Husqvarna 2016 FE 250 Owner's Manual
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Husqvarna 2016 FE 250 Owner's Manual

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OWNER'S MANUAL 2016
FE 250
Art. no. 3402063en

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Summary of Contents for Husqvarna 2016 FE 250

  • Page 1 OWNER'S MANUAL 2016 FE 250 Art. no. 3402063en...
  • Page 3 Husqvarna Motorcy- cles accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS Setting the kilometers or miles ......22 MEANS OF REPRESENTATION........5 Setting the clock ..........23 Symbols used ............5 Setting the service display........23 Formats used ............5 Speed, time, and DST distance 1 ....... 24 SAFETY ADVICE ...............
  • Page 5 TABLE OF CONTENTS 12.4 Cleaning the dust boots of the fork legs..... 42 13.6 Adding front brake fluid ........69 12.5 Removing the fork legs ........43 13.7 Checking the front brake linings ......70 12.6 Installing the fork legs ........
  • Page 6 TABLE OF CONTENTS TROUBLESHOOTING ........... 103 BLINK CODE ..............105 TECHNICAL DATA ............107 23.1 Engine ............... 107 23.2 Engine tightening torques......... 107 23.3 Capacities ............109 23.3.1 Engine oil............109 23.3.2 Coolant ............109 23.3.3 Fuel............... 109 23.4 Chassis ............. 109 23.5 Electrical system..........

  • Page 7: Means Of Representation

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interests of your own safety, have these jobs performed by an authorized Husqvarna Motorcycles workshop. There, your motorcycle will be optimally cared for by specially trained experts using the specialist tools required.

  • Page 8: Safety Advice

    Use definition – intended use (FE EU/AU) Husqvarna motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcy- cles comply with currently valid regulations and categories of the top international motorsport organizations. Info The vehicle should only be used by trained persons.

  • Page 9: Safe Operation

    Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that pertain to the disposal of an end-of-life motorcycle. Your authorized Husqvarna Motorcycles dealer will be glad to advise you.

  • Page 10: Owner's Manual

    SAFETY ADVICE Owner's Manual It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual con- tains useful information and many tips on how to operate, handle, and maintain your motorcycle. Only then will you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury.

  • Page 11: Important Notes

    Manufacturer and implied warranty The work prescribed in the service schedule must be carried out by an authorized Husqvarna Motorcycles workshop only and con- firmed both in the customer's Service & Warranty Booklet and in the Husqvarna Motorcycles Dealer.net; otherwise, all warranty claims will be void.

  • Page 12: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example) H00237-10 Filler cap Air filter box lid Side stand ( p. 19) Engine number ( p. 12) Shift lever ( p. 18)

  • Page 13: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE View of vehicle, rear right (example) H00238-10 Fork compression adjustment Kill switch ( p. 14) Horn button ( p. 15) Light switch ( p. 15) Turn signal switch ( p. 15) Emergency OFF switch ( p. 15) Electric starter button ( p.

  • Page 14: Serial Numbers

    SERIAL NUMBERS Chassis number  The chassis number is stamped on the steering head on the right. 401945-10 Type label (FE EU/AU)  The type label is fixed to the front of the steering head. 401946-10 Key number (FE EU/AU) ...

  • Page 15: Shock Absorber Article Number

    SERIAL NUMBERS Shock absorber article number  The shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. 0 0 1 401948-10...

  • Page 16: Controls

    CONTROLS Clutch lever  The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. H00165-10 Hand brake lever  The hand brake lever is fitted on the right side of the handlebar. The hand brake lever is used to activate the front brake.

  • Page 17: Horn Button (Fe Eu/Au)

    CONTROLS Horn button (FE EU/AU)  The horn button is fitted on the left side of the handlebar. Possible states • Horn button in neutral position pressed – the horn is actuated in this position. • Horn button H00168-11 Light switch (FE EU/AU) ...

  • Page 18: Electric Starter Button (Fe Eu/Us)

    CONTROLS 6.11 Electric starter button (FE EU/US)  The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button in basic position pressed – the electric starter is actuated in this position. •...

  • Page 19: Closing The Filler Cap

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

  • Page 20: Idle Speed Adjusting Screw

    CONTROLS 6.17 Idle speed adjusting screw  Idle speed adjusting screw is located at the top left of the throttle valve body. The idle speed adjusting screw has two functions. Turning it controls the idle speed. Pulling it out all the way raises the idle speed during a cold start. Possible states RPM increase activated –...

  • Page 21: Side Stand

    CONTROLS 6.20 Side stand  The side stand is located on the left side of the vehicle. 401943-10 The side stand is used for parking the motorcycle. Info  When you are riding, the side stand must be folded up and secured with ...

  • Page 22: Unlocking The Steering (Fe Eu/Au)

    CONTROLS 6.23 Unlocking the steering (FE EU/AU) – Insert the key in the steering lock ( p. 19), turn it to the left, pull it out, and turn it to the right. Remove the key. You can now steer the bike again. Info Never leave the key in the steering lock.

  • Page 23: Speedometer

    Message on the speedometer Possible states Battery voltage of the speedometer – Battery voltage of the speedometer is too low. Change the battery. Service – A service is due. Contact an authorized Husqvarna Motorcy- cles workshop. 401901-01 Setting the speedometer Condition The motorcycle is stationary.

  • Page 24: Setting The Kilometers Or Miles

    SPEEDOMETER – Wait for 5 seconds. The speedometer changes to the next menu item. The symbol flashes. Resetting the time – Press the left button. The value decreases. Advancing the time – Press the right button. The value increases. 401912-01 –...

  • Page 25: Setting The Clock

    SPEEDOMETER Setting the clock Condition The motorcycle is stationary. – Press both buttons for 3–5 seconds. The Setup menu is displayed. The UNIT display flashes. – Wait for the menu of the clock to flash. – Press one of the buttons to select the 24h or 12h display of the clock. 401911-01 –...

  • Page 26: Speed, Time, And Dst Distance 1

    SPEEDOMETER Speed, time, and DST distance 1 – Press one of the buttons until DST appears on the speedometer. KM/H or M/H shows the speed. shows the time. DST shows the distance since the last reset, such as between two refueling stops. Info If the value of 39999.9 is exceeded, DST is automatically reset to 0.0.

  • Page 27: Preparing For Use

    When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized Husqvarna Motorcycles workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover.

  • Page 28: Running-In The Engine

    PREPARING FOR USE – Do not make any off-road trips that exceed your ability and experience. – Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. – If you carry any luggage, make sure you fix it firmly as close as possible to the center of the vehicle and ensure even weight dis- tribution between the front and rear wheels.

  • Page 29: Preparing For Rides On Dry Sand

    – Fit a dust cover on the air filter. Dust protection device for air filter (77206920100) Info See the Husqvarna Motorcycles accessories fitting instructions. B00435-01 – Fit a sand cover on the air filter. Sand protection device for air filter (59006922000) Info See the Husqvarna Motorcycles accessories fitting instructions.

  • Page 30: Preparing For Rides On Wet And Muddy Surfaces

    Preparing for rides on wet and muddy surfaces – Fit a waterproofing device on the air filter. Waterproofing device for air filter (77206921100) Info See the Husqvarna Motorcycles accessories fitting instructions. B00437-01 – Fit the steel sprocket. – Clean the motorcycle. ( p.

  • Page 31: Riding Instructions

    RIDING INSTRUCTIONS Checks and maintenance work when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the engine oil level. ( p. 96) –...

  • Page 32: Starting Off

    Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up. Info If you hear unusual noises while riding, stop immediately, switch off the engine, and contact an authorized Husqvarna Motorcycles workshop.

  • Page 33: Stopping, Parking

    RIDING INSTRUCTIONS Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. –...

  • Page 34: Refueling

    – In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards.

  • Page 35: Service Schedule

    Final check: Check the vehicle for roadworthiness and take a test ride. ○ ● ● Read out the fault memory after the test ride using the Husqvarna Motorcycles diagnostics tool. ○ ● ● Make the service entry in the Husqvarna Motorcycles Dealer.net and in the Service and Warranty Booklet.

  • Page 36: Service Work (As Additional Order)

    SERVICE SCHEDULE ○ One-time interval ● Periodic interval 10.2 Service work (as additional order) Annually Every 135 operating hours Every 70 operating hours after sporting use Every 45 operating hours Once after 15 operating hours ● Change the front brake fluid. ●...

  • Page 37: Tuning The Chassis

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info The effect of the low-speed setting can be seen in slow to normal compression of the shock absorber.

  • Page 38: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info The effect of the high-speed setting can be seen in fast compression of the shock absorber.

  • Page 39: Measuring Rear Wheel Sag Unloaded

    TUNING THE CHASSIS 11.6 Measuring rear wheel sag unloaded Preparatory work – Raise the motorcycle with a lift stand. ( p. 42) Main work – Measure the distance – as vertically as possible – between the rear axle and a fixed point such as a mark on the side cover.

  • Page 40: Adjusting The Spring Preload Of The Shock Absorber

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.

  • Page 41: Checking Basic Setting Of Fork

    TUNING THE CHASSIS Main work – Choose and mount a suitable spring. Guideline Spring rate Weight of rider: 65… 75 kg (143… 51 N/mm (291 lb/in) 165 lb.) Weight of rider: 75… 85 kg (165… 54 N/mm (308 lb/in) 187 lb.) Weight of rider: 85…...

  • Page 42: Adjusting The Rebound Damping Of The Fork

    TUNING THE CHASSIS Guideline Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 11.13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. –...
  • Page 43 TUNING THE CHASSIS –  Remove screws . Take off the handlebar clamps. Take off the handlebar and lay it to one side. Info Cover the components to protect them against damage. Do not bend the cables and lines. – ...

  • Page 44: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (81329955100) Neither wheel is in contact with the ground.

  • Page 45: Removing The Fork Legs

    SERVICE WORK ON THE CHASSIS Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. – Clean and oil the dust boots and inner fork tubes of both fork legs.

  • Page 46: Removing The Fork Protector

    SERVICE WORK ON THE CHASSIS –  Tighten screws Guideline Screw, top triple clamp 17 Nm (12.5 lbf ft) –  Tighten screws Guideline Screw, bottom triple clamp 15 Nm (11.1 lbf ft) H00179-11 –  Position the brake caliper, and mount and tighten screws Guideline Screw, front brake caliper 25 Nm...

  • Page 47: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS Main work – Open cable holder  in front of the right radiator and detach the wiring harness. H00215-10 –   Remove screw . Remove screw , take off the upper triple clamp with the handlebar and set it aside.
  • Page 48 SERVICE WORK ON THE CHASSIS – Position the fork legs.  Bleeder screws are positioned toward the front. Info The compression damping is located in left fork leg COMP (white adjusting screw). The rebound damping is located in right fork leg REB (red adjusting screw).

  • Page 49: Checking The Steering Head Bearing Play

    Warning Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam- aged over time.

  • Page 50: Lubricating The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS 12.13 Lubricating the steering head bearing – Remove the lower triple clamp. p. 44) – Install the lower triple clamp. p. 45) 800010-10 12.14 Removing the front fender Preparatory work – Switch off all power consumers and switch off the engine. –...

  • Page 51: Removing The Shock Absorber

    SERVICE WORK ON THE CHASSIS – Check the headlight setting. ( p. 88) 12.16 Removing the shock absorber Preparatory work – Raise the motorcycle with a lift stand. ( p. 42) – Remove the right side cover. ( p. 52) –...

  • Page 52: Mounting The Seat

    SERVICE WORK ON THE CHASSIS 12.19 Mounting the seat – Mount the front of the seat on the collar bushing of the fuel tank, lower the seat at the rear, and simultaneously push the seat forward. The seat is correctly engaged. H00183-10 –...

  • Page 53: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS Main work – Push air filter holding bracket  toward the air filter at position  , and detach it  at end – Swivel the air filter holding bracket to one side and remove the air filter with the air filter support.

  • Page 54: Sealing The Air Filter Box

    SERVICE WORK ON THE CHASSIS – Check the intake flange for damage and looseness. Finishing work – Install the air filter. p. 51) – Install the air filter box lid. ( p. 50) 12.25 Sealing the air filter box Preparatory work –...

  • Page 55: Installing The Main Silencer

    SERVICE WORK ON THE CHASSIS Main work – Disconnect spring  Spring hook (50305017000) –  Remove screws and take off the main silencer. B01814-11 12.29 Installing the main silencer Main work –  Mount the main silencer. Mount screws but do not tighten yet.

  • Page 56: Changing The Glass Fiber Yarn Filling Of The Main Silencer

    SERVICE WORK ON THE CHASSIS 402269-10 Main work –    Remove screws and take off silencer cap with O-ring Warning Danger to health Soot particles irritate the eyes and mucuous membranes. – Wear suitable breathing and eye protection when cleaning the main silencer and carbon screen. –...
  • Page 57 SERVICE WORK ON THE CHASSIS Main work (FE EU/AU) – Remove all screws on the main silencer. –   Take off silencer cap and O-ring –   Take off outer tube and O-ring – Remove glass fiber yarn filling ...

  • Page 58: Removing The Manifold

    SERVICE WORK ON THE CHASSIS 12.32 Removing the manifold Preparatory work – Raise the motorcycle with a lift stand. ( p. 42) – Remove the seat. ( p. 49) – Remove the right side cover. ( p. 52) – Remove the main silencer. ( p.

  • Page 59: Installing The Manifold

    SERVICE WORK ON THE CHASSIS –  Remove screw – Raise the rear frame slightly and lower the shock absorber. H00242-10 (FE EU) – Remove the fuel tank. p. 59) –  Disconnect plug-in connector of the lambda sensor and remove the cable binder.
  • Page 60 SERVICE WORK ON THE CHASSIS –  Mount and tighten screw Guideline Remaining screws, chassis 25 Nm (18.4 lbf ft) H00243-11 (FE EU) –  Connect plug-in connector of the lambda sensor, route the cable without tension, and secure with a new cable tie. –...

  • Page 61: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS Info Raise the wheel slightly to be able to mount the screw more easily. Finishing work – Install the main silencer. ( p. 53) – Install the right side cover. ( p. 52) – Mount the seat. ( p.

  • Page 62: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS (FE US) – Remove screws  with the collar bushings. S00906-10 –  Remove screw with the rubber bushing. H00189-10 – Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank. H00190-10 12.35 Installing the fuel tank...

  • Page 63: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS (FE EU/AU) – Position the collar bushings and horn, and mount and tighten screws  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Connect the connector of the horn. H00188-11 (FE US) – ...

  • Page 64: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS Info The service life of the chain depends largely on its maintenance. Preparatory work – Raise the motorcycle with a lift stand. ( p. 42) Main work – Clean the chain regularly and then treat with chain spray. Offroad chain spray ( p.

  • Page 65: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide

    SERVICE WORK ON THE CHASSIS Main work – Loosen nut  –  Loosen nuts –  Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 55… 58 mm (2.17… 2.28 in)  Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference ...
  • Page 66 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the bottom edge of the chain bolt is in line with or below the chain sliding guard: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated. »...

  • Page 67: Checking The Frame

    If the frame exhibits cracks or deformation due to a mechanical impact: – Change the frame. Info Always replace a frame that has been damaged due to a mechan- ical impact. Repair of the frame is not authorized by Husqvarna Motorcycles. 401799-01 12.42 Checking the swingarm –...

  • Page 68: Checking The Rubber Grip

    SERVICE WORK ON THE CHASSIS 12.44 Checking the rubber grip – Check the rubber grips on the handlebar for damage, wear, and looseness. » If a rubber grip is damaged, worn, or loose: – Change and secure the rubber grip. Grip adhesive (00062030051) ( p.

  • Page 69: Changing The Hydraulic Clutch Fluid

    SERVICE WORK ON THE CHASSIS 12.48 Changing the hydraulic clutch fluid Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –...

  • Page 70: Brake System

    BRAKE SYSTEM 13.1 Checking free travel of hand brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due to overheating.

  • Page 71: Checking The Brake Discs

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized Husqvarna Motor- cycles workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 72: Checking The Front Brake Linings

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized Husqvarna Motor- cycles workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 73: Changing The Front Brake Linings

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized Husqvarna Motor- cycles workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.

  • Page 74: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM –   Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. 100397-01 –   Insert the new brake linings, insert pin , and mount cotter pins Info Always change the brake linings in pairs.

  • Page 75: Adjusting The Basic Position Of The Foot Brake Lever

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized Husqvarna Motor- cycles workshop will be glad to help.) – Stand the vehicle upright.

  • Page 76: Adding Rear Brake Fluid

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized Husqvarna Motor- cycles workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 77: Checking The Rear Brake Linings

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized Husqvarna Motor- cycles workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
  • Page 78 BRAKE SYSTEM – Stand the vehicle upright. –   Remove screw cap with membrane and the O-ring. B01793-10 – Press the brake caliper onto the brake disc by hand in order to push back the brake piston and ensure that brake fluid does not flow out of the brake fluid reser- voir, extracting it by suction if it does.

  • Page 79: Wheels, Tires

    WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 42) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes.

  • Page 80: Removing The Rear Wheel

    WHEELS, TIRES – Lift the front wheel into the fork, position it, and insert the wheel spindle. The brake linings are correctly positioned. –  Mount and tighten screw Guideline Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft) –...

  • Page 81: Installing The Rear Wheel

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

  • Page 82: Checking The Tire Air Pressure

    Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.
  • Page 83 WHEELS, TIRES – Tap each spoke with a screwdriver. Info The sound frequency depends on the length and thickness of the spoke. If there are different sound frequencies in spokes with the same length and thickness, this indicates different spoke tensions. You should hear a high note.

  • Page 84: Electrical System

    ELECTRICAL SYSTEM 15.1 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –...

  • Page 85: Charging The Battery

    Environmental hazard Batteries contain environmentally-hazardous materials. – Do not dispose of batteries as household waste. – Return batteries to your authorized Husqvarna Motorcycles dealer or dispose of them at a collection point for used bat- teries. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 86: Changing The Main Fuse

    ELECTRICAL SYSTEM 15.4 Changing the main fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never bypass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the air filter box lid. Preparatory work –...

  • Page 87: Removing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM – Remove the defective fuse. Guideline Fuse 1 - 10 A - EFI control unit Fuse 2 - 10 A - fuel pump Fuse 3 - 10 A - high beam, low beam, parking light, tail light, license plate lamp Fuse 4 - 10 A - horn, brake light, turn signal, radiator fan Fuses res - 10 A - spare fuses H00207-10...

  • Page 88: Installing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM –  Detach plug-in connector and take off the headlight mask with the head- light. S00893-10 15.7 Installing the headlight mask with the headlight Main work (FE EU/AU) –  Connect plug-in connectors H00220-11 –  Position the headlight mask and secure it with rubber bands The holding lugs engage in the fender.

  • Page 89: Changing The Headlight Bulb

    ELECTRICAL SYSTEM –   Position brake line and wiring harness in the brake line guide. S00894-10 Finishing work – Check the headlight setting. ( p. 88) 15.8 Changing the headlight bulb Note Damage to reflector Reduced brightness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.

  • Page 90: Changing The Turn Signal Bulb (Fe Eu/Au)

    ELECTRICAL SYSTEM 15.9 Changing the turn signal bulb (FE EU/AU) Note Damage to reflector Reduced brightness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.

  • Page 91: Adjusting The Headlight Range

    ELECTRICAL SYSTEM 15.11 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 88) Main work –  Loosen screw – Adjust the headlight range by pivoting the headlight. Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with driver (instructions on how to apply the mark: Checking the headlight setting).

  • Page 92: Cooling System

    COOLING SYSTEM 16.1 Cooling system  The water pump in the engine forces the coolant to flow. The pressure resulting from the warming of the cooling system is regulated by a valve  in radiator cap . The specified coolant temperature is therefore permissible with- out the danger of malfunctions.

  • Page 93: Checking The Coolant Level

    COOLING SYSTEM 16.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 94: Refilling Coolant

    COOLING SYSTEM 16.5 Refilling coolant Warning Danger of poisoning Coolant is poisonous and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swallowed, contact a physician immediately.

  • Page 95: Tuning The Engine

    TUNING THE ENGINE 17.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back  and forth slightly to ascertain play in the throttle cable. Play in throttle cable 3…...

  • Page 96: Adjusting The Idle Speed

    TUNING THE ENGINE 17.3 Adjusting the idle speed Warning Danger of accidents The engine may go out spontaneously if the idle speed is set too low. – Set the idle speed to the specified value. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
  • Page 97 TUNING THE ENGINE –  Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gearing. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle compo- nents during the shift procedure.

  • Page 98: Service Work On The Engine

    SERVICE WORK ON THE ENGINE 18.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...

  • Page 99: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen

    SERVICE WORK ON THE ENGINE »   If the engine oil is not at a level between lower edge and middle the level viewer: – Add engine oil. ( p. 98) 18.3 Changing the engine oil and oil filter, cleaning the oil screen Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden.

  • Page 100: Adding Engine Oil

    SERVICE WORK ON THE ENGINE –  Remove screws . Remove the oil filter cover with the O-ring. B01773-10 –  Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) – Completely drain the engine oil. –...
  • Page 101 SERVICE WORK ON THE ENGINE Main work – Remove the oil filler plug  with the O-ring from the clutch cover. –  Fill engine oil to the middle of the level viewer. Engine oil (SAE 10W/50) ( p. 113) Info For optimal performance of the engine oil, do not mix different types of engine oil.

  • Page 102: Cleaning, Care

    CLEANING, CARE 19.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts.

  • Page 103: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE 19.2 Checks and maintenance steps for winter operation Info If you use the vehicle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive road salt. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt.

  • Page 104: Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info Husqvarna Motorcycles recommends raising the motorcycle. – Raise the motorcycle with a lift stand. ( p. 42) –...

  • Page 105: Troubleshooting

    TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked (elec- Operating error Carry out the start procedure. ( p. 29) tric starter) – Battery is discharged Charge the battery. p. 83) – Check the charging voltage. – Check the closed current. –...
  • Page 106 TROUBLESHOOTING Faults Possible cause Action – Engine overheats Foam formation in cooling system Drain the coolant. p. 91) – Refill the coolant. p. 92) – Bent radiator hose Change the radiator hose. – Thermostat defective Check the thermostat. Guideline Opening temperature: 70 °C (158 °F) –...

  • Page 107: Blink Code

    BLINK CODE Blink code FI warning lamp (MIL) 02 FI warning lamp (MIL) flashes 2x short Error level condition Crankshaft position sensor - circuit fault Blink code FI warning lamp (MIL) 06 FI warning lamp (MIL) flashes 6x short Error level condition Throttle position sensor circuit A - input signal too low Throttle position sensor circuit A - input signal too high Blink code FI warning...
  • Page 108 BLINK CODE Blink code FI warning lamp (MIL) 45 FI warning lamp (MIL) flashes 4x long, 5x short Error level condition FE EU Lambda sensor heater cylinder 1, sensor 1 - short circuit to ground or open circuit Lambda sensor heater cylinder 1, sensor 1 - input signal too high...

  • Page 109: Technical Data

    TECHNICAL DATA 23.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 249.91 cm³ (15.2505 cu in) Stroke 52.3 mm (2.059 in) Bore 78 mm (3.07 in) Compression ratio 12.8:1 Idle speed 2,050… 2,150 rpm Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 32.5 mm (1.28 in)
  • Page 110 TECHNICAL DATA ® Loctite 243™ Screw, crankshaft position sensor 6 Nm (4.4 lbf ft) ® Screw, locking lever 6 Nm (4.4 lbf ft) Loctite 243™ ® Loctite 243™ Screw, oil pump cover 6 Nm (4.4 lbf ft) ® Screw, stator 6 Nm (4.4 lbf ft) Loctite 243™...

  • Page 111: Capacities

    TECHNICAL DATA 23.3 Capacities 23.3.1 Engine oil Engine oil 1.0 l (1.1 qt.) Engine oil (SAE 10W/50) ( p. 113) 23.3.2 Coolant Coolant 1.2 l (1.3 qt.) Coolant ( p. 113) 23.3.3 Fuel Total fuel tank capacity, 9.5 l (2.51 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p.

  • Page 112: Electrical System

    90/90 - 21 54M TT 110/100 - 18 64M TT Dunlop GEOMAX AT 81 F Dunlop GEOMAX AT 81 Additional information is available in the Service section under: www.husqvarna-motorcycles.com 23.7 Fork Fork part number 24.18.7P.67 WP Performance Systems Up Side Down 4860 MXMA 4CS...

  • Page 113: Shock Absorber

    TECHNICAL DATA 23.8 Shock absorber Shock absorber article number 18.15.7P.67 WP Performance Systems 5018 DCC Shock absorber Compression damping, low-speed Comfort 20 clicks Standard 18 clicks Sport 16 clicks Compression damping, high-speed Comfort 2.5 turns Standard 2 turns Sport 1.5 turns Rebound damping Comfort 20 clicks...
  • Page 114 TECHNICAL DATA – Remaining screws, chassis 25 Nm (18.4 lbf ft) – Screw, bottom triple clamp 15 Nm (11.1 lbf ft) – Screw, chain sliding piece 15 Nm (11.1 lbf ft) ® Screw, engine brace 33 Nm (24.3 lbf ft) Loctite 2701™...

  • Page 115: Substances

    SUBSTANCES Brake fluid DOT 4 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the cor- responding properties. Recommended supplier ® Bel‑Ray – Super DOT 4 Brake Fluid Coolant Guideline –...

  • Page 116: Auxiliary Substances

    AUXILIARY SUBSTANCES Air filter cleaning agent Recommended supplier ® Bel‑Ray – Foam Filter Cleaner & Degreaser Grip adhesive (00062030051) Recommended supplier KTM AG – GRIP GLUE High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier ® Bel‑Ray –...

  • Page 117: Standards

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

  • Page 118: Index Of Special Terms

    INDEX OF SPECIAL TERMS On-board diagnosis Vehicle system that monitors emission- and safety-related val-...

  • Page 119: List Of Abbreviations

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

  • Page 120: Lisy Of Symbols

    LISY OF SYMBOLS 29.1 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by yellow or orange symbols. FI Warning lamp (MIL) lights up/flashes orange – The OBD has detected an emission- or safety-critical fault. The low fuel warning lamp lights up orange –...

  • Page 121: Index

    INDEX INDEX fluid, changing ......67 Clutch lever ....... . 14 Accessories .
  • Page 122 INDEX Fork legs basic setting, checking ..... . . 39 Light switch ....... . 15 bleeding .
  • Page 123 INDEX Tire air pressure checking ....... . . 80 Safe operation .
  • Page 124 *3402063en* 3402063en 07/2015 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria Photo: Mitterbauer, www.husqvarna-motorcycles.com Husqvarna Motorcycles GmbH...

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