Husqvarna FC 250 2016 Repair Manual
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Husqvarna FC 250 2016 Repair Manual

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PIONEERING SINCE 1903
REPAIR MANUAL2016
FC250
®
Husqvarna
Art. no. 3403031 en
MOTORCYCLES

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Summary of Contents for Husqvarna FC 250 2016

  • Page 1 PIONEERING SINCE 1903 REPAIR MANUAL2016 FC250 ® Husqvarna Art. no. 3403031 en 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 seal ring MEANS OF REPRESENTATION ......7 retainer ..........24 Symbols used ........7 6.16 Checking the fork legs ......25 1 .2 Formats used ........7 6.17 Assembling the seal ring retainer ..26 SAFETY ADVICE ..........
  • Page 5 TABLE OF CONTENTS 12.4 Adjusting the spring preload of the Installing the right side cover ....94 shock absorber ........53 12.5 Removing the seat ......94 Adjusting the riding sag ...... 54 12.6 Mounting the seat ....... 95 Removing the shock absorber .... 55 12.7 Removing the fuel tank .......

  • Page 6: Removing The Clutch Cover

    TABLE OF CONTENTS 15. 7 Checking the capacitor ..... 133 17.3.21 primary gear, removing ....176 15.8 Checking the starter relay ....134 17.3.22 timing chain, removing ....176 17.3.23 Removing the force pump .... 176 BRAKE SYSTEM ........... 135 17.3.24 Removing the locking lever ..
  • Page 7 TABLE OF CONTENTS 17.4.22 valve springs, checking ....198 17 .5.25 Checking the valve clearance ..228 17.4.23 Checking the valve spring seat ..198 17 .5.26 Adjusting the valve clearance ..229 17.4.24 Checking the cam levers ....198 17 .5.27 Installing the starter motor ...
  • Page 8 TABLE OF CONTENTS THROTTLE VALVE BODY ......257 24.1 Adjusting the idle speed ....257 24.2 Executing the initialization run ..257 TECHNICAL DATA ........259 25.1 Engine ..........259 25.2 Tolerance, engine wear limits ... 260 25.3 Engine tightening torques ....261 25.4 Capacities .........

  • Page 9: Means Of Representation

    MEANS OF REPRESENTATION 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 that will help you repair and maintain your vehicle. This manual assumes that the necessary special Husqvarna tools and Husqvarna workplace and workshop equipment are available.

  • Page 11: Important Notes

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

  • Page 12: Serial Numbers

    4 SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steer­ ing head. 401945-10 e label The type label is fixed to the front of the steering head. 401946-10 En ine number The engine number is embossed on the left side of the engine over the engine sprocket.

  • Page 13: Shock Absorber Article Number

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

  • 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) (�...

  • Page 15: Starting The Motorcycle To Check The Function

    5 MOTORCYCLE Remove the plug-in stand Shift the transmission to idle. 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 at most 5 sec­ onds.

  • Page 16: Fork, Triple Clamp

    6 FORK, TRIPLE CLAMP Adjusting the com�ression dam�ing of the fork Info The hydraulic compression damping determines the fork suspension behavior. Turn white adjusting screw all the way clockwise. Info Adjusting screw is located at the upper end of the left fork leg.

  • Page 17: Bleeding The Fork Legs

    6 FORK, TRIPLE CLAMP Info Turn clockwise to increase damping; turn counter­ clockwise to reduce damping. Bleeding the fork legs Preparatory work Raise the motorcycle with a lift stand. (� p. 12) Main work Release bleeder screws ✓ Any excess pressure escapes from the interior of the fork.

  • Page 18: Removing The Fork Legs

    6 FORK, TRIPLE CLAMP Remove the motorcycle from the lift stand. (� p. 12) Removing the fork legs Preparatory work Raise the motorcycle with a lift stand. (� p. 12) Remove the front wheel. (� p. 112) Main work Remove screws and take off the clamp.

  • Page 19: Removing The Fork Protector

    6 FORK, TRIPLE CLAMP Tighten screws Guideline Screw, top triple 17 Nm (12.5 lbf ft) clamp Tighten screws@). Guideline Screw, bottom triple 12 Nm (8.9 lbf ft) clamp Position the brake caliper. Mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft) ®...

  • Page 20: Performing A Fork Service

    6 FORK, TRIPLE CLAMP Performing a fork service Condition The fork legs have been removed. Disassemble the fork legs. (� p. 18) Remove the spring. (� p. 20) � Disassemble the cartridge.(� p. 21) Disassemble the piston rod. (ll!l p. 22) Disassemble the hydrostop unit.
  • Page 21 6 FORK, TRIPLE CLAMP Loosen the screw cover Mounting tool (T14047) (!!:,!Ip. 299) Info The cartridge cannot be taken off yet. 201701-10 Unclamp the fork leg. Slide the outer tube down. Drain the fork oil. Clamp the fork leg with the axle clamp. Release hydrostop unit and remove it.

  • Page 22: Removing The Spring

    6 FORK, TRIPLE CLAMP Remove lock ring@. Info The lock ring has a beveled end where a screwdriver can be applied. Warm up the outer tube in area of the lower sliding bush­ ing. Guideline (122 °F) Pull the outer tube from the inner tube with a jerk. Info Lower sliding bushing @ must be pulled from its 803528-13...

  • Page 23: Disassembling The Cartridge

    6 FORK, TRIPLE CLAMP Clamp the open end wrench in the vise. Release screw but do not remove it yet. Mounting tool (T14047) p. 299) Pull the spring downward. Remove the open end wrench. Remove the screw cap. Remove the spring with the preload spacer(s). Disassembling the cartridge Info The procedures are the same on both fork legs.

  • Page 24: Disassembling The Piston Rod

    6 FORK, TRIPLE CLAMP Degrease the cartridge and clamp it with the special tool. I Clamping stand (T14049S) (l!!l p. 299) Release seal ring retainer and remove with the washer. Remove lock ring (D. Pull reservoir @ out of the cartridge. Pull sleeve out of the reservoir.
  • Page 25 6 FORK, TRIPLE CLAMP Main work Degrease the piston rod. Clamp the piston rod with the special tool as far up as possi- ble. Clamping stand (T14049S) (� p. 299) Release hydrostop needle and remove it from the piston rod. ✓...

  • Page 26: Disassembling The Hydrostop Unit

    6 FORK, TRIPLE CLAMP Remove valve needle@) from the piston rod. Info The adjusting tube can be used for this. Disassemblin the hydrostop unit Info The procedures are the same on both fork legs. Preparatory work Disassemble the fork legs. (!!:,!I p.

  • Page 27: Checking The Fork Legs

    6 FORK, TRIPLE CLAMP Main work Remove pilot bushing support Remove 0-ring and seal ring (s). R00013-10 6.16 Checkin the fork le s Condition The fork legs have been disassembled. Check the inner tube and axle clamp for damage. If there is damage: Change the inner tube.

  • Page 28: Assembling The Seal Ring Retainer

    6 FORK, TRIPLE CLAMP Measure the inside diameter at multiple locations of the outer tube. Inside diameter of outer :s; 49.20 mm (s 1.937 in) tube If the measured value is larger than the specified value: Change the outer tube. Check the outer tube for damage.

  • Page 29: Assembling The Hydrostop Unit

    6 FORK, TRIPLE CLAMP Assembling the hydrostoR unit Info The procedures are the same on both fork legs. Mount and grease O-ring Lubricant (T158) (llill p. 282) Mount washer @. Mount shim stack @) with the smaller washers facing down- ward.
  • Page 30 6 FORK, TRIPLE CLAMP Position the spring. Mount compression shim stack with the smaller shims facing downward. Info Note the setting list. R00031-10 Grind the piston on both sides on a surfacing plate using 1200 grit sandpaper. Clean the piston. Lubricate the piston ring.

  • Page 31: Cartridge, Assembling

    6 FORK, TRIPLE CLAMP cartridge, assembling Info The procedures are the same on both fork legs. Preparatory work Assemble the seal ring retainer. (!,JI p. 26) Assemble the piston rod. (!,JI p. 27) Main work Mount and grease seal rings and O-ring Lubricant (T158) (!!:!

  • Page 32: Assembling The Fork Legs

    6 FORK, TRIPLE CLAMP Slide piston rod into the cartridge. • Info Check that the piston ring is correctly seated. Mount spring seat B04096-10 Clamp piston rod with the special tool. I Clamping stand (T14049S) (� p. 299) Screw spring guide � all the way on. Info The nut must be firmly tightened against the stop by hand.
  • Page 33 6 FORK, TRIPLE CLAMP Lubricant (T14034) (� p. 282) • Info Sealing lip downward, open side upward. Push on support ring Remove the special tool. Sand the edges of the sliding bushings with 600 grit sandpa- per; then clean and grease the bushings. Fork oil (SAE 4) (48601166S1) (�...
  • Page 34 6 FORK, TRIPLE CLAMP Mount lock ring Info The lock ring engages audibly. Mount dust boot Mount fork protector ring G). Grease O-ring. I Fork oil (SAE 4) (48601166S1) (� p. 280) Slide the cartridge all the way into the fork leg. Turn the fork.
  • Page 35 6 FORK, TRIPLE CLAMP Clamp the fork vertically. Add the remaining quantity of fork oil. 202091-10 Pull out the piston rod and push it back in numerous times while pressing it to one side slightly. ✓ Air bubbles emerge and the cartridge is bled. Keep bleeding until no more air bubbles emerge.
  • Page 36 6 FORK, TRIPLE CLAMP Mount the adjuster. Mount and tighten screw@). Guideline 2.5 Nm (1.84 lbf ft) I Screw, adjuster M4x0.5 Alternative 1 Turn the adjuster for rebound damping (mark REB) and the adjuster for compression damping (mark clockwise all the way. COMP) Turn counterclockwise by the number of clicks corre­...

  • Page 37: Lubricating The Steering Head Bearing

    6 FORK, TRIPLE CLAMP 6.22 Lubricating the steering head bearing Remove the lower triple clamp. (l!,JI p. 35) Install the lower triple clamp. (l!,JI p. 36) Info The steering head bearing is cleaned and lubricated in the course of removal and installation of the lower triple clamp.

  • Page 38: Installing The Lower Triple Clamp

    6 FORK, TRIPLE CLAMP 6.24 Installing the lower tri�le clam� Main work Clean the bearing and sealing elements, check for damage, and grease. I High viscosity grease (I!!:! p. 282) Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.
  • Page 39 6 FORK, TRIPLE CLAMP Tighten screws (D. 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 40: Checking The Steering Head Bearing Play

    6 FORK, TRIPLE CLAMP Position the brake caliper. Mount and tighten screws 41). Guideline Screw, front 25 Nm (18.4 lbf ft) ® Loctite brake caliper ™ Position the brake line and clamp. Mount and tighten screws Finishing work Install front fender. (�...

  • Page 41: Changing The Steering Head Bearing

    6 FORK, TRIPLE CLAMP Check the steering head bearing and change if neces­ sary. Finishing work Remove the motorcycle from the lift stand. (illJ p. 12) 6.26 Changing the steering head bearing Preparatory work Raise the motorcycle with a lift stand. (illJ p.

  • Page 42: Adjusting The Steering Head Bearing Play

    6 FORK, TRIPLE CLAMP Press the new bearing ring up to the stop with special tool @) . Tool bracket (58429089000) p. 287) Pressing tool (58429091000) p. 287) Remove lower steering head bearing Remove the seal ring. Grease and mount the new seal ring. Press on the new bearing with a suitable tube as far as it will D00075-10 Finishing work...
  • Page 43 6 FORK, TRIPLE CLAMP Mount and tighten screw @. Guideline 20 Nm (14.8 lbf ft) Screw, top ® Loctite steering stem ™ Finishing work Check the steering head bearing play. (!!;!I p. 38) Remove the motorcycle from the lift stand. (!!;!I p.

  • Page 44: 7 Handlebar,Controls

    7 HANDLEBAR,CONTROLS Handlebar �osition The holes on the handlebar support 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. In this way, the handlebar can be mounted in the most comfortable position for the rider.

  • Page 45: Adjusting The Basic Position Of The Clutch Lever

    7 HANDLEBAR,CONTROLS Adjusting the basic �osition of the clutch lever Adjust the basic position of the clutch lever to your hand size by turning adjusting screw • Info When the adjusting screw is turned counterclockwise, the clutch lever moves away from the handlebar. When the adjusting screw is turned clockwise, the clutch lever moves closer to the handlebar.

  • Page 46: Checking The Play In The Throttle Cable

    7 HANDLEBAR,CONTROLS Main work Check the throttle cable routing. Both throttle cables must be routed to the throttle valve body side by side behind the handlebars and above the fuel tank bracket. Both throttle cables must be secured behind the rubber band of the fuel tank contact area. If the throttle cable is not routed as specified: Correct the throttle cable routing.

  • Page 47: Adjusting The Play In The Throttle Cable

    7 HANDLEBAR,CONTROLS 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 an effective exhaust extraction system when starting or running the engine in an enclosed space.

  • Page 48: Setting The Characteristic Map Of The Throttle Response

    7 HANDLEBAR,CONTROLS Finishing work Check the play in the throttle cable. (� p. 44) Install the fuel tank. (� p. 97) Mount the seat. (I!!;! p. 95) Install the air filter box cover. (I!!;! p. 90) Install the right side cover. (I!!;! p.
  • Page 49 7 HANDLEBAR,CONTROLS Clean the outside of the handlebar and the inside of the grip tube. Mount the grip tube on the handlebar. Attach the throttle cables to the guide plate and route cor­ rectly. Position half-shells (D, mount and tighten screws@. Guideline Screw, throttle grip I 5 Nm (3.7 lbf ft)

  • Page 50: 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 51 8 FRAME Position spring as shown. ✓ Spring G) engages in area (!). ✓ Press the spring with special tool @. Footrest spring plier (79029083000) (l!!',!l p. 294) ✓ The special tool is applied to area on the footrest. Mount pin 6). 311720-10 Mount the washer and split pin 311719-10...

  • Page 52: Shock Absorber, Swingarm

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

  • Page 53: The Shock Absorber

    9 SHOCK ABSORBER, SWINGARM Turn adjusting screw clockwise with a screwdriver up to the last perceptible click. Info Do not loosen fitting Turn counterclockwise by the number of clicks correspond­ ing to the shock absorber type. Guideline Compression damping, low-speed Comfort 17 clicks Standard...

  • Page 54: Measuring The Rear Wheel Sag Unloaded

    9 SHOCK ABSORBER, SWINGARM Measuring the rear wheel sag unloaded Preparatory work Raise the motorcycle with a lift stand. (� p. 12) Main work Position the sag gauge in the rear axle and measure the distance to marking SAG on the rear fender. Sag gauge (00029090500) Pin for sag gauge (0002999001 0) Note down the value as dimension 6).

  • Page 55: Checking The Riding Sag Of The Shock Absorber

    9 SHOCK ABSORBER, SWINGARM Checking the riding sag of the shock absorber Measure distance of rear wheel unloaded. (ta:!! p. 52) 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 56: Adjusting The Riding Sag

    9 SHOCK ABSORBER, SWINGARM Main work Loosen screw Turn adjusting ring until the spring is no longer under ten- sion. I Hook wrench (T1 06S) (ia:! p. 295) Measure the overall spring length while the spring is not under tension. Tighten the spring by turning adjusting ring to measure­...

  • Page 57: Removing The Shock Absorber

    9 SHOCK ABSORBER, SWINGARM Finishing work Install the shock absorber.(� p. 57) Check the free travel of the foot brake lever. (!!JJ p. 144) Check the static sag of the shock absorber. (!!JJ p. 52) Check the riding sag of the shock absorber. (�...
  • Page 58 9 SHOCK ABSORBER, SWINGARM 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 swingarm pivot. Push the swingarm back and secure it against falling over.

  • Page 59: Installing The Shock Absorber

    9 SHOCK ABSORBER, SWINGARM 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) ® Loctite 2701 shock absorber Position the swingarm and mount the swingarm pivot. Info Pay attention to flat area 6).

  • Page 60: Checking The Shock Absorber Linkage

    9 SHOCK ABSORBER, SWINGARM Mount and tighten screw@. Guideline Screw, bottom 60 Nm (44.3 lbf ft) shock absorber ® Loctite 2701 • Info Raise the wheel slightly to be able to mount the screw more easily. Position the frame protectors on the left and right. Mount and tighten screws Guideline Screw, frame pro­...
  • Page 61 9 SHOCK ABSORBER, SWINGARM •- -• 303096-10 Check needle bearings for damage and wear. If there is damage or wear: Change the needle bearings. Check spacers (3 and @ for damage and wear. If there is damage or wear: Change the spacers. Check the shaft seal rings for damage and wear.

  • Page 62: Servicing The Shock Absorber

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

  • Page 63: Removing The Spring

    9 SHOCK ABSORBER, SWINGARM Remove the spring. (ll!:! p. 61) Disassemble the damper. (ll!:! p. 62) Disassemble the piston rod. (� p. 63) Disassemble the seal ring retainer. (� p. 64) "oco, Check the damper. p. 66) l'.7� Remove the heim joint. p.

  • Page 64: Disassembling The Damper

    9 SHOCK ABSORBER, SWINGARM 9.14 Disassembling the dam�er Preparatory work Remove the spring.(� p. 61) 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. Slowly open screw ✓...

  • Page 65: Disassembling The Piston Rod

    9 SHOCK ABSORBER, SWINGARM Remove lock ring Info Check inner surface; do not scratch. Remove any burrs with sandpaper if needed. Remove the piston rod. Remove adjusting ring @ with the intermediate washer. Drain the oil. Remove compression adjuster @. Remove the spring and piston.

  • Page 66: Disassembling The Seal Ring Retainer

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

  • Page 67: Changing The Pilot Bushing

    9 SHOCK ABSORBER, SWINGARM Main work Remove spring Remove O-ring @. Remove rebound rubber 201405-10 Remove centering disk Remove seal ring 201406-10 Remove washer for seal ring Remove washer @. Remove dust boot. 201407-10 9.17 Changing the pilot bushing Preparatory work Remove the spring.

  • Page 68: Checking The Damper

    9 SHOCK ABSORBER, SWINGARM Slide the new pilot bushing onto the special tool. I Pressing tool (T1504) p. 299) Position the pilot bushing in the seal ring retainer using the special tool. I Pressing tool (T1504) p. 299) Support seal ring retainer with sleeve of the special tool.

  • Page 69: Removing The Heim Joint

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

  • Page 70: Installing The Heim Joint

    9 SHOCK ABSORBER, SWINGARM Place special tool underneath and press out heim -� joint using special tool - --- I Pressing tool (T1207S) (l!lll p. 297) � � G02068-10 Position the new heim joint and the special tool in the bench vise.

  • Page 71: Assembling Seal Ring Retainer

    9 SHOCK ABSORBER, SWINGARM 9.21 Mount dust boot with the special tool. Mounting sleeve (T1204) p. 296) Grease the sealing lip of the dust boot. Lubricant (T625) (� p. 282) 201408-10 Mount washer Position washer on seal ring 201409-10 Grease seal ring and mount with the washer facing down­...
  • Page 72 9 SHOCK ABSORBER, SWINGARM Main work Clamp the piston rod with the fork in a vise. Guideline I Use soft jaws. Mount rubber buffer and locking cap Position special tool on the piston rod. I Mounting sleeve (T1215) (!!;!I p. 297) Grease the dust boot and push seal ring retainer onto the G02056-11...

  • Page 73: Assembling The Damper

    9 SHOCK ABSORBER, SWINGARM Mount the rebound shim stack @ with the smaller shims facing upward. G02058-10 Mount washer with the collar facing downward. Grease the thread of the piston rod. Lubricant (T152) (� p. 282) Mount and tighten nut Guideline Nut, piston rod I M16x1...
  • Page 74 9 SHOCK ABSORBER, SWINGARM Clamp the damper in a bench vise. Guideline I Use soft jaws. Mount adjusting ring with the intermediate washer. Info The adjusting ring cannot be mounted after the piston rod has been mounted. Fill the damper cartridge about half full. I Shock absorber fluid (SAE 2.5) (50180751 S1) (ll!:!l p.

  • Page 75: Bleeding And Filling The Damper

    9 SHOCK ABSORBER, SWINGARM Turn adjusting screw all the way clockwise with a socket wrench. Turn counterclockwise by the number of turns corre­ sponding to the shock absorber type. Guideline Compression damping, high-speed Comfort 2.5 turns Standard 2 turns Sport 1.5 turns Turn adjusting screw @) clockwise up to the last percep­...
  • Page 76 9 SHOCK ABSORBER, SWINGARM Remove the screw from the filling port. Mount adapter on the damper. • Info Hand-tighten only without using a tool. Connect adapter to connector @ of the vacuum pump. I Vacuum pump (T1240S) p. 298) Clamp the damper with soft jaws or hold it as shown in the figure.
  • Page 77 9 SHOCK ABSORBER, SWINGARM When the pressure gauge reaches the required value, turn control lever Damper to Pressure. Guideline 0 bar ✓ Oil is pumped into the damper. ✓ The pressure gauge increases to the required value. 3 bar When the pressure gauge reaches the required value, turn control lever Damper to Vacuum.
  • Page 78 9 SHOCK ABSORBER, SWINGARM When the pressure gauge reaches the required value, turn control lever Damper to Vacuum. Guideline 3 bar ✓ The pressure gauge drops to the required value. 0 bar When the pressure gauge reaches the required value, acti­ vate the On/Off switch.

  • Page 79: Filling The Damper With Nitrogen

    9 SHOCK ABSORBER, SWINGARM 9.25 Filling the dam�er with nitrogen Screw in screw by approx. 2 rotations but do not tighten. Info The piston rod is fully extended. Clamp the special tool in the vise. Filling tool (T170S1) (!!l p. 300) Connect the special tool to the pressure regulator of the filling cylinder.

  • Page 80: Installing The Spring

    9 SHOCK ABSORBER, SWINGARM 9.26 Installing the s ring Ensure that adjusting ring is screwed on with the interme­ diate washer. Measure the overall spring length while the spring is not under tension. Position the spring. Guideline Spring rate Weight of rider: 65 ... 42 N/mm (240 lb/in) 75 kg (143 ...

  • Page 81: Checking The Swingarm

    9 SHOCK ABSORBER, SWINGARM I Hook wrench (T106S) (l!!ll p. 295) Tighten screw Guideline Screw, shock 5 Nm (3.7 lbf ft} absorber adjusting ring G02091-10 9.27 Checking the swingarm Check the swingarm for damage, cracking, and deformation. If the swingarm shows signs of damage, cracking, or deformation: Change the swingarm.

  • Page 82: Removing The Swingarm

    9 SHOCK ABSORBER, SWINGARM Finishing work Remove the motorcycle from the lift stand. (� p. 12) 9.29 Removing the swingarm Preparatory work Raise the motorcycle with a lift stand. (� p. 12) Remove the rear wheel. (� p. 116) Remove the air filter box cover. (�...

  • Page 83: Installing The Swingarm

    9 SHOCK ABSORBER, SWINGARM Remove fitting Lower the swingarm. Remove the cable ties. Remove screws Remove screws with the washers. Remove the frame protectors on the left and right. Remove nut @. Remove the swingarm pivot. Remove the swingarm. Main work Position the swingarm.
  • Page 84 9 SHOCK ABSORBER, SWINGARM Lift the swingarm. &. Mount and tighten fitting Guideline Nut, linkage lever on M 14x1 .5 80 Nm (59 lbf ft) swingarm 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 85: Changing The Swingarm Bearing

    9 SHOCK ABSORBER, SWINGARM Remove the motorcycle from the lift stand. (ll!;,! p. 12) 9.31 Changing the swingarm bearing Preparatory work Raise the motorcycle with a lift stand. (I!!;! p. 12) Remove the rear wheel. (I!!;! p. 116) Remove the air filter box cover. (I!!;! p.
  • Page 86 9 SHOCK ABSORBER, SWINGARM Mount bushing R02758-10 Grease the shaft seal rings. Long-life grease (� p. 282) Position collar bushings with the shoulder facing inward. R02763-10 Right swingarm bearing Remove collar bushings Q). R02760-10 Remove bushing@. R02761-10...
  • Page 87 9 SHOCK ABSORBER, SWINGARM 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 R02762-10 Mount bushing@ . R02761-10 Grease the shaft seal rings. I Long-life grease (ll!ll p.

  • Page 88: 10 Exhaust

    10 EXHAUST Removing the manifold 10.1 Preparatory work Raise the motorcycle with a lift stand. (� p. 12) Remove the right side cover. (� p. 94) Remove the main silencer. (� p. 88) Main work Remove screw Remove fitting Info Raise the link fork slightly to be able to remove the screws more easily.

  • Page 89: Installing The Manifold

    EXHAUST 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 90: Removing The Main Silencer

    10 EXHAUST Position the angle lever and linkage lever. &. Mount and tighten fitting Guideline M 14x1 .5 Nut, linkage lever to 80 Nm (59 lbf ft) angle lever Info Raise the link fork slightly to be able to mount the screw more easily.

  • Page 91: Changing The Glass Fiber Yarn Filling Of The Main Silencer

    EXHAUST Tighten screws Guideline 10 Nm (7.4 lbf ft) Remaining screws, chassis Finishing work Install the right side cover. (ll!;!I p. 94) Chan lass fiber yarn fillin 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 92: 11 Air Filter

    11 AIR FILTER Removing the air filter box cover Pull off the air filter box cover sideways in areas and remove toward the front. Installing the air filter box cover Position air filter box cover on collar bushings and push toward the rear. Engage the air filter box cover in areas 11.3 Removin the air filter...

  • Page 93: Installing The Air Filter

    11 AIR FILTER Main work Detach retaining tab Remove air filter with air filter sup­ port. Take off 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 94: Sealing The Air Filter Box

    11 AIR FILTER Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. I Air filter cleaning agent (� p. 282) • Info Only press the air filter to dry it, never wring it out. Oil the dry air filter with a high quality filter oil.

  • Page 95: Fuel Tank, Seat, Trim

    FUEL TANK, SEAT, TRIM 12.1 O�ening the 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 96: Removing The Right Side Cover

    12 FUEL TANK, SEAT, TRIM Removing the right side cover Remove screw Pull off the side cover sideways in areas remove toward the front. 12.4 Installing the right side cover Position side cover on collar bushings, and push toward the rear. Engage side cover in areas Mount and tighten screw Guideline...

  • Page 97: Mounting The Seat

    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 98: Removing The Fuel Tank

    12 FUEL TANK, SEAT, TRIM 12.7 Removing the fuel tank Danger Fuel is highly flammable. Fire hazard The fuel in the fuel tank expands when warm and can escape if overfilled. Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. Switch off the engine for refueling.

  • Page 99: Installing The Fuel Tank

    FUEL TANK, SEAT, TRIM Remove screws Remove screw with the rubber bushing. Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank. H00298-10 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.
  • Page 100 12 FUEL TANK, SEAT, TRIM Main work Check the throttle cable routing. (llill p. 43) Position the fuel tank and fit the two spoilers to the sides of the radiator bracket. Make sure that no cables or throttle cables are trapped or damaged.

  • Page 101: Checking The Fuel Pressure

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

  • Page 102: Changing The Fuel Pump

    12 FUEL TANK, SEAT, TRIM Guideline Maximum duration of the 3 min actuator test Check the fuel pressure with the filler cap closed. Fuel pressure When the fuel pump is 3.3 ... 3. 7 bar (48 ... active 54 psi) If the specification is not reached: Open the filler cap.
  • Page 103 FUEL TANK, SEAT, TRIM Warning 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 104: Changing The Fuel Filter

    12 FUEL TANK, SEAT, TRIM Position the fuel pump. Mount fuel connection with the gasket but do not tighten yet. Mount and tighten nut with the gasket. Guideline Nut, fuel pump fas­ M12x1.75 15 Nm (11.1 lbf ft) tener Tighten fuel connection Guideline Fuel connection on M8x1 .25...
  • Page 105 FUEL TANK, SEAT, TRIM Warning Fuel is poisonous and a health hazard. Danger of poisoning Avoid skin, eye and clothing contact with fuel. Immediately consult a doctor if you swallow fuel. Do not inhale fuel vapors. In case of skin contact, rinse the affected area with plenty of water. Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
  • Page 106 12 FUEL TANK, SEAT, TRIM Pull out the fuel pump. Remove hose clamps Remove fuel filter D00571-10 Press lock (D. Pull back fuel pump housing@. 305317-10 Change fuel screen Mount the fuel pump housing.
  • Page 107 FUEL TANK, SEAT, TRIM Mount fuel filter ✓ Arrow points away from the fuel pump. Mount hose clamps Hose clamp plier (60029057000) p. 289) Position the fuel pump. Mount fuel connection with the gasket but do not tighten yet. Mount and tighten nut with the gasket.

  • Page 108: Changing The Fuel Screen

    12 FUEL TANK, SEAT, TRIM 12.12 Changing the fuel screen 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 109 FUEL TANK, SEAT, TRIM Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. Always make sure there is sufficient ventilation when running the engine. Use an effective exhaust extraction system when starting or running the engine in an enclosed space.

  • Page 110: 13 Mask, Fender

    13 MASK, FENDER 13.1 Removing front fender Preparatory work Remove the start number plate. p. 109) Main work Remove screws 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 111: Removing The Start Number Plate

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

  • Page 112: 14 Wheels

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

  • Page 113: Checking The Wheel Bearing For Play

    14 WHEELS If the tires are more than 5 years old: Change the tires. Checking the wheel bearing for Ria� 14.3 Preparatory work Raise the motorcycle with a lift stand. (l!!:!J p. 12) Place a load on the rear of the vehicle. ✓...

  • Page 114: Checking Spoke Tension

    14 WHEELS Check the front and rear brake discs for damage, cracking, and deformation. If the brake disc exhibits damage, cracking, or deforma­ tion: Change the front brake disc. p. 114) Change the rear brake disc. p. 118) Checking s�oke tension Warning Incorrectly tensioned spokes impair the handling characteristic and result in Danger of accidents...

  • Page 115: Installing The Front Wheel

    14 WHEELS Main work Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pis­ tons.

  • Page 116: Changing The Front Brake Disc

    14 WHEELS • Check the wheel bearing for damage and wear. If the wheel bearing is damaged or worn: Change front wheel bearing. p. 115) Clean and grease shaft seal rings and contact surfaces of the spacers. I Long-life grease p.

  • Page 117: Changing Front Wheel Bearing

    14 WHEELS 14.6.4 Changing front wheel bearing Preparatory work Raise the motorcycle with a lift stand. (� p. 12) Remove the front wheel. (� p. 112) Main work Remove shaft seal rings Press out bearing using a suitable tool. • Info Spacing tube can be pushed aside.

  • Page 118: Rear Wheel

    14 WHEELS Grease new shaft seal rings and press in until they are flush. Finishing work Install the front wheel. p. 113) 14.7 Rear wheel Removing the rear wheel 14.7.1 Preparatory work Raise the motorcycle with a lift stand. (� p.

  • Page 119: Installing The Rear Wheel

    14 WHEELS GO'? Remove spacers f� c::=C>� �◊) H00936-10 Installing the rear wheel 14.7.2 Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. Always keep the brake discs free of oil and grease. Clean the brake discs with brake cleaner when necessary. Main work Check the wheel bearing for damage and wear.

  • Page 120: Changing The Rear Brake Disc

    14 WHEELS Position chain adjuster (5) . Mount nut but do not tighten it yet. Make sure that chain adjusters (5) are fitted correctly on adjusting screws Check the chain tension. (� p. 119) Tighten nut Guideline M25x1.5 80 Nm (59 lbf ft) Info The wide adjustment range of the chain adjusters (32 mm (1.26 in)) enables different secondary ratios...

  • Page 121: Checking The Chain Tension

    14 WHEELS 14.7.4 Checking 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 122: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    14 WHEELS Main work Loosen nut Loosen nuts Adjust the chain tension by turning adjusting screws (D left and right. Guideline Chain tension 55 ... 58 mm (2.17 ... 2.28 in) Turn adjusting screws (D on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks f).
  • Page 123 14 WHEELS Pull at the top part of the chain with the specified weight f). Guideline 10 ... 15 kg (22 ... 33 lb.) Weight, chain wear mea­ surement Measure distance (;) of 18 chain rollers in the lower chain section.
  • Page 124 14 WHEELS Check the chain sliding piece for wear. If the lower edge of the chain pins is in line with or below the chain sliding piece: Change the chain sliding piece. Check that the chain sliding piece is firmly seated. If the chain sliding piece is loose: Tighten the screw on the chain sliding piece.

  • Page 125: Checking For Chain Dirt Accumulation

    14 WHEELS 14.7.7 Checking for chain dirt accumulation Check the chain for coarse dirt accumulation. If the chain is very dirty: Clean the chain. (!!;!I p. 123) 400678-01 14. 7 .8 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces the road grip. Remove the lubricant from the tires using a suitable cleaning agent.
  • Page 126 14 WHEELS Main work Remove screws Remove the engine sprocket cover. Have an assistant operate the rear brake. Remove screw with washer. Remove the rear wheel. (!!;!I p. 116) Remove connecting link of the chain. Info Cover the components to protect them against dam­ age.

  • Page 127: Changing The Rear Wheel Bearing

    14 WHEELS Slide new engine sprocket onto the countershaft. Mount the new chain. Connect the chain with connecting link Guideline The closed side of the chain joint lock must face in the direction of travel. Install the rear wheel. (!ill p.
  • Page 128 14 WHEELS Main work Remove shaft seal ring Remove lock ring@. Remove shaft seal ring (D. Using a suitable tool, press bearing out from the inside to the outside. Remove spacing tube Using a suitable tool, press bearing (D out from the inside to the outside.
  • Page 129 14 WHEELS Clean, grease, and mount spacing tube Long-life grease (� p. 282) Press new bearing all the way in from the outside to the inside. Info Only press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in. Grease new shaft seal ring and press it in until it is flush.

  • Page 130: 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 131: Removing The Battery

    15 WIRING HARNESS, BATTERY Removing the batte� Warning Risk of injury Batteries contain harmful substances. Keep batteries out of the reach of children. Keep sparks and open flames away from the batteries. Only charge batteries in well-ventilated rooms. Maintain a minimum clearance from inflammable materials when charging batteries. 1 m (3 ft) Minimum clearance Do not charge deeply discharged batteries if charge is already below the minimum voltage.

  • Page 132: Installing The Battery

    15 WIRING HARNESS, BATTERY Installing the batte� Main work Position the battery into the battery compartment with the terminals facing forward and secure with holding bracket I Battery (C22S) p. 264) Mount and tighten screw Guideline Screw, battery sup­ 10 Nm (7.4 lbf ft) port bracket •...
  • Page 133 Warning Environmental hazard Batteries contain environmentally-hazardous materials. Do not dispose of batteries as household waste. Return batteries to your authorized Husqvarna Motorcycles dealer or dispose of them at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 134: Checking The Charging Voltage

    15 WIRING HARNESS, BATTERY Guideline The charging current, charging voltage, and charging time must not be exceeded. Charge the battery regularly 3 months when the motorcycle is not in use Finishing work Mount the seat. p. 95) Install the air filter box cover. p.

  • Page 135: Checking The Capacitor

    15 WIRING HARNESS, BATTERY Main work Disconnect the negative cable of the battery. Measure the current between battery ground (-) and the neg­ ative cable. • Info The value of the quiescent current applies only to vehicles in the original state, i.e. without additional power consumers.

  • Page 136: Checking The Starter Relay

    15 WIRING HARNESS, BATTERY 15.8 Checking the starter rela� Preparatory work Press and hold the kill switch � while the engine is idling until the engine stops. Remove the air filter box cover. p. 90) Remove the seat. p. 94) Main work Pull starter relay from the holder.

  • Page 137: Brake System

    BRAKE SYSTEM Checking the front brake linings Warning Worn-out brake linings reduce the braking effect. Danger of accidents Ensure that worn-out brake linings are replaced immediately. Check the brake linings for minimum thickness f). I Minimum thickness f) I � 1 mm (� 0.04 in) If the minimum thickness is less than specified: Change the front brake linings.
  • Page 138 16 BRAKE SYSTEM Move the brake fluid reservoir mounted on the handlebar to a horizontal position. Remove screws Remove cover with membrane Manually press the brake caliper to the brake disc to push back the brake pistons. Ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suction if it does.

  • Page 139: Hand Brake Lever

    BRAKE SYSTEM Add brake fluid up to level f). Guideline 5 mm (0.2 in) Level f) (brake fluid level below reservoir rim) Brake fluid DOT 4 (llill p. 280) Position cover@ with membrane@). Mount and tighten screws • Info Clean up overflowed or spilled brake fluid immediately with water.

  • Page 140: Checking The Front Brake Fluid Level

    16 BRAKE SYSTEM Main work Adjust the basic position of the hand brake lever to your hand size by turning adjusting screw Info Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the han­ dlebar.

  • Page 141: Adding Front Brake Fluid

    BRAKE SYSTEM Adding front brake fluid 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 142: Changing The Front Brake Fluid

    16 BRAKE SYSTEM Main work Move the brake fluid reservoir mounted on the handlebar to a horizontal position. Remove screws Remove cover with membrane Add brake fluid to level f) . Guideline Level f) (brake fluid level 5 mm (0.2 in) below reservoir rim) Brake fluid DOT 4 (�...
  • Page 143 BRAKE SYSTEM Move the brake fluid reservoir mounted on the handlebar to a horizontal position. Cover the painted parts. Remove screws Remove cover with membrane. Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid. Syringe (50329050000) (�...

  • Page 144: Checking The Brake Linings Of The Rear Brake

    16 BRAKE SYSTEM Add brake fluid to level (!). Guideline 5 mm (0.2 in) Level (!) (brake fluid level below container rim) I Brake fluid DOT 4 (l!lll p. 280) Position the cover with the membrane. Mount and tighten the screws.
  • Page 145 BRAKE SYSTEM Warning Danger of accidents Old brake fluid reduces the braking effect. Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. Warning 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 146: Brake Lever

    16 BRAKE SYSTEM Insert the new brake linings, insert pin and mount cotter pins (5). Info Always change the brake linings in pairs. Make sure that decoupling plate @ is mounted on the piston side brake lining. Operate the foot brake lever repeatedly until the brake lin­ ings are in contact with the brake disc and there is a pressure point.

  • Page 147: Adjusting The Basic Position Of The Foot Brake Lever

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

  • Page 148: Adding Rear Brake Fluid

    16 BRAKE SYSTEM Preparatory work Check the brake linings of the rear brake. (l!!,!I p. 142) Main work Stand the vehicle upright. Check the brake fluid level in level viewer If the brake fluid has dropped below marking f): Add rear brake fluid. (l!l:! p.

  • Page 149: Changing The Rear Brake Fluid

    BRAKE SYSTEM Main work Stand the vehicle upright. Remove screw cap with membrane f!} and the O-ring. Add brake fluid to level fj. Brake fluid DOT 4 (!ill p. 280) Mount and tighten the screw cap with the membrane and O­ ring.
  • Page 150 16 BRAKE SYSTEM Mount bleeder cover I Bleeder cover (00029013006) (� p. 284) Connect the bleeding device. I Bleeding device (00029013100) (� p. 284) Open shut-off valve • Info Follow the operating instructions of the bleeding device. Ensure that the inflation pressure is correctly set at pressure gauge If necessary, adjust the inflation pressure at pres­...
  • Page 151 BRAKE SYSTEM Info Clean up overflowed or spilt brake fluid immediately with water. Check the foot brake lever for a firm pressure point.

  • Page 152: 17 Engine

    17 ENGINE 17.1 Removing the engine Preparatory work Raise the motorcycle with a lift stand. (� p. 12) Drain the coolant. (� p. 240) Remove the right side cover. (� p. 94) Remove the air filter box cover. (� p. 90) Remove the seat.
  • Page 153 17 ENGINE 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 up the subframe and secure it. Remove screw Pivot the shock absorber toward the rear and twist it slightly.
  • Page 154 17 ENGINE Remove springs I Spring hook (50305017000) (� p. 286) Remove screw Gi) with washer. Take off the manifold. Remove fittings Take off the engine brace. Disconnect plug-in connector Disconnect plug-in connectors 41).
  • Page 155 17 ENGINE Disconnect plug-in connector Remove the cable tie(s). Remove the cable clamps and expose the cable. Push back protection cap Unplug the connector. Gs). Loosen hose clip Pull off the radiator hose. Loosen hose clip Pull off the radiator hose.
  • Page 156 17 ENGINE Pull capacitor 4E) off of the holder and hang to one side. Disconnect spark plug connector 41). Remove screw fl!). Remove screw •. Take off the engine sprocket cover. Remove screws �. Take off the slave cylinder of the clutch and hang it to one side.
  • Page 157 17 ENGINE Remove the connecting link of the chain. Take off the chain. Remove screw Take off the engine sprocket. Remove screw .. with the washers. Take off the shift lever. Loosen hose clip Pull the throttle valve body off of the cylinder head toward the rear and hang it to one side.
  • Page 158 17 ENGINE Remove spring fl!). Remove fitting Remove screws Ci). 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 swingarm pivot. Carefully pull the swingarm back, and secure the swingarm.

  • Page 159: Installing The Engine

    17 ENGINE Remove screws Lift out the engine sideways. • Info The help of an assistant is useful in this step. Make sure that the engine is sufficiently secured against falling over. Protect the frame and attachments against damage. Main work Position the engine in the frame.
  • Page 160 17 ENGINE Position the brake line in the guide. Mount the foot brake cylinder on push rod and position it. • Info Ensure that the dust boot is correctly seated. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis Position the linkage lever.
  • Page 161 17 ENGINE Mount the vent hose and hose clamp Position the throttle valve body. Tighten hose clip 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.
  • Page 162 17 ENGINE Position clutch slave cylinder with the new gasket. Mount and tighten screws 41). Guideline Screw, clutch slave 10 Nm (7.4 lbf ft) cylinder Position the engine sprocket cover. Mount and tighten screw Guideline Screw, clutch slave 10 Nm (7.4 lbf ft) cylinder Mount and tighten screw Guideline...
  • Page 163 17 ENGINE Mount the radiator hose. Position and tighten hose clip�- Plug in the connector. Position protection cap @i). Route the cable without tension and secure with cable clips and cable ties. Connect plug-in connector .. of the gear position sensor. Connect plug-in connector of the crankshaft position sensor.
  • Page 164 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 60 Nm (44.3 lbf ft) screw Position the manifold. Mount screw � with washer but do not tighten yet. Guideline Remaining screws, 25 Nm (18.4 lbf ft)
  • Page 165 17 ENGINE 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 166 17 ENGINE Connect negative cable@). Guideline Screw, battery termi- 2.5 Nm (1.84 lbf ft) • Info Contact disk must be mounted between screw and cable lug � with the claws facing downward. Position the frame protectors on the left and right. Mount and tighten screw�- Guideline Screw, frame pro­...

  • Page 167: Engine Disassembly

    (� p. 240) Execute the initialization run. p. 257) Go for a short test ride. Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. Check the engine for leak tightness. Check the engine oil level. (� p. 242) Check the coolant level.

  • Page 168: 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 169: Gear Position Sensor, Removing

    17 ENGINE 17.3.5 gear position sensor, removing Remove screws Remove the protective plate and the gear position sensor . 17.3.6 Removing the spark plug Remove the spark plug with special tool Spark plug wrench with link (77229172000) (� p. 292) 17.3.7 Removing the valve cover Remove screws...

  • Page 170: Starter Motor, Removing

    17 ENGINE Remove spark plug shaft insert (D . 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.

  • Page 171: Positioning The Engine At Ignition Top Dead Center

    17 ENGINE 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. Remove screw Info Check through the hole whether the position notch of the crankshaft is visible. Mount and tighten screw without the washer.

  • Page 172: Removing The Camshafts

    17 ENGINE 17.3.11 Removing the camshafts Loosen and remove screws from the outside to the inside. Take off guide rail Take off the camshaft bearing bridge. Info Ensure that the dowel pins remain in place. Take the timing chain from the camshaft gear. Remove the camshafts.

  • Page 173: Removing The Piston

    17 ENGINE Remove cylinder head gasket (5). 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. Remove the piston pin retainer Remove the piston pin. Take off the cylinder and piston.

  • Page 174: Starter Drive, Removing

    17 ENGINE Insert special tool into the crankshaft. I Protection cap (75029090000) (I!!;! p. 291) Attach special tool @) to the rotor. Hold it tight using the special tool and pull off the rotor by turning the screw in. I Extractor (79229032044) (I!!;! p.

  • Page 175: 17.3.17 Water Pump Impeller, Removing

    17 ENGINE Remove O-ring (D. Take off suction pump Remove needle roller 17.3.17 water pump impeller, removing Remove screws Take off the water pump cover. Remove gasket...
  • Page 176 17 ENGINE Remove nut Take off two-part water pump impeller 17.3.18 Removing the clutch cover Remove screws Take off the clutch cover. Remove clutch cover gasket 17.3.19 Removing the clutch discs Loosen screws and remove together with the washers and springs. Take off the pressure cap.

  • Page 177: Removing The Clutch Basket

    17 ENGINE Completely remove clutch discs Remove pressure piece Removing the clutch basket 17 .3.20 Remove two opposite sleeves Bend up the lock washer. Hold the inner clutch hub with the special tool. Loosen Holding wrench (51129003000) (!ill p. 287) Remove the nut with the lock washer.

  • Page 178: Primary Gear, Removing

    17 ENGINE 17.3.21 primary gear, removing Remove nut • Info Left-handed thread! Position the special tool in the crankshaft. I Protection cap (75029090000) p. 291) Pull off primary gear using the special tool. I Puller (46129021000) (� p. 286) 17.3.22 timing chain, removing Remove screws Remove the timing chain guide rail...

  • Page 179: Removing The Locking Lever

    17 ENGINE Remove lock ring Take off washer Remove oil pump gear (D. Remove pin @. Remove screws @. Take off the oil pump cover. Remove pin Push oil pump shaft Ci) inward and take it out of the engine from the ignition side.

  • Page 180: Shift Drum Locating Unit, Removing

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

  • Page 181: Shift Rails, Removing

    17 ENGINE Insert the special tool into the crankshaft. Protection cap (75029090000) (� p. 291) Mount special tool with suitable screws. Puller (79229048000) (� p. 295) • Info Use the 792 drill hole. Pull off the section of the engine case. Info Do not tension the section of the engine case.

  • Page 182: Shift Forks, Removing

    17 ENGINE 17.3.31 shift forks, removing 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 Take out crankshaft Take off the right section of the engine case.

  • Page 183: 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 184 17 ENGINE Press in shaft seal ring of the crankshaft with the open side facing out so it is flush. 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)

  • Page 185: 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 alternator cooling. Remove oil nozzle for piston cooling. Remove screws (D. Remove the bearing retainers. Remove any remnants of sealing compound and clean the engine case section thoroughly.

  • Page 186: Work On The Clutch Cover

    17 ENGINE Guideline Oil nozzle for 2 Nm (1.5 lbf ft) ® Loctite ™ clutch lubrica- tion Mount and tighten oil nozzle Guideline Oil nozzle, pis­ 2 Nm (1.5 lbf ft) Loctite ® ™ ton cooling Position all bearing locks. Mount and tighten screws (D.
  • Page 187 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 188: Checking The Oil Pressure Regulator Valve

    17 ENGINE Blow out the oil channel with compressed air and check that it is clear. 17.4.4 Checking the oil pressure regulator valve Remove screw plug with sealing washer Remove pressure spring and ball 310341-10 Measure the spring length of the oil pressure regulator valve. Oil pressure regulator valve Minimum length of 23.5 mm (0.925 in)

  • Page 189: Checking The Lubrication System

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

  • Page 190: Installing The Crankshaft Bearing Inner Race

    17 ENGINE 17.4.7 Installing the crankshaft bearing inner race Main work Fix the crankshaft in the vise. Info Use soft jaws. Slide on compensating disk Info The compensating disks have a larger diameter than 310421-10 the crankshaft stub. Ensure that the compensating disks are centered and fixed with a small amount of grease.
  • Page 191 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 G). X If the oil holes are not correctly aligned, the conrod bear­ ing will not be supplied with oil.

  • Page 192: Checking The Crankshaft Run-Out At The Bearing Pin

    17 ENGINE Position special tool with the heel pointing down. I Crankshaft pressing tool insert (79029008000) (� p. 293) 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 193: 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 fitted bushings. Mount the left section of the engine case. Mount and tighten screws. Guideline Screw, engine case 10 Nm (7.4 lbf ft) Mount the dial gauge support on the engine case and mea­...

  • Page 194: Installing The Drive Wheel Of The Balancer Shaft

    17 ENGINE 17 .4.12 Installing the drive wheel of the balancer shaft Ensure that woodruff key is seated properly. Warm drive wheel of the balancer shaft and push it onto the balancer shaft. Guideline 1100 °C (212 °F) 310342-10 17.4.13 Cylinder - Nikasil ®...

  • Page 195: 17 .4.15 Piston, Checking/Measuring

    17 ENGINE 17 .4.15 piston, checking/measuring Use the special tool to measure clearance of the piston rings in the piston ring groove. e -• ­ Guideline • Piston ring - groove clear­ � 0.08 mm(� 0.0031 in) ance Feeler gauge (59029041100) (�...

  • Page 196: Measuring The Piston/Cylinder Mounting Clearance

    17 ENGINE Info Piston dimensions are marked on the piston head. 17.4.16 Measuring the piston/cylinder mounting clearance Check/measure the cylinder. p. 192) Check/measure the piston. p. 193) The smallest piston/cylinder mounting clearance equals the smallest cylinder bore diameter minus the largest piston diameter.

  • Page 197: 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 198: Valves, Removing

    17 ENGINE Remove camshaft bearing bridge again. Compare the Plastigauge clearance gauge with the specifications 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 199: 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. Valve stem seals plier (77229010000) (�...

  • Page 200: Valve Springs, Checking

    17 ENGINE 17.4.22 valve springs, checking Check the valve springs for breakage and wear (visual check). If the valve spring is broken or worn: Change the valve spring. Measure the length of the valve springs. Valve spring Minimum length, outer 42.40 mm (1.6693 in) intake valve 310438-10...

  • Page 201: Checking The Cylinder Head

    17 ENGINE 17 .4.25 Checking the cylinder head Check valve guides using the special tool. Limit plug gauge (77229026000) (lll:!l p. 291) If the special tool is easy to insert in the valve guide: Change the valve guide and valve. Check the sealing area of the spark plug thread and the valve seats from damage and cracking.

  • Page 202: Checking The Freewheel

    17 ENGINE Tension the valve spring with a special tool. Valve spring mounter (59029019000) (I!\:! p. 288) Insert for valve spring lever (79029060000) (I!\:! p. 294) Insert for valve spring lever (77029041200) p. 291) Mount valve keys • Info When mounting the valve keys, check that they are seated correctly;...

  • Page 203: 17.4.28 Freewheel, Removing

    17 ENGINE 17.4.28 freewheel, removing Remove lock ring 310363-10 Press expansion ring @ 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...

  • Page 204: Checking The Electric Starter Drive

    17 ENGINE Mount spreader ring ',:::�-. � . � • ✓ :�� J;,.,t •, ·. ,:� � ...-,; 310366-10 Ensure that all lugs of the expansion ring pass through slots of the freewheel and engage in groove of the primary gear. 310367-10 Mount lock ring 310363-11...

  • Page 205: Checking The Timing Assembly

    17 ENGINE If there is damage or wear: Change the starter idler gear. Check the gear mesh and bearing of torque limiter for damage and wear. If there is damage or wear: Change the torque limiter. Check the gear mesh and bearing of freewheel gear for damage and wear.

  • Page 206: Preparing The Timing Chain Tensioner For Installation

    17 ENGINE If there is damage or wear: Replace the timing chain guide rail. Check the timing chain securing guide for damage and wear. If there is damage or wear: Replace the timing chain securing guide. Check camshaft gears for damage and wear. If there is damage or wear: Change the camshaft.

  • Page 207: Checking The Clutch

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

  • Page 208: 17.4.34 Shift Mechanism, Checking

    17 ENGINE If there is discoloration or scoring: Change all clutch facing discs. Check the thickness of clutch facing discs Gi). 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.

  • Page 209: Preassembling The Shift Shaft

    17 ENGINE If the bearings do not move freely or are worn: Change the bearings. Check the shift rollers for damage and wear. If there is damage or wear: Change the shift rollers. Check shift rails for run-out on a flat surface. If there is run-out: Change the shift rail.

  • Page 210: Main Shaft, Disassembling

    17 ENGINE 17.4.36 main shaft, disassembling Secure the main shaft with the toothed end facing downward in the vice. Guideline I Use soft jaws. Mount a suitable screw in main shaft f). ✓ The screw rests against the transmission shaft, not the sleeve.

  • Page 211: Disassembling The Countershaft

    17 ENGINE 17 .4.37 Disassembling the counters haft 310357-10 Fix the countershaft in the vice with the toothed end facing downward. Guideline I Use soft jaws. Remove stop disk and first-gear idler gear@. Remove needle bearing and stop disk Remove fifth-gear sliding gear Remove lock ring (D.
  • Page 212 17 ENGINE Check needle bearings for damage and wear. If there is damage or wear: Change the needle bearings. Check the pivot points of main shaft and countershaft for damage and wear. If there is damage or wear: Change the main shaft and/or countershaft. Check the tooth profiles of main shaft and countershaft for damage and wear.

  • Page 213: Main Shaft, Assembling

    17 ENGINE If there is damage or wear: Change the stop disks. Check sleeve for damage and wear. If there is damage or wear: Change the sleeve. Use new lock rings (D with every repair. 17.4.39 main shaft, assembling Info Use new lock rings with every repair.

  • Page 214: Countershaft, Assembling

    17 ENGINE Mount fourth-gear idler gear@). Mount 2nd-gear fixed gear Ci). Press sleeve on all the way. Finally, check all gear wheels for smooth operation. 17.4.40 countershaft, assembling Info Use new lock rings with every repair. Preparatory work Check the transmission. (�...

  • Page 215: Engine Assembly

    17 ENGINE Mount stop disk Mount needle bearing and first-gear idler gear Mount stop disk Ii). Finally, check all gear wheels for smooth operation. 17.5 En ine assembly 17.5.1 Installing the crankshaft Position the right section of the engine case in the engine work stand.

  • Page 216: Shift Forks, Installing

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

  • Page 217: 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. 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 218: Installing The Spacer

    17 ENGINE 17.5.7 Installing the spacer Grease the shaft seal ring. I Long-life grease p. 282) Mount spacer Set the crankshaft to top dead center and lock it with screw 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...

  • Page 219: Installing The Force Pump

    17 ENGINE 17 .5.11 Installing the force pump Oil the oil pump shaft, internal rotor, and external rotor before assembly. Engine oil (SAE 1 0W/50) (� p. 280) Position force pump ✓ The rounded side of the force pump faces the engine case.

  • Page 220: Installing The Suction Pump

    17 ENGINE 17.5.12 Installing the suction pump Insert needle roller Position suction pump fj. ✓ The rounded sides of the external rotor face the engine case. Crank the oil pump gear wheel and ensure that it can move easily. Mount 0-ring Position the oil pump cover Mount and tighten screws Guideline...

  • Page 221: Installing The Timing Chain

    17 ENGINE 17.5.13 Installing the timing chain Mount balancer shaft with the timing chain and timing chain securing guide. Info If the timing chain was used before, ensure it is run­ ning in the correct direction. Mount and tighten screw Guideline Screw, timing 10 Nm (7.4 lbf ft)

  • Page 222: Installing The Clutch Basket

    17 ENGINE 17.5.15 Installing the clutch basket Mount collar sleeve and needle bearing Slide the clutch basket onto the gearbox main shaft. Turn the oil pump gear until the gear of the clutch basket meshes. Slide on washer and inner clutch hub@». Position the new lock washer and mount nut (D.

  • Page 223: Installing The Clutch Discs

    17 ENGINE 17.5.16 Installing the clutch discs Thoroughly oil the clutch facing discs. Engine oil (SAE 1 0W/50) (ll!:!l p. 280) Insert the intermediate clutch disc. Guideline Thickness 11 mm (0.04 in) Place the clutch facing and intermediate discs into the clutch basket.

  • Page 224: Water Pump Cover, Installing

    17 ENGINE Position the clutch cover. Info Ensure that the shaft seal rings of the water pump and the crankshaft are not damaged. Mount screws fj but do not tighten yet. Guideline Screw, clutch cover M6x25 1 10 Nm (7.4 lbf ft) Mount screws but do not tighten yet.

  • Page 225: Starter Drive, Installing

    17 ENGINE 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. Guideline Screw, water pump M6x25 10 Nm (7.4 lbfft) cover Mount screw b ut do not tighten yet.

  • Page 226: Installing The Rotor And Ignition Pulse Generator

    17 ENGINE 17.5.20 Installing the rotor and ignition pulse generator Ensure that the woodruff key is seated properly. Mount the rotor. Info To simplify installation, turn the starter idler gear coun­ terclockwise. Mount and tighten screw Guideline Rotor screw M10x1 70 Nm (51.6 lbf ft) Thread, oiled with engine oil/cone...
  • Page 227 17 ENGINE Thinly apply sealing compound to area G). Loctite 5910 ® Position the cylinder base gasket. Info Ensure that the dowel pins are seated properly. Cover the engine case opening with a cloth. Feed the timing chain through the chain shaft. Mount the piston pin. Info For purposes of illustration, the following operations are shown on the removed piston.

  • Page 228: Cylinder Head, Installing

    17 ENGINE Remove the cloth. Keep the timing chain taut. Press the cylinder down carefully and bring dowel pins into contact. 17.5.22 cylinder head, installing Mount dowels Put on cylinder head gasket Put the cylinder head in place. Mount nuts with the washers and tighten in a crisscross pattern.

  • Page 229: Installing The Camshafts

    17 ENGINE 17.5.23 Installing the camshafts Pull up the timing chain and insert the intake camshaft Place the timing chain over the camshaft gear of intake camshaft. ✓ Marking is positioned and is aligned with the edge of the cylinder head. Ensure that bleeder is correctly positioned.

  • Page 230: Checking The Valve Clearance

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

  • Page 231: Adjusting The Valve Clearance

    17 ENGINE Check the valve clearance at all valves between the camshaft and cam lever. Guideline Valve clearance Intake at: 20 °C (68 °F) 0.10 ... 0.15 mm (0.0039 ... 0.0059 in) . . . Exhaust at: 20 °c (68 °F) 0.13 ...

  • Page 232: 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. 282) Mount and tighten screws Guideline I Screw, starter motor 10 Nm (7.4 lbf ft) Position torque limiter Position gasket Info Ensure that the dowel pins are seated properly. Position the alternator cover.

  • Page 233: Installing The Valve Cover

    17 ENGINE 17.5.28 Installing the valve cover Grease O-rings and mount spark plug shaft insert Position gasket Apply a thin layer of sealing compound in area Loctite 5910 ® Position the valve cover with the gasket. Mount and tighten screws (i). Guideline Screw, valve cover I 8 Nm (5.9 lbf ft}...

  • Page 234: Spark Plug, Installing

    17 ENGINE 17.5.29 spark plug, installing Mount and tighten the spark plug with special tool &. Guideline Spark plug M1 0x1 10 ... 12 Nm (7.4 ... 8.9 lbf ft) I Spark plug wrench with link (77229172000) (� p. 292) 17.5.30 gear position sensor, installing Position gear position sensor.

  • Page 235: Installing The Oil Screen

    17 ENGINE 17.5.32 Installing the oil screen Mount and tighten oil drain plug with the O-ring. Guideline Oil drain plug I M14x1 .5 15 Nm (11.1 lbf ft) Mount and tighten oil drain plug with the magnet and a new seal ring. Guideline Oil drain plug with M12x1 .5...

  • Page 236: Installing The Clutch Push Rod

    17 ENGINE 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. I Holder and fitting for work stand (79229002000) (� p. 294) Remove the engine from the engine assembly stand. Info Work with an assistant or a motorized hoist.

  • Page 237: 18 Clutch

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

  • Page 238: Changing The Hydraulic Clutch Fluid

    18 CLUTCH Changing the h}!draulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation. Keep brake fluid out of the reach of children. Wear suitable protective clothing and safety glasses. Do not allow brake fluid to come into contact with the skin, the eyes or clothing. Consult a doctor immediately if brake fluid has been swallowed.
  • Page 239 18 CLUTCH Inject the liquid into the system only 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 240: 19 Water Pump, Cooling System

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

  • Page 241: 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 242: Draining The Coolant

    19 WATER PUMP, COOLING SYSTEM Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
  • Page 243 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 Coolant (ll!:! p. 280) Mount the radiator cap.

  • Page 244: Lubrication System

    LUBRICATION SYSTEM 20.1 Oil circuit H02388-10 Oil screen Force pump Oil pressure regulator valve Oil filter Oil nozzle for conrod bearing lubrication Oil nozzle for cam lever lubrication Oil nozzle, piston cooling Oil nozzle for alternator cooling Oil nozzle for clutch lubrication �...

  • Page 245: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen

    20 LUBRICATION SYSTEM Condition The engine is cold. Check the engine oil level. The engine oil reaches the middle of level viewer If the engine oil does not reach the middle of the level viewer: Add engine oil. (I!!:! p. 246) Condition The engine is at operating temperature.
  • Page 246 LUBRICATION SYSTEM Main work Place a suitable container under the engine. Remove oil drain plug with the magnet and seal ring. Info Do not remove screws @ on both sides. Remove screw plug with oil screen Completely drain the engine oil. Thoroughly clean the parts and sealing surfaces.
  • Page 247 20 LUBRICATION SYSTEM Pull oil filter out of the oil filter housing. Lock ring plier (51012011000) (i!!,!l p. 286) Completely drain the engine oil. Thoroughly clean the parts and sealing surfaces. Lay the motorcycle on its side and fill the oil filter housing to about½...

  • Page 248: Adding Engine Oil

    LUBRICATION SYSTEM Adding engine oil Info Too little engine oil or poor-quality engine oil results in premature wear of the engine. Main work Remove oil filler plug with the O-ring from the clutch cover. Fill engine oil to the middle of the level viewer.
  • Page 249 20 LUBRICATION SYSTEM Main work Remove screw Position the special tool. Mount and tighten the banjo bolt. Guideline Banjo bolt I M10x1 I 8 Nm (5.9 lbf ft) Oil pressure adapter (77329006000) p. 292) Connect the pressure tester to the special tool without the T­ plate.
  • Page 250 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 251: Ignition System

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

  • Page 252: Removing The Stator And Crankshaft Position 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 253 IGNITION SYSTEM Position the stator and ignition pulse generator in the alterna­ tor cover. Mount and tighten screws@. Guideline Screw, stator 6 Nm (4.4 lbf ft) ® Loctite ™ Position retaining bracket. Mount and tighten screws@). Guideline Screw, 6 Nm (4.4 lbf ft) Loctite ®...

  • Page 254: 22 Cylinder Head

    22 CYLINDER HEAD 22.1 Checking the valve clearance Preparatory work Remove the right side cover. p. 94) Remove the air filter box cover. p. 90) Remove the seat. p. 94 ) Remove the fuel tank. p. 96) Main work Pull capacitor off of the holder and hang to one side.
  • Page 255 22 CYLINDER HEAD 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 256 22 CYLINDER HEAD Mount and tighten screw@). Guideline Screw, alternator M24x1.5 18 Nm (13.3 lbf ft) cover Clean and degrease the sealing surface. Apply a thin layer of sealant to area G). I Loctite 5910 ® Mount gasket @. Position the valve cover with the gasket. Mount and tighten screws (D.

  • Page 257: Adjusting The Valve Clearance

    22 CYLINDER HEAD Mount capacitor Finishing work Install the fuel tank. (li!:,!l p. 97) Mount the seat. (!!,!I p. 95) Install the air filter box cover. (!!,!I p. 90) Install the right side cover. (!!:!I p. 94) Adjusting the valve clearance Info For purposes of illustration, the following operations are shown with the engine removed.

  • Page 258: 23 Electric Starter

    23 ELECTRIC STARTER 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 259: 24 Throttle Valve Body

    24 THROTTLE VALVE BODY 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 an effective exhaust extraction system when starting or running the engine in an enclosed space.
  • Page 260 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 an effective exhaust extraction system when starting or running the engine in an enclosed space.

  • Page 261: 25 Technical Data

    25 TECHNICAL DATA 25.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 249.91 cm (15.2505 cu in) Stroke 52.3 mm (2.059 in) Bore 78 mm (3.07 in) Compression ratio 14.4:1 Idle speed 2,250 ... 2,350 rpm Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 32.5 mm (1.28 in)

  • Page 262: 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 263: Engine Tightening Torques

    25 TECHNICAL DATA 25.3 Engine tightening tor�ues Nozzle, crank chamber ventilation 2 Nm (1.5 lbf ft) ® Loctite ™ Oil nozzle for alternator cooling 2 Nm (1.5 lbf ft) Loctite ® ™ Oil nozzle for balancer shaft lubri- 2 Nm (1.5 lbf ft) ®...
  • Page 264 25 TECHNICAL DATA Screw, shift lever 14 Nm (10.3 lbf ft) Loctite ® ™ 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) ®...

  • Page 265: Capacities

    25 TECHNICAL DATA M20x1 .5 15 Nm (11.1 lbf ft) Screw plug, oil screen Plug, timing chain tensioner M24x1 .5 40 Nm (29.5 lbf ft) Screw, alternator cover M24x1.5 18 Nm (13.3 lbf ft) 25.4 Capacities 25.4.1 Engine oil Engine oil 11.0 I (1 .1 qt.) Engine oil (SAE 1 0W/50) (�...

  • Page 266: Electrical System

    80/100 - 21 51M TT 100/90 - 19 57M TT Dunlop Geomax MX52F Dunlop Geomax MX52 The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: www.husqvarna-motorcycles.com 25.8 Fork Fork part number 24.18.7P.55 Fork...

  • Page 267: Shock Absorber

    25 TECHNICAL DATA 25.9 Shock absorber Shock absorber article number 18.18. 7P.55 Shock absorber WP Performance Systems 5018 DCC Link Compression damping, low-speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping, high-speed Comfort 2.5 turns Standard 2 turns Sport 1.5 turns Rebound damping...
  • Page 268 25 TECHNICAL DATA Remaining screws, chassis 10 Nm (7.4 lbf ft) Screw, ball joint of push rod on 10 Nm (7.4 lbf ft) ® Loctite ™ foot brake cylinder Screw, battery support bracket 10 Nm (7.4 lbf ft) Screw, chain sliding guard 6 Nm (4.4 lbf ft) Loctite ®...
  • Page 269 25 TECHNICAL DATA Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) Screw, front wheel spindle M20x1 .5 35 Nm (25.8 lbf ft) Screw, top steering head M20x1 .5 12 Nm (8.9 lbf ft) Screw-in nozzles, cooling system M20x1 .5 12 Nm (8.9 lbf ft) ®...

  • Page 270: 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 271 26 CLEANING/PROTECTIVE TREATMENT After the motorcycle has cooled off, lubricate all moving parts and bearings. Clean the chain. (� p. 123) Treat bare metal parts (except for brake discs and the exhaust system) with a corrosion inhibitor. Preserving materials for paints, metal and rubber (�...

  • Page 272: 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 273: Putting Into Operation After Storage

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

  • Page 274: 28 Service Schedule

    Every 30 operating hours 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 battery. • •...

  • Page 275: Recommended Work

    • • • • Final check: Check the vehicle for operating safety and take a test ride. Read out the fault memory after the test ride using the Husqvarna Motorcycles diagnostics • • • tool. Make the service entry in the Husqvarna Motorcycles Dealer.net...
  • Page 276 t : : 1 «! . · � 1 " 1 -" . R/ 4 NfC/2 l. x1 9 EB/ 4 • -C10 -521 -M10 -G101 1+ � �K/4 ""ij ,'!-, EB/ 4 r BR/ 4 FC/2 � � I -X1 9 ·...

  • Page 277: 29 Wiring Diagram

    29 WIRING DIAGRAM Components: A 11 EFI control unit Capacitor Battery Alternator Starter relay with main fuse Power relay Starter motor Voltage regulator Electric starter button X295 Diagnostics connector...
  • Page 278 � HY/33 HY/33 HY/33 HY/33 HY/33 �HY/33 HY/33 1 ·X16 1·X16 1·X16 1·X16 � ��i is� �I " ��; � - a .0.0 l.x 2 1 . x 1 . x s f 1 , 2 -BF/1 i CX/2 f r 1 2 A/ 1 -520 -P25...
  • Page 279 29 WIRING DIAGRAM Components: A 11 EFI control unit Fuel pump Injection valve (cylinder 1) warning lamp (MIL) CAN bus terminating resistor Kill switch X295 Diagnostics connector...
  • Page 280 -© -A11 " ' l " ' 1�, . 1" "' 1 1 " l" l" 1 � m 1 1 � ru 1 � 1" "' -X16 -X16 -X16 -X16 -X16 -X16 -X16 -X16 -X16 -X16 " "" • "...
  • Page 281 29 WIRING DIAGRAM Components: A 11 EFI control unit Intake air temperature sensor Coolant temperature sensor (cylinder 1) Rollover sensor Gear position sensor Crankshaft position sensor Manifold absolute pressure sensor (cylinder 1) Throttle position sensor Ignition coil (cylinder 1) switch for ride mode (optional) switch (optional) Map-Select Cable colors:...

  • Page 282: 30 Substances

    30 SUBSTANCES Brake fluid DOT 4 Standard/classification Guideline Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corresponding properties. Recommended supplier ® Bel-Ray Super DOT 4 Brake Fluid Coolant Guideline Only use high-grade, silicate-free coolant with corrosion inhibitor additive for aluminum motors.
  • Page 283 30 SUBSTANCES Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification p. 301) (SAE 2.5) Guideline Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification DIN EN 228 (ROZ 95/RON 95/PON 91) Guideline...

  • Page 284: Auxiliary Substances

    AUXILIARY SUBSTANCES Air filter cleaning agent Recommended supplier ® Bel-Ray Foam Filter Cleaner & Degreaser High viscosi't}f grease Recommended supplier ® LGHB 2 Long-life grease Recommended supplier ® Bel-Ray Waterproof Grease Lubricant (I158) Recommended supplier Lubcon ® ® Turmogrease PP 300 Lubricant 14034 Recommended supplier...
  • Page 285 31 AUXILIARY SUBSTANCES Oil for foam air filter Recommended supplier ® Bel-Ray Foam Filter Oil Preserving materials for �aints metal and rubber Recommended supplier ® Bel-Ray Silicone Detailer & Protectant Spray Universal oil s�ra}! Recommended supplier ® Bel-Ray 6 in 1...

  • Page 286: 32 Special Tools

    32 SPECIAL TOOLS Bleeder cover Art. no.: 00029013005 00029013005 H00504-01 Bleeder cover Art. no.: 00029013006 00029013006 H00505-01 Bleeding device Art. no.: 00029013100 00029013100 H00518-01 EU batte charger XCharge- rofessional Art. no.: 00029095050 Feature EU safety plug Nominal voltage 230 V Mains fuse Power cable length 5 m (16 ft)
  • Page 287 32 SPECIAL TOOLS US batterY charger XCharge-�rofessional Art. no.: 00029095051 Feature US plug Nominal voltage 120 V Mains fuse 32 A Power cable length 5 m (16 ft) approx. Charger cable 5 m (16 ft) H01065-01 length approx. e-professional Art. no.: 00029095052 Feature UK safety plug Nominal voltage...
  • Page 288 32 SPECIAL TOOLS Puller Art. no.: 46129021000 46129021000 H01519-01 S�ring hook Art. no.: 50305017000 50305017000 H00973-01 S}'ringe Art. no.: 50329050000 50329050000 H00565-01 Lock ring lier Art. no.: 51012011000 51012011000 H00572-01...
  • Page 289 32 SPECIAL TOOLS 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 Pressing tool Art. no.: 58429091000 58429091000 H00604-01...
  • Page 290 32 SPECIAL TOOLS Pressing tool Art. no.: 58429092000 58429092000 H00605-01 Torgue wrench set Art. no.: 58429094000 Feature Torque 3 ... 15 Nm (2.2 ... 11 .1 lbf ft) Open ended bit 3.9 mm (0.154 in) ..)P.,P� Open ended bit 4.9 mm (0.193 in) ��...
  • Page 291 32 SPECIAL TOOLS Plastigauge clearance gauge Art. no.: 60029012000 Feature 0.025 ... 0.175 mm (0.00098 ... 0.00689 in) 60029012000 H00627-01 Piston ring mounting tool Art. no.: 60029015000 Feature Height 80 mm (3.15 in) Diameter 57 ... 125 mm (2.24 ... 4.92 in) 60029015000 H00628-01 Hose clam�...
  • Page 292 32 SPECIAL TOOLS 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 ring Art. no.: 75029005000 75029005000 H00705-01 Crankshaft ressing tool Art. no.: 75029047000 75029047000 H00714-01...
  • Page 293 32 SPECIAL TOOLS 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 Limit auge Art. no.: 77229026000 Feature Diameter I 5.55 mm (0.2185 in) 77229026000 H00753-01...
  • Page 294 32 SPECIAL TOOLS Protection ca� Art. no.: 77229031000 77229031000 H00755-01 Se�arator �late Art. no.: 77229032000 77229032000 H00756-01 S ark �lug wrench with link Art. no.: 77229172000 Feature Drive 3/8 in Hexagonal part 14 mm (0.55 in) Length 130 mm (5.12 in) 77229172000 H00761-01 Oil ressure ada ter...
  • Page 295 32 SPECIAL TOOLS Insertion for �iston ring lock Art. no.: 77729030100 77729030100 H01126-01 Mounting tool for lock ring Art. no.: 79029005000 79029005000 H00800-01 Crankshaft ressing tool insert Art. no.: 79029008000 79029008000 H00801-01 Art. no.: 79029009000 79029009000 H00802-01...
  • Page 296 32 SPECIAL TOOLS Insert for valve s�ring lever Art. no.: 79029060000 79029060000 H00803-01 Footrest s�ring �lier Art. no.: 79029083000 79029083000 H00804-01 Holder and fitting for work stand Art. no.: 79229002000 2xffi& 79229002000 H01127-01 Extractor Art. no.: 79229032044 79229032044 H00808-01...
  • Page 297 32 SPECIAL TOOLS Puller Art. no.: 79229048000 79229048000 H00809-01 Engine work stand Art. no.: 80329001000 80329001000 H01047-01 Lift stand Art. no.: 81329955100 Feature Height 315 ... 425 mm (12.4 ... 16.73 in) Load s; 150 kg (:5 331 lb.) 81329955100 H00985-01 Hook wrench Art.
  • Page 298 32 SPECIAL TOOLS De th micrometer Art. no.: T107S T107S H00842-01 Drift Art. no.: T120 Feature I Diameter 8 mm (0.31 in) T120 H00844-01 Mounting sleeve Art. no.: T1204 Feature I Diameter 25.5 ... 30.5 mm (1 .004 ... 1 .201 in) T1204 H00878-01 Calibrating unit...
  • Page 299 32 SPECIAL TOOLS Pressing tool Art. no.: T1206 & Feature Diameter 1 15 ... 30 mm (0.59 ... 1 .18 in) � T1206 H00880-01 Pressing tool Art. no.: T1207S &.&. �� T1207S H00881-01 Mounting sleeve Art. no.: T1215 Feature Diameter 1 18 mm (0.71 in) T1215 H00886-01...
  • Page 300 32 SPECIAL TOOLS Vacuum �um� Art. no.: T1240S � T1240S H00890-01 Protecting sleeve Art. no.: T1401 Feature I Diameter I 48 mm (1.89 in) T1401 H00894-01 Clam�ing stand Art. no.: T1403S £. Feature Diameter 48 mm (1.89 in) Diameter 60 mm (2.36 in) ��...
  • Page 301 32 SPECIAL TOOLS Mounting tool Art. no.: T14047 Feature Drive 1/2 in Narrow diameter 34 mm (1 .34 in) Wide diameter 42.7 mm (1.681 in) T14047 H00923-01 Clam�ing stand Art. no.: T14049S Feature Diameter 8 mm (0.31 in) Diameter 24.8 mm (0.976 in) T14049S H00924-01 Pressing tool...
  • Page 302 32 SPECIAL TOOLS Mounting tool Art. no.: T150S T150S H00852-01 Filling tool Art. no.: T170S1 £ £ T170S1 H00855-01...

  • Page 303: Standards

    STANDARDS JASOT903MA Different technical development directions required a separate specification for motorcycles - the JASO T903 MA 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 304: 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 305: Index

    INDEX engine oil ....164, 245, 263 Cartridge ......9 Accessories of fork legs, assembling .
  • Page 306 INDEX clutch cover, installing ....221 crankshaft bearing inner race, removing . . . 187 crankshaft end play, measuring ..191 clutch discs, installing crankshaft run-out, checking at bearing pin .
  • Page 307 INDEX rotor, removing ....171 piston rod, assembling ....27 shift drum locating unit, removing .
  • Page 308 INDEX Implied warranty ..... . . 9 Rebound damping fork, adjusting ..... . 14 Initialization run shock absorber, adjusting ....
  • Page 309 INDEX Spark plug connector Type label ......1 0 checking ......249 Spoke tension Valve clearance checking .
  • Page 310 I 1 1 11 1 11 1 1 1 1 11 1 1 1 111 1 11 1 1 1 1 111 1 11 1 1 1 11 1 1 11 1 I I I I I I II I I II 3403031en 05/2017 ® Husqvarna llmi Husqvarna Motorcycles GmbH StallhofnerstraBe 3 5230 Mattighofen Austria fiiiHiAv � LZZa" ·...

This manual is also suitable for:

F2101

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