Husqvarna FC 250 2018 Repair Manual
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Husqvarna FC 250 2018 Repair Manual

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PIONEERING SINCE 1903
REPAIR MANUAL2018
FC250
®
Husqvarna
Art. no. 3403058en
MOTORCYCLES

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Summary of Contents for Husqvarna FC 250 2018

  • Page 1 PIONEERING SINCE 1903 REPAIR MANUAL2018 FC250 ® Husqvarna Art. no. 3403058en 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 9.10 12.8 Installing the shock absorber ....61 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: Checking The Starter Motor

    TABLE OF CONTENTS 15.9 Checking the capacitor ..... 140 17.3.21 Removing the primary gear wheel ..........189 15.10 Checking the starter relay ....141 17.3.22 timing chain, removing ....189 BRAKE SYSTEM ........... 142 17.3.23 Removing the force pump .... 190 16.1 Checking the front brake linings ..
  • Page 7 TABLE OF CONTENTS 17.4.22 valve springs, checking ....210 17 .5.26 Adjusting the valve clearance ..241 17.4.23 Checking the valve spring seat ..211 17 .5.27 Installing the starter motor ... 242 17.4.24 Checking the cam levers ....211 17 .5.28 Installing the valve cover ....
  • Page 8 TABLE OF CONTENTS THROTTLE VALVE BODY ......275 24.1 Adjusting the idle speed ....275 24.2 Performing the initialization run ..275 TECHNICAL DATA ........277 25.1 Engine ..........277 25.2 Tolerance, engine wear limits ... 278 25.3 Engine tightening torques ....279 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 17 clicks Standard 12 clicks Sport 7 clicks • Info Turn clockwise to increase damping; turn counter­ clockwise to reduce damping. Mount protection cap Bleeding the fork le s Preparatory work Raise the motorcycle with a lift stand. p.

  • Page 20: Removing The Fork Legs

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

  • Page 21: Installing The Fork Legs

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

  • Page 22: Installing The Fork Protector

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

  • Page 23: Disassembling The Fork Legs

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

  • Page 27: Disassembling The Air Cartridge

    FORK, TRIPLE CLAMP 6 Remove upper 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. Degrease and clamp the top of the piston rod. I Clamping stand (T14016S) p. 317) 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. 318) 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. 300) 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. 317) Fill with fork oil. Oil capacity, right 380 ml Fork oil (SAE 4) cartridge (12.85 fl.
  • Page 34 6 FORK, TRIPLE CLAMP Mount spring pack ✓ The wide side of spring guide is mounted facing down. Slot end stop onto the piston rod. ✓ The cone points downward. Clamp the piston rod underneath the end stop. I Clamping stand (T14016S) p.

  • Page 35: Assembling The Fork Legs

    (ra!l (ra!l (ra!l FORK, TRIPLE CLAMP 6 Position fluid barrier ✓ The cut-out faces upward. Mount lock ring Ci). 4D . Mount and tighten valve core Fill the cartridge with air . Guideline Minimum air pressure 7 bar (102 psi) Maximum air pressure 15 bar (218 psi) Adjust air pressure with special tool...
  • Page 36 6 FORK, TRIPLE CLAMP ✓ The sealing lip points downward, the open side upward. Remove the special tool. Push on support ring Sand the edges of the slide bearings with 600 grit sand- paper; then clean and grease the bearings. Fork oil (SAE 4) (48601166S1) (il!:!I p.
  • Page 37 FORK, TRIPLE CLAMP 6 Mount dust boot Mount fork protector ring G). B03520-13 Assemble the individual components that belong together. • Info Air cartridge (left fork leg): cartridge with blue adapter axle clamp with brake mount and outside fork tube with warning label screw cartridge @.
  • Page 38 6 FORK, TRIPLE CLAMP Lubricate O-ring on the air cartridge. Lubricant (T158) p. 300) Push the outside fork tube upwards. Clamp the outside fork tube in the area of the lower triple clamp. Clamping stand (T1403S) p. 318) B03542-10 Tighten air cartridge Q). Guideline Cartridge on the M51x1 .5...
  • Page 39 FORK, TRIPLE CLAMP 6 Push on support ring Sand the edges of the slide bearings with 600 grit sand- paper; then clean and grease the bearings. I Fork oil (SAE 4) (48601166S1) p. 299) Slide on lower slide bearing Mount upper slide bearing (D . Info Without using a tool, pull the stack slightly apart by hand.
  • Page 40 6 FORK, TRIPLE CLAMP Assemble the individual components that belong together. • Info Shock absorber cartridge (right fork leg): cartridge with silver adapter (9, axle clamp without brake mount, and outside fork tube without warning label, rebound adjuster B03544-10 Slide the shock absorber cartridge into the inside fork tube.

  • Page 41: Lubricating The Steering Head Bearing

    FORK, TRIPLE CLAMP 6 Tighten the shock absorber cartridge. Guideline Cartridge on the M51x1.5 50 Nm (36.9 lbf ft) outside fork tube I Ring wrench (T14017) p. 317) Mount adjuster of the compression damping. Mount and tighten the screw. Guideline Screw, compres­...

  • Page 42: Removing The Lower Triple Clamp

    6 FORK, TRIPLE CLAMP 6.21 Removing the lower tri�le clam� Preparatory work Raise the motorcycle with a lift stand. p. 12) Remove the front wheel. p. 118) Remove the fork legs. p. 18) Remove the start number plate. p. 114) Remove front fender.

  • Page 43: Installing The Lower Triple Clamp

    FORK, TRIPLE CLAMP 6 6.22 Installing the lower tri�le clam� Main work Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease (ll!:!I p. 300) Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. Check whether upper steering head seal is correctly posi­...
  • Page 44 6 FORK, TRIPLE CLAMP Tighten screws (3. Guideline Screw, bottom triple 12 Nm (8.9 lbf ft) clamp Tighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head Mount and tighten screw Guideline Screw, top 20 Nm (14.8 lbf ft) ®...

  • Page 45: Checking Steering Head Bearing Play

    FORK, TRIPLE CLAMP 6 Finishing work Install front fender. p. 113) Install the start number plate. p. 114) Install the front wheel. p. 119) Check that the wiring harness, throttle cables, and brake and clutch lines can move freely and are routed correctly. Check steering head bearing play.

  • Page 46: Changing The Steering Head Bearing

    6 FORK, TRIPLE CLAMP 6.24 Changing the steering head bearing Preparatory work Raise the motorcycle with a lift stand. p. 12) Remove the front wheel. p. 118) Remove the fork legs. p. 18) Remove the start number plate. p. 114) Remove front fender.

  • Page 47: Adjusting Steering Head Bearing Play

    FORK, TRIPLE CLAMP 6 Remove lower steering head bearing Remove the seal ring. Grease and mount the new seal ring. Press on the new bearing with a suitable tube as far as it will Info Only press the bearing in via the inner bearing race. R04788-10 Finishing work Install the lower triple clamp.

  • 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. S01965-01 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. 312) ✓ 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. 314) 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 9 SHOCK ABSORBER, LINK FORK (Option: MAGURA) Remove screws @. Pull off foot brake cylinder from the push rod. Remove the connecting link of the chain. Take off the chain. Info Cover the components to protect them against dam­ age. Remove nut and pull out the fork pivot.

  • Page 63: Installing The Shock Absorber

    SHOCK ABSORBER, LINK FORK 9 9.10 Installing the shock absorber Main work Carefully position the shock absorber into the vehicle from the bottom. Mount and tighten screw Guideline Screw, top 60 Nm (44.3 lbf ft) ™ shock absorber ® Loctite 2701 Position link fork and mount fork pivot.

  • Page 64: Checking The Shock Absorber Linkage

    9 SHOCK ABSORBER, LINK FORK Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis Position the angle lever and linkage lever. Mount and tighten fitting C). Guideline Nut, linkage lever to M14x1 .5 80 Nm (59 lbf ft) angle lever •...
  • Page 65 SHOCK ABSORBER, LINK FORK 9 Remove fitting@). Take off the angle lever. •- -• 303096-10 Check needle bearings for damage and wear. If there is damage or wear: Change the needle bearings. Check spacers and @ for damage and wear. If there is damage or wear: Change the spacers.

  • Page 66: Servicing The Shock Absorber

    9 SHOCK ABSORBER, LINK FORK Position the angle lever. Mount fitting but do not tighten yet. Guideline Nut, angle lever to M14x1.5 80 Nm (59 lbf ft) link fork Mount screw but do not tighten yet. Guideline Screw, bottom 60 Nm (44.3 lbf ft) ®...

  • 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. 319) Position the pilot bushing in the seal ring retainer using the special tool. I Pressing tool (T1504) (!Sl p. 319) 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. 316) 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. 300) 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. 300) 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 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. Remove nut Remove the link fork pivot. Take off the link fork. Main work Position the link fork.
  • Page 87 SHOCK ABSORBER, LINK FORK 9 Lift the link fork. Mount and tighten fitting Guideline Nut, angle lever to M14x1 .5 80 Nm (59 lbf ft) link fork Mount the chain. Connect the chain with connecting link Guideline The closed side of the chain joint lock must face in the direction of travel.

  • Page 88: Changing The Fork Bearing

    9 SHOCK ABSORBER, LINK FORK 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. 83) Left fork bearing Remove collar bushings R02757-10 Remove bushing@.
  • Page 89 SHOCK ABSORBER, LINK FORK 9 Mount bushing R02758-10 Grease the shaft seal rings. I Long-life grease p. 300) 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. 316) 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).

  • 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. 300) • 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 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 p. 3 07) I Hose clamp plier (600 2 9057000) 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 Loosen screw by several rotations. Loosen screws Press on screw to push the wheel spindle out of the axle clamp. Remove screw 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.

  • Page 122: Changing The Front Brake Disc

    14 WHEELS Position the front wheel and insert the wheel spindle. ✓ The brake linings are correctly positioned. Mount and tighten screw Guideline Screw, front wheel M20x1.5 35 Nm (25.8 lbf ft) spindle Operate the hand brake lever several times until the brake linings are seated correctly against the brake disc.
  • Page 123 WHEELS 14 Main work Remove shaft seal rings Press out bearing (D using a suitable tool. • Info Spacing tube can be pushed aside. Remove the spacing tube. Press out bearing using a suitable tool. Press in new bearing all the way using a suitable tool. Info Only press the bearing in via the outer bearing race otherwise the bearing will be damaged when it is...

  • Page 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 (Option: Brembo) Press the brake caliper onto the brake disc by hand in order to push back the brake piston. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake...

  • Page 125: Installing The Rear Wheel

    WHEELS 14 (Option: MAGURA) Press the brake caliper onto the brake disc by hand in order to push back the brake piston. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston.

  • Page 126: Changing The Rear Brake Disc

    14 WHEELS Main work Check the wheel bearing for damage and wear. If the wheel bearing is damaged or worn: Change the rear wheel bearing. p. 132) Clean and grease shaft seal rings and contact surfaces of the spacers. I Long-life grease p.

  • Page 127: Checking The Chain Tension

    WHEELS 14 Main work Remove screws Remove the brake disc. Clean the contact surface of the brake disc. Position the new brake disc with the label facing outward. Mount and tighten screws Guideline 14 Nm (10.3 lbf ft) Screw, rear brake disc Loctite ®...

  • Page 128: Adjusting The Chain Tension

    14 WHEELS 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 129 WHEELS 14 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. 130) • Info The engine sprocket, rear sprocket and chain should always be replaced together.
  • Page 130 14 WHEELS 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 131: Checking For Chain Dirt Accumulation

    WHEELS 14 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 132: Changing The Drivetrain Kit

    14 WHEELS Main work Rinse off loose dirt with a soft jet of water. Remove old grease residue with chain cleaner. I Chain cleaner p. 300) After drying, apply chain spray. I Off-road chain spray p. 301) 400725-01 Finishing work Remove the motorcycle from the lift stand.
  • Page 133 WHEELS 14 Remove engine sprocket Remove fittings Ci). 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 134: Changing The Rear Wheel Bearing

    14 WHEELS 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 135 WHEELS 14 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 136: 15 Wiring Harness, Battery

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

  • Page 137: Of The 12 V Battery

    WIRING HARNESS, BATTERY 15 15.2 Disconnecting the negative cable of the 12 V batterY Preparatory work Press and hold the kill switch Q9 while the engine is idling until the engine stops. Remove the air filter box cover. (ra!l p. 95) Remove the seat.

  • Page 138: Removing The 12 V Battery

    15 WIRING HARNESS, BATTERY 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 139: Installing The 12 V Battery

    WIRING HARNESS, BATTERY 15 Installing the 12 V batterY Main work Position the 12 V battery in the battery compartment with the terminals facing forward, and secure with holding bracket 112 V battery (HJTZ5S-FP) p. 282) Mount and tighten screw Guideline 10 Nm (7.4 lbf ft) Info...
  • Page 140 15 WIRING HARNESS, BATTERY Note Environmental hazard 12 V batteries contain environmentally hazardous materials. Do not dispose of 12 V batteries as household waste. Dispose of 12 V batteries at a collection point for used batteries. 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.

  • Page 141: Checking The Charging Voltage

    WIRING HARNESS, BATTERY 15 Disconnect the battery charger after charging the 12 V bat­ tery. 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.

  • Page 142: Checking The Capacitor

    15 WIRING HARNESS, BATTERY 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. imum open-circuit cur- <...

  • Page 143: Checking The Starter Relay

    WIRING HARNESS, BATTERY 15 15.10 Checking the starter rela� Preparatory work Press and hold the kill switch Q9 while the engine is idling until the engine stops. Remove the air filter box cover. (ra!l p. 95) Remove the seat. (ra!l p.

  • Page 144: 16 Brake System

    16 BRAKE SYSTEM Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. Ensure that worn-out brake linings are replaced immediately. (Option: Brembo) Check the brake linings for minimum thickness 6) . I � Minimum thickness 6) 1 mm (�...
  • Page 145 BRAKE SYSTEM 16 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 Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.
  • Page 146 16 BRAKE SYSTEM Insert the new brake linings, insert pin and mount cotter pin • Info Always change the brake linings in pairs. Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.

  • Page 147: Checking The Free Travel Of The Hand Brake Lever (Option: 17.3.26 Brembo)

    BRAKE SYSTEM 16 Check that spring plate in the brake caliper and slid­ ing plate @ in the brake caliper bracket are seated cor­ rectly. H02377-10 Insert the new brake linings. Mount pin Q). ✓ Spring plate engages in the groove on the pin. Info •...

  • Page 148: Hand Brake Lever

    16 BRAKE SYSTEM Push the hand brake lever forward and check free travel f). Free travel of hand brake ?: 3 mm (?: 0.12 in) lever If the free travel does not match the specification: Adjust the basic position of the hand brake lever. p.

  • Page 149: Checking The Front Brake Fluid Level

    BRAKE SYSTEM 16 Checking the front 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 150 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 151: Changing The Front Brake Fluid

    BRAKE SYSTEM 16 (Option: MAGURA) Move the brake reservoir mounted on the handlebar to a horizontal position. Remove screws Take off cover with membrane@). Add brake fluid to level f). Guideline 5 mm (0.2 in) Level f) (brake fluid level below reservoir rim) Brake fluid DOT 4 / DOT 5.1 p.
  • Page 152 16 BRAKE SYSTEM (Option: Brembo) Move the brake reservoir mounted on the handlebar to a horizontal position. Cover painted parts. Remove screws Take off cover with the membrane. Extract the old brake fluid from the brake fluid reservoir using a syringe and fill with fresh brake fluid. Syringe (50329050000) p.
  • Page 153 BRAKE SYSTEM 16 Disconnect the bleeding device. Remove the bleeder cover. Add brake fluid up to level (9. Guideline 5 mm (0.2 in) Level (9 (brake fluid level below reservoir rim) I Brake fluid DOT 4 / DOT 5.1 (IUI p.

  • Page 154: Checking The Brake Linings Of The Rear Brake

    16 BRAKE SYSTEM Pull off protection cap of the brake caliper bleeder screw. Connect the bleeder bottle hose. Bleeding device (00029013100) (!el p. 303) Open bleeder screw by approx. one half turn. Info Drain until fresh brake fluid emerges in the bleeder bottle hose without bubbles.

  • Page 155: Changing The Rear Brake Linings

    BRAKE SYSTEM 16 (Option: Brembo) Check the brake linings for minimum thickness I Minimum thickness I � 1 mm (� 0.04 in) If the minimum thickness is less than specified: Change the rear brake linings. p. 153) Check the brake linings for damage and cracking. If damage or wear is encountered: Change the rear brake linings.
  • Page 156 16 BRAKE SYSTEM Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container.
  • Page 157 BRAKE SYSTEM 16 Add brake fluid to level f). I Brake fluid DOT 4 / DOT 5.1 p. 298) Mount and tighten screw cap with membrane @ and the O-ring. Info Clean up overflowed or spilled brake fluid immedi­ ately with water. (Option: MAGURA) Stand the vehicle upright.

  • Page 158: Brake Lever

    16 BRAKE SYSTEM Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. Add brake fluid to level fj . Brake fluid DOT 4 DOT 5.1 p. 298) Mount and tighten screw cap with membrane the shim.
  • Page 159 BRAKE SYSTEM 16 (Option: Brembo) Detach spring Loosen nut and, with push rod turn it back until you have maximum free travel. To adjust the basic position of the foot brake lever to indi­ vidual requirements, loosen nut and turn screw accordingly.

  • Page 160: Checking The Rear Brake Fluid Level

    16 BRAKE SYSTEM Guideline Nut, foot brake 20 Nm (14.8 lbf ft) 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 161 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 162: Changing The Rear Brake Fluid

    16 BRAKE SYSTEM (Option: MAGURA) Stand the vehicle upright. Remove the cable tie on the frame protector. Remove screw cap with membrane and the shim. Add brake fluid up to the marking f). Brake fluid DOT 4 / DOT 5.1 p.
  • Page 163 BRAKE SYSTEM 16 Mount bleeder cover I Bleeder cover (00029013006) p. 302) Connect the bleeding device. I Bleeding device (00029013100) p. 303) Open shut-off valve • Info Follow the instructions in the Owner's Manual of the bleeding device. Ensure that the filling pressure is set on pressure gauge 6).
  • Page 164 16 BRAKE SYSTEM Check the foot brake lever for a firm pressure point. (Option: MAGURA) Remove the cable tie. Cover painted parts. Remove screw cap with membrane @ and the shim. Extract the old brake fluid from the brake fluid reservoir using a syringe and fill with fresh brake fluid.
  • Page 165 BRAKE SYSTEM 16 Open the bleeder screw again until brake fluid stops emerging. • Info Overfilling the brake fluid reservoir is prevented. Tighten the bleeder screw. Remove the bleeder bottle hose. Attach the protection cap. Disconnect the bleeding device. Remove the bleeder cover.

  • Page 166: 17 Engine

    17 ENGINE 17.1 Removing the engine Preparatory work Raise the motorcycle with a lift stand. p. 12) Drain the coolant. p. 257) Remove the right side cover. p. 99) Remove the air filter box cover. p. 95) Remove the seat. p.
  • Page 167 ENGINE 17 Push back protection cap Unplug the connector. Pull rollover sensor off of the holder and hang to one side. Remove screw (D. Loosen screw Repeat these steps on the opposite side. Pivot the subframe up and secure it. Remove screw Pivot the shock absorber toward the rear and twist it slightly.
  • Page 168 17 ENGINE Remove springs I Spring hook (5030501700004) p. 314) 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). Disconnect plug-in connector...
  • Page 169 ENGINE 17 Remove the cable tie. Remove the cable clamps and expose the cable. Push back protection cap Unplug the connector. Loosen hose clip �. Pull the radiator hose. Loosen hose clip Pull the radiator hose. Pull capacitor of the holder and hang to one side.
  • Page 170 17 ENGINE Disconnect spark plug connector Gi). Remove screw Ci) 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. Info Do not kink the clutch line.
  • Page 171 ENGINE 17 Remove screw fJ) with the washer. Take off the engine sprocket. Remove screw .. with the washers. Take off the shift lever. Loosen hose clip Ci). Pull the throttle valve body off of the cylinder head toward the rear and hang it to one side.
  • Page 172 17 ENGINE Remove fitting �. @Ii). 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. Remove screws...

  • Page 173: Installing The Engine

    ENGINE 17 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. Main work Position the engine in the frame.
  • Page 174 17 ENGINE 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. Mount and tighten fitting Guideline Nut, linkage lever to M14x1.5...
  • Page 175 ENGINE 17 Position the shift lever. Mount and tighten screw Ci) with washers. Guideline Screw, shift 14 Nm (10.3 lbf ft) ® Loctite lever ™ Slide on the engine sprocket with the collar facing the engine. Mount screw with the washer but do not tighten yet. Guideline Screw, engine 60 Nm (44.3 lbf ft)
  • Page 176 17 ENGINE Position the engine sprocket cover. Mount and tighten screw 41). 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 Plug in spark plug connector G!). Mount capacitor Mount the radiator hose.
  • Page 177 ENGINE 17 Plug in the connector. 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. Join plug-in connectors of the alternator.
  • Page 178 17 ENGINE 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 (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 179 ENGINE 17 Remove the locking piece and position the subframe. Info Watch out for the intake flange. Mount and tighten screw fl!). Guideline Screw, sub­ 30 Nm (22.1 lbf ft) ® Loctite 2701 frame Remove screw Ci). Mount and tighten screw Ci). Guideline Screw, sub­...
  • Page 180 17 ENGINE Connect negative cable Guideline Screw, battery termi- 2.5 Nm (1.84 lbf ft) • Info Contact disk must be mounted under screw and the cable lug @ with the claws facing down. Position the frame protectors on the left and right. Mount and tighten screw �.

  • Page 181: Engine Disassembly

    Refill with coolant. p. 257) Perform the initialization run. p. 275) 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. (ll!:!l p.

  • Page 182: Removing The Oil Filter

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

  • Page 183: Removing The Spark Plug

    ENGINE 17 17.3.6 Removing the spark plug Remove the spark plug with special tool Spark plug wrench with link (77229172000) (� p. 310) 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 (D.

  • Page 184: Starter Motor, Removing

    17 ENGINE 17.3.8 starter motor, removing Remove screws Take off the alternator cover. Remove gasket Remove torque limiter (D. 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.

  • Page 185: Removing The Timing Chain Tensioner

    ENGINE 17 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 (D.

  • Page 186: Cylinder Head, Removing

    17 ENGINE 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 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 187: Removing The Rotor

    ENGINE 17 Take off cylinder base gasket 17 .3.14 Removing the rotor Remove screw Insert special tool into the crankshaft. Protection cap (75029090000) p. 309) Mount special tool on the rotor. Hold it tight using the special tool and pull off the rotor by turning the screw in. Extractor (79229032044) p.

  • Page 188: Removing The Suction Pump

    17 ENGINE Take off freewheel gear (D. Removing the suction pump 17.3.16 Remove screws Take off oil pump cover@. Remove O-ring (D. Take off suction pump Remove needle roller...

  • Page 189: 17.3.17 Water Pump Impeller, Removing

    ENGINE 17 17.3.17 water pump impeller, removing Remove screws Take off the water pump cover. Remove gasket Remove nut (D. 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 190: Removing The Clutch Discs

    17 ENGINE 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 @). 17.3.20 Removing the clutch basket Remove two opposite sleeves Bend up the lock washer. Hold the inner clutch hub with the special tool.

  • Page 191: Removing The Primary Gear Wheel

    ENGINE 17 Take off needle bearing and collar sleeve@. 17 .3.21 Removing the primary gear wheel Remove nut • Info LH thread! Position the special tool in the crankshaft. Protection cap (75029090000) p. 309) Pull off primary gear wheel using the special tool. Puller (46129021000) p.

  • Page 192: Removing The Force Pump

    17 ENGINE 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 0). Remove pin@. «D. Remove screws Take off the oil pump cover.

  • Page 193: Shift Drum Locating Unit, Removing

    ENGINE 17 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 194: Shift Rails, Removing

    17 ENGINE Insert the special tool into the crankshaft. I Protection cap (75029090000) p. 309) Mount special tool with suitable screws. I Puller (79229048000) p. 313) • 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 195: Removing The Shift Forks

    ENGINE 17 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 196: Working On Individual Parts

    17 ENGINE Working on individual arts 17.4 17.4.1 Working on the right section of the engine case Remove all dowels. Remove shaft seal ring of the crankshaft. Remove nozzle Remove oil nozzle for conrod bearing lubrication. Remove screw Remove the oil nozzle for piston cooling. Remove screws Remove the bearing retainers.
  • Page 197 ENGINE 17 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) Loctite ® conrod bearing ™ lubrication Mount the oil nozzle for piston cooling.

  • Page 198: Working On The Left Section Of The Engine Case

    17 ENGINE 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 199: Work On The Clutch Cover

    ENGINE 17 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 (3.
  • Page 200 17 ENGINE Press out bearing toward the inside. B03752-10 Mount lock ring Press the shaft seal ring all the way in from the inside to the outside with the open side facing in. Press the new bearing all the way in from the inside to the outside using a suitable tool.

  • Page 201: Checking The Oil Pressure

    ENGINE 17 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 23.5 mm (0.925 in) Minimu ':1 length of pres- sure spring If the measured value does not meet specifications:...

  • Page 202: Checking The Lubrication System

    17 ENGINE 17.4.5 Checking the lubrication system ✓ 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 203: Installing The Crankshaft Bearing Inner Race

    ENGINE 17 17.4.7 Installing the crankshaft bearing inner race Main work Fix the crankshaft in the vise. Guideline Use soft jaws. • . · -�/H�.c­ Slide on compensating disk ·•�i.� �� Info -:--'s,.' ·-· _,)p The compensating disks have a larger diameter than -✓(:, the crankshaft stub.
  • Page 204 17 ENGINE Press the crank pin out of the lower crankweb. Press in new crank pin all the way. ✓ Oil hole is aligned with oil hole@). X If the oil holes are not correctly aligned, the conrod bear­ ing will not be supplied with oil. Blow compressed air through the oil channel to check that it is clear.

  • Page 205: Checking The Crankshaft Run-Out At The Bearing Pin

    ENGINE 17 Position special tool with the heel pointing down. Insert for crankshaft pressing tool (79029008000) p. 311) 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 206: Measuring The Crankshaft End Play

    17 ENGINE 17.4.10 Measuring the crankshaft end play Insert the crankshaft into the right section of the engine case. Info Do not forget the dowels. Mount the left section of the engine case. Mount and tighten the screws. Guideline Screw, engine case 110 Nm (7.4 lbf ft) Mount the dial gauge support on the engine case and mea­...

  • Page 207: Installing The Drive Gear Wheel Of The Balancer Shaft

    ENGINE 17 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 oc (212 OF) 310342-10 17.4.13 Cylinder - Nikasil...

  • Page 208: Checking/Measuring The Piston

    17 ENGINE 17.4.15 Checking/measuring the piston Use the special tool to measure clearance of the piston rings in the piston ring groove. e -' ­ Guideline Piston ring - groove clear­ :S 0.08 mm (:S 0.0031 in) ance I Feeler gauge (59029041100) (IUI p.

  • Page 209: Measuring The Piston/Cylinder Mounting Clearance

    ENGINE 17 Info Piston size is marked on the side of the piston . 17.4.16 Measuring the piston/cylinder mounting clearance Check/measure the cylinder. (!el p. 205) Check/measure the piston. (!el p. 206) The smallest piston/cylinder mounting clearance equals the smallest cylinder bore diameter minus the largest piston diameter.

  • Page 210: Camshafts, Checking

    17 ENGINE 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 211: Valves, Removing

    ENGINE 17 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 212: Valves, Checking

    17 ENGINE 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. I Valve stem seals plier (77229010000) p.

  • Page 213: Checking The Valve Spring Seat

    ENGINE 17 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 214: Installing The Valves

    17 ENGINE Using a straightedge and the special tool, check the sealing area of the cylinder for distortion. I Feeler gauge (59029041100) p. 307) � 0.10 mm (� 0.0039 in) Cylinder/cylinder head - dis- tortion of sealing area If the measured value does not meet specifications: Change the cylinder head.

  • Page 215: Checking The Freewheel

    ENGINE 17 Mount valve keys 6). 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 216: Freewheel, Installing

    17 ENGINE Press expansion ring (i} together with suitable pliers and take off. 310364-10 Remove freewheel (D. 310365-10 17.4.29 freewheel, installing Thoroughly oil all parts. Mount freewheel Info Note the direction of rotation. 310365-11 Mount spreader ring (i}. 310366-10 Ensure that all the holding lugs of the expansion ring pass through slots of the freewheel and engage in groove of the rotor.

  • Page 217: Checking The Electric Starter Drive

    ENGINE 17 Mount lock ring 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 218: Checking The Timing Assembly

    17 ENGINE Change the starter motor. 17.4.31 Checking the timing assembly 00• • 0 - --- • - 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 219: Preparing The Timing Chain Tensioner For Installation

    ENGINE 17 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 220: Checking The Clutch

    17 ENGINE 17.4.33 Checking the clutch •- -• 310351-10 Check clutch throw-out for damage and wear. there is damage or wear: Change the clutch push rod. Check axial bearing for damage and wear. there is damage or wear: Change the axial bearing. Place the clutch push rod on a flat surface and check for run-out.

  • Page 221: Checking The Shift Mechanism

    ENGINE 17 Check the thickness of clutch facing discs �- 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.

  • Page 222: Preassembling The Shift Shaft

    17 ENGINE 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 223: Disassembling The Main Shaft

    ENGINE 17 17.4.36 Disassembling the main shaft Secure the main shaft in the vise with the gear teeth facing downward. Guideline 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 224: Disassembling The Countershaft

    17 ENGINE 17.4.37 Disassembling the countershaft D05798-10 Secure the countershaft in the bench vise with the toothed end facing downward. Guideline Use soft jaws. Remove stop disk and first-gear idler gear Remove needle bearing and stop disk Remove fourth-gear sliding gear Remove lock ring Remove stop disk @.
  • Page 225 ENGINE 17 Check needle bearings for damage and wear. If there is damage or wear: Change the needle bearings. Check the pivot points of main shaft and countershaft (D for damage and wear. If there is damage or wear: Change the main shaft and/or countershaft. Check the tooth profiles of main shaft @ and countershaft (D for damage and wear.

  • Page 226: Assembling The Main Shaft

    17 ENGINE 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 227: Assembling The Countershaft

    ENGINE 17 Mount needle bearing Mount fifth-gear idler gear @) . Mount second-gear fixed gear Press sleeve � 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 228: Engine Assembly

    17 ENGINE 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 Gi) and lock ring Mount fourth-gear sliding gear with the shift groove facing downward.

  • Page 229: Shift Forks, Installing

    ENGINE 17 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 230: Left Engine Case, Installing

    17 ENGINE 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. I Loctite 5910 ® Mount the left section of the engine case. If necessary, strike it lightly with a rubber mallet and turn the transmission shafts.

  • Page 231: Shift Shaft, Installing

    ENGINE 17 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 232: Installing The Suction Pump

    17 ENGINE Position the oil pump cover. ✓ Marking faces upward. Mount and tighten screws Guideline Screw, oil pump 6 Nm (4.4 lbf ft) Loctite ® cover ™ Insert pin Position oil pump gear wheel 0). Mount washer @. Mount lock ring Crank the oil pump gear wheel and ensure that it can move easily.

  • Page 233: Installing The Timing Chain

    ENGINE 17 Mount 0-ring (D. 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 234: Installing The Primary Gear Wheel

    17 ENGINE 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 are aligned. Mount and tighten nut Guideline Nut, primary M18LHx1.5 100 Nm (73.8 lbf ft) ®...

  • Page 235: Installing The Clutch Discs

    ENGINE 17 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 ® ™ Holding wrench (51129003000) (�...

  • Page 236: Installing The Clutch Cover

    17 ENGINE 17.5.17 Installing the clutch cover Producing tool (special screw): A conventional screw is required. Cut screw f) to a length of Guideline Screw M6x70 60 mm (2.36 in) Length G) Cut a slot into the top end of the screw. D05933-10 Mount screw f) and tighten hand-tight.

  • Page 237: Water Pump Cover, Installing

    ENGINE 17 17.5.18 water pump cover, installing Mount two-part water pump impeller Mount and tighten the nut Guideline Nut, water 6 Nm (4.4 lbf ft) ® Loctite ™ pump impeller Mount gasket (D. Mount the water pump cover. Info Ensure that the dowel pins are seated properly. Mount screw with the seal ring b ut to not tighten yet.

  • Page 238: Starter Drive, Installing

    17 ENGINE 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) idler gear Loctite ® 243™ 17.5.20 Installing the rotor Ensure that the woodruff key is seated properly. Mount the rotor.
  • Page 239 ENGINE 17 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 240: Installing The Cylinder Head

    17 ENGINE 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. I Insertion for piston ring lock (77729030100) p. 311) Ensure that the piston ring lock is in the correct position on both sides.

  • Page 241: Installing The Camshafts

    ENGINE 17 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 242: Installing The Timing Chain Tensioner

    17 ENGINE 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 243: Adjusting The Valve Clearance

    ENGINE 17 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 244: Installing The Starter Motor

    17 ENGINE 17.5.27 Installing the starter motor Grease the 0-ring. Position the starter motor. I Long-life grease p. 300) Mount and tighten screws Guideline Screw, starter motor 110 Nm (7.4 lbf ft) Thoroughly oil the bearing pin of the torque limiter. Position torque limiter@.

  • Page 245: Spark Plug, Installing

    ENGINE 17 Position gasket Thinly apply sealing compound to area f). Loctite 5910 ® Position the valve cover with the gasket. Mount and tighten screws Guideline Screw, valve cover I 8 Nm (5.9 lbf ft) 17.5.29 spark plug, installing Mount and tighten the spark plug with special tool Guideline Spark plug M10x1...

  • Page 246: Installing The Oil Filter

    17 ENGINE 17.5.31 Installing the oil filter Tilt the motorcycle to one side and fill the oil filter housing to about ½ full with engine oil. Insert oil filter into the oil filter housing. Oil the O-ring of the oil filter cover. Mount oil filter cover@.

  • Page 247: Installing The Clutch Push Rod

    ENGINE 17 Mount and tighten screw plug with the O-ring. Guideline M20x1 .5 15 Nm (11.1 lbfft) Screw plug, oil 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 248: 18 Clutch

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

  • Page 249: Changing The Hydraulic Clutch Fluid

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

  • Page 250: Checking The Clutch

    18 CLUTCH Now inject the liquid into the system until it emerges from drill hole of the master cylinder without bubbles. Now and then, extract fluid from the master cylinder reservoir to prevent overflow. Tighten the bleeder screw and remove the bleeding syringe with the hose.
  • Page 251 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 252 18 CLUTCH Remove clutch discs completely. Bend up the lock washer. Hold the inner clutch hub with the special tool. Loosen nut@). I Holding wrench (51129003000) (IUI p. 305) Remove the nut with the lock washer. Take off inner clutch hub Gi) and washer Info The washer usually sticks to the inner clutch hub.
  • Page 253 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 254 18 CLUTCH 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. If there is damage or wear: Change the washer.
  • Page 255 CLUTCH Mount sleeves Thoroughly oil clutch facing discs Insert the intermediate clutch disc Qi). Guideline Thickness mm (0.04 in) Place the clutch facing and intermediate discs into the clutch basket. Insert the intermediate clutch disc Qi). Guideline Thickness mm (0.04 in) Mount clutch throw-out with clutch push rod (D.
  • Page 256 18 CLUTCH Attach spring Place vehicle in upright position and rest on the plug-in stand. T01346-10 Finishing work Check the engine oil level. (l!ll p. 259)

  • Page 257: Water Pump, Cooling System 19

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

  • Page 258: Checking The Coolant Level

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

  • Page 259: Draining The Coolant

    WATER PUMP, COOLING SYSTEM 19 Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
  • Page 260 19 WATER PUMP, COOLING SYSTEM Make sure that screw is tightened. Position the motorcycle upright. Pour coolant in up to measurement above the radiator fins. Guideline 10 mm (0.39 in) Distance above the radi- ator fins I Coolant (� p. 298) Mount the radiator cap.

  • Page 261: 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 Suction pump Oil channel, transmission lubrication Timing chain tensioner...

  • Page 262: 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 6) . If the engine oil does not reach the middle of the level viewer: Add engine oil. p. 263) Condition The engine is at operating temperature.
  • Page 263 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 264 LUBRICATION SYSTEM Pull oil filter out of the oil filter housing. I Lock ring plier (51012011000) p. 305) 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 about ½...

  • Page 265: 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 266: Checking The Oil Pressure

    LUBRICATION SYSTEM Main work Remove screw Position the special tool. I Oil pressure adapter (77329006000) p. 311) Mount and tighten the banjo bolt. Guideline I Banjo bolt M10x1 8 Nm (5.9 lbf ft) I Banjo bolt (79329006000) p. 313) Connect the pressure testing tool to the special tool without 401095-01 the T-plate.
  • Page 267 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 268: Ignition System

    IGNITION SYSTEM 21.1 winding Ignition coil - checking the seconda 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 269: 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 If the displayed value does not equal the setpoint value: Replace the stator.

  • Page 270: 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 (s). Guideline Screw, 6 Nm (4.4 lbf ft) crankshaft ®...
  • Page 271 IGNITION SYSTEM Plug in spark plug connector Mount capacitor Finishing work Install the fuel tank. p. 102) Mount the seat. p. 100) p. 9 5) Install the air filter box cover. Install the right side cover. p. 99)

  • Page 272: 22 Cylinder Head

    22 CYLINDER HEAD 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 273 CYLINDER HEAD 22 Remove screw Turn the crankshaft counterclockwise until markings flush with the edge of the cylinder head. Remove screw @) . C&. Remove washer Look through the hole to check that the position notch of the crankshaft is visible. Mount and tighten screw @) without the washer.
  • Page 274 22 CYLINDER HEAD Mount and tighten screw (D. 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). I Loctite 5910 ® Mount gasket Position the valve cover with the gasket.

  • Page 275: Adjusting The Valve Clearance

    CYLINDER HEAD 22 Mount capacitor Finishing work Install the fuel tank. p. 102) Mount the seat. p. 100) 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 276: 23 Electric Starter System

    23 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 277: Throttle Valve Body 24

    THROTTLE VALVE BODY 24 24.1 Adjusting the idle s�eed 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. Warning Danger of accidents The engine may go out spontaneously if the idle speed is set too low.
  • Page 278 THROTTLE VALVE BODY Danger Exhaust gases are toxic and Danger of poisoning inhaling them may result in unconsciousness and death. Always make sure there is sufficient ventilation when running the engine. Use effective exhaust extraction when starting or running the engine in an enclosed space. Start the engine without operating the throttle grip.

  • Page 279: Technical Data 25

    TECHNICAL DATA 25 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 280: Tolerance, Engine Wear Limits

    25 TECHNICAL DATA 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 281: Engine Tightening Torques

    TECHNICAL DATA 25 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 282 25 TECHNICAL DATA Screw, starter motor 10 Nm (7.4 lbf ft) Screw, timing chain guide rail 10 Nm (7.4 lbf ft) ® Loctite ™ Screw, timing chain securing 10 Nm (7.4 lbf ft) ® Loctite ™ guide Screw, valve cover 8 Nm (5.9 lbf ft) Screw, water pump cover 10 Nm (7.4 lbf ft)

  • Page 283: Capacities

    TECHNICAL DATA 25 25.4 Ca�acities 25.4.1 Engine oil 11.0 I (1 .1 qt.) Engine oil (SAE 1 0W/50) (!el p. 298) Engine oil 25.4.2 Coolant Coolant 0.95 I (1 qt.) Coolant (!el p. 298) 25.4.3 Fuel Super unleaded (ROZ 95/RON 95/PON 91) (!el p.

  • Page 284: 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 article number 34.18.SR.55 Fork...

  • Page 285: Shock Absorber

    TECHNICAL DATA 25 25.9 Shock absorber Shock absorber article number 18.18. 7R.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...
  • Page 286 25 TECHNICAL DATA Screw, frame protector 3 Nm (2.2 lbf ft} Screw, shock absorber adjusting 5 Nm (3.7 lbf ft} ring Screws on main silencer 7 Nm (5.2 lbf ft) Remaining nuts, chassis 10 Nm (7.4 lbf ft) Remaining screws, chassis 10 Nm (7.4 lbf ft} Screw, ball joint of push rod on 10 Nm (7.4 lbf ft)
  • Page 287 TECHNICAL DATA 25 Nut, angle lever to link fork M14x1 .5 80 Nm (59 lbf ft) Nut, frame to linkage lever M14x1 .5 80 Nm (59 lbf ft) Nut, linkage lever to angle lever M14x1 .5 80 Nm (59 lbf ft) Nut, fork pivot M16x1.5 100 Nm (73.8 lbf ft)

  • Page 288: 26 Cleaning/Protective Treatment

    26 CLEANING/PROTECTIVE TREATMENT 26.1 Cleaning the motorc�cle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.
  • Page 289 CLEANING/PROTECTIVE TREATMENT Push back the protection caps of the handlebar controls to allow any water that has penetrated to evaporate. After the motorcycle has cooled off, lubricate all moving parts and bearings. Clean the chain. p. 129) Treat bare metal parts (except for brake discs and the exhaust system) with a corrosion inhibitor.

  • Page 290: 27 Storage

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

  • Page 291: Putting Into Operation After Storage

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

  • Page 292: 28 Service Schedule

    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 293: 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 diag- nostics tool. • • • • Make the service entry in Husqvarna Motorcycles Dealer.net...
  • Page 294 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 295: 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 296 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 297 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 298 �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 299 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 300: 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 301 SUBSTANCES 30 Fork oil {SAE 4) {48601166S1 Standard/classification SAE(� p. 321) (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 302: Auxiliary Substances

    AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier ® MOTOREX Racing Bio Dirt Remover Chain cleaner Recommended supplier ® MOTOREX Chain Clean Fuel additive Recommended supplier ® MOTOREX Fuel Stabilizer High viscosi grease Recommended supplier ® LGHB 2 Long-life grease Recommended supplier ®...
  • Page 303 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 304: 32 Special Tools

    32 SPECIAL TOOLS Bleeder cover Art. no.: 00029013005 00029013005 H00504-01 Bleeder cover Art. no.: 00029013006 .& 00029013006 H00505-01 Bleeder cover Art. no.: 00029013019 � 00029013019 H02440-01 Bleeder cover Art. no.: 00029013020 .& 00029013020 H02441-01...
  • Page 305 SPECIAL TOOLS 32 Bleeding device Art. no.: 00029013100 00029013100 H00518-01 EU batte charger XCharge-�rofessional Art. no.: 00029095050 Feature EU safety plug Nominal voltage 230V Mains fuse Power cable length 5 m (16 ft) approx. Charger cable 5 m (16 ft) H01065-01 length approx.
  • Page 306 32 SPECIAL TOOLS CH batte� charger XCharge-�rofessional Art. no.: 00029095053 Feature CH plug Nominal voltage 230 V Mains fuse Power cable length 5 m (16 ft) approx. Charger cable 5 m (16 ft) H01065-01 length approx. Tachometer Art. no.: 45129075000 45129075000 H00525-01 Puller...
  • Page 307 SPECIAL TOOLS 32 Lock ring �lier Art. no.: 51012011000 51012011000 H00572-01 Holding wrench Art. no.: 51129003000 & 51129003000 H00575-01 Puller Art. no.: 58429037037 & Feature Inside diameter 37.5 mm (1.476 in) � 58429037037 H00596-01 Tool bracket Art. no.: 58429089000 2x£ 58429089000 H00603-01...
  • Page 308 32 SPECIAL TOOLS Pressing tool Art. no.: 58429091000 58429091000 H00604-01 Pressing tool Art. no.: 58429092000 58429092000 H00605-01 Torgue wrench kit Art. no.: 58429094000 Feature Torque 3 ... 15 Nm (2.2 ... 11 .1 lbf ft) Open ended bit 3.9 mm (0.154 in) Open ended bit 4.9 mm (0.193 in) 5.5 mm (0.217 in)
  • Page 309 SPECIAL TOOLS 32 Feeler gauge Art. no.: 59029041100 Feature 0.10 ... 0.25 mm (0.0039 ... 0.0098 in) 5 piece 59029041100 H00616-01 Plastigauge clearance gauge Art. no.: 60029012000 Feature 0.025 ... 0.175 mm (0.00098 ... 0.00689 in) 60029012000 H00627-01 Piston ring com�ressor Art.
  • Page 310 32 SPECIAL TOOLS Testing hose Art. no.: 61029093000 61029093000 H00659-01 Pressure testing tool Art. no.: 61029094000 4x£ 61029094000 H00660-01 Release device for timing chain tensioner Art. no.: 61229021000 61229021000 H00675-01 Mounting tool for lock rin Art. no.: 75029005000 75029005000 H00705-01...
  • Page 311 SPECIAL TOOLS 32 Crankshaft �ressing tool Art. no.: 75029047000 75029047000 H00714-01 Protection ca� Art. no.: 75029090000 75029090000 H00726-01 Insert for valve s�ring lever Art. no.: 77029041200 77029041200 H00746-01 Valve stem seals lier Art. no.: 77229010000 77229010000 H00752-01...
  • Page 312 32 SPECIAL TOOLS Limit �lug gauge Art. no.: 77229026000 Feature I Diameter 5.55 mm (0.2185 in) 77229026000 H00753-01 Protection ca� Art. no.: 77229031000 77229031000 H00755-01 Se�arator �late Art. no.: 77229032000 77229032000 H00756-01 lug wrench with link Art. no.: 77229172000 Feature Drive 3/8 in 14 mm (0.55 in)
  • Page 313 SPECIAL TOOLS 32 Oil �ressure ada�ter Art. no.: 77329006000 77329006000 H00764-01 Insertion for �iston ring lock Art. no.: 77729030100 77729030100 H01126-01 Mounting tool for lock ring Art. no.: 79029005000 79029005000 HOOB00-01 Insert for crankshaft ressing tool Art. no.: 79029008000 79029008000 H00801-01...
  • Page 314 32 SPECIAL TOOLS Se�arator �late Art. no.: 79029009000 79029009000 H00802-01 Insert for valve s�ring lever Art. no.: 79029060000 79029060000 H00803-01 Footrest s�ring �lier Art. no.: 79029083000 79029083000 H00804-01 Holder and fittin for work stand Art. no.: 79229002000 2xffiffi 79229002000 H01127-01...
  • Page 315 SPECIAL TOOLS 32 Extractor Art. no.: 79229032044 79229032044 H00808-01 Puller Art. no.: 79229048000 79229048000 H00809-01 Banjo bolt Art. no.: 79329006000 79329006000 H02607-01 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...
  • Page 316 32 SPECIAL TOOLS Engine assembl� stand Art. no.: 80329001000 80329001000 H01047-01 Lift stand Art. no.: 81329955100 Feature Height 315 ... 425 mm (12.4 ... 16.73 in) Load :5 150 kg (:5 331 lb.) 81329955100 H00985-01 Hook wrench Art. no.: 90129051000 90129051000 H00831-01 S ring hook...
  • Page 317 SPECIAL TOOLS 32 De�th micrometer Art. no.: T107S T107S H00842-01 Drift Art. no.: T120 Feature Diameter 8 mm (0.31 in) T120 H00844-01 Mounting sleeve Art. no.: T1204 Feature Diameter 25.5 ... 30.5 mm (1.004 ... 1.201 in) T1204 H00878-01 Calibratin unit Art.
  • Page 318 32 SPECIAL TOOLS Pressing tool Art. no.: T1206 Feature I Diameter 15 ... 30 mm (0.59 ... 1.18 in) � T1206 H00880-01 Pressing tool Art. no.: T1207S .&&. � &l) T1207S H00881-01 Pressing tool Art. no.: T1216 Feature I Diameter I 38 ...
  • Page 319 SPECIAL TOOLS 32 Filling ada ter Art. no.: T1296 T1296 H01573-01 Protecting sleeve Art. no.: T1401 & Feature Diameter 48 mm (1 .89 in) cs)) T1401 H00894-01 Clam�ing stand Art. no.: T14016S 2x& Feature Diameter 112 mm (0.47 in) ill] T14016S H01036-01 Ring wrench...
  • Page 320 32 SPECIAL TOOLS Clam�ing stand Art. no.: T1403S .&. Feature Diameter 48 mm (1.89 in) Diameter 60 mm (2.36 in) �� T1403S H00896-01 Mounting tool Art. no.: T14040S Feature Diameter 48 mm (1.89 in) � T14040S H00922-01 Clam�ing stand Art. no.: T14072 £.
  • Page 321 SPECIAL TOOLS 32 S�ecial socket Art. no.: T14084 Feature Drive 1/2 in � Diameter 4 mm (0.94 in) T14084 H01518-01 Mounting sleeve Art. no.: T14092 Feature Diameter 34 mm (1 .34 in) T14092 H02261-01 Pressing tool Art. no.: T1504 Feature Diameter 118 mm (0.71 in) T1504...
  • Page 322 32 SPECIAL TOOLS Mounting sleeve Art. no.: T1515 Feature 1 18 mm (0.71 in) I Diameter T1515 H00900-01 Filling tool Art. no.: T170S1 £ £ T170S1 H00855-01...

  • Page 323: Standards 33

    STANDARDS 33 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 324: 34 List Of Abbreviations

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

  • Page 325: Index

    INDEX Capacitor 12 V battery checking charging Capacity installing coolant negative cable, connecting ... . 135 engine oil ....178, 262, 281 negative cable, disconnecting .
  • Page 326 INDEX piston/cylinder, mounting clearance measur- clutch push rod, installing ... . . 245 ing ......207 crankshaft, installing ....226 shift shaft, preassembling .
  • Page 327 INDEX shift forks, removing removing ......19 shift rails, removing Frame shift shaft, removing checking ......52 spacer, removing .
  • Page 328 INDEX shock absorber, adjusting ....55 Riding sag Link fork adjusting ......58 checking ......
  • Page 329 INDEX Spark plug Vehicle identification number ... . . 1 0 changing Spark plug connector Wheel bearing chec�ng ......266 checking ......116 Spoke tension of the front wheel, changing .
  • Page 330 I 1 1 11 1 11 1 1 1 1 11 1 1 1 111 1 11 1 1 1 1 111 1 111 1 1 11 1 1 1 1 1 I I I I I I II I I II 3403058en 06/2018 ® Husqvarna Husqvarna Motorcycles GmbH StallhofnerstraBe 3 5230 Mattighofen Austria � LZZa" www.husqvarna-motorcycles.com ..

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