Husqvarna FC 250 2017 Repair Manual
  1. Manuals
  2. Brands
  3. Husqvarna Manuals
  4. Motorcycle
  5. FC 250 2017
  6. Repair manual

Husqvarna FC 250 2017 Repair Manual

Hide thumbs Also See for FC 250 2017:
Table of Contents

Advertisement

Quick Links

Download this manual
PIONEERING SINCE 1903
REPAIR MANUAL2017
FC250
®
Husqvarna
Art. no. 3403040en
MOTORCYCLES

Advertisement

Table of Contents
loading

Related Manuals for Husqvarna FC 250 2017

Summary of Contents for Husqvarna FC 250 2017

  • Page 1 PIONEERING SINCE 1903 REPAIR MANUAL2017 FC250 ® Husqvarna Art. no. 3403040en MOTORCYCLES...
  • Page 3 Husqvarna accepts no liability for delivery options, deviations from figures and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 6.15 Disassembling the shock absorber MEANS OF REPRESENTATION ......7 cartridge ..........26 Symbols used ........7 6.16 Checking the fork legs ......28 1 .2 Formats used ........7 6.17 Assembling the shock absorber cartridge ..........29 SAFETY ADVICE ..........
  • Page 5 TABLE OF CONTENTS 12.8 9.10 Installing the shock absorber ....60 Installing the fuel tank ....... 102 9.11 Checking the shock absorber 12.9 Checking the fuel pressure ....104 linkage ..........62 12.10 Changing the fuel pump ....105 9.12 Servicing the shock absorber .....

  • Page 6: Chassis Tightening Torques

    TABLE OF CONTENTS 15.9 Checking the capacitor ..... 139 17.3.21 Removing the primary gear wheel ..........180 15.10 Checking the starter relay ....140 17.3.22 timing chain, removing ....180 BRAKE SYSTEM ........... 141 17.3.23 Removing the force pump .... 181 16.1 Checking the front brake linings ..
  • Page 7 TABLE OF CONTENTS 17.4.22 valve springs, checking ....201 17 .5.26 Adjusting the valve clearance ..232 17.4.23 Checking the valve spring seat ..202 17 .5.27 Installing the starter motor ... 233 17.4.24 Checking the cam levers ....202 17 .5.28 Installing the valve cover ....
  • Page 8 TABLE OF CONTENTS THROTTLE VALVE BODY ......266 24.1 Adjusting the idle speed ....266 24.2 Performing the initialization run ..266 TECHNICAL DATA ........268 25.1 Engine ..........268 25.2 Tolerance, engine wear limits ... 269 25.3 Engine tightening torques ....270 25.4 Capacities .........

  • Page 9: Means Of Representation 1

    MEANS OF REPRESENTATION 1 Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). Indicates a page reference (more information is provided on the specified page). Indicates information with more details or tips .

  • Page 10: Safety Advice

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

  • Page 11: Important Notes 3

    IMPORTANT NOTES 3 Manufacturer and im�lied warran The work prescribed in the service schedule must be carried out by an authorized Husqvarna Motorcycles workshop only and confirmed both in the customer's Service & Warranty Booklet and in the Husqvarna Motor­...

  • Page 12: Serial Numbers

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

  • Page 13: Shock Absorber Article Number

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

  • Page 14: Motorcycle

    5 MOTORCYCLE Raising the motorcycle with a lift stand Note The parked vehicle can roll away or fall over. Danger of damage Park the vehicle on a firm and level surface. Raise the motorcycle at the frame underneath the engine. I Lift stand (81329955100) p.

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

    MOTORCYCLE 5 Remove the plug-in stand Shift the transmission to the neutral position. 402001-10 Condition Ambient temperature: < 20 °C (< 68 °F) Push the cold start button in all the way. Press the electric starter button CD. Info Press the electric starter button for a maximum of 5 seconds.

  • Page 16: Fork, Triple Clamp

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

  • Page 17: Adjusting The Fork Air Pressure

    Info This is due to the volume of the hose and not due to a defect in the fork airpump or the fork. Read the accompanying instructions for Husqvarna Motorcycles accessories. Adjust the air pressure as specified. Guideline Air pressure 10.6 bar (154 psi)

  • Page 18: Adjusting The Compression Damping Of The Fork

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

  • Page 19: Bleeding The Fork Legs

    FORK, TRIPLE CLAMP 6 Guideline Rebound damping Comfort 20 clicks Standard 17 clicks Sport 12 clicks • Info Turn clockwise to increase damping; turn counter­ clockwise to reduce damping. Mount protection cap Bleeding the fork le s Preparatory work Raise the motorcycle with a lift stand. p.

  • Page 20: Removing The Fork Legs

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

  • Page 21: Installing The Fork Legs

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

  • Page 22: Installing The Fork Protector

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

  • Page 23: Disassembling The Fork Legs

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

  • Page 27: Disassembling The Air Cartridge

    FORK, TRIPLE CLAMP 6 Remove upper slide bearing Info Without using a tool, pull the stack slightly apart by hand. Take off lower slide bearing Take off support ring Ci). G, . Take off seal ring Take off lock ring @. Take off dust boot Unclamp the fork leg.

  • Page 28: Disassembling The Shock Absorber Cartridge

    6 FORK, TRIPLE CLAMP Remove the piston rod with the seal ring retainer. B03553-10 Degrease and clamp the top of the piston rod. I Clamping stand (T14016S) p. 309) Heat up the thread area of piston (D. Guideline I 50 °C (122 °F) Remove piston (D.
  • Page 29 FORK, TRIPLE CLAMP 6 Drain the shock absorber cartridge. Turn the shock absorber cartridge, degrease and clamp at the bottom. Clamping stand (T14072) p. 310) Remove lock ring Remove fluid barrier Heat up thread area of shock absorber cartridge f). Guideline (122 °F) Loosen seal ring retainer 0).

  • Page 30: Checking The Fork Legs

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

  • Page 31: Assembling The Shock Absorber Cartridge

    FORK, TRIPLE CLAMP 6 Measure the inside diameter at several places of the outside fork tube. Inside diameter of the out­ s 49.20 mm (s 1 .937 in) side fork tube If the measured value is greater than the specified value: Change the outside fork tube.
  • Page 32 6 FORK, TRIPLE CLAMP Lubricate seals on seal ring retainer I Lubricant (T14034) p. 292) Push the seal ring retainer onto the piston rod. ✓ The thread faces upward. Degrease and clamp the top of the piston rod. I Clamping stand (T14016S) p.

  • Page 33: Assembling The Air Cartridge

    FORK, TRIPLE CLAMP 6 Position fluid barrier Mount lock ring Gi). Turn the shock absorber cartridge around and clamp at top. Clamping stand (T14016S) p. 309) Fill with fork oil. Oil capacity, right 380 ml Fork oil (SAE 4) cartridge (12.85 fl.
  • Page 34 6 FORK, TRIPLE CLAMP Push spring guide and spring guide @t onto spring (D. Mount the spring. ✓ The narrow spring guide is located at the top. ✓ The wide spring guide is located at the bottom. Slot end stop @ onto the piston rod. ✓...

  • Page 35: Assembling The Fork Legs

    FORK, TRIPLE CLAMP 6 48 . Mount and tighten valve core Fill the cartridge with air . Guideline Minimum air pressure 7 bar (1 02 psi) Maximum air pressure 15 bar (218 psi) Adjust air pressure with special tool 41) as per specifications. Guideline Air pressure 110.6 bar (154 psi)
  • Page 36 6 FORK, TRIPLE CLAMP Info Without using a tool, pull the stack slightly apart by hand. Warm up the outside fork tube in area of the lower slide bearings. Guideline (122 °F) Hold the lower slide bearing with the longer side of the special tool.
  • Page 37 FORK, TRIPLE CLAMP 6 Assemble the individual components that belong together. • Info Air cartridge (left fork leg): cartridge with blue adapter (9, axle clamp with brake mount and outside fork tube with warning label screw cartridge@. B03541-10 Slide the air cartridge into the inside fork tube. B03524-10 Lubricate O-ring I Lubricant (T1 58)
  • Page 38 6 FORK, TRIPLE CLAMP Tighten air cartridge Guideline M51x1 .5 50 Nm (36.9 lbf ft) Cartridge on the outside fork tube Ring wrench (T14017) (ral p. 309) Right fork leg Clamp the inside fork tube using the axle clamp. Guideline Use soft jaws.
  • Page 39 FORK, TRIPLE CLAMP 6 Warm up the outside fork tube in area of the lower slide bearings. Guideline (122 °F) Hold the lower slide bearing with the longer side of the special tool. I Mounting tool (T14040S) (ll!:!l p. 309) Slide on the outside fork tube.
  • Page 40 6 FORK, TRIPLE CLAMP Slide the shock absorber cartridge into the inside fork tube. B03536-10 Lubricate O-ring @ on the rebound adjuster. Lubricant (T158) p. 292) Mount and tighten the rebound adjuster. Guideline Rebound adjuster M20x1 45 Nm (33.2 lbf ft) on the axle clamp Clamp the left fork leg vertically.

  • Page 41: Lubricating The Steering Head Bearing

    FORK, TRIPLE CLAMP 6 • Condition Value not determined on removal: Turn compression adjusting screw � and rebound adjusting screw clockwise all the way. Turn counterclockwise by the number of clicks corre­ sponding to the fork type. Guideline Compression damping Comfort 20 clicks Standard...

  • Page 42: Installing The Lower Triple Clamp

    6 FORK, TRIPLE CLAMP Main work Remove indicator lamp holder. Open cable holder on the left and detach the wiring har- ness. Remove screw Remove screw Take off the upper triple clamp with the handlebar and place to one side. Info Cover the components to protect them against dam­...
  • Page 43 FORK, TRIPLE CLAMP 6 Position the upper triple clamp with the handlebar. Mount screw but do not tighten yet. Position the fork legs. ✓ Air bleeder screw of the right fork leg is positioned to the front. ✓ Valve of the left fork leg faces the front. Info Grooves are milled into the side of the upper end of the fork legs.

  • Page 44: Checking Steering Head Bearing Play

    6 FORK, TRIPLE CLAMP Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses. Tighten screws Guideline Screw, top triple 17 Nm (12.5 lbf ft) clamp Secure the wiring harness with cable holder on the left. Mount indicator lamp holder.

  • Page 45: Changing The Steering Head Bearing

    FORK, TRIPLE CLAMP 6 Main work Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. Play should not be detectable on the steering head bear­ ing. If there is detectable play: Adjust steering head bearing play.

  • Page 46: Adjusting Steering Head Bearing Play

    6 FORK, TRIPLE CLAMP Remove upper bearing ring with special tool Tool bracket (58429089000) (i!!ll p. 297) Pressing tool (58429092000) p. 297) Remove the seal ring. Press the new bearing ring up to the stop with special tool@). Tool bracket (58429089000) (i!!ll p.
  • Page 47 FORK, TRIPLE CLAMP 6 Main work Loosen screws Remove screw Loosen and retighten screw Guideline Screw, top steering M20x1 .5 12 Nm (8.9 lbf ft) head Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses. Tighten screws Guideline Screw, top triple...

  • Page 48: 7 Handlebar,Controls

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

  • Page 49: Clutch Lever

    HANDLEBAR,CONTROLS 7 First bolt the handlebar clamp with screws onto the longer, higher side of the handlebar supports so that both parts touch. Tighten screws evenly. Guideline Screw, handlebar 20 Nm (14.8 lbf ft) clamp Finishing work Mount the handlebar cushion. Ad"usting the basic �osition of the clutch lever Adjust the basic position of the clutch lever to your hand size by turning adjusting screw...

  • Page 50: Checking Throttle Cable Routing

    7 HANDLEBAR,CONTROLS Checking throttle cable routing Preparatory work Remove the right side cover. p. 99) Remove the air filter box cover. p. 95) Remove the seat. p. 99) Remove the fuel tank. p. 101) Main work Check throttle cable routing. Both throttle cables must be routed, side by side, on the back of the handlebars and above the fuel tank bracket, to the throttle valve body.

  • Page 51: Adjusting Throttle Cable Play

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

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

    7 HANDLEBAR,CONTROLS Finishing work Check throttle cable play. p. 48) Install the fuel tank. p. 102) Mount the seat. p. 1 00) Install the air filter box cover. p. 95) Install the right side cover. p. 99) Settin g the characteristic map of the throttle response Info On the throttle grip, the characteristic map of the throttle response is changed by changing the guide plate.
  • Page 53 HANDLEBAR,CONTROLS 7 Clean the outside of the handlebar and the inside of the grip tube. Mount the grip tube on the handlebar. Attach the throttle cables to the guide plate and route cor­ rectly. Position half-shells@, mount and tighten screws Guideline Screw, throttle grip I 5 Nm (3.7 lbf ft)

  • Page 54: Frame

    Change the frame. Info Always replace a frame that has been damaged due to a mechanical impact. Repair of the frame is not authorized by Husqvarna Motorcycles. Changing the footrests Info The procedures are the same on both footrests.
  • Page 55 FRAME 8 Position spring as shown. (!). ✓ Spring G) engages in area ✓ Press the spring with special tool Footrest spring plier (79029083000) (ll!:!I p. 304) ✓ The special tool is applied to area on the footrest. Mount pin 311720-10 Mount the washer and splint R00445-10...

  • Page 56: Shock Absorber, Link Fork

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

  • Page 57: Adjusting The Rebound Damping Of The Shock Absorber

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

  • Page 58: Measuring The Rear Wheel Dimension Unloaded

    9 SHOCK ABSORBER, LINK FORK Measuring the rear wheel dimension unloaded Preparatory work Raise the motorcycle with a lift stand. p. 12) Main work Position the sag gage in the rear axle and measure the distance to marking SAG on the rear fender. Sag gauge (00029090500) Sag gage pin (00029990010) Note down the value as dimension 6).

  • Page 59: Checking The Riding Sag Of The Shock Absorber

    SHOCK ABSORBER, LINK FORK 9 Checking the riding sag of the shock absorber Measure dimension of rear wheel unloaded. p. 56) With another person holding the motorcycle, the rider, wear­ ing full protective clothing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down a few times.

  • Page 60: Adjusting The Riding Sag

    9 SHOCK ABSORBER, LINK FORK Main work Loosen screw Turn adjusting ring @ until the spring is no longer under ten- sion. I Hook wrench (90129051000) (iell p. 306) Measure the overall spring length while the spring is not under tension. Tighten the spring by turning adjusting ring to specified measurement...

  • Page 61: Removing The Shock Absorber

    SHOCK ABSORBER, LINK FORK 9 Check the static sag of the shock absorber. p. 56) Check the riding sag of the shock absorber. p. 57) Adjust the rebound damping of the shock absorber. p. 55) Remove the motorcycle from the lift stand. p.

  • Page 62: Installing The Shock Absorber

    9 SHOCK ABSORBER, LINK FORK Remove the connecting link of the chain. Take off the chain. Info Cover the components to protect them against dam­ age. Remove nut and pull out the fork pivot. Pull the link fork to the rear and secure it against falling over. Hold the shock absorber and remove screw Remove the shock absorber carefully at the bottom.
  • Page 63 SHOCK ABSORBER, LINK FORK 9 Position link fork and mount fork pivot. Info Pay attention to flat area Mount and tighten nut Guideline Nut, fork pivot I M16x1 .5 I 100 Nm (73.8 lbf ft) I Mount the chain. Connect the chain with connecting link Guideline The closed side of the chain joint lock must face in the direction of travel.

  • Page 64: Checking The Shock Absorber Linkage

    9 SHOCK ABSORBER, LINK FORK Position the frame protectors on the left and right. Mount and tighten screws@). Guideline Screw, frame pro­ Nm (2.2 lbf ft) tector Mount and tighten screws with the washers. Guideline Screw, frame pro­ 3 Nm (2.2 lbf ft) tector Mount the new cable ties.
  • Page 65 SHOCK ABSORBER, LINK FORK 9 •- -• 303096-10 Check needle bearings for damage and wear. If there is damage or wear: Change the needle bearings. Check spacers (3 and @ for damage and wear. If there is damage or wear: Change the spacers.

  • Page 66: Servicing The Shock Absorber

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

  • Page 67: Removing The Spring

    SHOCK ABSORBER, LINK FORK 9 Remove the spring. (il!:!I p. 65) � Disassemble the damper. (IUI p. 66) Disassemble the piston rod. (IUI p. 67) Disassemble the seal ring retainer. (IUI p. 68) Check the damper. (IUI p. 70) (lgl Remove the heim joint.

  • Page 68: Disassembling The Damper

    9 SHOCK ABSORBER, LINK FORK Remove the spring. Remove washer 9.14 Disassemblin the damper Preparatory work Remove the spring. p. 65) Main work Make a note of the present state of rebound and com­ pression damping @. Open the adjusters of the rebound and compression damp­ ing completely.

  • Page 69: Disassembling The Piston Rod

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

  • Page 70: Disassembling The Seal Ring Retainer

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

  • Page 71: Changing The Pilot Bushing

    SHOCK ABSORBER, LINK FORK 9 Main work Remove O-ring Remove rebound rubber B04414-10 Remove centering disk@) with spring Remove seal ring B04412-10 Remove washer (3 from seal ring Remove washer Remove dust boot. 201407-10 9.17 Changing the pilot bushing Preparatory work Remove the spring.

  • Page 72: Checking The Damper

    9 SHOCK ABSORBER, LINK FORK Slide the new pilot bushing onto the special tool. I Pressing tool (T1504) p. 310) Position the pilot bushing in the seal ring retainer using the special tool. I Pressing tool (T1504) (!Sl p. 310) Support seal ring retainer with sleeve of the special...

  • Page 73: Removing The Heim Joint

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

  • Page 74: Installing The Heim Joint

    9 SHOCK ABSORBER, LINK FORK Place special tool underneath and press out heim joint using special tool I Pressing tool (T1207S) (IOI p. 307) B04391-10 Position new heim joint and the special tool in the bench vise. Guideline I Use soft jaws. I Pressing tool (T1206) (IOI p.

  • Page 75: Assembling The Piston Rod

    SHOCK ABSORBER, LINK FORK 9 Mount washer Position washer on seal ring 201409-10 Grease seal ring and mount with the washer facing down­ ward. Lubricant (T14034) p. 292) Mount centering disk with spring (D. 804413-10 Mount rebound rubber Grease the 0-ring groove. Lubricant (T158) p.
  • Page 76 9 SHOCK ABSORBER, LINK FORK Mount rebound washer with cut-out facing down. Mount compression shim stack with the smaller washers facing downward. 802057-10 Sand down piston on both sides on a surface plate using 1200 grit sandpaper. Clean the piston. Mount the piston.

  • Page 77: Assembling The Damper

    SHOCK ABSORBER, LINK FORK 9 Lubricate the thread of the piston rod. Lubricant (T152) p. 292) Mount and tighten nut Guideline Nut, piston rod I M12x1 I 40 Nm (29.5 lbf ft) G02060-10 9.23 Assemblin the damper Preparatory work Assemble the seal ring retainer. p.
  • Page 78 9 SHOCK ABSORBER, LINK FORK Mount seal ring retainer and slide it under the ring groove. Mount lock ring • Info Do not scratch the inside surface. Pull out the piston rod until the seal ring retainer is flush with the lock ring.

  • Page 79: Bleeding And Filling The Damper

    SHOCK ABSORBER, LINK FORK 9 Alternative 2 Warning Danger of accident Modifications to the sus­ pension setting may seriously alter the handling characteristic. Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components. Only make adjustments within the recom­...
  • Page 80 9 SHOCK ABSORBER, LINK FORK Adjust the control lever as shown. ✓ Control lever is set to External tank Closed, is set to Damper Vacuum Oil reservoir set to Vacuum. Activate switch (3. On/Off ✓ The suction process begins. ✓ Pressure gauge @ drops to the required value. I <...
  • Page 81 SHOCK ABSORBER, LINK FORK 9 When the pressure gauge reaches the specified value, turn control lever Oil reservoir to Vacuum. Guideline 0 bar ✓ The vacuum gauge drops to the required value. 4 mbar When the vacuum gauge reaches the required value, turn control lever Oil reservoir to Equalize Pressure.

  • Page 82: Filling Damper With Nitrogen

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

  • Page 83: Installing The Spring

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

  • Page 84: Checking The Link Fork

    If the link fork exhibits damage, cracking, or deformation: Change the link fork. Info • Always replace a damaged link fork. Repair of the link fork is not authorized by Husqvarna Motorcycles. 9.28 Checking the fork bearing for play Preparatory work Raise the motorcycle with a lift stand.

  • Page 85: Removing The Link Fork

    SHOCK ABSORBER, LINK FORK 9 Main work Move the link fork up and down. If there is detectable play: Change the fork bearing. p. 86) Move the link fork from one side to the other. If there is detectable play: Change the fork bearing.

  • Page 86: Installing The Link Fork

    9 SHOCK ABSORBER, LINK FORK Remove connecting link of the chain. Take off the chain. Info Cover the components to protect them against dam­ age. Remove fitting Lower the link fork. Remove the cable ties. Remove screws Remove screws with the washers. Remove the frame protectors on the left and right.
  • Page 87 SHOCK ABSORBER, LINK FORK 9 Position the frame protectors on the left and right. Mount and tighten screws Guideline Screw, frame pro­ 3 Nm (2.2 lbf ft) tector Mount and tighten screws with the washers. Guideline Screw, frame pro­ 3 Nm (2.2 lbf ft) tector Mount the cable ties.

  • Page 88: Changing The Fork Bearing

    9 SHOCK ABSORBER, LINK FORK Remove the motorcycle from the lift stand. p. 12) 9.31 Changing the fork bearing Preparatory work Raise the motorcycle with a lift stand. p. 12) Remove the rear wheel. p. 122) Remove the link fork. p.
  • Page 89 SHOCK ABSORBER, LINK FORK 9 Mount bushing R02758-10 Grease the shaft seal rings. I Long-life grease p. 292) Position the collar bushings with the shoulder facing inward. R02763-10 Right fork bearing Remove collar bushings 0). R02760-10 Remove bushing @ . R02761-10...

  • Page 90: Changing The Heim Joint

    9 SHOCK ABSORBER, LINK FORK Remove shaft seal rings using a suitable tool. Press out bearing using a suitable tool. Using a suitable tool, press in new bearing Press in shaft seal rings @. Mount bushing@. R02761-10 Grease the shaft seal rings. Long-life grease p.
  • Page 91 SHOCK ABSORBER, LINK FORK 9 Press the heim joint against a lock ring using the special tool. Pressing tool (T1207S) p. 307) Remove second lock ring B04390-10 Place special tool underneath and press out heim joint using special tool Ci). Pressing tool (T1207S) p.

  • Page 92: Checking The Heim Joint For Play

    9 SHOCK ABSORBER, LINK FORK Remove the motorcycle from the lift stand. p. 12) 9.33 Checking the heim joint for play Preparatory work Raise the motorcycle with a lift stand. p. 12) Place a load on the front of the vehicle. ✓...

  • Page 93: Exhaust System

    EXHAUST SYSTEM Removing the manifold 10.1 Preparatory work Raise the motorcycle with a lift stand. (ra:!l p. 12) Remove the right side cover. p. 99) Remove the main silencer. p. 93) Main work Remove screw Remove fitting Info Raise the link fork slightly to be able to remove the screws more easily.

  • Page 94: Installing The Manifold

    10 EXHAUST SYSTEM Remove screw Turn the shock absorber and lower it. Take off the manifold. Main work Slip in the manifold and position it. Position the shock absorber and mount and tighten screw Guideline Screw, top 60 Nm (44.3 lbf ft) ®...

  • Page 95: Removing The Main Silencer

    EXHAUST SYSTEM Position the angle lever and linkage lever. Mount and tighten fitting Guideline Nut, linkage lever to M14x1 .5 80 Nm (59 lbf ft) angle lever Info • Raise the link fork slightly to be able to mount the screw more easily.

  • Page 96: Changing The Glass Fiber Yarn Filling Of The Main Silencer

    10 EXHAUST SYSTEM Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis Finishing work Install the right side cover. p. 99) Changing the glass fiber am filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. Allow the exhaust system to cool down before performing any work on the vehicle.

  • Page 97: Air Filter 11

    AIR FILTER 11 Removing the air filter box cover Pull off the air filter box cover sideways in areas 6) , and (9 , and remove toward the front. Installing the air filter box cover Position air filter box cover on collar bushings and push toward the rear.

  • Page 98: Installing The Air Filter

    11 AIR FILTER Main work Detach retaining tab Remove air filter with air filter support. Remove air filter from air filter support. 11.4 lnstallin the air filter Main work Mount the clean air filter on the air filter support. Grease the air filter in area f). I Long-life grease p.

  • Page 99: Sealing The Air Filter Box

    AIR FILTER 11 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner (!Sl p. 292) • Info Only press the air filter to dry it, never wring it out. Oil the dry air filter with a high-grade air filter oil.

  • Page 100: 12 Fuel Tank, Seat, Trim

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

  • Page 101: Removing The Right Side Cover

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

  • Page 102: Mounting The Seat

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

  • Page 103: Removing The Fuel Tank

    FUEL TANK, SEAT, TRIM 12.7 Removing 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 104: Installing The Fuel Tank

    12 FUEL TANK, SEAT, TRIM Remove screws Remove screw with the rubber bushing. Pull both spoilers laterally off the radiator and take off the fuel tank upwards. 12.8 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.

  • Page 105: Remaining Screws, M5

    FUEL TANK, SEAT, TRIM Main work Check throttle cable routing. p. 48) Position the fuel tank and fit the two spoilers laterally to the radiator. Make sure that no cables or throttle cables are trapped or damaged. Attach the fuel tank breather hose to the fuel tank lid. Mount and tighten screw with the rubber bushing.

  • Page 106: Checking The Fuel Pressure

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

  • Page 107: Changing The Fuel Pump

    FUEL TANK, SEAT, TRIM Guideline Maximum duration of the 3 min actuator test Check the fuel pressure with the fuel tank filler cap closed. Fuel pressure When the fuel pump is 3.3 ... 3.7 bar (48 ... 54 psi) active If the specification is not reached: Open fuel tank filler cap.
  • Page 108 12 FUEL TANK, SEAT, TRIM Note Environmental hazard Improper handling of fuel is a danger to the environment. Do not allow fuel to enter the groundwater, the soil, or the sewage system. Preparatory work Drain the fuel from the fuel tank into a suitable container. Remove the right side cover.
  • Page 109 FUEL TANK, SEAT, TRIM Position the new fuel pump. Mount nut with gasket, but do not tighten yet. Pull out the fuel pump. ✓ The fuel filter remains in the fuel tank. • Info Make sure that the fuel filter is not pulled out too far. Keep the fuel pump with hose tensioned, turn clockwise and position.

  • Page 110: Changing The Fuel Filter

    12 FUEL TANK, SEAT, TRIM Install the air filter box cover. p. 95) Install the right side cover. p. 99) 12.11 Changing the fuel filter Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
  • Page 111 FUEL TANK, SEAT, TRIM •- · , Remove screws -.· r®::: � R00449-10 Pull out the fuel pump. Remove hose clamps Remove fuel filter R00450-11 Press locking mechanism Pull back fuel pump housing@. 305317-10 @) _ Change fuel screen Mount the fuel pump housing.
  • Page 112 12 FUEL TANK, SEAT, TRIM Mount the new fuel filter ✓ Arrow points away from the fuel pump. Mount hose clamps I Hose clamp plier (60029057000) p. 299) R00451-10 Position the fuel pump. Mount nut with gasket, but do not tighten yet. Pull out the fuel pump.

  • Page 113: Changing The Fuel Screen

    FUEL TANK, SEAT, TRIM Mount fuel connection with the gasket but do not tighten yet. Tighten nut Guideline Nut, fuel pump fas­ M12x1 .75 15 Nm (11.1 lbf ft) tener Tighten fuel connection Guideline Fuel connection on M8x1.25 10 Nm (7.4 lbf ft) fuel tank Finishing work Install the fuel tank.
  • Page 114 12 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. Info Remaining fuel may flow out of the fuel hose.

  • Page 115: Mask, Fender 13

    MASK, FENDER 13 13.1 Removing front fender Preparatory work Remove the start number plate. p. 114) Main work Remove screws and @.Take off the front fender. Main work Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis Finishing work Install the start number plate.

  • Page 116: Removing The Start Number Plate

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

  • Page 117: Wheels 14

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

  • Page 118: Checking The Wheel Bearing For Play

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

  • Page 119: Checking Spoke Tension

    WHEELS 14 If the brake disc exhibits damage, cracking, or deforma­ tion: Change the front brake disc. p. 120) Change the rear brake disc. p. 124) Checkin spoke tension Warning Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary damage.

  • Page 120: Frontwheel

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

  • Page 121: Installing The Front Wheel

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

  • Page 122: Changing The Front Brake Disc

    14 WHEELS Mount and tighten screw fj. Guideline Screw, front wheel M20x1.5 35 Nm (25.8 lbf ft) spindle Operate the hand brake lever several times until the brake linings are seated correctly against the brake disc. Remove the motorcycle from the lift stand. p.
  • Page 123 WHEELS 14 Press out bearing using a suitable tool. • Info Spacing tube can be pushed aside. Remove the spacing tube. Press out bearing using a suitable tool. Press in new bearing all the way using a suitable tool. Info Only press the bearing in via the outer bearing race otherwise the bearing will be damaged when it is pressed in.

  • Page 124: Rear Wheel

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

  • Page 125: Installing The Rear Wheel

    WHEELS 14 14.8.2 Installing the rear wheel Warning Oil or grease on the brake discs reduces the braking effect. Danger of accidents Always keep the brake discs free of oil and grease. Clean the brake discs with brake cleaner when necessary. Main work Check the wheel bearing for damage and wear.

  • Page 126: Changing The Rear Brake Disc

    14 WHEELS 14.8.3 Changing the rear brake disc Info If the brake discs are changed, the brake linings must also be changed. Preparatory work Raise the motorcycle with a lift stand. p. 12) Remove the rear wheel. p. 122) Main work Remove screws Remove the brake disc.

  • Page 127: Adjusting The Chain Tension

    WHEELS 14 14.8.5 Adjusting the chain tension Warning Incorrect chain tension damages components and results in accidents. Danger of accidents If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.
  • Page 128 14 WHEELS Main work Shift the transmission to the neutral position. Check the rear sprocket and engine sprocket for wear. If the rear sprocket or engine sprocket is worn: Change the drivetrain kit. (� p. 129) Info The engine sprocket, rear sprocket and chain should always be replaced together.
  • Page 129 WHEELS 14 Check the chain sliding guard for wear. If the lower edge of the chain pins is in line with, or below, the chain sliding guard: Change the chain sliding guard. Check that the chain sliding guard is firmly seated. If the chain sliding guard is loose: Tighten the screws on the chain sliding guard.

  • Page 130: Checking For Chain Dirt Accumulation

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

  • Page 131: Changing The Drivetrain Kit

    WHEELS 14 Main work Rinse off loose dirt with a soft jet of water. Remove old grease residue with chain cleaner. Chain cleaner (!el p. 292) After drying, apply chain spray. Off-road chain spray (!el p. 293) 400725-01 Finishing work Remove the motorcycle from the lift stand.
  • Page 132 14 WHEELS Remove engine sprocket Remove fittings 0). Take off the rear sprocket. Position the new rear sprocket. Mount and tighten the fit­ tings. Guideline Nut, rear 35 Nm (25.8 lbf ft) ® Loctite 2701 sprocket screw Slide new engine sprocket onto the countershaft.

  • Page 133: Changing The Rear Wheel Bearing

    WHEELS 14 Position the engine sprocket cover. Mount and tighten screw with the washer. Guideline Screw, clutch slave 10 Nm (7.4 lbf ft) cylinder Mount and tighten screw @. Guideline Screw, engine 20 Nm (14.8 lbf ft) sprocket cover Finishing work Install the air filter box cover.
  • Page 134 14 WHEELS Using a suitable tool, press bearing out from the inside to the outside. Check spacer washer @ for damage and wear. If the spacer washer is damaged or worn: Replace the spacer washer. Position spacer washer @. Press new bearing all the way in from the outside to the inside.

  • Page 135: Wiring Harness, Battery 15

    WIRING HARNESS, BATTERY 15 Changing the main fuse Warning Fire hazard Incorrect fuses overload the electrical system. Only use fuses with the required ampere value. Do not bypass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the seat.

  • Page 136: Of The 12 V Battery

    15 WIRING HARNESS, BATTERY 15.2 Disconnecting the negative cable of the 12 V batterY Preparatory work Press and hold the kill switch � while the engine is idling until the engine stops. Remove the air filter box cover. p. 95) Remove the seat.

  • Page 137: Removing The 12 V Battery

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

  • Page 138: Installing The 12 V Battery

    15 WIRING HARNESS, BATTERY Installing the 12 V batte� Main work Position the 12 V battery in the battery compartment with the terminals facing forward and secure with holding bracket 112 V battery (C22S) p. 273) Mount and tighten screw Guideline Screw, battery sup­...
  • Page 139 WIRING HARNESS, BATTERY 15 Note Environmental hazard Hazardous substances cause environmental damage. Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Even when there is no load on the 12 V battery, it discharges steadily. The charging level and the method of charging are very important for the service life of the 12 V battery.

  • Page 140: Checking The Charging Voltage

    15 WIRING HARNESS, BATTERY Guideline The charging current, charging voltage, and charging time must not be exceeded. Recharge the 12 V battery 3 months regularly when the motorcy- cle is not being used Finishing work Connect the negative cable of the 12 V battery. p.

  • Page 141: Checking The Capacitor

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

  • Page 142: Checking The Starter Relay

    15 WIRING HARNESS, BATTERY 15.10 Checking the starter rela� Preparatory work Press and hold the kill switch � while the engine is idling until the engine stops. Remove the air filter box cover. p. 95) Remove the seat. p. 99) Disconnect the negative cable of the 12 V battery.

  • Page 143: Brake System 16

    BRAKE SYSTEM 16 Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. Ensure that worn-out brake linings are replaced immediately. Check the brake linings for minimum thickness f). Minimum thickness 2:: 1 mm (2:: 0.04 in) If the minimum thickness is less than specified: Change the front brake linings.
  • Page 144 16 BRAKE SYSTEM Move the brake reservoir mounted on the handlebar to a hori­ zontal position. Remove screws Take off cover with membrane Manually press the brake caliper toward the brake disc to push back the brake pistons. Ensure that brake fluid does not flow out of the brake fluid reservoir, if necessary extract excess.

  • Page 145: Hand Brake Lever

    BRAKE SYSTEM 16 Add brake fluid up to level f) . Guideline Level f) (brake fluid level 5 mm (0.2 in) below reservoir rim) Brake fluid DOT 4 / DOT 5.1 p. 290) Position cover with membrane Mount and tighten screws Info Clean up overflowed or spilled brake fluid immediately with water.

  • Page 146: Checking The Front Brake Fluid Level

    16 BRAKE SYSTEM Info Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the han­ dlebar. Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the handlebar. The range of adjustment is limited. Only turn the adjusting screw by hand, and do not use force.
  • Page 147 BRAKE SYSTEM 16 Warning Brake fluid causes skin irritation. Skin irritation Keep brake fluid out of the reach of children. Wear suitable protective clothing and safety glasses. Do not allow brake fluid to come into contact with the skin, the eyes or clothing. Consult a doctor immediately if brake fluid has been swallowed.

  • Page 148: Changing The Front Brake Fluid

    16 BRAKE SYSTEM Changing the front brake fluid Warning Brake fluid causes skin irritation. Skin irritation Keep brake fluid out of the reach of children. Wear suitable protective clothing and safety glasses. Do not allow brake fluid to come into contact with the skin, the eyes or clothing. Consult a doctor immediately if brake fluid has been swallowed.
  • Page 149 BRAKE SYSTEM 16 Open shut-off valve -4!) • Info Follow the instructions in the Owner's Manual of the bleeding device. Ensure that the filling pressure is set on pressure gauge f). Correct the filling pressure on pressure regulator if neces­ sary.

  • Page 150: Checking The Brake Linings Of The Rear Brake

    16 BRAKE SYSTEM Checking the brake linings of the rear brake Warning Worn-out brake linings reduce the braking effect. Danger of accidents Ensure that worn-out brake linings are replaced immediately. Check the brake linings for minimum thickness I Minimum thickness I �...
  • Page 151 BRAKE SYSTEM 16 Stand the vehicle upright. Remove screw cap with membrane and the O-ring. Manually press the brake caliper toward the brake disc to push back the brake piston. Ensure that brake fluid does not flow out of the brake fluid reservoir, if necessary extract excess.

  • Page 152: Checking The Free Travel Of Foot

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

  • Page 153: Checking The Rear Brake Fluid Level

    BRAKE SYSTEM 16 Hold screw and tighten nut@}. Guideline 20 Nm (14.8 lbf ft) Nut, foot brake lever stop Attach spring Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail. If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.
  • Page 154 16 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 155: Changing The Rear Brake Fluid

    BRAKE SYSTEM 16 Changing the rear brake fluid Warning Skin irritation Brake fluid causes skin irritation. Keep brake fluid out of the reach of children. Wear suitable protective clothing and safety glasses. Do not allow brake fluid to come into contact with the skin, the eyes or clothing. Consult a doctor immediately if brake fluid has been swallowed.
  • Page 156 16 BRAKE SYSTEM Open shut-off valve • Info Follow the instructions in the Owner's Manual of the bleeding device. Ensure that the filling pressure is set on pressure gauge f). Correct the filling pressure on pressure regulator if neces­ sary. Guideline I Filling pressure I 2 ...

  • Page 157: Engine 17

    ENGINE 17 17.1 Removing the engine Preparatory work Raise the motorcycle with a lift stand. (ra:!l p. 12) Drain the coolant. (ra:!l p. 248) Remove the right side cover. p. 99) Remove the air filter box cover. p. 95) Remove the seat. p.
  • Page 158 17 ENGINE Push back protection cap Unplug the connector. Pull rollover sensor of the holder and hang to one side. Remove screw (D. Loosen screw Repeat these steps on the opposite side. Pivot the subframe up and secure it. Remove screw @. Pivot the shock absorber toward the rear and twist it slightly.
  • Page 159 ENGINE 17 Remove springs Spring hook (5030501700004) p. 306) Remove screw Gi) with the washer. Take off the manifold. Remove fittings Take off the engine brace. Disconnect plug-in connector Disconnect plug-in connectors G).
  • Page 160 17 ENGINE Disconnect plug-in connector Remove the cable tie. Remove the cable clamps and expose the cable. Push back protection cap �. Unplug the connector. Gs). Loosen hose clip Pull off the radiator hose. Loosen hose clip Pull off the radiator hose.
  • Page 161 ENGINE 17 Pull capacitor off of the holder and hang to one side. Disconnect spark plug connector Remove screw fl!) with the washer. Remove screw Take off the engine sprocket cover. Remove screws �. Take off the clutch slave cylinder with the gasket and hang it to the side.
  • Page 162 17 ENGINE Remove the connecting link of the chain. Take off the chain. Info Cover the components to protect them against dam­ age. Remove screw with the washer. Take off the engine sprocket. Remove screw fJ) with the washers. Take off the shift lever. Loosen hose clip �.
  • Page 163 ENGINE 17 Remove spring �- Remove fitting fJ). Remove screws Remove the foot brake cylinder and allow it to hang tension­ free to the side. Take the brake line out of the guide. Remove nut Remove the link fork pivot. Carefully pull the link fork back, and secure it.

  • Page 164: Installing The Engine

    17 ENGINE Remove screws �. Lift out the engine sideways. • Info The help of an assistant is useful in this step. Make sure that the engine is sufficiently secured against falling over. Cover the components to protect them against dam­ age.
  • Page 165 ENGINE 17 Position the brake line in the guide. Mount the foot brake cylinder on push rod and position it. Info Ensure that the dust boot is correctly seated. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis Position the linkage lever.
  • Page 166 17 ENGINE Mount the vent hose and position hose clamp Position the throttle valve body. Tighten hose clip@). Position the shift lever. Mount and tighten screw � with washers. Guideline Screw, shift 14 Nm (10.3 lbf ft) Loctite ® ™ lever Slide on the engine sprocket with the collar facing the engine.
  • Page 167 ENGINE 17 Position clutch slave cylinder with the new gasket. Mount and tighten screws Guideline Screw, clutch slave 10 Nm (7.4 lbfft) cylinder Position the engine sprocket cover. Mount and tighten screw Guideline Screw, clutch slave 10 Nm (7.4 lbf ft) cylinder Mount and tighten screw�­...
  • Page 168 17 ENGINE Mount the radiator hose. Position and tighten hose clip G). Plug in the connector. fl!>. Position the protection cap Route the cable without tension and secure with cable clips and cable ties. Join plug-in connector .. of the gear position sensor. Join plug-in connector of the crankshaft speed sensor.
  • Page 169 ENGINE 17 Position the engine brace. Mount and tighten fittings �- Guideline Screw, engine 25 Nm (18.4 lbf ft) ® brace Loctite 2701 Tighten screws Guideline Engine carrying 60 Nm (44.3 lbf ft) screw Position the manifold. Mount screw � with the washer but do not tighten yet. Guideline Remaining screws, 25 Nm (18.4 lbf ft)
  • Page 170 17 ENGINE Remove the locking piece and position the subframe. Info Watch out for the intake flange. Mount and tighten screw @i). Guideline Screw, sub­ 30 Nm (22.1 lbf ft) ® Loctite 2701 frame Remove screw �. Mount and tighten screw �. Guideline Screw, sub­...
  • Page 171 ENGINE 17 Connect negative cable G). Guideline Screw, battery termi- 2.5 Nm (1 .84 lbf ft) • Info Contact disk must be mounted under screw and the cable lug Ci) with the claws facing down. Position the frame protectors on the left and right. Mount and tighten screw Guideline Screw, frame pro­...

  • Page 172: Engine Disassembly

    248) Perform the initialization run. (ll!:!I p. 266) Go for a short test ride. Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. Check the engine for leak tightness. Check the engine oil level. (!!l p. 250) Check the coolant level.

  • Page 173: Removing The Oil Filter

    ENGINE 17 Remove the oil drain plug with the magnet and seal ring. Remove oil drain plug (D with the O-ring. Completely drain the engine oil. 17.3.4 Removing the oil filter Remove screws Remove the oil filter cover with the O-ring.

  • Page 174: Removing The Spark Plug

    17 ENGINE 17.3.6 Removing the spark plug Remove the spark plug with special tool I Spark plug wrench with link (77229172000) (� p. 302) 17.3.7 Removing the valve cover Remove screws Take off the valve cover with the valve cover seal. Remove gasket Remove spark plug wrench insert...

  • Page 175: Starter Motor, Removing

    ENGINE 17 17.3.8 starter motor, removing Remove screws Take off the alternator cover. Remove gasket Remove torque limiter Remove screws and the starter motor. 17.3.9 Positioning the engine at ignition top dead center Turn the crankshaft counterclockwise until marking flush with the edge of the cylinder head. B03740-10...
  • Page 176 17 ENGINE Remove screw Info Check through the hole whether the position notch of the crankshaft is visible. Mount and tighten screw without the washer. 17.3.10 Removing the timing chain tensioner Loosen screw Remove screw with the seal ring. Pull out timing chain tensioner Remove O-ring 17.3.11 Removing the camshafts...

  • Page 177: Cylinder Head, Removing

    ENGINE 17 17.3.12 cylinder head, removing 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 (D. Remove dowels 17 .3.13 Removing the piston Push the cylinder upward. Info Only push the cylinder as far up as necessary to take the piston pin out.

  • Page 178: Removing The Rotor

    17 ENGINE Take off cylinder base gasket@. 17.3.14 Removing the rotor Remove screw Insert special tool into the crankshaft. I Protection cap (75029090000) (i!!;!I p. 300) Mount special tool on the rotor. Hold it tight using the special tool and pull off the rotor by turning the screw in. I Extractor (79229032044) p.

  • Page 179: Removing The Suction Pump

    ENGINE 17 Take off freewheel gear 6) . Removing the suction pump 17 .3.16 Remove screws Take off oil pump cover Remove O-ring 6) . Take off suction pump Remove needle roller...

  • Page 180: 17.3.17 Water Pump Impeller, Removing

    17 ENGINE 17.3.17 water pump impeller, removing Remove screws Take off the water pump cover. Remove gasket @. Remove nut Take off two-part water pump impeller 17.3.18 Removing the clutch cover Remove screws Take off the clutch cover. Remove clutch cover gasket @.

  • Page 181: Removing The Clutch Discs

    ENGINE 17 17 .3.19 Removing the clutch discs Loosen screws and remove with the washers and springs. Take off the clutch pressure cap. Remove clutch discs completely. Remove clutch throw-out (D. 17 .3.20 Removing the clutch basket Remove two opposite sleeves Bend up the lock washer.

  • Page 182: Removing The Primary Gear Wheel

    17 ENGINE Take off needle bearing (3 and collar sleeve@. 17.3.21 Removing the primary gear wheel Remove nut • Info LH thread! Position the special tool in the crankshaft. I Protection cap (75029090000) p. 300) Pull off primary gear wheel @ using the special tool. I Puller (46129021000) p.

  • Page 183: Removing The Force Pump

    ENGINE 17 17.3.23 Removing the force pump Remove lock ring Take off washer@}. Take off oil pump idler gear with the washer. Remove lock ring Take off washer Take off oil pump gear wheel C). Remove pin Remove screws Take off the oil pump cover. Remove pin Push oil pump shaft Ci) inward and take it out of the engine from the ignition side.

  • Page 184: Shift Drum Locating Unit, Removing

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

  • Page 185: Shift Rails, Removing

    ENGINE 17 Insert the special tool into the crankshaft. Protection cap (75029090000) p. 300) Mount special tool with suitable screws. Puller (79229048000) p. 304) • Info Use the drill hole with marking 792. Pull off the section of the engine case. Info Do not tension the section of the engine case.

  • Page 186: Removing The Shift Forks

    17 ENGINE 17.3.31 Removing the shift forks Remove shift forks 17.3.32 Removing the transmission shafts Remove lock ring Pull both transmission shafts out of the bearing seats together. 17.3.33 Removing the crankshaft Remove crankshaft Take off the right section of the engine case.

  • Page 187: Working On Individual Parts

    ENGINE 17 Working on individual �arts 17.4 17.4.1 Working on the right section of the engine case Remove all dowels. Remove shaft seal ring of the crankshaft. Remove nozzle Remove oil nozzle for conrod bearing lubrication. Remove screw Remove the oil nozzle for piston cooling. Remove screws Remove the bearing retainers.
  • Page 188 17 ENGINE Mount and tighten nozzle Guideline Nozzle, crank 2 Nm (1.5 lbf ft) ® Loctite chamber venti- ™ lation Mount and tighten oil nozzle Guideline Oil nozzle for 2 Nm (1.5 lbf ft) ® conrod bearing Loctite ™ lubrication Mount the oil nozzle for piston cooling.

  • Page 189: Working On The Left Section Of The Engine Case

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

  • Page 190: Work On The Clutch Cover

    17 ENGINE Guideline Oil nozzle for 2 Nm (1.5 lbf ft) ® Loctite clutch lubrica- ™ tion Mount and tighten oil nozzle Guideline Oil nozzle, pis­ 2 Nm (1.5 lbf ft) Loctite ® ton cooling ™ Position all bearing retainers. Mount and tighten screws (D.
  • Page 191 ENGINE 17 Press out bearing toward the inside. B03752-10 Mount lock ring @. Press the shaft seal ring all the way in from the inside to the outside with the open side facing in. Press the new bearing all the way in from the inside to the outside using a suitable tool.

  • Page 192: Checking The Oil Pressure

    17 ENGINE 17.4.4 Checking the oil pressure control valve Remove screw plug with sealing washer Remove pressure spring @> and ball 310341-10 Measure the spring length of the oil pressure control valve. Oil pressure control valve Minimu ':7 length of pres- 23.5 mm (0.925 in) sure spring If the measured value does not meet specifications:...

  • Page 193: Checking The Lubrication System

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

  • Page 194: Installing The Crankshaft Bearing Inner Race

    17 ENGINE 17.4.7 Installing the crankshaft bearing inner race Main work Fix the crankshaft in the vise. Guideline I Use soft jaws. Slide on compensating disk Info The compensating disks have a larger diameter than the crankshaft stub. 310421-10 Ensure that the compensating disks are centered and fixed with a small amount of grease.
  • Page 195 ENGINE 17 Press the crank pin out of the lower crankweb. Press in new crank pin all the way. ✓ Oil hole is aligned with oil hole G). X If the oil holes are not correctly aligned, the conrod bear­ ing will not be supplied with oil.

  • Page 196: Checking The Crankshaft Run-Out At The Bearing Pin

    17 ENGINE Position special tool with the heel pointing down. Insert for crankshaft pressing tool (79029008000) p. 303) Press in the upper crankweb as far as possible. Info The press mandrel must be positioned over the crank pin. Take the crankshaft out of the special tool and check that the connecting rod can move freely.

  • Page 197: Measuring The Crankshaft End Play

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

  • Page 198: Installing The Drive Gear Wheel Of The Balancer Shaft

    17 ENGINE 17.4.12 Installing the drive gear wheel of the balancer shaft Ensure that woodruff key is seated properly. Warm drive gear wheel of the balancer shaft and push it onto the balancer shaft. Guideline 1100 °C (212 °F) 310342-10 17.4.13 Cylinder- Nikasil ®...

  • Page 199: Checking/Measuring The Piston

    ENGINE 17 17.4.15 Checking/measuring the piston Use the special tool to measure clearance of the piston rings in the piston ring groove. e -• ­ Guideline • Piston ring - groove clear­ s 0.08 mm (s 0.0031 in) ance Feeler gauge (590290411 00) (�...

  • Page 200: Measuring The Piston/Cylinder Mounting Clearance

    17 ENGINE Info Piston size is marked on the side of the piston . 17.4.16 Measuring the piston/cylinder mounting clearance Check/measure the cylinder. p. 196) Check/measure the piston. p. 197) The smallest piston/cylinder mounting clearance equals the smallest cylinder bore diameter minus the largest piston diameter.

  • Page 201: Camshafts, Checking

    ENGINE 17 17.4.18 camshafts, checking Check the camshafts for damage and wear. If there is damage or wear: Change the camshafts. If the surface of the cams is damaged, check the oil supply to the camshaft and cam lever. 311564-10 17.4.19 Checking the pivot points of the camshafts Check the pivot points of the camshafts.

  • Page 202: Valves, Removing

    17 ENGINE Remove camshaft bearing support again. Compare clear­ ance gauge Plastigauge with the data on the packaging. Guideline Camshaft bearing - sleeve bearing Radial clearance 0.020 ... 0.054 mm (0.00079 ... 0.00213 in) Wear limit 0.065 mm (0.00256 in) 310433-10 •...

  • Page 203: Valves, Checking

    ENGINE 17 Remove the valve spring retainer and valve springs. Mark the valve springs according to their normal built-in posi­ tion. Pull the valve down out of the valve guide. Remove valve stem seal with the special tool. Valve stem seals plier (77229010000) p.

  • Page 204: Checking The Valve Spring Seat

    17 ENGINE Minimum length, inner 39.20 mm (1.5433 in) intake valve Minimum length, outlet 40.40 mm (1.5905 in) valve If the measured value does not meet specifications: Change the valve springs. 17.4.23 Checking the valve spring seat Check the valve spring seat for breakage and wear (visual check).

  • Page 205: Installing The Valves

    ENGINE 17 Using a straightedge and the special tool, check the sealing area of the cylinder for distortion. Feeler gauge (59029041100) p. 298) Cylinder/cylinder head - dis- :;; 0.10 mm (:;; 0.0039 in) tortion of sealing area If the measured value does not meet specifications: Change the cylinder head.

  • Page 206: Checking The Freewheel

    17 ENGINE Mount valve keys (D. Info When mounting the valve keys, check that they are seated correctly; preferably, fix the valve keys to the valve with a little grease. Position cam levers in the positions they had before they were removed.

  • Page 207: Freewheel, Installing

    ENGINE 17 Press expansion ring @ together with suitable pliers and take off. 310364-10 Remove freewheel 310365-10 17.4.29 freewheel, installing Thoroughly oil all parts. Mount freewheel �- Info ...• Note the direction of rotation. �" " • - � � �...

  • Page 208: Checking The Electric Starter Drive

    17 ENGINE Mount lock ring (D . 310363-11 17.4.30 Checking the electric starter drive •-• �- 310350-10 Check the gear mesh and bearing of starter idler gear for damage and wear. If there is damage or wear: Change the starter idler gear. Check the gear mesh and bearing of torque limiter for damage and wear.

  • Page 209: Checking The Timing Assembly

    ENGINE 17 Change the starter motor. 17.4.31 Checking the timing assembly 00• • C)--- ..310344-10 Check timing chain sprocket for damage and wear. If there is damage or wear: Change the timing chain sprocket. Check the timing chain tensioning rail for damage and wear.

  • Page 210: Preparing The Timing Chain Tensioner For Installation

    17 ENGINE 17.4.32 Preparing the timing chain tensioner for installation Press the timing chain tensioner together completely. Info This requires some force, as the oil must be pressed out. Release the timing chain tensioner. ✓ Without pressure, the timing chain tensioner expands fully.

  • Page 211: Checking The Clutch

    ENGINE 17 17 .4.33 Checking the clutch •- -• 310351-10 Check clutch throw-out for damage and wear. If there is damage or wear: Change the clutch push rod. Check axial bearing for damage and wear. If there is damage or wear: Change the axial bearing.

  • Page 212: Checking The Shift Mechanism

    17 ENGINE Check the thickness of clutch facing discs Ci). Clutch facing discs - thickness of total package I ?: 23.3 mm (?: 0.917 in) If the clutch facing discs do not meet specifications: Change all clutch facing discs. Check washer for damage and wear.

  • Page 213: Preassembling The Shift Shaft

    ENGINE 17 If there is damage or wear: Change the shift rollers. Check shift rails on a flat surface for run-out. If there is run-out: Change the shift rails. Check the shift rails for scoring, wear, and smooth operation in the shift forks. If there is scoring or corrosion, or if the shift fork is stiff: Change the shift rails.

  • Page 214: Disassembling The Main Shaft

    17 ENGINE 17.4.36 Disassembling the main shaft Secure the main shaft in the vise with the gear teeth facing downward. Guideline I Use soft jaws. Mount a suitable screw in the main shaft. ✓ The screw is supported on the transmission shaft and not on the sleeve.

  • Page 215: Disassembling The Countershaft

    ENGINE 17 17 .4.37 Disassembling the countershaft D05798-10 Secure the countershaft in the bench vise with the toothed end facing downward. Guideline I Use soft jaws. Remove stop disk and first-gear idler gear Remove needle bearing and stop disk Remove fourth-gear sliding gear Remove lock ring (D.
  • Page 216 17 ENGINE Check needle bearings for damage and wear. If there is damage or wear: Change the needle bearings. Check the pivot points of main shaft and countershaft 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 217: Assembling The Main Shaft

    ENGINE 17 Check sleeve for damage and wear. If there is damage or wear: Change the sleeve. Use new lock rings in every repair. 17.4.39 Assembling the main shaft Info • Use new lock rings with every repair. Preparatory work Check the transmission.

  • Page 218: Assembling The Countershaft

    17 ENGINE Mount needle bearing Mount fifth-gear idler gear Mount second-gear fixed gear Press sleeve Gi) all the way in. Finally, check all the gear wheels for smooth operation. 17.4.40 Assembling the countershaft Info Use new lock rings with every repair. Preparatory work Check the transmission.

  • Page 219: Engine Assembly

    ENGINE 17 Position lock ring on special tool and push down with sleeve G). ✓ The lock ring engages in the groove of the transmission shaft. Mount stop disk Mount needle bearing and third-gear idler gear with the shift dogs facing upward. Mount stop disk �...

  • Page 220: Shift Forks, Installing

    17 ENGINE 17.5.3 shift forks, installing Shift fork has a smaller inside diameter; mount this in the shift groove of the main shaft. Mount shift fork in the lower shift groove of the counter­ shaft. Mount shift fork in the upper shift groove of the counter­ shaft.

  • Page 221: Left Engine Case, Installing

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

  • Page 222: Shift Shaft, Installing

    17 ENGINE 17.5.8 shift shaft, installing Slide shift shaft with the washer into the bearing seat. 17.5.9 shift drum locating unit, installing Push away sliding plate from the shift drum locating unit, and position shift drum locating unit @. Info The flat surfaces of the shift drum locating unit are not symmetric.

  • Page 223: Installing The Suction Pump

    ENGINE 17 Position the oil pump cover. ✓ Marking faces upward. C, . Mount and tighten screws Guideline Screw, oil pump 6 Nm (4.4 lbf ft) ® Loctite cover ™ Insert pin Position oil pump gear wheel C). Mount washer @. Mount lock ring Crank the oil pump gear wheel and ensure that it can move easily.

  • Page 224: Installing The Timing Chain

    17 ENGINE Mount 0-ring Position the oil pump cover Mount and tighten screws Guideline Screw, oil pump 6 Nm (4.4 lbf ft) ® Loctite cover ™ 17.5.13 Installing the timing chain Mount balancer shaft with the timing chain and timing chain securing guide.

  • Page 225: Installing The Primary Gear Wheel

    ENGINE 17 17 .5.14 Installing the primary gear wheel Position primary gear wheel ✓ The wide tooth of the primary gear wheel engages in the wide recess of the crankshaft. ✓ Markings and G) are aligned. Mount and tighten nut@}. Guideline Nut, primary M18LHx1.5...

  • Page 226: Installing The Clutch Discs

    17 ENGINE Position the new lock washer and mount nut (D. Tighten the nut, holding the inner clutch hub with a special tool. Guideline Nut, inner M18x1 .5 100 Nm (73.8 lbf ft) clutch hub ® Loctite ™ I Holding wrench (51129003000) (�...

  • Page 227: Installing The Clutch Cover

    ENGINE 17 17 .5.17 Installing the clutch cover Producing tool (special screw): A conventional screw is required. Cut screw f) to a length of G). Guideline I Screw I M6x70 I 60 mm (2.36 in) I Length G) Cut a slot into the top end of the screw. D05933-10 Mount screw f) and tighten hand-tight.

  • Page 228: Water Pump Cover, Installing

    17 ENGINE 17.5.18 water pump cover, installing Mount two-part water pump impeller Mount and tighten the nut Guideline Nut, water­ 5 Nm (3. 7 lbf ft) ® Loctite ™ pump wheel Mount gasket Mount the water pump cover. Info Ensure that the dowel pins are seated properly. Mount screw with the seal ring but to not tighten yet.

  • Page 229: Starter Drive, Installing

    ENGINE 17 17 .5.19 starter drive, installing Position freewheel gear Mount starter idler gear Mount and tighten screw with washer. Guideline Screw starter 10 Nm (7.4 lbf ft) Loctite ® 243™ idler gear 17.5.20 Installing the rotor Ensure that the woodruff key is seated properly. Mount the rotor.
  • Page 230 17 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 dam­ aged. 310370-10 Ensure that piston marking faces the exhaust side.

  • Page 231: Installing The Cylinder Head

    ENGINE 17 Insert the special tool and press it with force towards the pis­ ton. Turn the special tool clockwise, thereby pushing the piston ring lock into the groove. Insertion for piston ring lock (77729030100) p. 302) Ensure that the piston ring lock is in the correct position on both sides.

  • Page 232: Installing The Camshafts

    17 ENGINE Guideline Nut, cylinder M10x1 .25 Tightening sequence: Tighten diagonally. head 1st tightening stage 10 Nm (7.4 lbf ft) 2nd tightening stage 30 Nm (22.1 lbf ft) 3rd tightening stage 50 Nm (36.9 lbf ft) Thread and washer oiled with engine oil Mount and tighten nut with the washer.

  • Page 233: Installing The Timing Chain Tensioner

    ENGINE 17 Guideline Screw, M7x1 14 Nm (10.3 lbf ft) Lubricated with engine camshaft bearing support 17.5.24 Installing the timing chain tensioner Position timing chain tensioner and insert it with new 0- ring Mount and tighten screw plug with the seal ring. Guideline Plug, timing chain M24x1 .5...

  • Page 234: Adjusting The Valve Clearance

    17 ENGINE Position the engine at ignition top dead center. ✓ Markings must line up with the edge of the cylinder head. Mount and tighten screw without the washer. Check the valve clearance at all valves between the camshaft and cam lever. Guideline Valve clearance Intake at: 20 °C (68 °F)

  • Page 235: Installing The Starter Motor

    ENGINE 17 17.5.27 Installing the starter motor Grease the O-ring. Position the starter motor. Long-life grease (ll!:!I p. 292) Mount and tighten screws Guideline Screw, starter motor 10 Nm (7.4 lbf ft) Thoroughly oil the bearing pin of the torque limiter. Position torque limiter Position gasket (D.

  • Page 236: Spark Plug, Installing

    17 ENGINE Position gasket Thinly apply sealing compound to area 6). I Loctite 5910 ® Position the valve cover with the gasket. Mount and tighten screws (D. Guideline Screw, valve cover 8 Nm (5.9 lbf ft) 17.5.29 spark plug, installing Mount and tighten the spark plug with special tool Guideline Spark plug...

  • Page 237: Installing The Oil Filter

    ENGINE 17 17.5.31 Installing the oil filter Tilt the motorcycle to one side and fill the oil filter housing to about½ 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@).

  • Page 238: Installing The Clutch Push Rod

    17 ENGINE Mount and tighten screw plug with the O-ring. Guideline Screw plug, oil M20x1.5 15 Nm (11.1 lbf ft) screen 17.5.33 Installing the clutch push rod Mount clutch push rod 17.5.34 Removing the engine from the engine assembly stand Remove the fitting from the special tool.

  • Page 239: Clutch

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

  • Page 240: Changing The Hydraulic Clutch Fluid

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

  • Page 241: Checking The Clutch

    CLUTCH Now inject the liquid into the system until it emerges from drill hole of the master cylinder without bubbles. Now and then, extract fluid from the master cylinder reservoir to prevent overflow. Tighten the bleeder screw and remove the bleeding syringe with the hose.
  • Page 242 18 CLUTCH Detach spring Remove screws Take off the clutch cover. Loosen screws and remove with the washers and springs. Take off clutch pressure cap Take off clutch throw-out with clutch push rod Q). Remove sleeves...
  • Page 243 CLUTCH Remove clutch discs completely. Bend up the lock washer. Hold the inner clutch hub with the special tool. Loosen nut@). Holding wrench (51129003000) p. 296) Remove the nut with the lock washer. Take off inner clutch hub Ci) and washer Info The washer usually sticks to the inner clutch hub.
  • Page 244 18 CLUTCH R00004-01 Check clutch throw-out for damage and wear. If there is damage or wear: Change the clutch push rod. Check axial bearing for damage and wear. If there is damage or wear: Change the axial bearing. Place the clutch push rod on a flat surface and check for run-out.
  • Page 245 CLUTCH I � I Clutch facing discs - thickness of total package 23.3 mm (� 0.917 in) If the clutch facing discs do not meet specifications: Change all clutch facing discs. Check washer for damage and wear. If there is damage or wear: Change the washer.
  • Page 246 18 CLUTCH Mount sleeves Thoroughly oil clutch facing discs G). Gs,. Insert the intermediate clutch disc Guideline I Thickness 1 mm (0.04 in) Place the clutch facing and intermediate discs into the clutch basket. Insert the intermediate clutch disc Qi). Guideline I Thickness mm (0.04 in)
  • Page 247 CLUTCH Attach spring Place vehicle in upright position and rest on the plug-in stand. R00441-11 Finishing work Check the engine oil level. (� p. 250)

  • Page 248: 19 Water Pump, Cooling System

    19 WATER PUMP, COOLING SYSTEM Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap @. This ensures that operat­ ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 249: Checking The Coolant Level

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

  • Page 250: Draining The Coolant

    19 WATER PUMP, COOLING SYSTEM Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
  • Page 251 WATER PUMP, COOLING SYSTEM 19 Make sure that screw is tightened. Position the motorcycle upright. Pour coolant in up to measurement above the radiator fins. Guideline 10 mm (0.39 in) Distance above the radi- ator fins Coolant (il!:!I p. 290) Mount the radiator cap.

  • Page 252: Lubrication System

    LUBRICATION SYSTEM 20.1 Oil circuit H02388-10 Oil screen Force pump Oil pressure control valve Oil filter Oil nozzle for conrod bearing lubrication Oil nozzle for cam follower lubrication Oil nozzle for piston cooling Oil nozzle for alternator cooling Oil nozzle for clutch lubrication 4l&...

  • Page 253: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen

    LUBRICATION SYSTEM Condition The engine is cold. Check the engine oil level. The engine oil reaches the middle of level viewer f). If the engine oil does not reach the middle of the level viewer: Add engine oil. (!el p. 254) Condition The engine is at operating temperature.
  • Page 254 LUBRICATION SYSTEM Main work Place an appropriate container under the engine. Remove oil drain plug with the magnet and seal ring. Info Do not remove screws @. Remove screw plug with oil screen Completely drain the engine oil. Thoroughly clean the parts and sealing surfaces. Position oil screen with the O-rings on a pin wrench.
  • Page 255 LUBRICATION SYSTEM Pull oil filter out of the oil filter housing. Lock ring plier (51012011000) p. 296) Completely drain the engine oil. Thoroughly clean the parts and sealing surfaces. Lay the motorcycle on its side and fill the oil filter housing to about½...

  • Page 256: Adding Engine Oil

    LUBRICATION SYSTEM Adding engine oil Info Too little engine oil or poor-quality engine oil will result in premature wear of the engine. �-• Main work Remove oil filler plug with the O-ring from the clutch cover. Add the same engine oil used when the last oil change was carried out.

  • Page 257: Checking The Oil Pressure

    LUBRICATION SYSTEM Main work Remove screw Position the special tool. Oil pressure adapter (77329006000) p. 302) Mount and tighten the banjo bolt. Guideline Banjo bolt I M10x1 I 8 Nm (5.9 lbf ft) Banjo bolt (79329006000) p. 305) Connect the pressure testing tool to the special tool without 401095-01 the T-plate.
  • Page 258 LUBRICATION SYSTEM Warning Danger of burns Some vehicle components get very hot when the machine is driven. Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Remove the special tools. Mount and tighten screw Guideline Screw, unlocking M10x1...

  • Page 259: Ignition System

    IGNITION SYSTEM 21.1 Ignition coil - checking the seconda� winding Condition The ignition coil is disconnected. Spark plug connector cylinder 1 has been removed. Ignition coil cylinder 1 - check the secondary winding resistance Measure the resistance between the specified points. Ignition coil pin 2 (-) - Ignition coil pin 3 Ignition coil Secondary winding...

  • Page 260: Crankshaft Speed Sensor

    IGNITION SYSTEM �6.3mm P00023-10 Stator winding - check for short circuit to ground (terminal 31) Measure the resistance between the specified points. Alternator, connector - Measuring point Ground, wiring harness/frame Resistance oo Q If the displayed value does not equal the setpoint value: Replace the stator.

  • Page 261: Changing The Spark Plug

    IGNITION SYSTEM Position the stator and crankshaft speed sensor in the alter­ nator cover. Mount and tighten screws Guideline Screw, stator 6 Nm (4.4 lbf ft) ® Loctite ™ Position the retaining bracket. Mount and tighten screws ti). Guideline Screw, 6 Nm (4.4 lbf ft) crankshaft ®...
  • Page 262 IGNITION SYSTEM Plug in spark plug connector Mount capacitor Finishing work Install the fuel tank. (l!ll p. 102) Mount the seat. (l!ll p. 1 00) Install the air filter box cover. (l!ll p. 95) Install the right side cover. p. 99)

  • Page 263: Cylinder Head 22

    CYLINDER HEAD 22 22.1 Checking the valve clearance Preparatory work Remove the right side cover. p. 99) Remove the air filter box cover. p. 95) Remove the seat. p. 99) Remove the fuel tank. p. 101) Main work Pull capacitor off of the holder and hang to one side.
  • Page 264 22 CYLINDER HEAD Remove screw Turn the crankshaft counterclockwise until markings flush with the edge of the cylinder head. Remove screw Remove washer Ci). Look through the hole to check that the position notch of the crankshaft is visible. Mount and tighten screw without the washer.
  • Page 265 CYLINDER HEAD 22 Mount and tighten screw Guideline Screw, alternator M24x1 .5 18 Nm (13.3 lbf ft) cover Clean and degrease the sealing surface. Apply a thin layer of sealing compound to area G). Loctite ® 5910 Mount gasket Position the valve cover with the gasket. Mount and tighten screws Cs).

  • Page 266: Adjusting The Valve Clearance

    22 CYLINDER HEAD Mount capacitor Finishing work Install the fuel tank. p. 102) Mount the seat. p. 1 00) Install the air filter box cover. p. 95) Install the right side cover. p. 99) Adjusting the valve clearance Info For purposes of illustration, the following operations are shown with the engine removed. Removal is not necessary.

  • Page 267: Electric Starter System

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

  • Page 268: 24 Throttle Valve Body

    24 THROTTLE VALVE BODY 24.1 Adjusting the idle s�eed Danger Exhaust gases are toxic and inhaling them may result in unconsciousness and Danger of poisoning death. Always make sure there is sufficient ventilation when running the engine. Use effective exhaust extraction when starting or running the engine in an enclosed space. Warning The engine may go out spontaneously if the idle speed is set too low.
  • Page 269 THROTTLE VALVE BODY Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. Always make sure there is sufficient ventilation when running the engine. Use effective exhaust extraction when starting or running the engine in an enclosed space. Start the engine without operating the throttle grip.

  • Page 270: 25 Technical Data

    25 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 14.4:1 Idle speed 2,250 ... 2,350 rpm Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 32.5 mm (1.28 in)

  • Page 271: Tolerance, Engine Wear Limits

    TECHNICAL DATA 25 25.2 Tolerance, engine wear limits Camshaft bearing - sleeve bearing Radial clearance 0.020 ... 0.054 mm (0.00079 ... 0.00213 in) Wear limit 0.065 mm (0.00256 in) Valve spring Minimum length, outer intake valve 42.40 mm (1.6693 in) Minimum length, inner intake valve 39.20 mm (1.5433 in) Minimum length, outlet valve...

  • Page 272: Engine Tightening Torques

    25 TECHNICAL DATA 25.3 Engine tightening tor ues Nozzle, crank chamber ventilation 2 Nm (1 .5 lbf ft) ® Loctite ™ Oil nozzle for alternator cooling 2 Nm (1 .5 lbf ft) Loctite ® ™ Oil nozzle for balancer shaft lubri- 2 Nm (1 .5 lbf ft) ®...
  • Page 273 TECHNICAL DATA 25 Screw, starter motor 10 Nm (7.4 lbf ft) Screw, timing chain guide rail 10 Nm (7.4 lbf ft) ® Loctite ™ Screw, timing chain securing 10 Nm (7.4 lbf ft) Loctite ® ™ guide Screw, torque limiter cover 10 Nm (7.4 lbf ft) Screw, valve cover 8 Nm (5.9 lbf ft)

  • Page 274: Capacities

    25 TECHNICAL DATA M24x1.5 118 Nm (13.3 lbf ft) I Screw, alternator cover 25.4 Ca�acities 25.4.1 Engine oil I Engine oil 11.0 I (1.1 qt.) I Engine oil (SAE 10W/50) p. 290) 25.4.2 Coolant I Coolant 0.95 I (1 qt.) I Coolant p.

  • Page 275: Electrical System

    110/90 - 19 62M TT Dunlop Geomax MX-3S F Dunlop Geomax MX-3S The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: www.husqvarna-motorcycles.com 25.8 Fork Fork part number 34.18.80.55 Fork...

  • Page 276: Shock Absorber

    25 TECHNICAL DATA 25.9 Shock absorber Shock absorber article number 18.18.7Q.55 Shock absorber WP Suspension 5018 DCC Link Lowspeed compression damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Highspeed compression damping Comfort 2.5 turns Standard 2 turns Sport 1.5 turns Rebound damping Comfort...
  • Page 277 TECHNICAL DATA 25 Screw, ball joint of push rod on 10 Nm (7.4 lbf ft) Loctite ® foot brake cylinder ™ Screw, battery support bracket 10 Nm (7.4 lbf ft) Screw, chain sliding guard 6 Nm (4.4 lbf ft) Loctite ®...
  • Page 278 25 TECHNICAL DATA Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) Screw-in nozzles, cooling system M20x1.5 12 Nm (8.9 lbf ft) ® Loctite ™ Nut, rear wheel spindle M25x1.5 80 Nm (59 lbf ft)

  • Page 279: Cleaning/Protective Treatment

    CLEANING/PROTECTIVE TREATMENT 26.1 Cleaning the motorc}!cle Note Components become damaged or destroyed if a pressure cleaner is used incorrectly. Material damage 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 280 26 CLEANING/PROTECTIVE TREATMENT Push back the protection caps of the handlebar controls to allow any water that has penetrated to evaporate. After the motorcycle has cooled lubricate all moving parts off, and bearings. Clean the chain. p. 128) Treat bare metal parts (except for brake discs and the exhaust system) with a corrosion inhibitor.

  • Page 281: Storage 27

    Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info Husqvarna Motorcycles recommends raising the motorcycle. Raise the motorcycle with a lift stand. p. 12) Cover the vehicle with a tarp or similar cover that is perme-...

  • Page 282: Putting Into Operation After Storage

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

  • Page 283: Service Schedule 28

    Every 20 operating hours Every 10 operating hours/after every race Once after 1 operating hour • • • Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. • • • Check and charge the 12 V battery. •...

  • Page 284: Recommended Work

    • • • • Final check: Check the vehicle for safe operation 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 Husqvarna Motorcycles Dealer.net...
  • Page 285 SERVICE SCHEDULE 28...
  • Page 286 t : : 1 «! . ·X16 u , , "E "E " " " " " " { } rn "E "E -" "" lB j-x1 N fC/2 N A F/4 �l EB /4 1•N -C10 -521 -M10 -G10 �- 1 1' "...

  • Page 287: Wiring Diagram 29

    WIRING DIAGRAM 29 Components: A 11 EFI control unit Capacitor 12 V battery Alternator Starter relay with main fuse Power relay Electric starter system Voltage regulator E-tip switch X295 Diagnostics connector...
  • Page 288 HY/33 HY/33 HY/33 HY/33 HY/33 �HY/33 HY/33 ·X16 ·X16 1·X16 · X16 ·X16 ·X16 ·X16 � ��i is� �I " ��; � - a .0.0 l. x2 -BF/1 iCX/2 . x s f 1 , 2 f r 1 2 -520 -P25 - X 295...
  • Page 289 WIRING DIAGRAM 29 Components: A 11 EFI control unit Fuel pump Injection valve Malfunction indicator lamp CAN-bus terminating resistor 1 Kill switch X295 Diagnostics connector...
  • Page 290 �1 1 ·X16 1 ·X16 1 ·X16 1·X16 1·X16 1·X16 1 ·X16 1·X16 ·X16 �{ � "' { HY/33 HY/33 HY/33 HY/33 HY/33 HY/33 HY/33 HY/33 HY/33 HY/33 l! f � � n.,, · . H U : , !· �! l.x2 0 - X11...
  • Page 291 WIRING DIAGRAM 29 Components: A 11 EFI control unit Intake air temperature sensor Coolant temperature sensor Rollover sensor Gear position sensor Crankshaft speed sensor Induction manifold pressure sensor Throttle valve position sensor Ignition coil Map select switch Cable colors: Black Brown Blue Green...

  • Page 292: 30 Substances

    30 SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification Guideline Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol REACT PERFORMANCE DOT 4 ® MOTOREX Brake Fluid DOT 5.1 Coolant...
  • Page 293 SUBSTANCES 30 Fork oil {SAE 4) {48601166S1 Standard/classification SAE(� p. 312) (SAE 4) Guideline Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Shock absorber fluid {SAE 2.5) {50180751S1) Standard/classification p.

  • Page 294: Auxiliary Substances

    AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier ® MOTOREX Racing Bio Dirt Remover Chain cleaner Recommended supplier ® MOTOREX Chain Clean Fuel additive Recommended supplier ® MOTOREX Fuel Stabilizer High viscosi grease Recommended supplier ® LGHB Long-life grease Recommended supplier ®...
  • Page 295 AUXILIARY SUBSTANCES 31 Lubricant (!159) Recommended supplier ® Bel-Ray ® MC-11 Motorc�cle cleaner Recommended supplier ® MOTOREX Moto Clean Multi- urRose grease (00062010051) Recommended supplier ® Kluber Lubrication CENTOPLEX 2 EP Off-road chain SRra� Recommended supplier MOTOREX ® Chainlube Offroad Oil for foam air filter Recommended supplier ®...

  • Page 296: 32 Special Tools

    32 SPECIAL TOOLS Bleeder cover Art. no.: 00029013005 00029013005 H00504-01 Bleeder cover Art. no.: 00029013006 00029013006 H00505-01 Bleeding device Art. no.: 00029013100 00029013100 H00518-01 EU batte charger XCharge- rofessional Art. no.: 00029095050 Feature EU safety plug Nominal voltage 230 V Mains fuse Power cable length 5 m (16 ft)
  • Page 297 SPECIAL TOOLS 32 US batterY charger XCharge-�rofessional Art. no.: 00029095051 Feature US plug Nominal voltage 120 V Mains fuse 32 A Power cable length 5 m (16 ft) approx. Charger cable 5 m (16 ft) H01065-01 length approx. e-professional Art. no.: 00029095052 Feature UK safety plug Nominal voltage...
  • Page 298 32 SPECIAL TOOLS Puller Art. no.: 46129021000 46129021000 H01519-01 S�ringe Art. no.: 50329050000 50329050000 H00565-01 Lock ring lier Art. no.: 51012011000 51012011000 H00572-01 Holding wrench Art. no.: 51129003000 51129003000 H00575-01...
  • Page 299 SPECIAL TOOLS 32 Puller Art. no.: 58429037037 Feature Inside diameter 37.5 mm (1.476 in) 58429037037 H00596-01 Tool bracket Art. no.: 58429089000 58429089000 H00603-01 Pressing tool Art. no.: 58429091000 ® 58429091000 H00604-01 Pressing tool Art. no.: 58429092000 ® 58429092000 H00605-01...
  • Page 300 32 SPECIAL TOOLS Torgue wrench kit Art. no.: 58429094000 Feature Torque 3 ... 15 Nm (2.2 ... 11 .1 lbfft) Open ended bit 3.9 mm (0.154 in) Open ended bit 4.9 mm (0.193 in) 5.5 mm (0.217 in) Open ended bit Open ended bit 6.8 mm (0.268 in) 58429094000...
  • Page 301 SPECIAL TOOLS 32 Piston ring com�ressor Art. no.: 60029015000 Feature Height 80 mm (3.15 in) 57 ... 125 mm (2.24 ... 4.92 in) Diameter 60029015000 H00628-01 Hose clam� �lier Art. no.: 60029057000 60029057000 H00650-01 Testing hose Art. no.: 61029093000 � 61029093000 H00659-01 Pressure testin tool...
  • Page 302 32 SPECIAL TOOLS Release device for timing chain tensioner Art. no.: 61229021000 61229021000 H00675-01 Mounting tool for lock ring Art. no.: 75029005000 75029005000 H00705-01 Crankshaft �ressing tool Art. no.: 75029047000 � � 75029047000 H00714-01 Protection ca Art. no.: 75029090000 75029090000 H00726-01...
  • Page 303 SPECIAL TOOLS 32 Insert for valve s�ring lever Art. no.: 77029041200 77029041200 H00746-01 Valve stem seals �lier Art. no.: 77229010000 77229010000 H00752-01 Limit lug gauge Art. no.: 77229026000 Feature Diameter 5.55 mm (0.2185 in) 77229026000 H00753-01 Protection ca Art. no.: 77229031000 77229031000 H00755-01...
  • Page 304 32 SPECIAL TOOLS Se�arator �late Art. no.: 77229032000 77229032000 H00756-01 S�ark �lug wrench with link Art. no.: 77229172000 Feature Drive 3/8 in Hexagonal part 14 mm (0.55 in) Length 130 mm (5.12 in) 77229172000 H00761-01 Oil �ressure ada�ter Art. no.: 77329006000 77329006000 H00764-01 Insertion for iston ring lock...
  • Page 305 SPECIAL TOOLS 32 Mounting tool for lock ring Art. no.: 79029005000 79029005000 H00S00-01 Insert for crankshaft �ressing tool Art. no.: 79029008000 79029008000 H00801-01 Se�arator late Art. no.: 79029009000 79029009000 H00802-01 Insert for valve s ring lever Art. no.: 79029060000 79029060000 H00803-01...
  • Page 306 32 SPECIAL TOOLS Footrest s�ring �lier Art. no.: 79029083000 79029083000 H00804-01 Holder and fitting for work stand Art. no.: 79229002000 2x&& 79229002000 H01127-01 Extractor Art. no.: 79229032044 79229032044 H00808-01 Puller Art. no.: 79229048000 79229048000 H00809-01...
  • Page 307 SPECIAL TOOLS 32 Banjo bolt Art. no.: 79329006000 79329006000 H02607-01 Fork air�um� Art. no.: 79412966000 Feature Maximum pressure 20 bar (290 psi) Display Digital pressure gauge Valve connection Schrader valve Units bar, psi and kg/cm Material Aluminum tube 79412966000 H01687-01 Engine assembl}' stand Art.
  • Page 308 32 SPECIAL TOOLS Hook wrench Art. no.: 90129051000 90129051000 H00831-01 S�ring hook Art. no.: 5030501700004 5030501700004 H00973-01 De�th micrometer Art. no.: T107S T107S H00842-01 Drift Art. no.: T120 Feature I Diameter 8 mm (0.31 in) T120 H00844-01...
  • Page 309 SPECIAL TOOLS 32 Mounting sleeve Art. no.: T1204 Feature Diameter 25.5 ... 30.5 mm (1.004 ... 1.201 in) T1204 H00878-01 Calibrating unit Art. no.: T1205 Feature Diameter 1 18 mm (0.71 in) T1205 H00879-01 Pressing tool Art. no.: T1206 Feature Diameter 1 15 ...
  • Page 310 32 SPECIAL TOOLS Pressing tool Art. no.: T1216 Feature I Diameter 38 ... 49 mm (1 .5 ... 1.93 in) T1216 H00887-01 Vacuum RUm Art. no.: T1240S T1240S H00890-01 Filling adaRter Art. no.: T1296 T1296 H01573-01 Protecting sleeve Art. no.: T1401 Feature I Diameter 48 mm (1.89 in)
  • Page 311 SPECIAL TOOLS 32 Clam�ing stand Art. no.: T14016S Feature Diameter 112 mm (0.47 in) T14016S H01036-01 Ring wrench Art. no.: T14017 Feature Hexagonal part 50 mm (1 .97 in) T14017 H00904-01 Clam�ing stand Art. no.: T1403S 2x£ Feature Diameter 48 mm (1 .89 in) Diameter 60 mm (2.36 in) ��...
  • Page 312 32 SPECIAL TOOLS Clam�ing stand Art. no.: T14072 £ Feature I Diameter 37 mm (1.46 in) T14072 H00928-01 Protecting sleeve Art. no.: T14073 Feature I Diameter 111.5 mm (0.453 in) T14073 H00929-01 S ecial socket Art. no.: T14084 Feature Drive 1/2 in Diameter 24 mm (0.94 in)
  • Page 313 SPECIAL TOOLS 32 Mounting tool Art. no.: T150S T150S H00852-01 Mounting sleeve Art. no.: T1515 Feature Diameter 1 18 mm (0.71 in) T1515 H00900-01 Filling tool Art. no.: T170S1 2x.&. 3x.£. T170S1 H00855-01...

  • Page 314: 33 Standards

    33 STANDARDS JASO T903 MA2 Different technical development directions required a separate specification for motorcycles - the JASO T903 MA2 standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 315: List Of Abbreviations 34

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

  • Page 316: Index

    INDEX Capacitor 12 V battery checking charging Capacity installing coolant ......272 negative cable, connecting ... . 134 engine oil .
  • Page 317 INDEX piston/cylinder, mounting clearance measur- clutch push rod, installing ... . . 236 ing ......198 crankshaft, installing ....217 shift shaft, preassembling .
  • Page 318 INDEX shift forks, removing removing ......19 shift rails, removing Frame shift shaft, removing checking ......52 spacer, removing .
  • Page 319 INDEX shock absorber, adjusting ....55 Riding sag Link fork adjusting ......58 checking ......82 installing ......
  • Page 320 INDEX Spark plug Vehicle identification number ... . . 1 0 changing Spark plug connector Wheel bearing checking ......257 checking .
  • Page 321 I 1 1 11 1 11 1 1 1 1 11 1 1 1 111 1 11 1 1 1 1 111 1 1 11 1 1 1 111 1 1 1 I I I I I I II I I II 3403040en 06/2018 ® Husqvarna Husqvarna Motorcycles GmbH StallhofnerstraBe 3 5230 Mattighofen Austria � LZZa" www.husqvarna-motorcycles.com ..

This manual is also suitable for:

F2101q1

Table of Contents