Husqvarna FE 250 EU 2014 Repair Manual
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Husqvarna FE 250 EU 2014 Repair Manual

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PIONEERING SINCE 1903
REPAIR MANUAL2015
leJ
FE 250 EU
FE 250 AU
FE 250 US
®
Husqvarna
Art. no. 3403014en
MOTORCYCLES

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Summary of Contents for Husqvarna FE 250 EU 2014

  • Page 1 PIONEERING SINCE 1903 REPAIR MANUAL2015 FE 250 EU FE 250 AU FE 250 US ® Husqvarna Art. no. 3403014en MOTORCYCLES...
  • Page 3 Husqvarna accepts no lia­ bility for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Adjusting the handlebar position ......37 MEANS OF REPRESENTATION ........6 Adjusting the basic position of the clutch Symbols used ............6 lever ..............37 1 .2 Formats used ............6 Checking the routing of the throttle cable ..

  • Page 5: Consumers

    TABLE OF CONTENTS 11.5 Cleaning the air filter and air filter box ....7 4 16.3 Checking free travel of hand brake lever ..110 11.6 Sealing the air filter box ........7 4 16.4 Adjusting the basic position of the hand brake lever (FE US) ..
  • Page 6 TABLE OF CONTENTS 18.3.31 Removing the shift forks ......146 18.5.5 Installing the shift rails ........175 18.3.32 Removing the transmission shafts ....146 18.5.6 Installing the left engine case ....... 175 18.3.33 Removing the crankshaft ......146 18.5. 7 Installing the spacer ........
  • Page 7 TABLE OF CONTENTS THROTTLE VALVE BODY ..........205 24.1 Adjusting the idle speed ........205 24.2 Executing the initialization run ......205 TECHNICAL DATA ............206 25.1 Engine ............... 206 25.2 Tolerance, engine wear limits ......206 25.3 Engine tightening torques ......... 207 25.4 Capacities ............

  • Page 8: Means Of Representation

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

  • Page 9: Safety Advice

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

  • Page 10: Important Notes

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

  • Page 11: Serial Numbers

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

  • Page 12: Shock Absorber Article Number

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

  • Page 13: Motorcycle

    MOTORCYCLE Raising the motorc cle with a lift stand Note Danger of damage The parked vehicle can roll away or fall over. Park the vehicle on a firm and level surface. Raise the motorcycle at the frame underneath the engine. Lift stand (81329955000) (�...

  • Page 14: Starting The Motorcycle For A Check

    MOTORCYCLE Startin the motorc cle for a check Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. Always make sure there is sufficient ventilation when running the engine. Use an effective exhaust extraction system when starting or running the engine in an enclosed space. Info Press the starter for a maximum of 5 seconds.

  • Page 15: Fork, Triple Clamp

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

  • Page 16: Cleaning The Dust Boots Of The Fork Legs

    FORK, TRIPLE CLAMP Main work Release bleeder screws ✓ Any excess pressure escapes from the interior of the fork. Tighten the bleeder screws. 402556-10 Finishing work Remove the motorcycle from the lift stand. (il!) p. 11) Cleaning the dust boots of the fork legs Preparatory work Raise the motorcycle with a lift stand.

  • Page 17: Positioning The Fork Protector

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

  • Page 18: Removing The Fork Protector

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

  • Page 19: Performing A Fork Service

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

  • Page 21: Removing The Spring

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

  • Page 22: Disassembling The Cartridge

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

  • Page 23: Disassembling The Piston Rod

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

  • Page 24: Disassembling The Hydrostop Unit

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

  • Page 25: Checking The Fork Legs

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

  • Page 26: Assembling The Seal Ring Retainer

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

  • Page 27: Assembling The Piston Rod

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

  • Page 28: Assembling The Cartridge

    FORK, TRIPLE CLAMP Grind the piston on both sides on a surfacing plate using 1200 grit sandpaper. Clean the piston. Lubricate the piston ring. Fork oil (SAE 4) (48601166S1) p. 262) Mount the piston with chamfer facing down. Mount the rebound shim stack with the smaller washers facing upward.

  • Page 29: Assembling The Fork Legs

    FORK, TRIPLE CLAMP Position sleeve in the reservoir. Clamp the tube of the cartridge into a vise. Clamping stand (T14049S) (� p. 276) Slide reservoir onto the tube. • Info Hold the sleeve in the reservoir to prevent it from sliding out. Mount lock ring Mount seal ring retainer @ with the washer and tighten.
  • Page 30 FORK, TRIPLE CLAMP Lubricate and mount dust boot Lubricant (T511) (� p. 264) Info Always change the dust boot, seal ring, lock ring and support ring. Mount the sealing lip with the spring expander facing downward. Slide on lock ring(!}. Lubricate and slide on seal ring (5).
  • Page 31 FORK, TRIPLE CLAMP Mount lock ring Info The lock ring must engage audibly. Mount dust boot Mount fork protection ring G). Lubricate the O-ring. Slide the cartridge all the way into the fork leg. Fork oil (SAE 4) (48601166S1) (� p.
  • Page 32 FORK, TRIPLE CLAMP Pull out the piston rod and push it back in numerous times while pressing it to one side slightly. ✓ Air bubbles emerge and the cartridge is bled. Keep bleeding until no more air bubbles emerge. ✓ The piston rod moves out automatically to the middle of the total stroke distance.

  • Page 33: Lubricating The Steering Head Bearing

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

  • Page 34: Installing The Lower Triple Clamp

    FORK, TRIPLE CLAMP Remove screw (D , take off the upper triple clamp with the Remove screw handlebar and set it aside. • Info Cover the components to protect them against damage. Do not kink the cables and lines. Remove O-ring Remove protective ring Take off the lower triple clamp with the steering stem.
  • Page 35 FORK, TRIPLE CLAMP Tighten screws (3. Guideline Screw, bottom triple clamp 15 Nm (11.1 lbf ft) Tighten screw •. Guideline Screw, top steering head M20x1.5 112 Nm (8.9 lbf ft) Mount and tighten screw@. Guideline Screw, top steering stem 17 Nm Loctite ®...

  • Page 36: Adjusting The Steering Head Bearing Play

    FORK, TRIPLE CLAMP Checkin Warning Incorrect steering head bearing play impairs the handling characteristic and damages components. Danger of accidents Correct incorrect steering head bearing play immediately. Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time.

  • Page 37: Bearing

    FORK, TRIPLE CLAMP 6.29 Changing the steering head bearin Preparatory work Switch off all power consumers and switch off the engine. Remove the headlight mask with the headlight. (� p. 87) Raise the motorcycle with a lift stand.(� p. 11) Remove the front wheel.
  • Page 38 FORK, TRIPLE CLAMP Install the front fender. p. 86) Install the front wheel. p. 91) Install the headlight mask with the headlight. p. 87) Check that the wiring harness, throttle cables, and brake and clutch lines can move freely and are routed correctly. Check the play of the steering head bearing.

  • Page 39: Handlebar,Controls

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

  • Page 40: Checking The Routing Of The Throttle Cable

    HANDLEBAR,CONTROLS Checkin the routing of the throttle cable Preparatory work Remove the seat. (!ill p. 76) Remove the fuel tank. (!ill p. 77) Main work Check the routing of the throttle cable. Both throttle cables must be routed to the throttle valve body side by side behind the handlebars and above the fuel tank bearing.

  • Page 41: Adjusting The Play In The Throttle Cable

    HANDLEBAR,CONTROLS in the throttle cable Preparatory work Remove the seat. (� p. 76) Remove the fuel tank. (� p. 77) Check the routing of the throttle cable. (� p. 38) Main work Move the handlebar to the straight-ahead position. Push back sleeves Loosen nut @.

  • Page 42: Frame

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

  • Page 43: Shock Absorber, Swingarm

    SHOCK ABSORBER, SWINGARM Ad"ustin Caution Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly. The shock absorber is filled with highly compressed nitrogen. Please follow the description provided. Info The effect of the high-speed setting can be seen in fast compression of the shock absorber. Turn adjusting screw all the way clockwise with a socket wrench.

  • Page 44: Adjusting The Rebound Damping Of The Shock Absorber

    SHOCK ABSORBER, SWINGARM Ad"ustin the rebound dam in of the shock absorber Caution Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly. Risk of injury The shock absorber is filled with highly compressed nitrogen. Please follow the description provided.

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

    SHOCK ABSORBER, SWINGARM sag of the shock absorber Measure distance of rear wheel unloaded. p. 42) With another person holding the motorcycle, the rider, wearing protective full clothing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down a few times.

  • Page 46: Adjusting The Riding Sag

    SHOCK ABSORBER, SWINGARM Main work Loosen screw Turn adjusting ring @ until the spring is no longer under tension. Hook wrench (T106S) (I!!:! p. 274) Measure the overall spring length while the spring is not under tension. Tighten the spring by turning adjusting ring @ to measurement f). Guideline Spring preload 13 mm (0.51 in)

  • Page 47: Removing The Shock Absorber

    SHOCK ABSORBER, SWINGARM Remove the motorcycle from the lift stand. p. 11) Check the static sag of the shock absorber. p. 42) Check the riding sag of the shock absorber. (� p. 43) Adjust the rebound damping of the shock absorber. p.
  • Page 48 SHOCK ABSORBER, SWINGARM Remove fitting (D. Take off the angle lever. 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.

  • Page 49: Servicing The Shock Absorber

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

  • Page 50: Removing The Spring

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

  • Page 51: Disassembling The Piston Rod

    SHOCK ABSORBER, SWINGARM Press in seal ring retainer (3 using the special tool. Disassembly tool (T1216) p. 275) Remove lock ring @. Info Do not scratch the inner surface. Remove the piston rod. Remove adjusting ring (;) with the intermediate washer. Drain the oil.

  • Page 52: Disassembling The Seal Ring Retainer

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

  • Page 53: Changing The Pilot Bushing

    SHOCK ABSORBER, SWINGARM Remove centering disk Remove seal ring 201406-10 Remove washer for seal ring Remove washer @. Remove dust boot. 201407-10 9.17 Chan ilot bushin Preparatory work Remove the spring. p. 48) Disassemble the damper. p. 48) Disassemble the piston rod. p.

  • Page 54: Checking The Damper

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

  • Page 55: Installing The Heim Joint

    SHOCK ABSORBER, SWINGARM Remove seal rings on both sides. Press the heim joint against a lock ring using the special tool. Pressing tool (T1207S) (il!l p. 275) Remove the second lock ring Place special tool underneath and press out heim joint with special tool@).

  • Page 56: Assembling The Seal Ring Retainer

    SHOCK ABSORBER, SWINGARM Position both collar bushings and press them in. 9.21 Mount dust boot using the special tool. Mounting sleeve (T1204) p. 274) Lubricate the sealing lip of the dust boot. Lubricant (T625) (l!ll p. 264) Mount washer@}. Position washer (Don seal ring 201409-10 Grease seal ring and mount with the washer facing downward.

  • Page 57: Assembling The Piston Rod

    SHOCK ABSORBER, SWINGARM 9.22 Assembling the iston rod Preparatory work Assemble the seal ring retainer. (ll!;!l p. 54) Main work Clamp the piston rod with the fork in a vise. Guideline Use soft jaws. Mount rubber buffer and locking cap Position special tool on the piston rod.

  • Page 58: Assembling The Damper

    SHOCK ABSORBER, SWINGARM Mount washer with the collar facing downward. Grease the thread of the piston rod. Lubricant (T152) p. 264) Mount and tighten nut Guideline Nut, piston rod M16x1 45 Nm (33.2 lbf ft) 9.23 Assemblin Preparatory work Assemble the seal ring retainer. p.
  • Page 59 SHOCK ABSORBER, SWINGARM Install the seal ring bearer and push it under the ring groove. Mount lock ring • Info Do not scratch the inner surface. Pull out the piston rod so that the seal ring retainer rests against the lock ring. Mount locking cap (3 of the damper cartridge.

  • Page 60: Bleeding And Filling The Damper

    SHOCK ABSORBER, SWINGARM Alternative 2 Warning Danger of accident Modifications to the suspension setting may seriously alter the handling characteristic. Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components. Only make adjustments within the recommended range. Ride slowly to start with after making adjustments to get the feel of the new handling characteristic.
  • Page 61 SHOCK ABSORBER, SWINGARM When the vacuum pressure gauge reaches the specified value, turn the Oil reser­ voir control lever to Equalize pressure. Guideline 4 mbar ✓ The pressure gauge increases to the specified value. 0 bar When the pressure gauge reaches the specified value, turn the Damper control lever...

  • Page 62: Filling The Damper With Nitrogen

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

  • Page 63: Installing The Spring

    SHOCK ABSORBER, SWINGARM Open filler tap G). Fill the damper for at least 15 seconds. Guideline Gas pressure 1 1 0 bar (145 psi) • Info Watch the pressure regulator dial. Make sure that the damper is filled to the specified pressure. Close the filling port screw using tap handle f).

  • Page 64: Checking The Swingarm

    If the swingarm shows signs of damage, cracking, or deformation: Change the swingarm. • Info Always change a damaged swingarm. Repair of the swingarm is not authorized by Husqvarna M otorcycles. 9.28 Removing the swingarm Preparatory work Raise the motorcycle with a lift stand.

  • Page 65: Installing The Swingarm

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

  • Page 66: Changing The Swingarm Bearing

    SHOCK ABSORBER, SWINGARM Position the engine sprocket cover and mount it in the holder. Mount and tighten screws Guideline Screw, clutch slave cylinder 10 Nm (7.4 lbf ft) Mount and tighten screws Guideline Remaining screws, chassis 25 Nm (18.4 lbf ft) Position the brake caliper and pull it back.
  • Page 67 SHOCK ABSORBER, SWINGARM Main work Remove collar bushings G01813-10 Remove bushing G01814-10 Remove shaft seal rings using a suitable tool. Press out the bearing with a suitable tool. Press in the new bearing until it is flush using a suitable tool.
  • Page 68 SHOCK ABSORBER, SWINGARM Press in shaft seal rings Mount bushing(!}. G01814-10 Grease the shaft seal rings. Long-life grease p. 264) •- Position collar bushings with the shoulder facing inward. G01819-10 Finishing work Install the swingarm. (l!l,,!l p. 63) Install the rear wheel. (l!l,,!l p.

  • Page 69: Exhaust

    EXHAUST 10.1 Removin the manifold Preparatory work Raise the motorcycle with a lift stand. (!:JI p. 11) Remove the seat. (!:JI p. 76) Remove the right side cover. (!:JI p. 75) Remove the main silencer. (!:JI p. 69) Main work Remove fitting •...

  • Page 70: Installing The Manifold

    EXHAUST (FE EU) Remove the fuel tank. (I!!:! p. 77) Disconnect the plug-in connector of the lambda sensor and remove the cable tie. Remove springs@. Spring hook (50305017000) (ll::! p. 267) Remove screw and take off the manifold. Main work Position the manifold and mount springs Spring hook (50305017000) (I!!:!

  • Page 71: Removing The Main Silencer

    EXHAUST Lift the rear frame slightly and position the shock absorber. Mount and tighten screw Guideline Screw, top shock 60 Nm Loctite ® 2701 (44.3 lbf ft) absorber Position the rear frame. Mount and tighten screws on both sides. Guideline Screw, subframe 35 Nm Loctite...

  • Page 72: Installing The Main Silencer

    EXHAUST Main work Disconnect spring Spring hook (50305017000) (I!!:! p. 267) Remove screws and take off the main silencer. Installing the main silencer Main work Mount the main silencer. Mount screws but do not tighten yet. Reconnect spring Spring hook (50305017000) (I!!:! p.

  • Page 73: Cleaning The Spark Arrestor (Fe Us)

    EXHAUST (FE US) Remove screws of connecting cap Remove connecting cap with the perforated pipe, O-ring (D , and glass fiber yarn filling Remove screws and silencer cap (3 with O-ring @. Remove screws G) and insert together with insulating pad G,i). Remove the insulating pad from the insert.
  • Page 74 EXHAUST •--® •--� �--• �--• 402269-10 Main work Remove screws and take off silencer cap @ with 0-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. Clean main silencer housing and filter (3 of the spark arrestor with compressed air.

  • Page 75: Air Filter

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

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

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

  • Page 77: Fuel Tank, Seat, Trim

    FUEL TANK, SEAT, TRIM 12.1 0 ening filler ca Danger Fire hazard Fuel is highly flammable. 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 78: Installing The Right Side Cover

    FUEL TANK, SEAT, TRIM Position the side cover and engage in area f). Mount and tighten screw Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) Removin the seat Remove screws in the recessed grips on the left and right. Raise the rear of the seat, push the seat back, and lift it off.

  • Page 79: Removing The Fuel Tank

    FUEL TANK, SEAT, TRIM 12.7 Removin 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. Switch off the engine for refueling.

  • Page 80: Installing The Fuel Tank

    FUEL TANK, SEAT, TRIM (FE US) Remove screws with the collar bushings. Remove screw with the rubber bushing. Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank. 12.8 Installing the fuel tank Danger Fire hazard Fuel is highly flammable.

  • Page 81: Changing The Fuel Screen

    FUEL TANK, SEAT, TRIM Position the fuel tank and fit the two spoilers to the sides of the radiator bracket. Make sure that no cables are trapped or damaged. Mount the fuel tank breather. Mount and tighten screw with the rubber bushing. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft)

  • Page 82: Changing The Fuel Filter

    FUEL TANK, SEAT, TRIM Clean plug-in connection of the fuel line thoroughly with compressed air. • Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve! Disconnect the plug-in connection of the fuel line. •...
  • Page 83 FUEL TANK, SEAT, TRIM Main work Remove nut with the gasket. Remove fuel connection with the gasket. 305313-10 Remove screws Pull out the fuel pump. 305314-10 Remove hose clamps Remove fuel filter@). 305315-10 Press lock (D. Pull back fuel pump housing @. 305317-10 Change fuel screen Mount the fuel pump housing.

  • Page 84: Changing The Fuel Pump

    FUEL TANK, SEAT, TRIM Position the fuel pump. Mount fuel connection fj with the gasket but do not tighten yet. Guideline Fuel connection on fuel pump 10 Nm (7.4 lbf ft) Mount and tighten nut with the gasket. Guideline Nut, fuel pump fixation Nm (11.1 lbf ft) Tighten fuel connection fj.

  • Page 85: Checking The Fuel Pressure

    FUEL TANK, SEAT, TRIM Main work Remove nut with the gasket. Remove fuel connection with the gasket. 305313-10 Remove screws Pull out the fuel pump. 305314-10 Position the fuel pump. Mount fuel connection @ with the gasket but do not tighten yet. Guideline Fuel connection on fuel pump 10 Nm (7.4 lbf ft)
  • Page 86 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 87 FUEL TANK, SEAT, TRIM Remove the special tools. Join the fuel hose connection.

  • Page 88: Mask, Fender

    MASK, FENDER 13.1 Removin the front fender Preparatory work Switch off all power consumers and switch off the engine. Remove the headlight mask with the headlight. (� p. 87) Main work Remove screws Remove screws Remove the front fender. Main work &.

  • Page 89: Removing The Headlight Mask With The Headlight

    MASK, FENDER 13.3 Removin the headlight mask with the headlight Preparatory work Switch off all power consumers and switch off the engine. Main work Take the brake line and wiring harness out of the brake line guide. Open rubber bands on the fork legs.

  • Page 90: Wheels

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

  • Page 91: Checking The Brake Discs

    WHEELS Checkin the brake discs Warning Danger of accidents Worn-out brake discs reduce the braking effect. Make sure that worn-out brake discs are replaced immediately. Check the thickness of the front and rear brake discs at several places on the disk to see if it conforms to measurement t).

  • Page 92: Checking The Rim Run-Out

    WHEELS Checkin the rim run-out Warning Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary damage. The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes is too low, then lat­ eral and radial run-out will form in the wheel.

  • Page 93: Installing The Front Wheel

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

  • Page 94: Installing The Front Brake Disc

    WHEELS Main work Remove screws Take off the brake disc. 14.6.4 Installing the front brake disc Main work Clean the contact surface of the brake disc. Position the brake disc with the label facing outward. Mount and tighten screws Guideline Screw, front brake disc 14 Nm Loctite...

  • Page 95: Rear Wheel

    WHEELS Position spacing tube Press in the new bearing all the way using a suitable tool. Info • Only press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in. Grease new shaft seal rings @ and and press in until they are flush.

  • Page 96: Installing The Rear Wheel

    WHEELS Remove spacers 14.7.2 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 97: Removing The Rear Brake Disc

    WHEELS 14.7.3 Removing the rear brake disc Preparatory work Raise the motorcycle with a lift stand. p. 11) Remove the rear wheel. p. 93) Main work Remove screws Take off the brake disc. 14.7.4 Installing the rear brake disc Main work Clean the contact surface of the brake disc.

  • Page 98: Adjusting The Chain Tension

    WHEELS 14.7.6 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in 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 99 WHEELS Pull on the upper part of the chain with the specified weight 6). Guideline Weight of chain wear measurement 110 ... 15 kg (22 ... 33 lb.) Measure the distance G) of 18 chain links in the lower chain section. Info •...

  • Page 100: Checking For Chain Dirt Accumulation

    WHEELS Check the chain guide for wear. • Info Wear is visible on the front of the chain guide. If the light part of the chain guide is worn: Change the chain guide. Check that the chain guide is firmly seated. If the chain guide is loose: Tighten the chain guide.

  • Page 101: Changing The Drivetrain Kit

    WHEELS Main work Clean the chain regularly and then treat with chain spray. Offroad chain spray (l!!,!J p. 264) 400725-01 Finishing work Remove the motorcycle from the lift stand. (il!) p. 11) 14.7.10 Changing the drivetrain kit Preparatory work Raise the motorcycle with a lift stand. (Ii!:,!! p.

  • Page 102: Changing The Rear Wheel Bearing

    WHEELS Remove fittings (D. Take off the rear sprocket. Position the new rear sprocket. Mount and tighten the fittings. Guideline Nut, rear sprocket screw 35 Nm Loctite ® 2701 (25.8 lbf ft) Slide new engine sprocket onto the countershaft. Mount the new chain. Connect the chain with connecting link Guideline The closed side of the chain joint lock must face in the direction of travel.
  • Page 103 WHEELS Main work Remove shaft seal ring Remove lock ring Remove shaft seal ring (5). Using a suitable tool, press bearing out from the inside to the outside. Remove spacing tube Using a suitable tool, press bearing out from the inside to the outside. Press new bearing all the way in from the outside to the inside.
  • Page 104 WHEELS Grease new shaft seal ring and press it in until it is flush. Mount lock ring@. ✓ The lock ring engages audibly. Grease new shaft seal ring and press it in until it is flush. Finishing work Install the rear wheel. (ilill p.

  • Page 105: Wiring Harness, Battery

    WIRING HARNESS, BATTERY 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. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the air filter box lid. Preparatory work Switch off all power consumers and switch off the engine.

  • Page 106: Checking The Starter Relay

    WIRING HARNESS, BATTERY Remove the defective fuse. Guideline Fuse 1 - 10 A - EFI control unit Fuse 2 - 10 A- fuel pump Fuse - 10 A - high beam, low beam, parking light, tail light, license plate lamp Fuse - 10 A - horn, brake light, turn signal, radiator fan Fuses...

  • Page 107: Removing The Battery

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

  • Page 108: Recharging The Battery

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

  • Page 109: Checking The Charging Voltage

    WIRING HARNESS, BATTERY 15.7 Checkin the charging volta e Condition The battery must be fully functional and completely charged. Carry out the start procedure. (!el p. 11) Measure the voltage between the specified points. (+) - Measuring point Measuring point Plus Ground Charging voltage...

  • Page 110: Brake System

    Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 111 BRAKE SYSTEM Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container.

  • Page 112: Checking Free Travel Of Hand Brake Lever

    BRAKE SYSTEM Correct the brake fluid to level Guideline 5 mm (0.2 in) Level (brake fluid level below con- tainer rim) Brake fluid DOT 4 p. 262) Position cover with membrane Mount and tighten screws Info Clean up overflowed or spilt brake fluid immediately with water. J------ M00411-10 Checking free travel of hand brake lever...

  • Page 113: Checking The Front Brake Fluid Level

    BRAKE SYSTEM Info Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the handlebar. The range of adjustment is limited. Turn the adjusting screw by hand only, and do not apply any force.

  • Page 114: Changing The Front Brake Fluid

    BRAKE SYSTEM 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 115 BRAKE SYSTEM Warning Hazardous substances cause environmental damage. Environmental hazard Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container.

  • Page 116: Checking The Rear Brake Linings

    BRAKE SYSTEM Add brake fluid to level Guideline 5 mm (0.2 in) Measurement of Brake fluid DOT 4 (� p. 262) Position the cover with the membrane. Mount and tighten the screws. • Info Clean up overflowed or spilt brake fluid immediately with water. >------400379-10 Check the hand brake lever for a firm pressure point.
  • Page 117 Brake linings which have not been approved alter the braking efficiency. Danger of accidents Not all brake linings are tested and approved for Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.

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

    BRAKE SYSTEM Add brake fluid to level 6). Brake fluid DOT 4 p. 262) Mount screw cap with membrane @ and 0-ring. Info Clean up overflowed or spilled brake fluid immediately with water. Checking the free travel of foot brake lever Warning Danger of accidents The brake system fails in the event of overheating.

  • Page 119: Checking The Rear Brake Fluid Level

    BRAKE SYSTEM Disconnect spring and, with push rod Ci) , turn it back until you have maximum free Loosen nut travel. To adjust the basic position of the foot brake lever individually, loosen nut turn screw accordingly. • Info The range of adjustment is limited. Turn push rod Ci) accordingly until you have free travel If necessary, adjust the basic position of the foot brake lever.

  • Page 120: Changing The Rear Brake Fluid

    BRAKE SYSTEM 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 121 BRAKE SYSTEM Warning Hazardous substances cause environmental damage. Environmental hazard Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container.
  • Page 122 BRAKE SYSTEM Stand the vehicle upright. Correct the brake fluid up to marking (9. Brake fluid DOT 4 p. 262) Fit and tighten plug with oil screen and 0-ring. Info • Clean up overflowed or spilt brake fluid immediately with water. Check the foot brake lever for a firm pressure point.

  • Page 123: Lighting System, Instruments

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

  • Page 124: Setting The Kilometers Or Miles

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

  • Page 125: Setting The Service Display

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

  • Page 126: Adjusting The Headlight Range

    LIGHTING SYSTEM, INSTRUMENTS If the light-dark border does not meet specifications: Adjust the headlight range. (� p. 124) 17.7 Ad"usting the headlight range Preparatory work Check the headlight setting. (I!!:! p. 123) 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...

  • Page 127: Engine

    ENGINE 18.1 Removin the engine Preparatory work Remove the engine guard. (� p. 40) Drain the coolant. (� p. 195) Raise the motorcycle with a lift stand.(� p. 11) Remove the right side cover. (!!ll p. 75) Remove the main silencer. (!!ll p.
  • Page 128 ENGINE Remove screws Loosen screw (D. Repeat these steps on the opposite side. Swing up the subframe and secure it. Remove screw Swing back the shock absorber. Remove springs@). Spring hook (50305017000) (� p. 267) Remove screw Take off the manifold. Push back the cover.
  • Page 129 ENGINE G, . Loosen hose clip Pull off the radiator hose. 48 . Disconnect spring Remove screw Remove screw Take off the engine sprocket cover. Remove the connecting link of the chain. Take off the chain. Remove screws Take off the clutch slave cylinder and hang it to one side. •...
  • Page 130 ENGINE Loosen hose clip G). Pull off the throttle valve body toward the rear. Loosen hose clip�­ Pull off the radiator hose. Remove fittings Take off the engine braces. Remove nut�- Remove the swingarm pivot. Pull the swingarm toward the rear slightly. Remove screws Lift out the engine sideways.

  • Page 131: Installing The Engine

    ENGINE Main work Position the engine in the frame. Mount screws but do not tighten yet. Guideline Engine attachment bolt 60 Nm (44.3 lbf ft) Position the swingarm. Mount the swingarm pivot. Mount nut but do not tighten it yet. Guideline Nut, swingarm pivot M16x1.5...
  • Page 132 ENGINE Mount the throttle valve body. Position and tighten hose clip Ci) . Plug in connector (D . Position the protection cap. Plug in connector @ . Plug in connector @) . Mount the spark plug connector. Position the clutch slave cylinder with the gasket. Mount and tighten screws Guideline 1 10Nm(7.41bf ft)
  • Page 133 ENGINE Mount the radiator hose. Position and tighten hose clip Position the cable. Mount and tighten nut Position the cover. Position the manifold and mount springs Spring hook (50305017000) (!!l p. 267) Mount and tighten screw Guideline Remaining screws, chassis 25 Nm (18.4 lbf ft) Position the shock absorber.
  • Page 134 ENGINE Remove the locking piece and position the subframe. • Info Watch out for the intake flange. Mount and tighten screws �. Guideline Screw, subframe 35 Nm Loctite 2701 ® (25.8 lbf ft) Remove screw �. Mount and tighten screw �. Guideline 35 Nm Screw, subframe...

  • Page 135: Engine Disassembly

    Execute the initialization run. p. 205) Finishing work Take a 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. 197) Check the coolant level.

  • Page 136: Removing The Clutch Push Rod

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

  • Page 137: Removing The Oil Filter

    ENGINE 18.3.5 Removing the oil filter Remove screws Remove the oil filter cover@ with the O-ring. Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) (� p. 268) 18.3.6 Removing the spark plug •--"' Remove the spark plug using special tool Spark plug wrench (77229172000) (�...

  • Page 138: Removing The Alternator Cover

    ENGINE Remove spark plug shaft insert 18.3.8 Removing the alternator cover Remove screws Take the alternator cover. Take alternator cover gasket ✓ Dowels remain in the engine case. 18.3.9 Removing the torque limiter Remove torque limiter 18.3.10 Positioning the engine at ignition top dead center Turn the crankshaft counterclockwise until marking is flush with the edge of the cylinder head.

  • Page 139: Removing The Timing Chain Tensioner

    ENGINE Remove screw Info • Check through the hole whether the position notch of the crankshaft is visible. Mount and tighten screw without the washer. 18.3.11 Removing the timing chain tensioner Loosen screw Remove screw (!} with the seal ring. Pull out timing chain tensioner Remove O-ring 18.3.12...

  • Page 140: Removing The Cylinder Head

    ENGINE 18.3.13 Removing the cylinder head Remove nut with the washer. Loosen nuts @ in a crisscross pattern and remove them with the washers. Remove the cylinder head. Remove cylinder head gasket 18.3.14 Removing the piston Push the cylinder upward. •...

  • Page 141: Removing The Starter Drive

    ENGINE 18.3.15 Removing the starter drive Remove screw Insert special tool into the crankshaft. Protection cap (75029090000) p. 271) Attach special tool to the rotor. Hold it tight using the special tool and pull off the rotor by turning the screw in. Extractor (58012009000) (�...

  • Page 142: Removing The Suction Pump

    ENGINE Remove freewheel gear G). 18.3.16 Removing the suction pump Remove screws Take off oil pump cover fj. Remove O-ring (D. Take off suction pump Remove needle roller...

  • Page 143: Removing The Water Pump Wheel

    ENGINE 18.3.17 Removing the water pump wheel Remove screws Take off the water pump cover. Remove nut @ . Take off the two-part water pump impeller @) . 18.3.18 Removing the clutch cover Remove screws Take off the clutch cover. Remove the clutch cover seal.

  • Page 144: Removing The Clutch Basket

    ENGINE Take off pretension ring Take off pressure cap Remove clutch disc pack (D entirely. Remove clutch pressure piece@. 18.3.20 Removing the clutch basket Bend up the lock washer. Hold the inner clutch hub with the special tool. Loosen nut Clutch holder (51129003000) (l!l;!J p.

  • Page 145: Removing The Shift Shaft

    ENGINE 18.3.21 Removing the shift shaft Push sliding plate away from the shift drum locating unit @. Remove shift shaft with the washer. 18.3.22 Removing the shift drum locating unit Remove screw Push away locking lever @ from shift drum locating unit and remove the shift drum locating unit.

  • Page 146: Removing The Primary Gear

    ENGINE Remove pin@. Remove screws Take off the oil pump cover. Remove pin@). Push oil pump shaft inward and take it out of the engine from the ignition side. Remove force pump 18.3.25 Removing the primary gear Remove nut • Info Left-handed thread! Position the special tool in the crankshaft.

  • Page 147: Removing The Spacer

    ENGINE 18.3.27 Removing the spacer Remove spacer of the crankshaft. 18.3.28 Removing the left section of the engine case Remove screws Tilt the left section of the engine case upward and remove the screw connections of the engine fixing arm. Insert the special tool into the crankshaft.

  • Page 148: Removing The Shift Drum

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

  • Page 149: Working On Individual Parts

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

  • Page 150: Work On The Left Section Of The Engine Case

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

  • Page 151: Work On The Clutch Cover

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

  • Page 152: Checking The Oil Pressure Regulator Valve

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

  • Page 153: Checking The Lubrication System

    ENGINE Check ball and the sealing seat. If there is damage or wear: Change the ball and machine the sealing seat. Install ball and pressure spring fs). Mount and tighten screw plug with sealing washer Guideline Plug, oil pressure regulator valve M12x1.5 20 Nm (14.8 lbf ft} 308784-10...

  • Page 154: Installing The Crankshaft Bearing Inner Race

    ENGINE Take off the compensating disk. Repeat the operation on the opposite side. 18.4.7 Installing the crankshaft bearing inner race Main work Fix the crankshaft in the vise. • Info Use soft jaws. Slide on compensating disk • Info The compensating disks have a larger diameter than the crankshaft stub. 306538-10 Ensure that the compensating disks are centered and fixed with a small amount of grease.
  • Page 155 ENGINE Press in the new crank pin as far as possible. ✓ Oil hole is aligned with oil hole X If the oil holes are not correctly aligned, the conrod bearing will not be sup­ plied with oil. Check that the oil channel is clear using compressed air. Mount new connecting rod Info Thoroughly oil bearing...

  • Page 156: Checking The Crankshaft Run-Out At The Bearing Pin

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

  • Page 157: Installing The Drive Wheel Of The Balancer Shaft

    ENGINE 18.4.12 Installing the drive wheel of the balancer shaft Ensure that woodruff key is seated properly. Warm drive wheel @ of the balancer shaft and push it onto the balancer shaft. Guideline 1100 °C (212 °F) 303077-10 18.4.13 Cylinder - Nikasil ®...

  • Page 158: Checking/Measuring The Piston

    ENGINE 18.4.15 Checking/measuring the piston Use the special tool to measure clearance of the piston rings in the piston ring groove. e -• ­ Guideline Piston ring - groove clearance $ 0.08 mm ($ 0.0031 in) Feeler gauge (590290411 00) (�...

  • Page 159: Checking The Piston Ring End Gap

    ENGINE Guideline Piston/cylinder - mounting clearance Size I 0.035 ... 0.057 mm (0.00138 ... 0.00224 in) Size II 0.037 ... 0.060 mm (0.00146 ... 0.00236 in) Wear limit 0.070 mm (0.00276 in) 18.4.17 Checking the piston ring end gap Remove the piston ring from the piston. Place the piston ring in the cylinder and align with the piston.

  • Page 160: Checking The Pivot Points Of The Camshafts

    ENGINE 18.4.20 Checking the pivot points of the camshafts Check the pivot points of the camshafts. If there is damage or wear: Change the cylinder head with the camshaft bearing bridge. 306759-10 Position the camshafts. ✓ The valves are not activated. Insert the Plastigauge clearance gauge in area f).

  • Page 161: Removing The Valves

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

  • Page 162: Checking The Valves

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

  • Page 163: Checking The Cam Levers

    ENGINE 18.4.25 Checking the cam levers Check the cam levers and cam lever shafts for damage and wear. If there is damage or wear: Change the cam levers and/or cam lever shafts. 302718-10 18.4.26 Checking the cylinder head Check valve guides using the special tool.

  • Page 164: Checking The Freewheel

    ENGINE Pre-tension the valve spring using the special tool. Valve spring mounter (59029019000) (� p. 269) Insert for valve spring lever (77229060000) (� p. 273) Mount valve keys (D. • Info When mounting the valve keys, ensure that they are seated properly; it is recommended to adhere the valve keys to the valves with a small amount of grease.

  • Page 165: Removing The Freewheel

    ENGINE 18.4.29 Removing the freewheel Remove lock ring � 1"],.! ,: , , · I · ' - ✓ "'' ► l'\, I ' ·, •-�� � I:•: Press expansion ring together with suitable pliers and take off. Take freewheel out of the primary gear.

  • Page 166: Checking The Electric Starter Drive

    ENGINE Ensure that all lugs of the expansion ring pass through slots of the free wheel and engage in groove of the primary gear. Mount lock ring 6) . 18.4.31 Checking the electric starter drive ·-• 305006-10 Check the gear mesh and bearing of starter idler gear for damage and wear.

  • Page 167: Checking The Timing Assembly

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

  • Page 168: Preparing The Timing Chain Tensioner For Installation

    ENGINE Preparing the timing chain tensioner for installation 18.4.33 Press the timing chain tensioner together completely. • Info This requires some force, as the oil must be pressed out. Release the timing chain tensioner. ✓ Without pressure, the timing chain tensioner expands fully. Place two compensating disks or similar aids next to the timing chain tensioner piston.
  • Page 169 ENGINE If there is damage or wear: Change the spring retainer. Check pretension ring for damage and wear. If there is damage or wear: Change the pretension ring. Check spring washer for damage and wear. If there is damage or wear: Change the spring washer.

  • Page 170: Checking The Shift Mechanism

    ENGINE 18.4.35 Checking the shift mechanism • � 306554-10 Check shift forks on disc for damage and wear (visual check). If there is damage or wear: Change the shift fork. Check shift grooves of shift drum @ for wear. If the shift groove is worn: Change the shift drum.

  • Page 171: Preassembling The Shift Shaft

    ENGINE Change the sliding plate. Preassemble the shift shaft. (� p. 169) Check clearance between the sliding plate and the shift quadrant. Shift shaft - sliding plate/shift quad­ 0.40 ... 0.80 mm (0.0157 ... 0.0315 in) rant clearance If the measured value does not meet specifications: Change the sliding plate.

  • Page 172: Disassembling The Countershaft

    ENGINE 18.4.38 Disassembling the countershaft 306577-10 Secure the countershaft with the toothed end facing downward in the bench vise. Guideline Using soft jaws Remove stop disk and first-gear idler gear Remove needle bearing and stop disk Remove sixth-gear sliding gear Remove lock ring (3.

  • Page 173: Assembling The Main Shaft

    ENGINE 306578-10 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 174: Assembling The Countershaft

    ENGINE Preparatory work Check the transmission. p. 170) Carefully lubricate all parts before assembling. Main work 306576-11 Secure the main shaft with the toothed end facing downward in the bench vise. Guideline Using soft jaws Mount needle bearing and mount fifth-gear idler gear with the shift dogs facing up.

  • Page 175: Engine Assembly

    ENGINE Main work 306577-11 Secure the countershaft with the toothed end facing downward in the bench vise. Guideline Using soft jaws Mount needle bearing and the second-gear idler gear onto the countershaft with the protruding collar facing down. Mount stop disk (D and lock ring Mount the sixth-gear sliding gear with the shift groove facing up.
  • Page 176 ENGINE 18.5.2 Installing the transmission shafts Oil the bearing. Slide both transmission shafts into the bearing seats together. Mount lock ring @ . 18.5.3 Installing the shift forks Shift fork has a smaller inside diameter; mount this in the shift groove of the main shaft.

  • Page 177: Installing The Shift Rails

    ENGINE 18.5.5 Installing the shift rails Install shift rail together with upper spring and the lower spring. Install shift rail (D together with upper spring 18.5.6 Installing the left engine case Mount the dowels. Degrease the sealing area. Apply the sealing compound to the left section of the engine case.

  • Page 178: Installing The Spacer

    ENGINE 18.5.7 Installing the spacer Grease the shaft seal ring. Mount spacer 18.5.8 Installing the timing chain Mount balancer shaft with the timing chain and timing chain securing guide. • Info If the timing chain was used before, ensure it is running in the correct direction.

  • Page 179: Installing The Force Pump

    ENGINE 18.5.10 Installing the force pump Oil the oil pump shaft, internal rotor and external rotor before assembly. Position force pump ✓ The rounded side of the force pump faces the engine case. Mount the oil pump shaft from the ignition side. Mount pin (5).

  • Page 180: Installing The Locking Lever

    ENGINE Position suction pump ✓ The rounded sides of the external rotor face the engine case. Crank the oil pump gear wheel and ensure that it can move easily. Mount O-ring (D . Position the oil pump cover Mount and tighten screws Guideline Screw, oil pump cover Loctite...

  • Page 181: Installing The Shift Shaft

    ENGINE 18.5.14 Installing the shift shaft Slide shift shaft with the washer into the bearing seat. Push sliding plate away from the shift drum locating unit Insert the shift shaft all the way. Let the sliding plate engage in the shift drum locating unit. Shift through the transmission.

  • Page 182: Installing The Clutch Discs

    ENGINE 18.5.16 Installing the clutch discs Thoroughly oil the clutch facing discs. Beginning with an intermediate clutch disc, alternately insert all other clutch fac- ing discs and intermediate clutch discs into the clutch basket. Mount pressure piece Position pressure cap @. Mount pretension ring with the marking facing up.

  • Page 183: Installing The Clutch Cover

    ENGINE Using a straightedge and the special tool, check the spring washers for distortion. Feeler gauge (590290411 00) (� p. 269) Spring washer distortion 0 ... 0.10 mm (0 ... 0.0039 in) If the specified value was not attained: Remove screws and mount the spring retainer with marking II.

  • Page 184: Installing The Water Pump Cover

    ENGINE Mount all screws and tighten in a crisscross pattern. 18.5.18 Installing the water pump cover Mount the two-part water pump impeller Mount and tighten nut@. Guideline Nut, water-pump wheel Loctite ® ™ (3.7 lbf ft) Mount the water pump cover with the seal ring. •...

  • Page 185: Installing The Piston

    ENGINE Grease the O-ring. Position the starter motor. Mount screws but do not tighten yet. Guideline Screw, starter motor 10 Nm (7.4 lbf ft) Position gasket • Info Ensure that the dowel pins are seated properly. Position the alternator cover. Mount and tighten screws Guideline Screw, alternator cover...
  • Page 186 ENGINE Position the piston with the special tool on the cylinder. Carefully slide the piston into the cylinder from the top. Info The piston rings should not catch or they will be damaged. 303078-10 Ensure that piston marking faces the exhaust side. Thinly apply sealing compound to area@).

  • Page 187: Installing The Cylinder Head

    ENGINE Insert the special tool and press it with force towards the piston. Turn the special tool clockwise, thereby pushing the piston ring lock into the groove. Insertion tool for piston ring lock (77729030100) p. 273) Ensure that the piston ring lock is in the correct position on both sides. Remove the cloth.

  • Page 188: Installing The Camshafts

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

  • Page 189: Checking The Valve Clearance

    ENGINE Mount and tighten screw plug with the seal ring. Guideline Plug, timing chain tensioner M24x1.5 40 Nm (29.5 lbf ft) Remove screw Press the timing chain tensioner toward the timing chain using special tool Release device for timing chain tensioner (61229021000) (l!!;!I p.

  • Page 190: 18.5.25 Adjusting The Valve Clearance

    ENGINE 18.5.25 Adjusting the valve clearance Main work Remove the timing chain tensioner. p. 137) Remove the camshaft. p. 137) Raise cam levers Correct the shims according to the findings from checking the valve clearance. Install the camshafts. p. 186) Install the timing chain tensioner.

  • Page 191: Installing The Valve Cover

    ENGINE 18.5.28 Installing the valve cover Grease O-rings and mount spark plug shaft insert Position gasket @. Apply a thin layer of sealing compound in area 6). Loctite 5910 ® Position the valve cover with the gasket. Mount and tighten screws (D. Guideline Screw, valve cover I 8 Nm (5.9 lbf ft)

  • Page 192: Installing The Oil Filter

    ENGINE 18.5.30 Installing the oil filter Tilt the motorcycle to one side and fill the oil filter housing to about ½ 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 Mount and tighten screws Guideline...

  • Page 193: Installing The Spacer

    ENGINE Mount and tighten screw plug with the O-ring. Guideline Screw plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) 18.5.32 Installing the spacer Grease the shaft seal ring before mounting. Position the O-ring. Mount spacer with the bevel facing inward. 18.5.33 Installing the clutch push rod Mount clutch push rod...

  • Page 194: Clutch

    CLUTCH Checkin /correctin the fluid level of the h draulic clutch Warning Brake fluid causes skin irritation. Skin irritation Keep brake fluid out of the reach of children. Wear suitable protective clothing and safety glasses. Do not allow brake fluid to come into contact with the skin, the eyes or clothing. Consult a doctor immediately if brake fluid has been swallowed.
  • Page 195 CLUTCH Fill bleeding syringe with the appropriate hydraulic fluid. Bleed syringe (50329050000) (ll!;!l p. 267) Brake fluid DOT 4 (ll!;!l p. 262) On the clutch slave cylinder, remove bleeder screw and mount bleeding syringe Inject the liquid into the system until it escapes from openings of the master cylinder without bubbles.

  • Page 196: Water Pump, Cooling System

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

  • Page 197: Checking The Coolant Level

    WATER PUMP, COOLING SYSTEM Mount the radiator cap. Checking the coolant level Warning During motorcycle operation, the coolant gets very hot and is under pressure. Danger of scalding 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 198: Refilling Coolant

    WATER PUMP, COOLING SYSTEM Position the motorcycle upright. Place a suitable 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 cover 10 Nm (7.4 lbf ft) Refilling coolant Warning...

  • Page 199: Lubrication System

    LUBRICATION SYSTEM 21.1 Oil circuit 401362-60 Oil screen Force pump Oil pressure regulator valve Oil filter Oil nozzle, conrod lubrication Oil nozzle for cam follower lubrication Oil nozzle, piston cooling Oil nozzle for alternator cooling Oil nozzle for clutch lubrication Suction pump Oil channel, transmission lubrication Timing chain tensioner...

  • Page 200: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen

    LUBRICATION SYSTEM Changing the engine oil and oil filter, cleaning the oil screen Warning Engine and gear oil get very hot when the motorcycle is ridden. Danger of scalding Wear suitable protective clothing and safety gloves. In the event of scalding, rinse the area affected immediately with lukewarm water. Warning Hazardous substances cause environmental damage.
  • Page 201 LUBRICATION SYSTEM Remove screws Remove the oil filter cover with the 0-ring. Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) (l!!l p. 268) Completely drain the engine oil. Thoroughly clean the parts and sealing area. Lay the motorcycle on its side and fill the oil filter housing to about ½...

  • Page 202: Adding Engine Oil

    LUBRICATION SYSTEM Adding engine oil Info Too little engine oil or poor-quality engine oil results in premature wear of the engine. Main work Remove oil filler plug with the O-ring from the clutch cover. Fill engine oil to the middle of the level viewer.
  • Page 203 LUBRICATION SYSTEM If the measured value is less than the specification: Check the oil pumps for wear. Check all oil holes for free flow. Switch off the engine. Warning Danger of burns Some vehicle components get very hot when the machine is driven.

  • Page 204: Ignition System

    IGNITION SYSTEM 22.1 Ignition coil - checking the seconds winding Condition Ignition coil cylinder 1 is disconnected. Spark plug connector cylinder 1 has been removed. Ignition coil cylinder 1 check the secondary winding resistance Measure the resistance between the specified points. Ignition coil cylinder 1 pin 2 (-) - Ignition coil cylinder 1 pin 3 Ignition coil Secondary winding resistance at:...

  • Page 205: Removing The Stator And Ignition Pulse Generator

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

  • Page 206: Electric Starter

    ELECTRIC ST ARTER 23.1 Checkin the starter motor Condition The starter motor has been removed. Connect the negative cable of a 12 volt power supply to the housing of the starter motor. Connect the positive cable of the power supply briefly to connector the starter motor.

  • Page 207: Throttle Valve Body

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

  • Page 208: Technical Data

    TECHNICAL DATA 25.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 249.91 cm (15.2505 cu in) Stroke 52.3 mm (2.059 in) Bore 78 mm (3.07 in) Compression ratio 12.8:1 2,050 ... 2,150 rpm Idle speed Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 32.5 mm (1.28 in)

  • Page 209: Engine Tightening Torques

    TECHNICAL DATA Piston - diameter Size I 77.955 ... 77.965 mm (3.06909 ... 3.06948 in) Size II 77.965 ... 77.975 mm (3.06948 ... 3.06988 in) Cylinder - drill hole diameter Size I 78.000 ... 78.012 mm (3.07086 ... 3.07133 in) Size II 78.012 ...

  • Page 210: Capacities

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

  • Page 211: Chassis

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

  • Page 212: Tires

    110/100 - 18 64M TT Dunlop GEOMAX AT 81 F Dunlop GEOMAX AT 81 The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: www.husqvarna-motorcycles.com Fork 25.8 Fork part number 24.18. 7N.67...

  • Page 213: Chassis Tightening Torques

    TECHNICAL DATA Weight of rider: 75 ... 85 kg (165 ... 187 lb.) 54 N/mm (308 lb/in) Weight of rider: 85 ... 95 kg (187 ... 209 lb.) 57 N/mm (325 lb/in) 260 mm (10.24 in) Spring length Gas pressure 10 bar (145 psi) Static sag 30 mm(1.18 in)
  • Page 214 TECHNICAL DATA 60 Nm (44.3 lbf ft) ® Screw, top shock absorber Loctite 2701 Nut, fuel pump fixation 15 Nm (11.1 lbf ft) Nut, angle lever on swingarm M14x1.5 80 Nm (59 lbf ft) Nut, frame on linkage lever M14x1.5 80 Nm (59 lbf ft) Nut, linkage lever on angle lever M14x1.5...

  • Page 215: Cleaning, Care

    CLEANING, CARE 26.1 Cleanin 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 216: Checks And Maintenance Steps For Winter Operation

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

  • Page 217: Storage

    • Info Husqvarna Motorcycles recommends raising the motorcycle. Raise the motorcycle with a lift stand.(� p. 11) Preferably cover the vehicle with a tarp or similar cover that is permeable to air. Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.

  • Page 218: Service Schedule

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

  • Page 219: Service Work As Additional Order

    SERVICE SCHEDULE One-time interval • Periodic interval 28.2 Service work as additional order Annually Every 135 operating hours Every 70 operating hours when used for motorsports Every 45 operating hours Once after 15 operating hours • Change the front brake fluid. p.

  • Page 221: Wiring Diagram

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

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  • Page 223 WIRING DIAGRAM Components: A 11 EFI control unit Radiator fan temperature switch Fuse Fuse Alternator Light relay Power relay Radiator fan Voltage regulator X295 Diagnostics connector...

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  • Page 225 WIRING DIAGRAM Components: A 11 EFI control unit Low beam, high beam Speedometer Horn Parking light Light switch, horn button, kill switch...

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  • Page 227 WIRING DIAGRAM Components: Brake light switch, front Brake light switch, rear License plate lamp Brake/tail light...

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  • Page 229 WIRING DIAGRAM Components: Turn signal relay Turn signal indicator light Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right Turn signal switch...

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  • Page 231 WIRING DIAGRAM Components: A 11 EFI control unit Fuel level indicator Lambda sensor (cylinder 1) Fuse Fuse Fuel pump Speedometer...

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  • Page 233 WIRING DIAGRAM Components: A 11 EFI control unit Wheel speed sensor, front Injector (cylinder 1) CAN-bus terminating resistor 1 Speedometer X295 Diagnostics connector...

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  • Page 235 WIRING DIAGRAM Components: A 11 EFI control unit Throttle position sensor circuit A Intake air temperature sensor Engine coolant temperature sensor (cylinder 1) Rollover sensor Ignition pulse generator Manifold absolute pressure sensor (cylinder 1) Ignition coil (cylinder 1) Map-Select switch for riding mode (optional) Map-Select switch for basic setting (optional) Cable colors:...
  • Page 237 WIRING DIAGRAM Components: Battery Starter relay with main fuse Starter motor Emergency OFF switch, electric starter button...

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  • Page 239 WIRING DIAGRAM Components: A 11 EFI control unit Radiator fan temperature switch Fuse Fuse Alternator Light relay Power relay Radiator fan Voltage regulator X295 Diagnostics connector...

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  • Page 241 WIRING DIAGRAM Components: A 11 EFI control unit Low beam, high beam Speedometer Horn Parking light Light switch, horn button, kill switch Emergency OFF switch, electric starter button...

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  • Page 243 WIRING DIAGRAM Components: Brake light switch, front Brake light switch, rear License plate lamp Brake/tail light...

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  • Page 245 WIRING DIAGRAM Components: Turn signal relay Turn signal indicator light Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right Turn signal switch...

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  • Page 247 WIRING DIAGRAM Components: A 11 EFI control unit Fuel level indicator Fuse Fuse Fuel pump Speedometer...

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  • Page 249 WIRING DIAGRAM Components: A 11 EFI control unit Wheel speed sensor, front Injector (cylinder 1) CAN-bus terminating resistor 1 Speedometer X295 Diagnostics connector...

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  • Page 251 WIRING DIAGRAM Components: A 11 EFI control unit Throttle position sensor circuit A Intake air temperature sensor Engine coolant temperature sensor (cylinder 1) Rollover sensor Ignition pulse generator Manifold absolute pressure sensor (cylinder 1) Ignition coil (cylinder 1) Map-Select switch for riding mode (optional) Map-Select switch for basic setting (optional) Cable colors:...
  • Page 253 WIRING DIAGRAM Components: Battery Starter relay with main fuse Starter motor Electric starter button...

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  • Page 255 WIRING DIAGRAM Components: A 11 EFI control unit Radiator fan temperature switch (optional) Fuse Fuse Alternator Light relay Power relay Radiator fan (optional) Voltage regulator X295 Diagnostics connector...

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  • Page 257 WIRING DIAGRAM Components: A 11 EFI control unit Low beam Parking light Tail light Kill switch Light switch...

  • Page 258: Fe Us)

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  • Page 259 WIRING DIAGRAM Components: A 11 EFI control unit Fuel tank sensor Fuse Fuse Fuel pump Speedometer...

  • Page 260: Fe Us)

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  • Page 261 WIRING DIAGRAM Components: A 11 EFI control unit Wheel speed sensor, front Injection valve (cylinder 1) Speedometer CAN bus terminating resistor 1 X295 Diagnostics connector...

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  • Page 263 WIRING DIAGRAM Components: A 11 EFI control unit Throttle position sensor circuit A Intake air temperature sensor Coolant temperature sensor (cylinder 1) Rollover sensor Crankshaft position sensor Manifold absolute pressure sensor (cylinder 1) Ignition coil (cylinder 1) Map-Select switch for ride mode (optional) Map-Select switch for basic position (optional) Cable colors:...

  • Page 264: Substances

    SUBSTANCES Brake fluid DOT 4 Standard/classification Guideline Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the cor- responding properties. Recommended supplier ® Bel-Ray Super DOT 4 Brake Fluid Coolant Guideline Only use high-grade, silicate-free coolant with corrosion inhibitor additive for aluminum motors.
  • Page 265 SUBSTANCES Su er unleaded ROZ 95/RON 95/PON 91 Standard/classification DIN EN 228 (ROZ 95/RON 95/PON 91) Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade. Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use. Info use fuel containing methanol (e.

  • Page 266: Auxiliary Substances

    AUXILIARY SUBSTANCES Air filter cleaning agent Recommended supplier ® Bel-Ray Foam Filter Cleaner & Degreaser Hi h viscosity rease Recommended supplier ® LGHB2 rease Recommended supplier ® Bel-Ray Waterproof Grease Lubricant (T158) Recommended supplier ® Lubcon ® Turmogrease PP 300 Lubricant (T511) Recommended supplier ®...
  • Page 267 AUXILIARY SUBSTANCES Preserving materials for aints, metal and rubber Recommended supplier ® Bel-Ray Silicone Detailer & Protectant Spray Universal oil s ray Recommended supplier ® Bel-Ray 6 in 1...

  • Page 268: Special Tools

    SPECIAL TOOLS Bleeder cover Art. no.: 00029013005 00029013005 H00504-01 Bleeder cover Art. no.: 00029013006 00029013006 H00505-01 Bleedin device Art. no.: 00029013100 00029013100 H00518-01 Battery charger XCharge-professional EU Art. no.: 00029095050 H01065-01 Batte� charger XCharge-�rofessional US Art. no.: 00029095051 H01065-01...
  • Page 269 SPECIAL TOOLS Art. no.: 00029095052 H01065-01 Batte rofessional CH Art. no.: 00029095053 H01065-01 Extractor Art. no.: 46129021000 46129021000 H01519-01 Spring hook Art. no.: 50305017000 50305017000 H00973-01 Bleed s�ringe Art. no.: 50329050000 50329050000 H00565-01...
  • Page 270 SPECIAL TOOLS Circli liers reverse Art. no.: 51012011000 51012011000 H00572-01 Clutch holder Art. no.: 51129003000 51129003000 H00575-01 Extractor Art. no.: 58012009000 58012009000 H00592-01 Tool for inner bearing race Art. no.: 58429037037 58429037037 H00596-01 Torgue wrench with various accessories in set Art.
  • Page 271 SPECIAL TOOLS Valve s ring mounter Art. no.: 59029019000 2x.£. 59029019000 H00610-01 Feeler Art. no.: 59029041100 c:;?7 59029041100 H00616-01 Graduated disc Art. no.: 60029010000 2x£ 60029010000 H00625-01 Plastigauge clearance gauge Art. no.: 60029012000 60029012000 H00627-01 Piston ring mounting tool Art. no.: 60029015000 60029015000 H00628-01...
  • Page 272 SPECIAL TOOLS Hose clam liers Art. no.: 60029057000 60029057000 H00650-01 Testin hose Art. no.: 61029093000 61029093000 H00659-01 Pressure tester Art. no.: 61029094000 4x £ 61029094000 H00660-01 Engine assembly stand Art. no.: 61229001000 61229001000 H00662-01 Release device for timing chain tensioner Art.
  • Page 273 SPECIAL TOOLS Pressin tool for crankshaft, com lete Art. no.: 75029047000 ©' 75029047000 H00714-01 Protection ca Art. no.: 75029090000 75029090000 H00726-01 Insert for crankshaft pressin tool Art. no.: 77029008000 ®� 77029008000 H00737-01 Separator plate Art. no.: 77029009001 � 77029009001 H00738-01 Engine fixing arm Art.
  • Page 274 SPECIAL TOOLS Pliers for valve stem seals Art. no.: 77229010000 77229010000 H00752-01 Limit Art. no.: 77229026000 77229026000 H00753-01 Protection cap Art. no.: 77229031000 77229031000 H00755-01 Separator plate Art. no.: 77229032000 77229032000 H00756-01 Puller Art. no.: 77229048000 2x.£. � 77229048000 H00758-01...
  • Page 275 SPECIAL TOOLS Insert for valve s lever Art. no.: 77229060000 77229060000 H00760-01 Art. no.: 77229172000 77229172000 H00761-01 Oil pressure adapter Art. no.: 77329006000 77329006000 H00764-01 Insertion tool for piston ring lock Art. no.: 77729030100 77729030100 H01126-01 Lift stand Art. no.: 81329955000 81329955000 H01015-01...
  • Page 276 SPECIAL TOOLS Hook wrench Art. no.: T106S T106S H00841-01 De th micrometer Art. no.: T107S T107S H00842-01 Art. no.: T120 T120 H00844-01 Mounting sleeve Art. no.: T1204 T1204 H00878-01 Calibration �in Art. no.: T1205 T1205 H00879-01...
  • Page 277 SPECIAL TOOLS Pressin tool Art. no.: T1206 T1206 H00880-01 Pressin tool Art. no.: T1207S T1207S H00881-01 Mountin sleeve Art. no.: T1215 T1215 H00886-01 Disassembly tool Art. no.: T1216 T1216 H00887-01 Vacuum �um� Art. no.: T1240S � T1240S H00890-01...
  • Page 278 SPECIAL TOOLS Protecting sleeve Art. no.: T1401 T1401 H00894-01 Clam in stand Art. no.: T1403S ❖ 2x£. T1403S H00896-01 Mountin tool Art. no.: T14040S � T14040S H00922-01 Special socket Art. no.: T14047 � T14047 H00923-01 Clam�ing stand Art. no.: T14049S 2x£.
  • Page 279 SPECIAL TOOLS Press-out tool Art. no.: T14051 T14051 H00926-01 Press drift Art. no.: T1504 T1504 H00899-01 Assembly tool Art. no.: T150S �o && T150S H00852-01 Nitrogen filling tool Art. no.: T170S1 2x£3x£ T170S1 H00855-01...

  • Page 280: Standards

    STANDARDS JASOT903MA Different technical development directions required a separate specification for 4-stroke motorcycles - the JASO T903 MA stan­ dard. 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, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 281: Index

    INDEX Chain guide checking ....... . . 96 'Accessories ....... . . 8 Chain tension 'Air filter adjusting .
  • Page 282 INDEX ignition pulse generator, removing ....203 valve cover, installing ..... . . 189 left engine case section .
  • Page 283 INDEX Fork legs Headlight adjustment assembling ....... 27 checking ....... . 123 bleeding .
  • Page 284 INDEX setting ....... . . 121 wheel circumference, setting Rear sprocket Spoke tension checking .
  • Page 285 INDEX page 1 of 8 ......218,234 page 2 of 6 ......252 page 2 of 8 ......
  • Page 286 I 1 1 11 1 11 1 1 1 1 11 1 1 1 111 1 11 1 1 1 1 111 1 11 1 1 1 1 11 1 11 1 I I I I I I II I I II 3403014en 07/2016 ® Husqvarna llmi Husqvarna Motorcycles GmbH StallhofnerstraBe 3 5230 Mattighofen Austria fiiiHiAv � LZZa" ·...

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