 3403072en 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 shock absorber MEANS OF REPRESENTATION ......7 cartridge ..........26 Symbols used ........7 6.16 Checking the fork legs ......28 1 .2 Formats used ........7 6.17 Assembling the shock absorber cartridge ..........29 SAFETY ADVICE ..........
  • Page 5 TABLE OF CONTENTS 12.7 Adjusting the riding sag ...... 59 Removing the fuel tank ..... 102 Removing the shock absorber .... 60 12.8 Installing the fuel tank ....... 103 9.10 Installing the shock absorber ....61 12.9 Checking the fuel pressure ....105 9.11 Checking the shock absorber 12.10...
  • Page 6 TABLE OF CONTENTS 15.8 Checking the open-circuit current..140 17.3.20 Removing the clutch discs ... 180 15.9 Checking the capacitor ..... 141 17.3.21 Removing the clutch basket ..182 15.10 Checking the starter relay ....142 17.3.22 Removing the torque limiter ..182 17.3.23 Removing the starter idler gear ..
  • Page 7 TABLE OF CONTENTS 17.4.19 17.5.14 Installing the torque limiter ... 227 Checking the piston ring end gap ..........201 17.5.15 Installing the clutch basket ... 227 17.4.20 Measuring the piston/cylinder 17.5.16 Installing the clutch discs ..... 228 mounting clearance ...... 201 17.5.17 Installing the clutch cover ....
  • Page 8 TABLE OF CONTENTS IGNITION SYSTEM ........269 29.3 Page 3 of 3 ........300 21.1 SUBSTANCES ..........302 Ignition coil - checking the secondary winding ......269 AUXILIARY SUBSTANCES ......304 21.2 Checking the spark plug connector .......... 269 SPECIAL TOOLS ........... 306 21.3 Changing the spark plug ....

  • Page 9: Means Of Representation 1

    MEANS OF REPRESENTATION 1 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 to help you repair and service 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 3 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 Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 401945-10 e label The type label is fixed to the front of the steering head. 401946-10 En ine number The engine number is stamped on the left side of the engine.

  • Page 13: Shock Absorber Article Number

    SERIAL NUMBERS 4 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. Use the motor guard underneath the motor to raise the vehi­ cle.

  • Page 15: Starting The Motorcycle To Check The 8 Function

    MOTORCYCLE 5 Remove the plug-in stand Shift the transmission to the neutral position. H02629-10 Condition Ambient temperature: < 20 °C (< 68 °F) Push the cold start button in all the way. Press the electric starter button 0. Info Press the electric starter button for a maximum of 5 seconds.

  • Page 16: Fork, Triple Clamp

    6 FORK, TRIPLE CLAMP Air sus ension AER 48 Air suspension WP Suspension AER 48 is used in the fork. In this system, suspension is located in the left fork leg and damping in the right fork leg. As fork springs are no longer required, a significant weight advantage is achieved when compared to conventional forks.

  • Page 17: Adjusting The Fork Air Pressure

    Info This is due to the volume of the hose and not due to a defect in the fork airpump or the fork. Read the accompanying instructions for Husqvarna Motorcycles accessories. Adjust the air pressure as specified. Guideline Air pressure 10.5 bar (152 psi)

  • Page 18: Adjusting The Compression Damping Of The Fork

    6 FORK, TRIPLE CLAMP ✓ When disconnecting, excess pressure will escape from the hose - the fork leg itself does not lose any air. ✓ The fork airpump indicator switches off automatically after 80 seconds. Mount the protection cap. Info Only mount the protection cap by hand.

  • Page 19: Bleeding The Fork Legs

    FORK, TRIPLE CLAMP 6 Guideline Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks • Info Turn clockwise to increase damping; turn counter­ clockwise to reduce damping. Mount protection cap Bleeding the fork le s Preparatory work Raise the motorcycle with a lift stand. p.

  • Page 20: Removing The Fork Legs

    6 FORK, TRIPLE CLAMP Warning Oil or grease on the brake Danger of accidents discs reduces the braking effect. Always keep the brake discs free of oil and grease. Clean the brake discs with brake cleaner when necessary. Clean and oil the dust boots and inner fork tubes of both fork legs.

  • Page 21: Installing The Fork Legs

    FORK, TRIPLE CLAMP 6 Installing the fork legs Main work Position the fork legs. ✓ Air bleeder screw of the right fork leg is positioned to the front. ✓ Valve of the left fork leg faces the front. Info Grooves are milled into the side of the upper end of the fork legs.

  • Page 22: Installing The Fork Protector

    6 FORK, TRIPLE CLAMP Installing the fork rotector 6.11 Position the fork protector on the left fork leg. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis Position the brake line and clamp. Mount and tighten screws@.

  • Page 23: Disassembling The Fork Legs

    FORK, TRIPLE CLAMP 6 6.13 Disassembling the fork legs Caution Disassembling pressurized parts can cause injuries. Danger of accidents The fork is filled with compressed air. Please follow the description provided. Condition The fork legs have been removed. • Left fork leg Clamp the fork leg in the area of the lower triple clamp .
  • Page 24 6 FORK, TRIPLE CLAMP Remove dust boot Remove fork protector ring G). Info The fork protector ring does not necessarily need to be removed for repair work. Remove lock ring • Info The lock ring has a beveled end where a screw­ driver can be applied.
  • Page 25 FORK, TRIPLE CLAMP 6 Right fork leg Remove protection cap Make a note of the present state of rebound compression damping@. Open the adjusters of the rebound and compression damping completely. Clamp the fork leg in the area of the lower triple clamp. I Clamping stand (T1403S) (ll!:!I p.
  • Page 26 6 FORK, TRIPLE CLAMP Clamp the fork leg with the axle clamp. Guideline Use soft jaws. Remove rebound adjuster Remove the cartridge. 803536-10 Remove dust boot (D. Remove fork protector ring G). Info The fork protector ring does not necessarily need to be removed for repair work.

  • Page 27: Disassembling The Air Cartridge

    FORK, TRIPLE CLAMP 6 Remove upper sliding bushing@). Info Without using a tool, pull the stack slightly apart by hand. Take off lower sliding bushing@). Take off support ring Ci). G, . Take off seal ring Take off lock ring @. Take off dust boot (D.

  • Page 28: Disassembling The Shock Absorber Cartridge

    6 FORK, TRIPLE CLAMP Remove the piston rod with the seal ring retainer. Degrease and clamp the top of the piston rod. I Clamping stand (T14016S) p. 322) Heat up the thread area of piston (D. Guideline I 50 °C (122 °F) Remove piston (D.
  • Page 29 FORK, TRIPLE CLAMP 6 Drain the shock absorber cartridge. Turn the shock absorber cartridge, degrease and clamp at the bottom. Clamping stand (T14072) p. 323) Remove lock ring Remove fluid barrier Heat up thread area of shock absorber cartridge f). Guideline (122 °F) Loosen seal ring retainer 0).

  • Page 30: Checking The Fork Legs

    6 FORK, TRIPLE CLAMP Remove the seal ring retainer from the piston rod. Remove adjusting tube from the piston rod. 6.16 Checking the fork legs Condition The fork legs have been disassembled. Check the inside fork tube and the axle clamp for damage. If damage is found: Change the inside fork tube.

  • Page 31: Assembling The Shock Absorber Cartridge

    FORK, TRIPLE CLAMP 6 Measure the inside diameter at several places of the outside fork tube. Inside diameter of the out­ s 49.20 mm (s 1 .937 in) side fork tube If the measured value is greater than the specified value: Change the outside fork tube.
  • Page 32 6 FORK, TRIPLE CLAMP Lubricate seals on seal ring retainer I Lubricant (T14034) p. 304) Push the seal ring retainer onto the piston rod. ✓ The thread faces upward. Degrease and clamp the top of the piston rod. I Clamping stand (T14016S) p.

  • Page 33: Assembling The Air Cartridge

    FORK, TRIPLE CLAMP 6 Position fluid barrier Mount lock ring Gi). Turn the shock absorber cartridge around and clamp at top. Clamping stand (T14016S) p. 322) Fill with fork oil. Oil capacity, right 380 ml Fork oil (SAE 4) cartridge (12.85 fl.
  • Page 34 6 FORK, TRIPLE CLAMP Mount spring pack ✓ The wide side of spring guide is mounted facing down. Slot end stop onto the piston rod. ✓ The cone points downward. Clamp the piston rod underneath the end stop. I Clamping stand (T14016S) p.

  • Page 35: Assembling The Fork Legs

    (ra!l (ra!l (ra!l FORK, TRIPLE CLAMP 6 Position fluid barrier ✓ The cut-out faces upward. Mount lock ring Ci). 4D . Mount and tighten valve core Fill the cartridge with air . Guideline Minimum air pressure 7 bar (102 psi) Maximum air pressure 15 bar (218 psi) Adjust air pressure with special tool...
  • Page 36 6 FORK, TRIPLE CLAMP ✓ The sealing lip points downward, the open side upward. Remove the special tool. Push on support ring Sand the edges of the sliding bushings with 600 grit sandpaper; then clean and grease the bushings. Fork oil (SAE 4) (48601166S1) (il!:!I p.
  • Page 37 FORK, TRIPLE CLAMP 6 Mount dust boot Mount fork protector ring G). B03520-13 Assemble the individual components that belong together. • Info Air cartridge (left fork leg): cartridge with blue adapter axle clamp with brake mount and outside fork tube with warning label screw cartridge @.
  • Page 38 6 FORK, TRIPLE CLAMP Lubricate O-ring on the air cartridge. Lubricant (T158) p. 304) Push the outside fork tube upwards. Clamp the outside fork tube in the area of the lower triple clamp. Clamping stand (T1403S) p. 323) B03542-10 Tighten air cartridge Q). Guideline Cartridge on the M51x1 .5...
  • Page 39 FORK, TRIPLE CLAMP 6 Push on support ring Sand the edges of the sliding bushings with 600 grit sandpaper; then clean and grease the bushings. I Fork oil (SAE 4) (48601166S1) p. 303) Push on lower sliding bushing Mount upper sliding bushing (D . Info Without using a tool, pull the stack slightly apart by hand.
  • Page 40 6 FORK, TRIPLE CLAMP Assemble the individual components that belong together. • Info Shock absorber cartridge (right fork leg): cartridge with silver adapter (9, axle clamp without brake mount, and outside fork tube without warning label, rebound adjuster B03544-10 Slide the shock absorber cartridge into the inside fork tube.

  • Page 41: Lubricating The Steering Head Bearing

    FORK, TRIPLE CLAMP 6 Tighten the shock absorber cartridge. Guideline Cartridge on the 50 Nm (36.9 lbf ft) M51x1.5 outside fork tube I Ring wrench (T14017) p. 322) Mount adjuster of the compression damping. Mount and tighten the screw. Guideline Screw, compres­...

  • Page 42: Removing The Lower Triple Clamp

    6 FORK, TRIPLE CLAMP 6.21 Removing the lower tri�le clam� Preparatory work Raise the motorcycle with a lift stand. p. 12) Remove the front wheel. p. 120) Remove the fork legs. p. 18) Remove the start number plate. p. 116) Remove front fender.

  • Page 43: Installing The Lower Triple Clamp

    FORK, TRIPLE CLAMP 6 6.22 Installing the lower tri�le clam� Main work @> Clean the bearing and sealing elements, check for damage, --� and grease . .-cf> High viscosity grease (ll!:!I p. 304) @ - o 8 - ® Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.
  • Page 44 6 FORK, TRIPLE CLAMP Tighten screws (3. 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 45: Checking Steering Head Bearing Play

    FORK, TRIPLE CLAMP 6 Finishing work Install front fender. p. 115) Install the start number plate. p. 116) Install the front wheel. p. 121) Check that the wiring harness, throttle cables, and brake and clutch lines can move freely and are routed correctly. Check steering head bearing play.

  • Page 46: Changing The Steering Head Bearing

    6 FORK, TRIPLE CLAMP 6.24 Changing the steering head bearing Preparatory work Raise the motorcycle with a lift stand. p. 12) Remove the front wheel. p. 120) Remove the fork legs. p. 18) Remove the start number plate. p. 116) Remove front fender.

  • Page 47: Adjusting Steering Head Bearing Play

    FORK, TRIPLE CLAMP 6 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 Install the lower triple clamp. p.

  • Page 48: 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. This allows the handlebar to be mounted in the most comfortable position for the rider.

  • Page 49: Clutch Lever

    HANDLEBAR,CONTROLS 7 First bolt the handlebar clamp with screws onto the longer, higher side of the handlebar supports so that both parts touch. Guideline Screw, handlebar 20 Nm (14.8 lbf ft) clamp Tighten screws evenly. Guideline Screw, handlebar 20 Nm (14.8 lbf ft) clamp Finishing work Mount the handlebar cushion.

  • Page 50: Checking Throttle Cable Routing

    7 HANDLEBAR,CONTROLS Check that screw is firmly seated. Guideline Screw, fixed 5 Nm (3.7 lbf ft) grip ® Loctite ™ I The diamond must be located at the top. 7 .5 Checkin throttle cable routin Preparatory work Remove the air filter box cover. p.

  • Page 51: Checking Throttle Cable Play

    HANDLEBAR,CONTROLS 7 Checking throttle cable �la� Check the throttle grip for smooth operation. Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable 3 ... 5 mm (0.12 ... 0.2 in) Throttle cable play If the throttle cable play does not meet specifications: Adjust throttle cable play.

  • Page 52: Adjusting The Characteristic Map Of The Throttle Response

    7 HANDLEBAR,CONTROLS Main work Move the handlebar to the straight-ahead position. Push back sleeve Loosen nut Turn adjusting screw in as far as possible. Loosen nut Push cold start button all the way to the stop. Turn adjusting screw so that the cold start button moves to the basic position when the throttle grip is turned to the front.
  • Page 53 HANDLEBAR,CONTROLS 7 Remove guide plate from handle tube � � ,,.,-- � � �� � Position the required guide plate on the grip tube. Guideline � � The label must be visible. Marking must be OUTSIDE � positioned at marking G). Grey guide plate (79002014000) Alternative 1 I Black guide plate (79002014100)

  • Page 54: Frame

    8 FRAME Remove screws Remove screw Remove the engine guard. K01066-10 Position the engine guard on the frame. Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis Mount and tighten screws Guideline lbf ft) Remaining screws, 10 Nm (7.4 chassis...

  • Page 55: Checking The 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 K01114-01 Motorcycles. Changing the footrests Condition The frame protectors have been removed on the left and right.
  • Page 56 8 FRAME Position spring as shown. (!). ✓ Spring engages in area ✓ Press the spring with special tool I Footrest spring plier (79029083000) p. 316) ✓ The special tool is applied to area on the footrest. Mount pin (D. Mount the washer and splint Repeat these steps on the opposite side.

  • Page 57: Shock Absorber, Link Fork 9

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

  • Page 58: Adjusting The Rebound Damping Of The Shock Absorber

    9 SHOCK ABSORBER, LINK FORK Turn adjusting screw clockwise with a screwdriver as far as the last perceptible click. • Info Do not loosen fitting@! Turn counterclockwise by the number of clicks correspond­ ing to the shock absorber type. Guideline Lowspeed compression damping Comfort 17 clicks...

  • Page 59: Measuring The Rear Wheel Dimension Unloaded

    SHOCK ABSORBER, LINK FORK 9 Measuring the rear wheel dimension unloaded Preparatory work Raise the motorcycle with a lift stand. (ra:!l p. 12) Main work Position the sag gage in the rear axle and measure the distance to marking SAG on the rear fender. Sag gauge (00029090500) Sag gage pin (00029990010) Note down the value as dimension f) .

  • Page 60: Checking The Riding Sag Of The Shock Absorber

    9 SHOCK ABSORBER, LINK FORK Checking the riding sag of the shock absorber Measure dimension 6) of rear wheel unloaded. p. 57) 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 61: Adjusting The Riding Sag

    SHOCK ABSORBER, LINK FORK 9 Main work Loosen screw Turn adjusting ring until the spring is no longer under ten- sion. Hook wrench (90129051000) p. 319) Measure the overall spring length while the spring is not under tension. Tighten the spring by turning adjusting ring to measure­...

  • Page 62: Removing The Shock Absorber

    (ll!:!I (ll!:!I 9 SHOCK ABSORBER, LINK FORK Check the static sag of the shock absorber. p. 57) Check the riding sag of the shock absorber. (ll!:!I p. 58) Adjust the rebound damping of the shock absorber. p. 56) Remove the motorcycle from the lift stand. (ll!:!I p.

  • Page 63: Installing The Shock Absorber

    SHOCK ABSORBER, LINK FORK 9 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 fork pivot. Push the link fork back and secure it against falling over. Hold the shock absorber and remove screw@).
  • Page 64 9 SHOCK ABSORBER, LINK FORK Position link fork and mount fork pivot. Info Pay attention to flat area f). Mount and tighten nut Guideline I Nut, fork pivot M16x1.5 100 Nm (73.8 lbf ft) 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 65: Checking The Shock Absorber Linkage

    SHOCK ABSORBER, LINK FORK 9 Attach frame protector in area and position. Mount and tighten screws with the washers. Guideline 3 Nm (2.2 lbf ft) Screw, frame pro­ tector Mount the new cable ties. Finishing work Check the free travel of the foot brake lever. p.
  • Page 66 9 SHOCK ABSORBER, LINK FORK 303096-10 @» Check needle bearings for damage and wear. If there is damage or wear: Change the needle bearings. Check spacers and @ for damage and wear. If there is damage or wear: Change the spacers. Check the shaft seal rings for damage and wear.

  • Page 67: Servicing The Shock Absorber

    SHOCK ABSORBER, LINK FORK 9 Mount screw but do not tighten yet. Guideline M 1 0 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.

  • Page 68: Removing The Spring

    9 SHOCK ABSORBER, LINK FORK Remove the spring. p. 66) Disassemble the damper. p. 67) Disassemble the piston rod. p. 68) Disassemble the seal ring retainer. p. 69) Oqzi v� Check the damper. p. 71) CU> © Remove the heim joint. p.

  • Page 69: Disassembling The Damper

    SHOCK ABSORBER, LINK FORK 9 Remove the spring. Remove washer 9.14 Disassemblin the damper Preparatory work Remove the spring. p. 66) 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.

  • Page 70: Disassembling The Piston Rod

    9 SHOCK ABSORBER, LINK FORK Remove lock ring Info Check inner surface; do not scratch. If necessary, remove any burrs with sandpaper. Remove the piston rod. 804400-10 Remove adjusting ring @ with the clamping ring. Drain the oil. Remove compression adjuster Remove the spring and piston.

  • Page 71: Disassembling The Seal Ring Retainer

    SHOCK ABSORBER, LINK FORK 9 Main work Clamp the piston rod with the fork in a bench vise. Guideline Use soft jaws. Remove nut Remove washer Remove rebound shim stack@). • Info Guide the rebound shim stack onto a screwdriver and put them aside together.

  • Page 72: Changing The Pilot Bushing

    9 SHOCK ABSORBER, LINK FORK Main work Remove O-ring Remove rebound rubber B04414-10 Remove centering disk@) with spring Remove seal ring B04412-10 Remove washer from seal ring Remove washer Remove dust boot. 201407-10 9.17 Changing the pilot bushing Preparatory work Remove the spring.

  • Page 73: Checking The Damper

    SHOCK ABSORBER, LINK FORK 9 Slide the new pilot bushing onto the special tool. Pressing tool (T1504) p. 324) Position the pilot bushing in the seal ring retainer using the special tool. Pressing tool (T1504) p. 324) Support seal ring retainer @ with sleeve of the special tool.

  • Page 74: Removing The Heim Joint

    9 SHOCK ABSORBER, LINK FORK 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 75: Installing The Heim Joint

    SHOCK ABSORBER, LINK FORK 9 Place special tool underneath and press out heim joint (Dusing special tool G). Pressing tool (T1207S) (I!!:! p. 321) B04391-10 Position new heim joint and the special tool in the bench vise. Guideline Use soft jaws. Pressing tool (T1206) p.

  • Page 76: Assembling The Piston Rod

    9 SHOCK ABSORBER, LINK FORK Mount washer Position washer on seal ring 201409-10 Grease seal ring and mount with the washer facing down­ ward. I Lubricant (T14034) p. 304) Mount centering disk with spring C). 804413-10 Mount rebound rubber Grease the 0-ring groove. I Lubricant (T158) p.
  • Page 77 SHOCK ABSORBER, LINK FORK 9 Mount rebound washer with cut-out facing down. Mount compression shim stack with the smaller washers facing downward. G02057-10 Sand down piston Q) on both sides on a surface plate using 1200 grit sandpaper. Clean the piston. Mount the piston.

  • Page 78: Assembling The Damper

    9 SHOCK ABSORBER, LINK FORK Lubricate the thread of the piston rod. I Lubricant (T152) p. 304) Mount and tighten nut Q). Guideline I Nut, piston rod M12x1 40 Nm (29.5 lbf ft) G02060-10 9.23 Assemblin the damper Preparatory work Assemble the seal ring retainer.
  • Page 79 SHOCK ABSORBER, LINK FORK 9 Mount seal ring retainer and slide it under the ring groove. Mount lock ring • Info Do not scratch the inside surface. Pull out the piston rod until the seal ring retainer is flush with the lock ring.

  • Page 80: Bleeding And Filling The Damper

    9 SHOCK ABSORBER, LINK FORK Alternative 2 Warning Modifications to the sus­ Danger of accident pension setting may seriously alter the handling characteristic. Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components. Only make adjustments within the recom­...
  • Page 81 SHOCK ABSORBER, LINK FORK 9 Adjust the control lever as shown. ✓ Control lever External tank is set to Closed, @» Damper is set to Vacuum Oil reservoir set to Vacuum. Activate On/Off switch (D. ✓ The suction process begins. ✓...
  • Page 82 9 SHOCK ABSORBER, LINK FORK When the pressure gauge reaches the specified value, turn control lever Oil reservoir to Vacuum. Guideline 0 bar ✓ The vacuum gauge drops to the required value. 4 mbar When the vacuum gauge reaches the required value, turn control lever Oil reservoir to Equalize Pressure.

  • Page 83: Filling Damper With Nitrogen

    SHOCK ABSORBER, LINK FORK 9 Info The floating piston must be positioned at exactly this point when the rod is fully extended; otherwise, damage will occur during compression of the shock absorber. Remove the special tool. Remove adapter from connector of the vacuum pump.

  • Page 84: Installing The Spring

    9 SHOCK ABSORBER, LINK FORK Info Watch the pressure regulator dial. Ensure that the damper is filled to the specified pres­ sure. Screw the filling port shut with tap handle f). Close spigot and take the damper out of the special tool. Tighten the filling port screw.

  • Page 85: Checking The Heim Joint For Play

    SHOCK ABSORBER, LINK FORK 9 Alternative 2 Warning Modifications to the sus­ Danger of accident pension setting may seriously alter the handling characteristic. Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components. Only make adjustments within the recom­...

  • Page 86: Changing The Heim Joint

    9 SHOCK ABSORBER, LINK FORK 9.28 Changing the heim joint Preparatory work Raise the motorcycle with a lift stand. p. 12) Remove the shock absorber. p. 60) Main work Clamp the shock absorber into the vise. Guideline I Use soft jaws. Remove both collar bushings of the heim joint with a spe­...

  • Page 87: Checking The Link Fork

    Check the link fork for damage, cracking, and deformation. If the link fork exhibits damage, cracking, or deformation: Change the link fork. Info Always replace a damaged link fork. Repair of the link fork is not authorized by Husqvarna Motorcycles. K01115-01 Checking the fork bearing for lay 9.30 Preparatory work Raise the motorcycle with a lift stand.

  • Page 88: Removing The Link Fork

    9 SHOCK ABSORBER, LINK FORK Main work Move the link fork up and down. If there is detectable play: Change the fork bearing. p. 87) Move the link fork from one side to the other. If there is detectable play: Change the fork bearing.

  • Page 89: Changing The Fork Bearing

    SHOCK ABSORBER, LINK FORK 9 Remove fitting Lower the link fork. Remove the cable ties. Remove screws with the washers. Detach frame protector in area and take off. Remove nut Remove the swingarm pivot. Remove the link fork. 9.32 Changing the fork bearing Preparatory work Raise the motorcycle with a lift stand.
  • Page 90 9 SHOCK ABSORBER, LINK FORK Left fork bearing Remove collar bushings R02757-10 Remove bushing R02758-10 Remove shaft seal rings (D using a suitable tool. Remove stop disks Press out bearing using a suitable tool. Using a suitable tool, press in new bearing Position the stop disks Press in shaft seal rings (D .
  • Page 91 SHOCK ABSORBER, LINK FORK 9 Grease the shaft seal rings. I Long-life grease p. 304) Position the collar bushings with the shoulder facing inward. R02763-10 Right fork bearing Remove collar bushings R02760-10 Remove bushing @. R02761-10 Remove shaft seal rings using a suitable tool.

  • Page 92: Installing The Link Fork

    9 SHOCK ABSORBER, LINK FORK Mount bushing R02761-10 Grease the shaft seal rings. Long-life grease (ll!:!I p. 304) Position the collar bushings with the shoulder facing inward. R02764-10 Finishing work Install the link fork. p. 90) Install the rear wheel. p.
  • Page 93 SHOCK ABSORBER, LINK FORK 9 Lift the link fork. Mount and tighten fitting (D. Guideline Nut, angle lever to M14x1 .5 80 Nm (59 lbf ft) link fork 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 94: 10 Exhaust System

    10 EXHAUST SYSTEM Removing the manifold Warning The exhaust system gets very hot when the vehicle is driven. Danger of burns Allow the exhaust system to cool down before performing any work on the vehicle. Detach springs I Spring hook (5030501700004) p.

  • Page 95: Removing The Main Silencer

    EXHAUST SYSTEM Attach springs Spring hook (5030501700004) p. 319) Attach spring Spring hook (5030501700004) p. 319) Tighten screw Guideline Remaining screws, 25 Nm (18.4 lbf ft) chassis Removing 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 96: Installing The Main Silencer

    10 EXHAUST SYSTEM Position the main silencer. Mount screws with the washers, but do not tighten yet. Attach spring I Spring hook (5030501700004) p. 319) Tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis Changing the glass fiber yarn filling of the main silencer Warning The exhaust system gets very hot when the vehicle is driven.
  • Page 97 EXHAUST SYSTEM Main work Remove all the screws on the silencer cap. Take off silencer cap and O-ring Pull glass fiber yarn filling out of the silencer cap. Pull glass fiber yarn filling from the inner tube. Clean the parts that need to be reinstalled and check for damage.

  • Page 98: 11 Air Filter

    11 AIR FILTER Pull off the air filter box cover sideways in areas f) , and (D and take off toward the rear. of the air filter box in area f) and push for­ Attach catch ward. (D and Engage the air filter box cover in areas 11.3 Removing the air filter Note...

  • Page 99: Installing The Air Filter

    AIR FILTER 11 Main work Detach retaining tab Remove air filter with air filter support. Remove 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). Long-life grease p.
  • Page 100 11 AIR FILTER Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. I Air filter cleaner p. 304) • Info Only press the air filter to dry it, never wring it out. Oil the dry air filter with a high-grade air filter oil.

  • Page 101: Fuel Tank, Seat, Trim

    FUEL TANK, SEAT, TRIM 12.1 O�ening fuel tank 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 102: Removing The Right Side Cover

    12 FUEL TANK, SEAT, TRIM 12.3 Removing the right side cover Preparatory work Remove the air filter box cover. p. 96) Remove the seat. p. 100) Main work Detach side cover in area pull off sideways in area and take off toward the rear. Installing the right side cover Main work Attach side cover with the holding lugs...

  • Page 103: Mounting The Seat

    FUEL TANK, SEAT, TRIM Main work Remove screw Raise the rear of the seat, pull the 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.

  • Page 104: 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 105: Installing The Fuel Tank

    FUEL TANK, SEAT, TRIM Remove screws Remove screw with the rubber bushing. Pull both spoilers laterally off the radiator and take off the fuel tank upwards. 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. Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
  • Page 106 12 FUEL TANK, SEAT, TRIM Main work Check throttle cable routing. p. 48) Position the fuel tank and fit the two spoilers laterally to the radiator. Make sure that no cables or throttle cables are trapped or damaged. Attach the fuel tank breather hose to the fuel tank lid. Mount and tighten screw with the rubber bushing.

  • Page 107: 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 108: Changing The Fuel Pump

    12 FUEL TANK, SEAT, TRIM Guideline Maximum duration of the 3 min actuator test Check the fuel pressure with the fuel tank filler cap closed. Fuel pressure When the fuel pump is 3.3 ... 3. 7 bar (48 ... 54 psi) active If the specification is not reached: Open fuel tank filler cap.
  • Page 109 FUEL TANK, SEAT, TRIM Note 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 air filter box cover.
  • Page 110 12 FUEL TANK, SEAT, TRIM Pull out the fuel pump. Position the new fuel pump. Mount nut with gasket, but do not tighten yet. Mount and tighten screws Guideline I Screw, fuel pump 2.3 Nm (1.7 lbf ft) EJOT ✓ The connector points downwards.

  • Page 111: Changing The Fuel Filter

    FUEL TANK, SEAT, TRIM Grease O-rings G) lightly. Multi-purpose grease (00062010051) p. 305) • Info Make sure that no grease gets into the fuel connec­ tion. Mount fuel connection with gaskets but do not tighten yet. ✓ The cut-out is aligned to the nut Tighten nut Guideline Nut, fuel pump fas­...
  • Page 112 12 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 113 FUEL TANK, SEAT, TRIM Pull out the fuel pump. Remove hose clamps Remove fuel filter (D. R03473-10 Press locking mechanism @. Pull back fuel pump housing@). D05070-10 Change fuel screen Mount the fuel pump housing. D05071-10 Mount the new fuel filter (D. ✓...
  • Page 114 12 FUEL TANK, SEAT, TRIM Position the fuel pump. Mount nut with gasket, but do not tighten yet. Guideline Nut, fuel pump fas­ M12x1.75 15 Nm (11.1 lbf ft) tener Mount and tighten screws Guideline I Screw, fuel pump 2.3 Nm (1.7 lbf ft) EJOT ✓...

  • Page 115: Changing The Fuel Screen

    FUEL TANK, SEAT, TRIM Install the air filter box cover. (� p. 96) 12.12 Changing the fuel screen 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 116 12 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 effective exhaust extraction when starting or running the engine in an enclosed space.

  • Page 117: Mask, Fender 13

    MASK, FENDER 13 13.1 Removing front fender Preparatory work Remove the start number plate. p. 116) Main work Remove screws and @.Take off 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 118: 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 119: Wheels 14

    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 pressure of the tires all have a major impact on the handling characteristic of the motorcycle.

  • Page 120: Checking The Wheel Bearing For Play

    14 WHEELS 14.3 Checking the wheel bearing for �la� Preparatory work Raise the motorcycle with a lift stand. p. 12) Place a load on the rear of the vehicle. ✓ The front wheel is not in contact with the ground. Main work Move the front wheel from side to side.

  • Page 121: Checking Spoke Tension

    WHEELS 14 If the brake disc exhibits damage, cracking, or deforma­ tion: Change the front brake disc. p. 122) Change the rear brake disc. p. 126) Checkin spoke tension Warning Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary damage.

  • Page 122: Front Wheel

    14 WHEELS Info A loose spoke can unbalance the wheel and other spokes may loosen within a short period. If the spokes are too tight, they can break due to local overload. Check the spoke tension regularly, especially on a new motorcycle. Check for lateral and radial run-out of the rims.

  • Page 123: Installing The Front Wheel

    WHEELS 14 Warning Danger of accidents Damaged brake discs reduce the braking effect. Always lay the wheel down in such a way that the brake disc is not damaged. Hold the front wheel and remove the wheel spindle. Take the front wheel out of the fork.

  • Page 124: Changing The Front Brake Disc

    14 WHEELS Align the brake disc guard so that distance G) and equal in size. Mount and tighten screw Guideline Screw, front wheel M20x1.5 35 Nm (25.8 lbf ft) spindle Operate the hand brake lever several times until the brake linings are seated correctly against the brake disc.
  • Page 125 WHEELS 14 Main work Remove shaft seal rings Press out bearing (D using a suitable tool. Info Spacing tube can be pushed aside. Remove the spacing tube. Press out bearing using a suitable tool. Press in new bearing all the way using a suitable tool. Info Only press the bearing in via the outer bearing race otherwise the bearing will be damaged when it is...

  • Page 126: Rear Wheel

    14 WHEELS 14.8 Rear wheel 14.8.1 Removing the rear wheel Preparatory work Raise the motorcycle with a lift stand. p. 12) Main work Press the brake caliper onto the brake disc by hand in order to push back the brake piston. •...

  • Page 127: Installing The Rear Wheel

    WHEELS 14 14.8.2 Installing the rear wheel Warning Oil or grease on the brake discs reduces the braking effect. Danger of accidents 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 128: Changing The Rear Brake Disc

    14 WHEELS 14.8.3 Changing the rear brake disc Info If the brake discs are changed, the brake linings must also be changed. Preparatory work Raise the motorcycle with a lift stand. p. 12) Remove the rear wheel. p. 124) Main work Remove screws Remove the brake disc.

  • Page 129: Adjusting The Chain Tension

    WHEELS 14 14.8.5 Adjusting 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 130 14 WHEELS Main work Shift the transmission to the neutral position. Check the rear sprocket and engine sprocket for wear. If the rear sprocket or engine sprocket is worn: Change the drivetrain kit.(� p. 131) Info The engine sprocket, rear sprocket and chain should always be replaced together.
  • Page 131 WHEELS 14 Check the chain sliding guard for wear. If the lower edge of the chain pins is in line with, or below, the chain sliding guard: Change the chain sliding guard. Check that the chain sliding guard is firmly seated. If the chain sliding guard is loose: Tighten the screws on the chain sliding guard.

  • Page 132: Checking For Chain Dirt Accumulation

    14 WHEELS Check that the chain guide is firmly seated. If the chain guide is loose: Tighten the screws on the chain guide. Guideline Remaining 10 Nm (7.4 lbf ft) screws, chassis Finishing work Remove the motorcycle from the lift stand. p.

  • Page 133: Changing The Drivetrain Kit

    WHEELS 14 Main work Rinse off loose dirt with a soft jet of water. Remove old grease residue with chain cleaner. Chain cleaner (!el p. 304) After drying, apply chain spray. Off-road chain spray (!el p. 305) 400725-01 Finishing work Remove the motorcycle from the lift stand.
  • Page 134 14 WHEELS Remove engine sprocket Remove fittings 0). Take off the rear sprocket. Position the new rear sprocket. Mount and tighten the fit­ tings. Guideline Nut, rear 35 Nm (25.8 lbf ft) ® Loctite 2701 sprocket screw Slide new engine sprocket onto the countershaft.

  • Page 135: Changing The Rear Wheel Bearing

    WHEELS 14 Position the engine sprocket cover. Mount and tighten screw with the washer. Guideline Screw, clutch slave 10 Nm (7.4 lbf ft) cylinder Mount and tighten screw @. Guideline Screw, engine 20 Nm (14.8 lbf ft) sprocket cover Finishing work Remove the motorcycle from the lift stand.
  • Page 136 14 WHEELS Using a suitable tool, press bearing out from the inside to the outside. Check spacer washer @ for damage and wear. If the spacer washer is damaged or worn: Replace the spacer washer. Position spacer washer @. Press new bearing all the way in from the outside to the inside.

  • Page 137: Wiring Harness, Battery 15

    WIRING HARNESS, BATTERY 15 Changing the main fuse Warning Fire hazard Incorrect fuses overload the electrical system. Only use fuses with the required ampere value. Do not bypass or repair fuses. Caution Danger of burns The voltage regulator gets very hot when the vehicle is driven. Allow the voltage regulator to cool down before performing any work.

  • Page 138: Disconnecting The Negative Cable

    15 WIRING HARNESS, BATTERY Finishing work Mount the seat. p. 101) Install the air filter box cover. p. 96) 15.2 Disconnecting the negative cable of the 12 V battel')' Preparatory work Press and hold the kill switch � while the engine is idling until the engine stops.

  • Page 139: Removing The 12 V Battery

    WIRING HARNESS, BATTERY 15 Removing the 12 V batte� Warning Risk of injury 12 V batteries contain harmful substances. Keep 12 V batteries out of the reach of children. Keep sparks and open flames away from 12 V batteries. Only charge 12 V batteries in well-ventilated rooms. Maintain a minimum clearance from inflammable materials when charging 12 V batteries.

  • Page 140: Installing The 12 V Battery

    15 WIRING HARNESS, BATTERY Installing the 12 V batte� Main work Position the 12 V battery in the battery compartment with the terminals facing forward, and secure with holding bracket 112 V battery (HJTZ5S-FP) (� p. 284) Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft)
  • Page 141 WIRING HARNESS, BATTERY 15 Note 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. Info Even when there is no load on the 12 V battery, it discharges steadily. The charging level and the method of charging are very important for the service life of the 12 V battery.

  • Page 142: Checking The Charging Voltage

    15 WIRING HARNESS, BATTERY Finishing work Connect the negative cable of the 12 V battery. p. 136) Mount the seat. p. 101) Install the air filter box cover. p. 96) 15.7 Checking the charging volta e Condition The 12 V battery must be fully functional and completely charged.

  • Page 143: Checking The Capacitor

    WIRING HARNESS, BATTERY 15 Main work Measure the current between 12 V battery ground (-) and the negative cable. • Info The value of the open-circuit current applies only to vehicles in the original condition, i.e., without addi­ tional power consumers. <...

  • Page 144: Checking The Starter Relay

    15 WIRING HARNESS, BATTERY Install the capacitor. 15.10 Checking the starter relay Preparatory work Press and hold the kill switch C><:l while the engine is idling until the engine stops. Remove the air filter box cover. p. 96) Remove the seat. p.

  • Page 145: Brake System 16

    BRAKE SYSTEM 16 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 f). Minimum thickness 2:: 1 mm (2:: 0.04 in) If the minimum thickness is less than specified: Change the front brake linings.
  • Page 146 16 BRAKE SYSTEM Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container.

  • Page 147: Hand Brake Lever

    BRAKE SYSTEM 16 Add brake fluid up to level f) . Guideline Level f) (brake fluid level 5 mm (0.2 in) below reservoir rim) Brake fluid DOT 4 / DOT 5.1 p. 302) Position cover with membrane Mount and tighten screws Info Clean up overflowed or spilled brake fluid immediately with water.

  • Page 148: Checking The Front Brake Fluid Level

    16 BRAKE SYSTEM 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. The range of adjustment is limited. Only turn the adjusting screw by hand, and do not use force.
  • Page 149 BRAKE SYSTEM 16 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 150: Changing The Front Brake Fluid

    16 BRAKE SYSTEM Changing the front brake fluid 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 151 BRAKE SYSTEM 16 Open shut-off valve -4!) • Info Follow the instructions in the Owner's Manual of the bleeding device. Ensure that the filling pressure is set on pressure gauge f). Correct the filling pressure on pressure regulator if neces­ sary.

  • Page 152: Checking The Brake Linings Of The Rear Brake

    16 BRAKE SYSTEM Checking the brake linings of the rear brake Warning Worn-out brake linings reduce the braking effect. Danger of accidents Ensure that worn-out brake linings are replaced immediately. Check the brake linings for minimum thickness I Minimum thickness I �...
  • Page 153 BRAKE SYSTEM 16 Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container.

  • Page 154: Checking The Free Travel Of Foot

    16 BRAKE SYSTEM Add brake fluid to level f). I Brake fluid DOT 4 / DOT 5.1 p. 302) Mount and tighten screw cap with membrane and the O-ring. Info Clean up overflowed or spilled brake fluid immediately with water. Checking the free travel of foot brake lever Warning The brake system fails in the event of overheating.

  • Page 155: Checking The Rear Brake Fluid Level

    BRAKE SYSTEM 16 Detach spring Loosen nut and, with push rod @t, turn it back until you have maximum free travel. To adjust the basic position of the foot brake lever to individ­ ual requirements, loosen nut and turn screw accord­...

  • Page 156: Adding Rear Brake Fluid

    16 BRAKE SYSTEM Main work Stand the vehicle upright. Check the brake fluid level in level viewer If the brake fluid level has dropped below the marking fj: Add rear brake fluid. p. 154) Addin rear brake fluid Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail.

  • Page 157: Changing The Rear Brake Fluid

    BRAKE SYSTEM 16 Main work Stand the vehicle upright. Remove screw cap with membrane f!} and the O-ring. Add brake fluid up to the mark f). Brake fluid DOT 4 / DOT 5.1 p. 302) Mount and tighten the screw cap with the membrane and O­ ring.
  • Page 158 16 BRAKE SYSTEM Mount bleeder cover I Bleeder cover (00029013006) p. 306) Connect the bleeding device. I Bleeding device (00029013100) p. 306) Open shut-off valve • Info Follow the instructions in the Owner's Manual of the bleeding device. Ensure that the filling pressure is set on pressure gauge 6). Correct the filling pressure on pressure regulator G) if neces­...
  • Page 159 BRAKE SYSTEM 16 Check the foot brake lever for a firm pressure point.

  • Page 160: 17 Engine

    17 ENGINE 17.1 Removing the engine Preparatory work Raise the motorcycle with a lift stand. p. 12) Remove the engine guard. p. 52) Drain the coolant. p. 255) Remove the air filter box cover. p. 96) Remove the seat. p. 100) Remove the right side cover.
  • Page 161 ENGINE 17 Push back hose clamp and pull off the vent hose. Remove screw Loosen screw (D. Repeat these steps on the opposite side. Pivot the subframe up and secure it. Remove springs @. Spring hook (5030501700004) p. 319) Remove screw Take off the manifold.
  • Page 162 17 ENGINE Remove screws Take off the engine braces. Remove the cable ties. Remove the cable clamps and expose the cable. Disconnect plug-in connector Ci). Disconnect plug-in connectors Expose the cable.
  • Page 163 ENGINE 17 Disconnect plug-in connector Push back protection cap Unplug the connector. Loosen hose clip Pull the radiator hose. Loosen hose clips Pull the radiator hoses. Disconnect spark plug connector �.
  • Page 164 17 ENGINE Remove screw with the washer. Remove screw Qi). Take off the engine sprocket cover. Remove screws G). Take off the clutch slave cylinder with the gasket and hang it to the side. Info Do not kink the clutch line. Do not activate the clutch lever while the slave cylin­...
  • Page 165 ENGINE 17 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. Push back protection cap � and remove the nut. Hang the positive cable to the side.

  • Page 166: Installing The Engine

    17 ENGINE Remove nut �- Remove the swingarm pivot. Carefully pull the link fork back, and secure it. 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.
  • Page 167 ENGINE 17 Position the link fork. Mount the fork pivot. Mount and tighten nut Guideline Nut, fork pivot I M16x1 .5 I 100 Nm (73.8 lbf ft) I Position the linkage lever. Mount and tighten fitting Guideline Nut, linkage lever to M14x1 .5 80 Nm (59 lbf ft) angle lever...
  • Page 168 17 ENGINE Position the shift lever. Mount and tighten screw @ with washers. Guideline Screw, shift 14 Nm (10.3 lbf ft) ® lever Loctite ™ Slide on the engine sprocket with the collar facing the engine. Mount screw G) with the washer but do not tighten yet. Guideline Screw, engine 60 Nm (44.3 lbf ft)
  • Page 169 ENGINE 17 Position the engine sprocket cover. Mount and tighten screw with the washer. Guideline Screw, clutch slave 10 Nm (7.4 lbfft) cylinder Mount and tighten screw Guideline Screw, engine 20 Nm (14.8 lbf ft) sprocket cover Plug in spark plug connector 41). Mount the radiator hoses.
  • Page 170 17 ENGINE Join plug-in connector of the gear position sensor. Join plug-in connectors Gi) of the alternator. Join plug-in connector G) of the crankshaft speed sensor. Route the cable without tension. Route the cable without tension and secure with cable clips and cable ties.

  • Page 171: Mount And Tighten Screw

    ENGINE 17 Position the engine braces. Mount and tighten screws �. Guideline Screw, engine 25 Nm (18.4 lbf ft) ® Loctite brace ™ Tighten screws Guideline Engine carrying 60 Nm (44.3 lbf ft) screw Position the manifold. Mount screw .. but do not tighten yet. Guideline Remaining screws, 25 Nm (18.4 lbf ft)
  • Page 172 17 ENGINE Guideline Screw, sub­ 30 Nm (22.1 lbf ft) ® frame Loctite 2701 Repeat the operation on the opposite side. Mount the vent hose and position hose clamp Plug in the connector. Mount protection cap �. Position and tighten hose clip Attach frame protector in area and position.
  • Page 173 Install the engine guard. p. 52) Perform the initialization run. p. 278) 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. 262) Check the coolant level.

  • Page 174: Engine Disassembly

    17 ENGINE 17.3 Engine disassembl� 17.3.1 Preparations Mount the special tool on the engine assembly stand. Holder and fitting for work stand (79429002000) (ll!:!l p. 317) Engine assembly stand (80329001000) (ll!:!l p. 318) Mount the engine on the special tool. Info Work with an assistant or a motorized hoist.

  • Page 175: Removing The Clutch Push Rod

    ENGINE 17 Remove screw plug with the short oil screen. Removing the clutch push rod 17.3.3 Remove clutch push rod 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. Lock ring plier (51012011000) (�...

  • Page 176: Removing The Starter Motor

    17 ENGINE 17.3.5 Removing the starter motor Remove screws and take the starter motor. 17.3.6 Removing the spark plug Remove the spark plug using the special tool. I Spark plug wrench with link (77229172000) p. 315) D04999-10 17.3.7 Removing the valve cover Remove screws Take off the valve cover with the valve cover seal.

  • Page 177: Removing The Alternator Cover

    ENGINE 17 17.3.8 Removing the alternator cover Remove screws Take off the alternator cover. Take off alternator cover gasket @. 17.3.9 Positioning the engine at ignition top dead center Align camshaft marking with the center of the retaining bracket G) on the cylinder head. Remove screw with washer.

  • Page 178: Removing The Timing Chain Tensioner

    17 ENGINE 17.3.10 Removing the timing chain tensioner Remove screw with the washer and spring. Remove screws Take off the chain adjuster with the gasket. 17.3.11 Removing the camshaft Remove screws Take off camshaft retaining bracket Pull the camshaft out of the bearing seats. Take the timing chain from the camshaft gear.

  • Page 179: Removing The Cylinder Head

    ENGINE 17 17 .3.12 Removing the cylinder head Remove screw Unscrew screws in a crisscross pattern and remove. Remove the cylinder head. Take off dowels (D . Remove cylinder head gasket 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.

  • Page 180: Removing The Rotor

    17 ENGINE Remove timing chain guide rail from the top. 17.3.14 Removing the rotor Remove nut with the spring washer. Mount special tool on the rotor. I Extractor (79229032044) (� p. 316) Hold it tight using the special tool and pull off the rotor by turning the screw in.

  • Page 181: Removing Suction Pump

    ENGINE 17 Take off the timing chain. Info If the timing chain is to be reused, mark the direction of travel. 17.3.16 Removing suction pump Remove screws Take off oil pump cover of the suction pump. Remove external rotor and internal rotor Take off pin Remove O-ring (D.

  • Page 182: Removing The Water Pump Cover

    17 ENGINE 17.3.18 Removing the water pump cover Remove screws Take off the water pump cover. Take off the water pump cover seal. 17.3.19 Removing the clutch cover Remove screws Take off the clutch cover. Info If work is to be performed on the water pump, unscrew the nut of the water pump impeller.
  • Page 183 ENGINE 17 Take off spring washer Take off pretension ring Remove clutch pressure cap Remove clutch disc pack completely. Remove clutch throw-out@. Remove special tool Locking screw (113080802) (IUI p. 307)

  • Page 184: Removing The Clutch Basket

    17 ENGINE 17.3.21 Removing the clutch basket Lock the clutch basket and primary gear wheel using special tool I Gear segment (80029004000) (IUI p. 318) Remove nut Info LH thread! Bend up the lock washer. Hold the inner clutch hub with the special tool. I Holding wrench (51129003000) (IUI p.

  • Page 185: Removing The Starter Idler Gear

    ENGINE 17 17 .3.23 Removing the starter idler gear Take off starter idler gear 17.3.24 Removing the force pump Remove lock ring Take off washer f!} . Remove oil pump idler gear (D. Remove lock ring Take off washer Take off oil pump gear wheel (i). Remove pin Remove screws @.

  • Page 186: Removing The Shift Shaft

    17 ENGINE Remove internal rotor and external rotor Remove the pin. Push oil pump shaft inward and take it out of the engine from the ignition side. 17.3.25 Removing the shift shaft Push sliding plate away from the shift drum locating unit. Remove shift shaft @ with the washer.

  • Page 187: Primary Gear Wheel, Removing

    ENGINE 17 17.3.28 primary gear wheel, removing Insert special tool into the crankshaft. Protection cap (75029090000) p. 314) Mount special tool Puller (75029021000) p. 313) Hold the special tool firm and pull off the primary gear wheel by turning the screw in. Remove the special tools.

  • Page 188: Removing The Shift Rails

    17 ENGINE Mount special tool with suitable screws. Puller (79229048000) p. 316) • Info Use the 794 drill hole. Tilt the left section of the engine case upward and remove the fitting of the engine fixing arm. Pull off the section of the engine case. Info Ensure that washer is not damaged.

  • Page 189: Removing The Shift Drum

    ENGINE 17 17.3.32 Removing the shift drum Swing shift forks to one side. • Info Do not misplace the shift rollers. Remove shift drum@. 17.3.33 Removing the shift forks Take shift forks out of the shift grooves. Info Do not misplace shift rollers Removing the transmission shafts 17 .3.34 Remove 0-ring...

  • Page 190: Removing The Crankshaft

    17 ENGINE Pull both transmission shafts out of the bearing seats together. Info Make sure not to misplace the washers. 17.3.35 Removing the crankshaft Remove crankshaft • Info Ensure that washer is not damaged. Take off the right section of the engine case. 17.4 Working on individual parts 17.4.1...
  • Page 191 ENGINE 17 Main work Remove all remaining dowels. Remove oil nozzle Remove screw @ and take off the bearing retainers. Remove the bearing retainer from main shaft bearing countershaft bearing and shift drum bearing Remove any remnants of sealing compound and clean the section of the engine case thoroughly.

  • Page 192: Working On The Left Section Of The Engine Case

    17 ENGINE Guideline Oil nozzle, pis­ 2 Nm (1.5 lbf ft) ® ton cooling Loctite ™ Blow compressed air through all oil channels and check that they are clear. H01549-01 Finishing work Install the oil pressure control valve. p. 192) 17.4.2 Working on the left section of the engine case Remove all remaining dowels.

  • Page 193: Oil Pressure Control Valve, Removing

    ENGINE 17 Info When pressing in, ensure that the section of the engine case lies flat in order prevent damage. Only press the bearings in using the outer bearing race; otherwise, the bearings will be damaged when they are pressed in. After the section of the engine case has cooled, check that the bearings are firmly seated.

  • Page 194: Spring Length Of The Oil Pressure Control Valve, Checking

    17 ENGINE 17.4.4 spring length of the oil pressure control valve, checking Preparatory work Remove the oil pressure control valve. p. 191) Main work Measure the spring length of the oil pressure control valve. Oil pressure control valve Minimum length of pres- 22.1 mm (0.87 in) sure spring If the measured value does not meet specifications:...

  • Page 195: Installing The Water Pump

    ENGINE 17 Remove balancer shaft Remove shaft seal ring D04962-10 Press out water pump shaft bearing toward the inside with an appropriate tool. Info Suitably support the clutch cover while pressing it out. D04963-10 Installing the water pump 17.4.8 Press bearing of the water pump shaft up to the stop with a suitable tool.

  • Page 196: Removing The Timing Chain

    17 ENGINE Mount special tool on the water pump shaft. I Protection cap (90129005000) p. 319) 310055-10 Mount balancer shaft • Info Be careful not to damage the shaft seal rings. Remove the special tool. I Protection cap (90129005000) p. 319) Mount water pump impeller Mount and tighten nut (D.

  • Page 197: Removing The Crankshaft Bearing Inner Race

    ENGINE 17 Warm up new timing chain sprocket and immediately push it onto the crankshaft. Guideline 1180 °c (356 °F) 17.4.11 Removing the crankshaft bearing inner race Fix the crankshaft in the vise. Guideline Use soft jaws. Warm up special tool Guideline 1150 °c (302 °F) Puller (58429037043)

  • Page 198: Changing The Connecting Rod, Conrod Bearing, And Crank Pin

    17 ENGINE Info After replacing the crankshaft bearings, the crankshaft end play must be measured. Finishing work Measure the crankshaft end play. p. 198) 17.4.13 Changing the connecting rod, conrod bearing, and crank pin Main work Position the crankshaft with special tool in the press.
  • Page 199 ENGINE 17 Mount new connecting rod (D. Info Thoroughly lubricate the bearing. 310044-10 Position special tools @ and on the press. Crankshaft pressing tool (75029047000) p. 313) Insert for crankshaft pressing tool (79429008000) p. 317) Insert the crankweb with the connecting rod and bearing. Position the second crankweb.

  • Page 200: Checking Crankshaft Run-Out At Bearing Pin

    17 ENGINE 17.4.14 Checking crankshaft run-out at 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 on � 0.16 mm (� 0.0063 in) bearing pin If the crankshaft run-out at the bearing pin is larger than the specification: Align the crankshaft.

  • Page 201: Cylinder - Nikasil ® - Coating

    ENGINE 17 17.4.16 Cylinder - Nikasil ® - coating ® Nikasil is a surface protection layer for a coating procedure developed by Mahle. The name is derived from the two materials used in this procedure - a layer of nickel into which is embedded the particularly hard silicone carbide.

  • Page 202: Checking/Measuring The Piston

    17 ENGINE 17.4.18 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 :S 0.08 mm (:S 0.0031 in) ance I Feeler gauge (59029041100) (IUI p.

  • Page 203: Checking The Piston Ring End Gap

    ENGINE 17 Measure the piston at the piston skirt, at right angles to the piston pin, at a distance f) . Guideline Distance f) 7 mm (0.28 in) Piston - diameter Size I 94.93 ... 94.96 mm (3.7374 ... 3.7386 in) Size II 94.94 ...

  • Page 204: Checking The Oil Pumps

    17 ENGINE Guideline Piston/cylinder - mounting clearance Size I 0.040 ... 0.082 mm (0.00157 ... 0.00323 in) Size II 0.043 ... 0.085 mm (0.00169 ... 0.00335 in) Wear limit 0.120 mm (0.00472 in) 17.4.21 Checking the oil pumps Info The following steps apply to both oil pumps. Use special tool to measure the play between the exter­...

  • Page 205: 17 .4.23 Assembling The Autodecompressor

    ENGINE 17 Pull autodecompression shaft 4!} out of the camshaft. 304674-10 ·� Release and remove autodecompression spring fi). Info Autodecompression weight cannot be taken off. 304675-10 17 .4.23 Assembling the autodecompressor Insert long flange of the autodecompression spring in the hole, push the autodecompression spring over bearing bolt 4!} and hook it into autodecompression weight fi).

  • Page 206: Checking Camshaft

    17 ENGINE 17.4.24 Checking camshaft Check the camshaft for damage and wear. If there is damage or wear: Change the camshaft. If the camshaft surface is damaged, check the oil supply of the camshaft and the rocker arm. Measure the cams of the camshaft. Camshaft - cam height Exhaust 33.10 ...

  • Page 207: Removing The Rocker Arm

    ENGINE 17 Check timing chain for damage and wear. If there is damage or wear: Replace the timing chain. Check the timing chain links for smooth operation. Let the timing chain hang down freely. The chain links no longer align in a straight line: Replace the timing chain.

  • Page 208: Changing The Camshaft Bearing

    17 ENGINE •• Mark the valves corresponding to their installation position. Info £'SI £ v -.ii • Place the valves in a box corresponding to their instal­ • lation position and label them. 200189-10 17.4.28 Changing the camshaft bearing Condition The valves are removed and the exhaust flange is removed.

  • Page 209: Checking The Valves

    ENGINE 17 Press the small camshaft bearing in until flush using special tool Pressing tool (75029044020) (IUI p. 313) D04987-10 Press the large camshaft bearing in all the way using special tool Pressing tool (75029044010) (IUI p. 313) D04988-10 17 .4.29 Checking the valves Info The valve stem is hard-chrome plated;...

  • Page 210: Checking Valve Springs

    17 ENGINE 17.4.30 Checking valve springs Check the valve springs for breakage and wear (visual check). If the valve spring is broken or worn: Change the valve spring. Measure the length of the valve springs. Valve spring Minimum length, intake 40.

  • Page 211: Checking The Rocker Arm Shafts

    ENGINE 17 Using a straightedge and the special tool, check the sealing area of the cylinder for distortion. Feeler gauge (59029041100) p. 311) Cylinder/cylinder head - :;; 0.10 mm (:;; 0.0039 in) sealing area distortion If the measured value does not meet specifications: Change the cylinder head.

  • Page 212: Installing The Rocker Arm

    17 ENGINE Pretension the valve springs using the special tool. Valve spring mounter (59029019000) p. 310) Insert for valve spring lever (77029041200) p. 314) Mount the valve keys. Info When mounting the valve keys, check that they are seated correctly; preferably, fix the valve keys to the valve with a little grease.

  • Page 213: Checking The Clutch

    ENGINE 17 Guideline Screw, rocker arm 15 Nm (11.1 lbf ft) bearing Remove special tool Feeler gauge (590290411 00) (� p. 311) Repeat these operations on the rocker arm of the exhaust side. 17.4.36 Checking the clutch 304690-10 Check clutch throw-out for damage and wear.

  • Page 214: Checking The Shift Mechanism

    17 ENGINE If there is damage or wear: Change the clutch center. Check damping rubber pieces for damage and wear. If there is damage or wear: Change the damping rubber pieces. Check inner clutch hub for damage and wear. If there is damage or wear: Change the inner clutch hub.
  • Page 215 ENGINE 17 If there is damage or wear: Change the shift fork. Check shift grooves G) of shift drum for wear. If the shift groove is worn: Change the shift drum. Check the seat of shift drum in bearing If the shift drum is not seated correctly: Change the shift drum and/or the bearing.

  • Page 216: Preassembling The Shift Shaft

    17 ENGINE 17.4.38 Preassembling the shift shaft Secure the short end of the shift shaft in the bench vise. Guideline I Use soft jaws. Mount sliding plate with the guide pin facing downward and put the guide pin on the shift quadrant. Mount pressure spring Slide on spring guide (D, push return spring with the...

  • Page 217: Disassembling The Countershaft

    ENGINE 17 17 .4.40 Disassembling the countershaft D04978-10 Secure the countershaft in the bench vise with the toothed end facing downward. Guideline I Use soft jaws. Remove stop disk and first-gear idler gear Remove needle bearing and stop disk Remove the fifth-gear sliding gear and lock ring (D.
  • Page 218 17 ENGINE D04979-10 Check needle bearings for damage and wear. If there is damage or wear: Change the needle bearings. Check the pivot points of main shaft and countershaft for damage and wear. If there is damage or wear: Change the main shaft and/or countershaft. Check the tooth profiles of main shaft and countershaft for damage and wear.

  • Page 219: Assembling The Main Shaft

    ENGINE 17 Check stop disks @ for damage and wear. If there is damage or wear: Change the stop disks. Use new lock rings in every repair. Check distance sleeve� for damage and wear. If there is damage or wear: Change distance sleeve.

  • Page 220: 17.4.43 Assembling The Countershaft

    17 ENGINE 17.4.43 Assembling the countershaft Info Use new lock rings with every repair. Preparatory work Lubricate all parts carefully before assembling. Check the transmission. p. 215) Main work D04978-11 Secure the countershaft in the bench vise with the toothed end facing downward. Guideline Use soft jaws.

  • Page 221: Checking The Starter Drive

    ENGINE 17 17.4.44 Checking the starter drive " 0 - • 310086-10 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. If there is damage or wear: Change the torque limiter.

  • Page 222: Checking The Freewheel

    17 ENGINE 17.4.45 Checking the freewheel Insert freewheel gear into primary gear wheel turning the primary gear wheel clockwise; do not wedge! Check the locking action of freewheel gear The primary gear wheel cannot be turned clockwise or does not lock counterclockwise: Change the freewheel.

  • Page 223: Engine Assembly

    ENGINE 17 Mount spreader ring 304705-10 Ensure that all the holding lugs of the expansion ring pass through slots of the freewheel and engage in groove G) of the primary gear wheel. 17.5 Engine assembl}' 17.5.1 Installing the crankshaft Position the right section of the engine case in the engine assembly stand.

  • Page 224: Installing The Transmission Shafts

    17 ENGINE 17.5.2 Installing the transmission shafts Lubricate all bearings. Slide both transmission shafts into the bearing seats. Info Make sure not to misplace the washers. Mount lock ring 17.5.3 Installing the shift forks Lubricate all parts thoroughly. Mount shift fork in the upper shift groove of the main •-�- shaft.

  • Page 225: Installing The Shift Drum

    ENGINE 17 17.5.4 Installing the shift drum Push shift drum into the bearing seat. Put shift forks in the shift drum. Info Do not misplace the shift rollers. 17.5.5 Installing the shift rails Install shift rails together with upper springs lower springs.

  • Page 226: Installing The Freewheel Gear

    17 ENGINE Mount the left section of the engine case. If necessary, strike lightly with a rubber mallet. Info Do not use the screws to pull the two sections of the engine case together. Mount screws but do not tighten yet. Guideline Screw, engine case M6x60...

  • Page 227: Installing The Locking Lever

    ENGINE 17 17.5.9 Installing the locking lever Mount locking lever with the washer, sleeve and spring. Mount and tighten screw Guideline Screw, locking 6 Nm (4.4 lbf ft) ® lever Loctite ™ 17 .5.10 Installing the shift drum locating unit Push away locking lever from the shift drum locating unit and position the shift drum locating unit...

  • Page 228: Installing The Starter Idler Gear

    17 ENGINE Position the oil pump cover ✓ The marking faces up. Mount and tighten screws Guideline Screw, pressure 10 Nm (7.4 lbf ft) ® Loctite pump cover ™ Insert pin (D. Position oil pump gear wheel Position washer Mount lock ring Mount oil pump idler gear Gi).

  • Page 229: Installing The Torque Limiter

    ENGINE 17 17.5.14 Installing the torque limiter Position the washer. Mount the torque limiter. Mount and tighten screw with the washer. Guideline Screw, torque 10 Nm (7.4 lbf ft) ® governor Loctite ™ 17 .5.15 Installing the clutch basket Mount collar bushing and both needle bearings@.

  • Page 230: Installing The Clutch Discs

    17 ENGINE Lock the clutch basket and primary gear wheel using special tool@). I Gear segment (80029004000) (IUI p. 318) Mount and tighten nut Guideline Nut, primary M20LHx1.5 100 Nm (73.8 lbf ft) gear wheel ® Loctite ™ Position crankshaft to TDC and lock with special tool �. I Locking screw (113080802) (IUI p.
  • Page 231 ENGINE 17 Position clutch pressure cap (i}. Mount pretension ring with marking Top facing up. Position spring washer Position spring retainer with marking I. Mount screws and tighten in a crisscross pattern. Guideline Screw, clutch spring 6 Nm (4.4 lbf ft) retainer...

  • Page 232: Installing The Clutch Cover

    17 ENGINE Using a straightedge and the special tool, check the spring washer for distortion. I Feeler gauge (59029041100) p. 311) Spring washer distortion 0 ... 0.10 mm (0 ... 0.0039 in) If the specified value is not reached: Remove screws and mount the spring retainer with marking II.

  • Page 233: Installing The Water Pump Cover

    ENGINE 17 Mount the clutch cover. Mount screws but do not tighten yet. Guideline Screw, clutch cover M6x25 10 Nm (7.4 lbf ft) Mount screw but do not tighten yet. Guideline Screw, clutch cover M6x55 I 10Nm(7.4Ibf ft) Mount screw and tighten all screws in a crisscross pat­...

  • Page 234: Installing The Suction Pump

    17 ENGINE 17.5.20 Installing the suction pump Oil the internal rotor and external rotor before mounting. Insert 0-ring Position pin Mount internal rotor and external rotor ✓ The rounded sides of the external rotor face the engine case. D04904-11 Position the oil pump cover Mount and tighten screws (D.

  • Page 235: 17.5.22 Installing The Rotor

    ENGINE 17 Thread in timing chain tensioning rail from above. Mount and tighten screw Guideline Screw, timing 10 Nm (7.4 lbf ft) ® Loctite ™ chain tension- ing rail 17.5.22 Installing the rotor Mount the woodruff key. Mount the rotor. Mount and tighten nut with the spring washer.
  • Page 236 17 ENGINE Mount timing chain guide rail from above. ✓ The timing chain guide rail engages in recess f). ✓ The holding lug engages in the recess (9. Info This step is illustrated with the rotor removed for a clearer view. Mount cylinder base gasket Info Ensure that locating pins...

  • Page 237: Installing The Cylinder Head

    ENGINE 17 Position the piston ring lock. Insert the special tool and press it with force towards the pis­ ton. Turn the special tool clockwise, thereby pushing the piston ring lock into the groove. Insertion for piston ring lock (77329030100) p.

  • Page 238: Installing The Camshaft

    17 ENGINE Put the cylinder head in place. Mount screws with the washers and tighten them in a crisscross pattern. Guideline Screw, cylinder M10x1 .25 1st stage 10 Nm (7.4 lbf ft) head 2nd stage 30 Nm (22.1 lbf ft) 3rd stage 50 Nm (36.9 lbf ft) Collar and thread oiled...

  • Page 239: Checking The Valve Clearance

    ENGINE 17 Position the timing chain tensioner with the gasket. Mount and tighten screws Guideline Screw, timing chain 10 Nm (7.4 lbf ft) tensioner Mount and tighten screw plug with washer spring Guideline Plug, timing chain 8 Nm (5.9 lbf ft) tensioner 17 .5.27 Checking the valve clearance...

  • Page 240: 17.5.28 Adjusting The Valve Clearance

    17 ENGINE Remove the special tool. I Locking screw (113080802) p. 307) Mount and tighten screw with washer. Guideline Screw plug, locking 10 Nm (7.4 lbf ft) screw 17.5.28 Adjusting the valve clearance Main work Remove the timing chain tensioner. p.

  • Page 241: Installing The Valve Cover

    ENGINE 17 17.5.30 Installing the valve cover Position gasket of the engine vent in the valve cover. D05026-10 Position the valve cover seal. Position the valve cover. Mount and tighten screws@. Guideline Screw, valve cover 10 Nm (7.4 lbf ft) 17.5.31 Installing the spark plug Mount and tighten the spark plug using the special tool.

  • Page 242: Installing The Oil Filter

    17 ENGINE 17.5.33 Installing the oil filter Tilt the motorcycle to one side and fill the oil filter housing to about 1 /3 full with engine oil. Insert oil filter into the oil filter housing. Oil the O-ring of the oil filter cover. Mount oil filter cover@.

  • Page 243: Removing The Engine From The Engine Assembly Stand

    ENGINE 17 Position the long oil screen with the O-rings on a pin wrench. Position the pin wrench through the drilled hole of the screw plug in the opposite section of the engine case. Push the oil screen all the way into the engine case. Mount and tighten screw plug with the O-ring.

  • Page 244: 18 Clutch

    18 CLUTCH Checking/correcting the fluid level of the h draulic clutch 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 245: Changing The Hydraulic Clutch Fluid

    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 246: Checking The Clutch

    18 CLUTCH Now inject the liquid into the system 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 247 CLUTCH Detach spring Remove screws Take off the clutch cover with the gasket. Loosen screws in a crisscross pattern and remove them. Take off spring retainer Take off spring washer Take off pretension ring (D.
  • Page 248 18 CLUTCH Take off clutch pressure cap Take off clutch throw-out with clutch push rod «&. Remove sleeves Remove clutch discs completely. Bend up the lock washer. Hold the inner clutch hub with the special tool. Loosen I Holding wrench (51129003000) (IUI p.
  • Page 249 CLUTCH Take off inner clutch hub and washer Info The washer usually sticks to the inner clutch hub. Take off clutch basket Take off needle bearing� and collar sleeve Info The needle bearing and collar sleeve may be in the clutch basket.
  • Page 250 18 CLUTCH If there is damage or wear: Change the spring washer. Check the contact surface of clutch pressure cap @ for damage and wear. If there is damage or wear: Change the clutch pressure cap. Check clutch center for damage and wear. If there is damage or wear: Change the clutch center.
  • Page 251 CLUTCH Mount clutch basket ✓ Turn clutch basket until the gear teeth mesh with the oil pump gear wheel. Mount washer and inner clutch hub 41). Position the new lock washer and mount nut Tighten the nut, holding the inner clutch hub with a special tool. Guideline Nut, inner clutch hub M18x1 .5...
  • Page 252 18 CLUTCH Mount clutch throw-out with clutch push rod ✓ The rounded side of the clutch push rod faces the clutch. Position clutch pressure cap @. Mount pretension ring Q) with marking Top facing up. Position spring washer Position spring retainer with marking I.
  • Page 253 CLUTCH Using a straightedge and the special tool, check the spring washer for distortion. Feeler gauge (59029041100) p. 311) Spring washer distortion 0 ... 0.10 mm (0 ... 0.0039 in) If the specified value is not reached: Remove screws and mount the spring retainer with marking II.
  • Page 254 18 CLUTCH Place vehicle in upright position and rest on the plug-in stand. R03480-10 Finishing work Check the engine oil level. p. 262)

  • Page 255: Water Pump, Cooling System 19

    WATER PUMP, COOLING SYSTEM 19 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 256: 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 257: Draining The Coolant

    WATER PUMP, COOLING SYSTEM 19 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 258: Changing The Coolant

    19 WATER PUMP, COOLING SYSTEM Main work 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) Distance above the radi- ator fins Coolant 1.20 I Coolant p.

  • Page 259: Changing The Coolant Pipe

    WATER PUMP, COOLING SYSTEM 19 Main work Position the motorcycle upright. Place an appropriate container under the water pump cover. Remove screw Take off radiator cap fj. Completely drain the coolant. Mount and tighten screw with a new seal ring. Guideline Screw, water pump 10 Nm (7.4 lbf ft)
  • Page 260 19 WATER PUMP, COOLING SYSTEM Remove screws Remove radiator shield on both sides. Loosen hose clips Pull off the radiator hoses. Remove the hose clips Detach radiator and remove to the side. Loosen hose clip (D. Pull off the radiator hose.
  • Page 261 WATER PUMP, COOLING SYSTEM 19 Remove coolant pipe @ using special tool fa). Mounting tool (79129081000) p. 316) Pull off connecting piece to the side and remove. Mount new connecting piece in the frame. Mount new coolant pipe @ with special tool fa) and tighten. Guideline Coolant pipe M24x1 .5...
  • Page 262 19 WATER PUMP, COOLING SYSTEM Detach the radiator and position. Position and tighten hose clips Mount the radiator hoses. Position and tighten hose clips Position the radiator shield on both sides. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis Mount overflow hose Finishing work...
  • Page 263 WATER PUMP, COOLING SYSTEM 19 Install the air filter box cover. (� p. 96) Refill with coolant. (� p. 255) Install the engine guard. (� p. 52)

  • Page 264: Lubrication System

    LUBRICATION SYSTEM 20.1 Oil circuit T02009-10 Oil screen Force pump Oil pressure control valve Oil filter Oil nozzle for conrod bearing lubrication Oil nozzles for piston cooling Oil nozzle for cam follower lubrication Suction pump Oil channel, transmission lubrication 4l& Oil nozzle for timing chain lubrication Oil nozzle for clutch lubrication Oil screen...

  • Page 265: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens

    LUBRICATION SYSTEM Condition The engine is cold. Check the engine oil level. The engine oil reaches the middle of level viewer f). If the engine oil does not reach the middle of the level viewer: Add engine oil. (!el p. 266) Condition The engine is at operating temperature.
  • Page 266 LUBRICATION SYSTEM Main work Place an appropriate container under the engine. Remove oil drain plug with the magnet and seal ring. Remove screw plug @ with the short oil screen and the O­ rings. Info Do not remove screw 6). Remove screw plug with the long oil screen and the...
  • Page 267 LUBRICATION SYSTEM i�, """ Mount and tighten screw plug with the O-ring. � "" • Guideline � � Screw plug, oil M20x1 .5 15 Nm (11.1 lbf ft) ,;i, �@ ·- � . " �3 screen .., · - ·- .:..�...

  • Page 268: Adding Engine Oil

    LUBRICATION SYSTEM 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 effective exhaust extraction when starting or running the engine in an enclosed space. Start the engine and check for tightness.

  • Page 269: Checking The Oil Pressure

    LUBRICATION SYSTEM 20.5 Checking the oil �ressure Main work Place an appropriate container under the engine. Remove screws Remove the oil filter cover with the O- ring. Remove the oil filter. Lock ring plier (51012011000) (IUI p. 309) Position special tool f!} with the O-ring. Mount and tighten the screws.
  • Page 270 LUBRICATION SYSTEM Warning Some vehicle components get Danger of burns 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. Grease the O-ring of the oil filter cover. Mount the oil filter cover.

  • Page 271: Ignition System

    IGNITION SYSTEM 21.1 Ignition coil - checking the seconda� winding Condition The ignition coil 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 pin 2 (-) - Ignition coil pin 3 Ignition coil Secondary winding...

  • Page 272: Alternator- Checking The Stator

    IGNITION SYSTEM Remove the spark plug with special tool I Spark plug wrench with link (77229172000) p. 315) Mount and tighten the new spark plug using the special tool. Guideline Spark plug M10x1 10 ... 12 Nm (7.4 ... 8.9 lbf ft) I Spark plug wrench with link (77229172000) p.

  • Page 273: Removing The Stator

    IGNITION SYSTEM 21.5 Removing the stator Condition The alternator cover has been removed. Remove screws Remove the retaining bracket. Remove screws Remove rubber grommet from the alternator cover. Remove the stator from the alternator cover. D00343-10 21.6 Installing the stator Position the stator in the alternator cover.

  • Page 274: 22 Cylinder Head

    22 CYLINDER HEAD 22.1 Checking valve clearance Preparatory work Remove the engine guard. p. 52) Raise the motorcycle with a lift stand. p. 12) Remove the air filter box cover. p. 96) Remove the seat. p. 1 00) Remove the right side cover. p.
  • Page 275 CYLINDER HEAD 22 Engage the highest gear. Turn the rear wheel until the engine is at ignition top dead center. ✓ The marking on the camshaft is aligned towards the center point of the retaining bracket G). Info Make sure that the crankshaft is at top dead center. Unscrew and remove screw Remove washer Mount and tighten screw...

  • Page 276: Adjusting The Valve Clearance

    22 CYLINDER HEAD Position gasket of the engine vent in the valve cover. D05100-10 Position the valve cover with the valve cover seal. Mount and tighten screws Guideline Screw, valve cover 10 Nm (7.4 lbf ft) Mount the vent hose and hose clamp Mount and tighten the spark plug using the special tool.
  • Page 277 CYLINDER HEAD Main work Remove screws Take off camshaft retaining bracket f!}. Remove screws Screw in a suitable screw into rocker arm shafts Guideline Screw Remove the rocker arm (D. Remove shims @ and set them down according to the installation position.
  • Page 278 22 CYLINDER HEAD Position the rocker arm and mount rocker arm shafts ✓ The rocker arm shaft with lubrication bore is installed on the intake side. ✓ The cut-outs G) face upward. Info Make sure that the tapped hole of the rocker arm shaft is facing outward.

  • Page 279: Electric Starter System

    ELECTRIC STARTER SYSTEM 23.1 Checking the starter motor Condition The starter motor has been removed. Connect the negative cable of a 12 volt power supply to the housing of the starter motor. Connect the positive cable of the power supply briefly with connector of the starter motor.

  • Page 280: Throttle Valve Body

    THROTTLE VALVE BODY Adjusting the idle s�eed Warning The engine may go out spontaneously if the idle speed is set too low. Danger of accidents Set the idle speed to the specified value. Run the engine until warm. ✓ The cold start button is deactivated - The cold start but­ ton is in its basic position.
  • Page 281 THROTTLE VALVE BODY 24 Start the engine without operating the throttle grip. Guideline Coolant temperature < 25 °C (< 77 °F) Let the engine warm up to the specified temperature at idle speed. Guideline Coolant temperature ao ... 90 °c (176 ... 194 °F) Info Do not operate the throttle grip during the initialization process.

  • Page 282: 25 Technical Data

    25 TECHNICAL DATA 25.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 449.9 cm (27.455 cu in) Stroke 63.4 mm (2.496 in) Bore 95 mm (3.74 in) Compression ratio 12.75:1 Idle speed 2,250 ... 2,350 rpm Control OHC, 4 valves controlled via rocker arm Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust...

  • Page 283: Tolerance, Engine Wear Limits

    TECHNICAL DATA 25 25.2 Tolerance, engine wear limits Camshaft - cam height Exhaust 33.10 ... 33.30 mm (1.3031 ... 1.311 in) Intake 33.90 ... 34.10 mm (1.3346 ... 1.3425 in) Valve spring Minimum length, intake (without valve spring 40. 7 mm (1 .602 in) seat) Minimum length, exhaust (without valve spring 40.
  • Page 284 25 TECHNICAL DATA Oil nozzle, rocker arm lub rication 2 Nm (1 .5 lbf ft) ® Loctite ™ Screw, b earing retainer 6 Nm (4.4 lbf ft) ® Loctite ™ Screw, clutch spring retainer 6 Nm (4.4 lbf ft) Screw, gear position sensor 5 Nm (3.7 lbf ft) ®...

  • Page 285: Capacities

    TECHNICAL DATA 25 60 Nm (44.3 lbf ft) Screw, engine sprocket ® Loctite 2701 Spark plug M10x1 10 ... 12 Nm (7.4 ... 8.9 lbf ft) Engine coolant temperature sen- M10x1 .25 12 Nm (8.9 lbf ft) Screw plug, rocker arm shaft M10x1 .25 10 Nm (7.4 lbf ft) Screw, cylinder head...

  • Page 286: Electrical System

    120/80 - 19 63M TT Dunlop GEOMAX MX-3S F Dunlop GEOMAX MX-3S The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: www.husqvarna-motorcycles.com 25.8 Fork Fork article number 34.18.8R.99 Fork...

  • Page 287: Shock Absorber

    TECHNICAL DATA 25 Comfort 20 clicks Standard 15 clicks Sport 10 clicks 10.5 bar (152 psi) Air pressure Fork length 950 mm (37.4 in) �g 6�� Oil capacity external mechanism 200 � ml (6.76 � fl. oz.) Fork oil (SAE 4) (48601166S1) right p.

  • Page 288: Chassis Tightening Torques

    25 TECHNICAL DATA 25.10 Chassis tightening torgues Screw, combination switch ® K50x18 2 Nm (1 .5 lbf ft) EJOT PT ® Screw, intake air temperature sen- EJOT DEL TA PT 45x12-Z 0. 7 Nm (0.52 lbf ft) ® Screw, pressure regulator EJOT PT K60x25-Z 2.3 Nm (1.7 lbf ft)
  • Page 289 TECHNICAL DATA 25 Screw, top steering stem 20 Nm (14.8 lbf ft) ® Loctite ™ Screw, top triple clamp 17 Nm (12.5 lbf ft) Fuel connection on fuel tank M8x1.25 10 Nm (7.4 lbf ft) Engine carrying screw 60 Nm (44.3 lbf ft) Remaining nuts, chassis 45 Nm (33.2 lbf ft) Remaining screws, chassis...

  • Page 290: 26 Cleaning/Protective Treatment

    26 CLEANING/PROTECTIVE TREATMENT 26.1 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 291 CLEANING/PROTECTIVE TREATMENT Push back the protection caps of the handlebar controls to allow any water that has penetrated to evaporate. After the motorcycle has cooled off, lubricate all moving parts and bearings. Clean the chain. p. 130) Treat bare metal (except for brake discs and the exhaust sys­ tem) with a corrosion inhibitor.

  • Page 292: 27 Storage

    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-...

  • Page 293: Preparing For Use After Storage

    STORAGE 27 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 exhaust system to rust.

  • Page 294: 28 Service Schedule

    Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up-to­ date service schedule can always be found on Husqvarna Motorcycles Dealer.net. Your authorized Husqvarna Motorcycles dealer will be glad to advise you.

  • Page 295: 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 and in the Service Husqvarna Motorcycles Dealer.net...
  • Page 296 SERVICE SCHEDULE Annually Every 100 operating hours Every 50 operating hours Once after 20 operating hours Once after 10 operating hours • Perform major engine service including removing and installing the engine. (Change valves, valve springs, valve spring seats, and valve spring retainers. Change the con- necting rod, conrod bearing and crank pin.
  • Page 297 SERVICE SCHEDULE 28...
  • Page 298 · � 1 · © i� i·X16 �----�-����������������������������������������������� � , � ; � ·a � , : · · · n� �� � � �� 11, , ,· · • 11, , � 10 � E Y \ - - C 10 -M10 �...

  • Page 299: Wiring Diagram 29

    WIRING DIAGRAM 29 Components: A 11 EFI control unit Capacitor 12 V battery Alternator Starter relay with main fuse Power relay Electric starter system Voltage regulator E-tip switch X295 Diagnostics connector...
  • Page 300 -A111 "" / 3 .A1 1" ' ' " "' " ' " 1 " ' "' -© l " l " 1 1 l " "' -X16 -X16 -X16 -X16 -X16 -X16 -X16 _. .o il 15.E -,q, � H �...
  • Page 301 WIRING DIAGRAM 29 Components: A 11 EFI control unit Fuel pump Injection valve (cylinder 1) Malfunction indicator lamp CAN bus terminating resistor Kill switch X295 Diagnostics connector...
  • Page 302 · ' � I · '° t� : ' 11� : ' 1�: ' 1�, � 1�:' 111�:' � 11�T 1� T 1�,� ll,f :.s B 0-------------� ,nfH • � l.x 11 1 - x 1 0 l.x 2 0 11.m iC R/1 N I F / 2...
  • Page 303 WIRING DIAGRAM 29 Components: A 11 EFI control unit Intake air temperature sensor Coolant temperature sensor (cylinder 1) Rollover sensor Gear position sensor Crankshaft speed sensor Induction manifold pressure sensor (cylinder 1) Throttle valve position sensor Ignition coil Map select switch Cable colors: Black Brown...

  • Page 304: Substances

    30 SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification Guideline Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol REACT PERFORMANCE DOT 4 ® MOTOREX Brake Fluid DOT 5.1 Coolant...
  • Page 305 SUBSTANCES 30 Fork oil {SAE 4) {48601166S1 Standard/classification (� p. 326) (SAE 4) Guideline Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Shock absorber fluid {SAE 2.5) {50180751S1) Standard/classification p.

  • Page 306: Auxiliary Substances

    AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier ® MOTOREX Racing Bio Dirt Remover Chain cleaner Recommended supplier ® MOTOREX Chain Clean Fuel additive Recommended supplier ® MOTOREX Fuel Stabilizer High viscosi grease Recommended supplier ® LGHB 2 Long-life grease Recommended supplier ®...
  • Page 307 AUXILIARY SUBSTANCES 31 Lubricant (!159) Recommended supplier ® Bel-Ray ® MC-11 Motorc�cle cleaner Recommended supplier ® MOTOREX Moto Clean Multi- urRose grease (00062010051) Recommended supplier ® Kluber Lubrication CENTOPLEX 2 EP Off-road chain SRra� Recommended supplier MOTOREX ® Chainlube Offroad Oil for foam air filter Recommended supplier ®...

  • Page 308: Special Tools

    32 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)
  • Page 309 SPECIAL TOOLS 32 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 310 32 SPECIAL TOOLS Bearing �uller Art. no.: 15112017000 15112017000 H00520-01 Internal bearing �uller Art. no.: 15112018100 .& Feature 1 18 ... 23 mm (0.71 ... 0.91 in) 15112018100 H00522-01 Tachometer Art. no.: 45129075000 �� 45129075000 H00525-01 ringe Art. no.: 50329050000 £&...
  • Page 311 SPECIAL TOOLS 32 Lock ring �lier Art. no.: 51012011000 51012011000 H00572-01 Holding wrench Art. no.: 51129003000 & 51129003000 H00575-01 Puller Art. no.: 58429037043 & Feature Inside diameter 43.9 mm (1.728 in) � 58429037043 H00598-01 Tool bracket Art. no.: 58429089000 2x£ 58429089000 H00603-01...
  • Page 312 32 SPECIAL TOOLS Pressing tool Art. no.: 58429091000 58429091000 H00604-01 Pressing tool Art. no.: 58429092000 58429092000 H00605-01 Torgue wrench kit Art. no.: 58429094000 Feature Torque 3 ... 15 Nm (2.2 ... 11 .1 lbf ft) Open ended bit 3.9 mm (0.154 in) Open ended bit 4.9 mm (0.193 in) 5.5 mm (0.217 in)
  • Page 313 SPECIAL TOOLS 32 Limit �lug gauge Art. no.: 59029026006 Feature Diameter 6.05 mm (0.2382 in) 59029026006 H00612-01 Feeler gauge Art. no.: 59029041100 & Feature 15 piece 0.10 ... 0.25 mm (0.0039 ... 0.0098 in) 59029041100 H00616-01 Piston ring com�ressor Art. no.: 60029015000 &.&...
  • Page 314 32 SPECIAL TOOLS Pressing tool Art. no.: 60029043040 60029043040 H00639-01 Hose clamQ Qlier Art. no.: 60029057000 60029057000 H00650-01 Testing hose Art. no.: 61029093000 � 61029093000 H00659-01 Pressure testin tool Art. no.: 61029094000 4x £ 61029094000 H00660-01...
  • Page 315 SPECIAL TOOLS 32 Puller Art. no.: 75029021000 75029021000 H00707-01 Pressing tool Art. no.: 75029044010 75029044010 H00712-01 Pressing tool Art. no.: 75029044020 75029044020 H00713-01 Art. no.: 75029047000 75029047000 H00714-01...
  • Page 316 32 SPECIAL TOOLS Clam�ing �late Art. no.: 75029050000 75029050000 H00719-01 Pressing tool Art. no.: 75029051000 75029051000 H00721-01 Protection ca� Art. no.: 75029090000 75029090000 H00726-01 Insert for valve s ring lever Art. no.: 77029041200 77029041200 H00746-01...
  • Page 317 SPECIAL TOOLS 32 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 Insertion for �iston ring lock Art. no.: 77329030100 77329030100 H00768-01 Locking screw Art.
  • Page 318 32 SPECIAL TOOLS Footrest s�ring �lier Art. no.: 79029083000 79029083000 H00804-01 Mounting tool Art. no.: 79129081000 Feature I Hexagonal driver 13mm(0.51 in) 79129081000 H02653-01 Extractor Art. no.: 79229032044 79229032044 H00808-01 Puller Art. no.: 79229048000 79229048000 H00809-01...
  • Page 319 SPECIAL TOOLS 32 Fork air�um� Art. no.: 79412966000 Feature Maximum pressure 20 bar (290 psi) Display Digital pressure gauge Valve connection Schrader valve Units bar, psi and kg/cm Material Aluminum tube 79412966000 H01687-01 Holder and fitting for work stand Art. no.: 79429002000 79429002000 H01081-01 Pressing tool...
  • Page 320 32 SPECIAL TOOLS Se�arator �late Art. no.: 79429009000 79429009000 H00812-01 Oil ressure ada�ter Art. no.: 79429094000 79429094000 H01045-01 Gear segment Art. no.: 80029004000 80029004000 H00813-01 En ine assembl stand Art. no.: 80329001000 80329001000 H01047-01...
  • Page 321 SPECIAL TOOLS 32 Lift stand Art. no.: 81329955100 Feature Height 315 ... 425 mm (12.4 ... 16.73 in) Load :-:; 150 kg($ 331 lb.) 81329955100 H00985-01 Protection ca� Art. no.: 90129005000 & 90129005000 H00816-01 Hook wrench Art. no.: 90129051000 & �...
  • Page 322 32 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 323 SPECIAL TOOLS 32 Pressing tool Art. no.: T1206 & Feature Diameter 1 15 ... 30 mm (0.59 ... 1.1 8 in) � T1206 H00880-01 Pressing tool Art. no.: T1207S &.&. �� T1207S H00881-01 Pressing tool Art. no.: T1216 Feature Diameter 1 3 8 ...
  • Page 324 32 SPECIAL TOOLS Filling ada�ter Art. no.: T1296 T1296 H01573-01 Protecting sleeve Art. no.: T1401 & Feature I Diameter I 48 mm (1.89 in) T1401 H00894-01 Clam�ing stand Art. no.: T14016S 2xffi Feature I Diameter I 12 mm(0.47in) ill] T14016S H01036-01 Rin wrench Art.
  • Page 325 SPECIAL TOOLS 32 Clam�ing stand Art. no.: T1403S 2x£. Feature Diameter 48 mm (1 .89 in) Diameter 60 mm (2.36 in) �� T1403S H00896-01 Mounting tool Art. no.: T14040S Feature Diameter 48 mm (1 .89 in) � T14040S H00922-01 Clam�ing stand Art.
  • Page 326 32 SPECIAL TOOLS S�ecial socket Art. no.: T14084 Feature Drive 1/2 in Diameter 24 mm (0.94 in) T14084 H01518-01 Mounting sleeve Art. no.: T14092 Feature I Diameter 34 mm (1.34 in) T14092 H02261-01 Pressing tool Art. no.: T1504 Feature I Diameter 118 mm (0.71 in) T1504 H00899-01...
  • Page 327 SPECIAL TOOLS 32 Mounting sleeve Art. no.: T1515 Feature 1 18 mm (0.71 in) Diameter T1515 H00900-01 Filling tool Art. no.: T170S1 2x£3x.£. T170S1 H00855-01...
  • Page 328 33 STANDARDS JASO T903 MA2 Different technical development directions required a separate specification for motorcycles - the JASO T903 MA2 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 329: List Of Abbreviations

    LIST OF ABBREVIATIONS 34 Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 330: Index

    INDEX Capacitor 12 V battery checking ......141 charging ......Capacity installing ......coolant ....256-257, 283 negative cable, connecting ...
  • Page 331 INDEX oil pumps, checking ....202 clutch basket, installing piston/cylinder, determining the mounting clutch cover, installing clearance ......201 clutch discs, installing rocker arm shafts, checking .
  • Page 332 INDEX oil filter, removing dust boots, cleaning ....17 piston, removing fork, servicing ..... . 20 preparations .
  • Page 333 INDEX Open-circuit current checking ......140 Idle speed adjusting Ignition coil Preparing for use secondary winding, checking ..269 after storage .
  • Page 334 INDEX seal ring retainer, assembling ... 73 fork ......284 seal ring retainer, disassembling ..69 shock absorber ....285 shock absorber, servicing .
  • Page 335 I 1 1 11 1 11 1 1 1 1 11 1 1 1 111 1 11 1 1 1 1 111 1 1 1 1 11 1 1 1 1 11 1 I I I I I I II I I II 3403072en 07/2018 ® Husqvarna Husqvarna Motorcycles GmbH StallhofnerstraBe 3 5230 Mattighofen Austria � LZZa" www.husqvarna-motorcycles.com ..

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