Husqvarna FS 450 2016 Repair Manual
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Husqvarna FS 450 2016 Repair Manual

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PIONEERING SINCE 1903
REPAIR MANUAL2016
FS 450
®
Husqvarna
Art. no. 3403034en
MOTORCYCLES

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Summary of Contents for Husqvarna FS 450 2016

  • Page 1 PIONEERING SINCE 1903 REPAIR MANUAL2016 FS 450 ® Husqvarna Art. no. 3403034en 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 6.16 Checking the fork legs ......27 MEANS OF REPRESENTATION ......7 6.17 Checking the fork legs - during a Symbols used ........7 minor fork service ....... 29 1 .2 Formats used ........7 6.18 Changing the pilot bushing ....31 SAFETY ADVICE ..........
  • Page 5 TABLE OF CONTENTS 12.2 Closing the filler cap ......100 Checking the static sag of the shock absorber ........60 12.3 Removing the right side cover ..101 Checking the riding sag of the 12.4 Installing the right side cover .... 101 shock absorber ........
  • Page 6 TABLE OF CONTENTS 15.5 Checking the charging voltage ..139 17.3.20 Removing the clutch discs ... 179 15.6 Checking the open-circuit current ..139 17.3.21 Removing the outer clutch hub ..180 15. 7 Checking the capacitor ..... 140 17.3.22 Removing the torque limiter ..
  • Page 7 TABLE OF CONTENTS 17.4.20 Disassembling the 17 .5.15 Installing the clutch basket ... 226 autodecompressor ....... 199 17 .5.16 Installing the clutch discs ..... 227 17.4.21 Assembling the 17 .5.17 Installing the clutch cover .... 228 autodecompressor ....... 200 17 .5.18 Installing the water pump 17.4.22 Checking camshaft ......
  • Page 8 TABLE OF CONTENTS IGNITION SYSTEM ........256 SUBSTANCES ..........286 21.1 AUXILIARY SUBSTANCES ......288 Ignition coil - checking the secondary winding ......256 SPECIAL TOOLS ........... 290 21.2 Checking the spark plug connector .......... 256 STANDARDS ..........310 21.3 Alternator - checking stator LIST OF ABBREVIATIONS ......

  • 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 stamped on the left side of the engine under 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 (80329955100) (�...

  • Page 15: Starting The Motorcycle To Check The Function

    5 MOTORCYCLE Remove 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 0. Info Press the electric starter button for at most 5 seconds. Wait for a least 5 seconds before trying again.

  • 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 adjusting screws clockwise all the way. Info Adjusting screws are located at the top end of the fork legs. Make the same adjustment on both fork legs.

  • Page 17: Bleeding The Fork Legs

    6 FORK, TRIPLE CLAMP Mount protection caps Bleeding the fork legs Preparatory work Raise the motorcycle with a lift stand. (l!!ll p. 12) Main work Release bleeder screws ✓ Any excess pressure escapes from the interior of the fork. Tighten the bleeder screws. 402556-10 Finishing work Remove the motorcycle from the lift stand.

  • Page 18: Removing The Fork Legs

    6 FORK, TRIPLE CLAMP Removing the fork legs Preparatory work Raise the motorcycle with a lift stand. (� p. 12) Remove the front wheel. (� p. 119) Main work Remove screws and take off the clamp. Allow the brake caliper and brake line to hang tension-free to the side.

  • Page 19: Removing The Fork Protector

    6 FORK, TRIPLE CLAMP Position the brake line and clamp. Mount and tighten screws K00292-11 Finishing work Install the front wheel. (� p. 120) Remove screws on the left fork leg. Take off the clamp. Remove screws on the left fork leg. Take off the left fork protector.

  • Page 20: Conducting Minor Fork Service

    6 FORK, TRIPLE CLAMP Disassemble the fork legs. p. 19) Disassemble the cartridge. p. 22) Disassemble the piston rod. p. 24) Disassemble the screw cap with the membrane holder. p.26) Disassemble the screw sleeve. p. 27) Check the fork legs. p.

  • Page 21: Disassembling The Fork Legs

    6 FORK, TRIPLE CLAMP Disassembling the fork legs Info The procedures are the same on both fork legs. Condition The fork legs have been removed. Remove protection cap f). Make a note of the present state of rebound and com- pression damping Open the adjusters of the rebound and compression damp­...
  • Page 22 6 FORK, TRIPLE CLAMP Unclamp the fork leg. Slide the outer tube down. Drain the fork oil. 201361-10 Clamp the fork leg with the axle clamp. Guideline I Use soft jaws. Loosen rebound adjustment Info Do not use an impact wrench. Place a container underneath as oil runs out in most cases.
  • Page 23 6 FORK, TRIPLE CLAMP Remove dust boot @) . Remove guide ring Info The guide ring does not necessarily need to be removed for repair work. Remove lock ring • Info The lock ring has a beveled end where a screwdriver can be applied.

  • Page 24: Disassembling The Cartridge

    6 FORK, TRIPLE CLAMP Disassembling the cartridge Info The steps are identical for both fork legs. Preparatory work Disassemble the fork legs. p. 19) Main work Remove adjusting tube and nut 200835-10 Clamp the cartridge into a vise. Info Use soft jaws. 200836-10 Remove filling screw Pierce the membrane with the needle of the special tool.
  • Page 25 6 FORK, TRIPLE CLAMP Loosen and remove screw cap with the membrane holder. Pin wrench (T1 03) p. 303) Unclamp the cartridge. Empty the cartridge. 200840-10 Reclamp the cartridge upside down. Guideline Use soft jaws. 200841-10 Heat the cartridge in area of pilot bushing Guideline 1100 °C (212 °F)

  • Page 26: Disassembling The Piston Rod

    6 FORK, TRIPLE CLAMP Remove filling screw @) and O-ring Ci) . · • 200845-10 Press check valve against the spring and remove it. 200846-10 Disassembling the �iston rod Info The steps are identical for both fork legs. Preparatory work Disassemble the fork legs.
  • Page 27 6 FORK, TRIPLE CLAMP Remove rebound shim stack Remove rebound piston Remove the piston ring from the piston. 200859-10 Remove compression shim stack (D. Remove spring @. Remove tap rebound Remove spring with the sleeve. Remove the valve with the spring from tap rebound Remove the O-rings.

  • Page 28: Disassembling The Screw Cap With 9.4 The Membrane Holder

    6 FORK, TRIPLE CLAMP Disassembling the screw ca� with the membrane holder Info The steps are identical for both fork legs. Preparatory work Disassemble the fork legs. (� p. 19) Disassemble the cartridge. (� p. 22) Main work Clamp the screw cap with the membrane holder and the spe­ cial tool into a vise.

  • Page 29: Disassembling The Screw Sleeve

    6 FORK, TRIPLE CLAMP Remove compression shim stack@). Remove 0-ring C!). 200872-10 Disassemblin the screw sleeve Info The steps are identical for both fork legs. Preparatory work Disassemble the fork legs. (!!ll p. 19) Disassemble the cartridge. (!!:!I p. 22) Disassemble the piston rod.
  • Page 30 6 FORK, TRIPLE CLAMP Check the inner tube and axle clamp for damage. If there is damage: Change the inner tube. 200728-10 Measure the outside diameter of the inner tube at several locations. Outside diameter of the 47.975 ... 48.005 mm inner tube (1.88878 ...

  • Page 31: Checking The Fork Legs - During A Minor Fork Service

    6 FORK, TRIPLE CLAMP Check the spring length. Guideline Spring length with preload 482 mm (18.98 in) spacer(s) If the measured value is greater than the specified value: Reduce the thickness of the preload spacers. If the measured value is less than the specified value: Increase the thickness of the preload spacers.
  • Page 32 6 FORK, TRIPLE CLAMP Measure the outside diameter of the inner tube at several locations. Outside diameter of the 47.975 ... 48.005 mm inner tube (1.88878 ... 1 .88996 in) If the measured value is less than the specified value: Change the inner tube.

  • Page 33: Changing The Pilot Bushing

    6 FORK, TRIPLE CLAMP 6.18 Changing the �ilot bushing Preparatory work Disassemble the fork legs. p. 19) Disassemble the cartridge. p. 22) Disassemble the piston rod. p. 24) Disassemble the screw sleeve. (!iJI p. 27) Main work Press the pilot bushing out of screw sleeve using the spe­...

  • Page 34: Assembling The Screw Sleeve

    6 FORK, TRIPLE CLAMP Assembling the screw sleeve Info The steps are identical for both fork legs. Mount and lubricate 0-ring I Lubricant (T158) (l!!l p. 288) Mount ring Mount lock ring Info The seal ring is mounted when the piston rod is assembled.

  • Page 35: Assembling The Piston Rod

    6 FORK, TRIPLE CLAMP Mount rebound damping washer Mount spring with the tighter coil at the bottom. Mount and tighten new nut @ with the collar facing down- ward. Guideline Nut, compression M6x0.5 3 Nm (2.2 lbf ft) piston ✓ The collar centers the rebound washer and the spring. Check the freedom of movement of the rebound washer against the spring.
  • Page 36 6 FORK, TRIPLE CLAMP Degrease the piston rod. Clamp the piston rod with the special tool. I Clamping stand (T14016S) (� p. 306) Mount spring with the sleeve. Mount and tighten tap rebound Guideline Tap rebound M9x1 18 Nm (13.3 lbf ft) ®...

  • Page 37: Assembling The Cartridge

    6 FORK, TRIPLE CLAMP Mount and tighten new nut @ with the collar facing down­ ward. Guideline Rebound nut I M6x0.5 I 5 Nm (3.7 lbf ft) • Info Do not twist the triangular plates! Secure the nut by locking. 201160-11 Take out the piston rod.
  • Page 38 6 FORK, TRIPLE CLAMP Place the special tool onto the piston rod. I Mounting sleeve (T14029) (I!\;! p. 307) Grease seal ring @ and slide onto the piston rod with the open side forward. Remove the special tool. I Lubricant (T14034) (I!\;! p.

  • Page 39: Assembling The Fork Legs

    6 FORK, TRIPLE CLAMP Mount adjusting tube 41). Screw nut all the way on with the collar facing forward. Info The nut must be screwed tightly against the stop. Do not use a tool. 200835-11 Assemblin the fork le s Info The operations are the same on both fork legs.
  • Page 40 6 FORK, TRIPLE CLAMP Sand the edges of the sliding bushings with 600 grit sandpa­ per; then clean and grease the bushings. I Fork oil (SAE 4) (48601166S1) (l!!ll p. 286) 200670-10 Push on support ring Push on lower sliding bushing Mount upper sliding bushing (D.
  • Page 41 6 FORK, TRIPLE CLAMP Mount dust boot Mount guide ring G). Mount the preload spacers and spring. Guideline Spring rate Weight of rider: 65 ... 4.8 N/mm (27.4 lb/in) 75 kg (143 ... 165 lb.) Weight of rider: 75 ... 5.0 N/mm (28.6 lb/in) 85 kg (165 ...
  • Page 42 6 FORK, TRIPLE CLAMP Clamp the fork vertically. Guideline I Use soft jaws. Fill with fork oil. Oil capacity fork leg 380 ml Fork oil (SAE 4) without cartridge (12.85 fl. oz.) (48601166S1) p. 286) 201369-10 Grease O-ring of the cartridge. I Lubricant (T158) (�...

  • Page 43: Bleeding And Filling The Cartridge

    6 FORK, TRIPLE CLAMP Alternative 2 Warning Danger of accident Modifications to the sus­ pension setting may seriously alter the handling characteristic. Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components. Only make adjustments within the recom­...
  • Page 44 6 FORK, TRIPLE CLAMP Connect adapter to the filling port of vacuum pump G). #UMj, I Vacuum pump (T1240S) (l!,!I p. 305) Clamp the control lever as shown in the figure. ✓ Control lever is set to External tank Closed; is set to @t is Damper...

  • Page 45: Filling The Cartridge With Nitrogen

    6 FORK, TRIPLE CLAMP Guideline 0 bar ✓ The vacuum pump is switched off. Disconnect the vacuum pump. Remove the special tool. Info • The filling port must be positioned at the highest point. Mount and tighten the filling screw with the O-ring. Guideline Cartridge filling 2 Nm (1 .5 lbf ft)

  • Page 46: Lubricating The Steering Head Bearing

    6 FORK, TRIPLE CLAMP Mount and tighten filling screw @ with the O-ring. Guideline Nitrogen filling screw M4x0.5 2.5 Nm (1.84 lbf ft) of the fork leg 6.26 Lubricatin the steerin head bearin Remove the lower triple clamp. (l!l:! p. 44) Install the lower triple clamp.

  • Page 47: Installing The Lower Triple Clamp

    6 FORK, TRIPLE CLAMP Remove O-ring Remove protective ring @t. Take off the lower triple clamp with the steering stem. Remove the upper steering head bearing. 6.28 lnstallin the lower triple clamp Main work Clean the bearing and sealing elements, check for damage, and grease.
  • Page 48 6 FORK, TRIPLE CLAMP Tighten screws (3. Guideline 12 Nm (8.9 lbf ft) Screw, bottom triple 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 49: Checking The Steering Head Bearing Play

    6 FORK, TRIPLE CLAMP Remove the motorcycle from the lift stand. (ll!;,! p. 12) Checking the steering head bearing play Warning Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components. Correct incorrect steering head bearing play immediately. Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become damaged over time.
  • Page 50 6 FORK, TRIPLE CLAMP Main work Remove lower bearing ring with special tool Tool bracket (58429089000) (� p. 293) Pressing tool (58429092000) p. 294) Press the new bearing ring up to the stop with special tool @) . Tool bracket (58429089000) (�...

  • Page 51: Adjusting The Steering Head Bearing

    6 FORK, TRIPLE CLAMP Install the start number plate. (!!:!l p. 115) Install the front wheel. (!!:!l p. 120) Check that the wiring harness, throttle cables, and brake and clutch lines can move freely and are routed correctly. Check the steering head bearing play. (!!:!l p.

  • Page 52: 7 Handlebar,Controls

    7 HANDLEBAR,CONTROLS Handlebar �osition On the upper triple clamp, there are two holes at a distance to each other. I Hole distance A 5 mm (0.59 in) The holes on the handlebar support are placed at a distance from the center. I Hole distance B 3.5 mm (0.138 in) The handlebar can be mounted in four different positions.

  • Page 53: 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 54: Checking The Play In The Throttle Cable

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

  • Page 55: Adjusting The Play In The Throttle Cable

    7 HANDLEBAR,CONTROLS 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 56: Adjusting The Characteristic Map Of The Throttle Response

    7 HANDLEBAR,CONTROLS Finishing work Check the play in the throttle cable. (� p. 52) Adjusting the characteristic ma� of the throttle res onse Info On the throttle grip, the characteristic map of the throttle response is changed by changing the guide plate.
  • Page 57 7 HANDLEBAR,CONTROLS Position half-shells mount and tighten screws 4i}. Guideline Screw, throttle grip I 5 Nm (3.7 lbf ft) Slide on sleeve and check the throttle grip for ease of movement. Finishing work Check the play in the throttle cable. (�...

  • Page 58: 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 402015-01 Motorcycles. Changing the footrests Info The procedures are the same on both footrests.
  • Page 59 8 FRAME Position spring as shown. ✓ Spring G) engages in area (!). ✓ Press the spring with special tool @. Footrest spring plier (79029083000) (l!!',!l p. 300) ✓ The special tool is applied to area on the footrest. Mount pin 6). Mount the washer and split pin D00725-10...

  • Page 60: 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 61: Adjusting The Rebound Damping Of 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 62: Measuring The Rear Wheel Dimension Unloaded

    9 SHOCK ABSORBER, SWINGARM Measuring the rear wheel dimension 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 63: Checking The Riding Sag Of The Shock Absorber

    9 SHOCK ABSORBER, SWINGARM Checking the riding sag of the shock absorber Measure dimension of rear wheel unloaded. (I!:! p. 60) 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 64: 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. 303) Measure the overall spring length while the spring is not under tension. Tighten the spring by turning adjusting ring to measure­...

  • Page 65: Removing The Shock Absorber

    9 SHOCK ABSORBER, SWINGARM Check the static sag of the shock absorber. (I!!:! p. 60) Check the riding sag of the shock absorber. (I!!:! p. 61) Adjust the rebound damping of the shock absorber. (I!!:! p. 59) Remove the motorcycle from the lift stand. p.

  • Page 66: Installing The Shock Absorber

    9 SHOCK ABSORBER, SWINGARM Remove the connecting link of the chain. Take off the chain. Remove nut and pull out the swingarm pivot. Push the swingarm back and secure it against falling over. Hold the shock absorber and remove screw Remove the shock absorber carefully at the bottom.
  • Page 67 9 SHOCK ABSORBER, SWINGARM Position the swingarm and mount the swingarm pivot. Info Pay attention to flat area Mount and tighten nut Guideline Nut, swingarm pivot M16x1 .5 1100 Nm (73.8 lbf ft) I Mount the chain. Connect the chain with the connecting link. Guideline The closed side of the chain joint lock must face in the direction of travel.

  • Page 68: Checking The Shock Absorber Linkage

    9 SHOCK ABSORBER, SWINGARM Position the frame protector on the left and right. Mount and tighten screws@. Guideline Screw, frame pro­ Nm (2.2 lbf ft) tector Mount and tighten screws with the washers. Guideline Screw, frame pro­ 3 Nm (2.2 lbf ft) tector Mount the new cable ties.
  • Page 69 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 70: 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 71: Removing The Spring

    9 SHOCK ABSORBER, SWINGARM Remove the spring. (ll!:! p. 69) Disassemble the damper. (ll!:! p. 70) Disassemble the piston rod. (� p. 71) Disassemble the seal ring retainer. (� p. 72) "oco, Check the damper. p. 7 4) l'.7� Remove the heim joint. p.

  • Page 72: Disassembling The Damper

    9 SHOCK ABSORBER, SWINGARM 9.14 Disassembling the dam�er Preparatory work Remove the spring. (� p. 69) Main work Make a note of the present state of rebound and com­ pression damping Open the adjusters of the rebound and compression damp­ ing completely.

  • Page 73: Disassembling The Piston Rod

    9 SHOCK ABSORBER, SWINGARM Remove the piston rod. Remove adjusting ring @ with the intermediate washer. Drain the oil. Remove compression adjuster Remove the spring and piston. 9.15 Disassembling the piston rod Preparatory work Remove the spring. p. 69) Disassemble the damper. p.

  • Page 74: Disassembling The Seal Ring Retainer

    9 SHOCK ABSORBER, SWINGARM Remove rebound shim stack@). Info Place the rebound shim stack onto a screwdriver and set it down as a unit. Remove piston Remove compression shim stack • Info Place the compression shim stack onto a screwdriver and set it down as a unit.

  • Page 75: Changing The Pilot Bushing

    9 SHOCK ABSORBER, SWINGARM Remove centering disk Remove seal ring 201406-10 Remove washer for seal ring Remove washer Remove dust boot. 201407-10 9.17 Changing the �ilot bushing Preparatory work Remove the spring. (� p. 69) Disassemble the damper. (� p. 70) Disassemble the piston rod.

  • Page 76: Checking The Damper

    9 SHOCK ABSORBER, SWINGARM Lubricate the special tool. Shock absorber fluid (SAE 2.5) (50180751 S1) (l!t! p. 287) Calibrating unit (T1205) (� p. 304) Support seal ring retainer with sleeve of the special tool. I Mounting tool (T150S) (� p. 309) Press the special tool through the new pilot bushing.

  • Page 77: Removing The Heim Joint

    9 SHOCK ABSORBER, SWINGARM Check the piston rings for damage and wear. If damage or a bronze-colored surface is visible: Change the piston. G02066-10 9.19 Removin the heim joint Condition The shock absorber has been removed. Clamp the shock absorber into the vise with soft jaws. Remove the collar bushing of the heim joint.

  • Page 78: Installing The Heim Joint

    9 SHOCK ABSORBER, SWINGARM Position new heim joint and the special tool into a vise as shown. Guideline I Use soft jaws. I Pressing tool (T1206) p. 304) Press the heim joint all the way in. Press the heim joint against the lock ring using the special tool.

  • Page 79: Assembling The Piston Rod

    9 SHOCK ABSORBER, SWINGARM Grease seal ring and mount with the washer facing down­ ward. Lubricant (T14034) (� p. 288) Mount centering disk 201410-10 Mount rebound rubber C). Grease the 0-ring groove. Lubricant (T158) (� p. 288) Mount 0-ring @. Mount spring 201411-10 9.22...
  • Page 80 9 SHOCK ABSORBER, SWINGARM Mount the compression shim stack with the smaller shims facing downward. G02057-10 Sand both sides of piston on a surface plate using 1200- grit sandpaper. Clean the piston. Assemble the piston. Guideline Piston from above View6) Piston from below View Mount the rebound shim stack @ with the smaller shims...

  • Page 81: Assembling The Damper

    9 SHOCK ABSORBER, SWINGARM 9.23 Assembling the dam�er Preparatory work Assemble the seal ring retainer. (� p. 76) Assemble the piston rod. (� p. 77) Main work Lubricate the O-rings of the compression adjuster. Lubricant (T158) (� p. 288) Lubricate the thread. Lubricant (T159) (�...
  • Page 82 9 SHOCK ABSORBER, SWINGARM Mount locking cap of the damper cartridge. Bleed and fill the damper. p. 81) Fill the damper with nitrogen. p. 84) Alternative 1 Turn adjusting screw @ clockwise with a screwdriver up to the last perceptible click. Turn counterclockwise by the number of clicks corre­...

  • Page 83: Bleeding And Filling The Damper

    9 SHOCK ABSORBER, SWINGARM Alternative 2 Warning Danger of accident Modifications to the sus­ pension setting may seriously alter the handling characteristic. Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components. Only make adjustments within the recom­...
  • Page 84 9 SHOCK ABSORBER, SWINGARM Clamp the control lever as shown in the figure. ✓ The control lever is External tank Closed, Damper on Vacuum, Oil reservoir on Vacuum. Operate the switch (D. On/Off ✓ The vacuum pump process starts. ✓ Pressure gauge @ drops to the specified value. I <...
  • Page 85 9 SHOCK ABSORBER, SWINGARM When the pressure gauge reaches the specified value, turn Oil reservoir control lever to Vacuum. Guideline 0 bar ✓ The vacuum gauge falls to the specified value. 8 mbar When the vacuum pressure gauge reaches the specified value, turn the control lever Oil reservoir...

  • Page 86: Filling The Damper With Nitrogen

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

  • Page 87: Installing The Spring

    9 SHOCK ABSORBER, SWINGARM Info Watch the pressure regulator dial. Make sure that the damper is filled to the specified pressure. Close the filling port screw using tap handle 6). Close spigot G) and take the damper out of the special tool. Tighten the filling port screw.

  • Page 88: Checking The Swingarm

    9 SHOCK ABSORBER, SWINGARM Alternative 2 Warning Danger of accident Modifications to the sus­ pension setting may seriously alter the handling characteristic. Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components. Only make adjustments within the recom­...

  • Page 89: Removing The Swingarm

    9 SHOCK ABSORBER, SWINGARM Main work Move the swingarm up and down. If there is detectable play: Change the swingarm bearing. p. 90) Move the swingarm from one side to the other. If there is detectable play: Change the swingarm bearing. p.

  • Page 90: Installing The Swingarm

    9 SHOCK ABSORBER, SWINGARM Remove connecting link of the chain. Info Cover the components to protect them against dam­ age. Take off the chain. 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.
  • Page 91 9 SHOCK ABSORBER, SWINGARM Position the frame protector on the left and right. Mount and tighten screws Guideline Screw, frame pro­ 3 Nm (2.2 lbf ft) tector Mount and tighten screws with the washers. Guideline Screw, frame pro­ 3 Nm (2.2 lbf ft) tector Mount the cable ties.

  • Page 92: Changing The Swingarm Bearing

    9 SHOCK ABSORBER, SWINGARM Position the brake line in the guide. Finishing work Install the air filter box cover. p. 97) Install the rear wheel. (ll\:!l p. 124) Remove the motorcycle from the lift stand. (ll\:!l p. 12) 9.31 Changing the swingarm bearing Preparatory work Raise the motorcycle with a lift stand.
  • Page 93 9 SHOCK ABSORBER, SWINGARM Remove shaft seal rings (D using a suitable tool. Remove stop disks Press out bearing using a suitable tool. Using a suitable tool, press in new bearing Position stop disks Press in shaft seal rings (D. Mount bushing @ .
  • Page 94 9 SHOCK ABSORBER, SWINGARM Remove bushing@. R02761-10 Remove shaft seal rings Q) using a suitable tool. Press out bearing using a suitable tool. Using a suitable tool, press in new bearing Q). Press in shaft seal rings Q). Mount bushing@. R02761-10 Grease the shaft seal rings.

  • Page 95: Exhaust

    EXHAUST Removing the manifold 10.1 Preparatory work Raise the motorcycle with a lift stand. p. 12) Remove the right side cover. p. 101) Remove the main silencer. p. 95) Main work Remove screw Remove fitting Info Raise the link fork slightly to be able to remove the screws more easily.

  • Page 96: Installing The Manifold

    10 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 97: Removing The Main Silencer

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

  • Page 98: Changing The Glass Fiber Yarn Filling Of The Main Silencer

    10 EXHAUST Finishing work Install the right side cover. (� p. 101) Changing the glass fiber yarn filling of the main silencer Warning The exhaust system gets very hot when the vehicle is driven. Danger of burns Allow the exhaust system to cool down before performing any work on the vehicle. Info Over time, the fibers of the glass fiber yarn escape and the damper "burns"...

  • Page 99: 11 Air Filter

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

  • Page 100: 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 101: 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. Air filter cleaning agent p. 288) -�� TwinAlr • 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 102: 12 Fuel Tank, Seat, Trim

    12 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 103: Removing The Right Side Cover

    FUEL TANK, SEAT, TRIM Removing the right side cover Remove screw Pull off the side cover sideways in areas and G), and remove toward the front. Position the side cover on collar bushings push toward the rear. Cs). Engage the side cover in areas Mount and tighten screw 6).

  • Page 104: Mounting The Seat

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

  • Page 105: Removing The Fuel Tank

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

  • Page 106: Installing The Fuel Tank

    12 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 107 FUEL TANK, SEAT, TRIM Main work Check the throttle cable routing. (l!!ll p. 51) 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 108: Checking The Fuel Pressure

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

  • Page 109: Changing The Fuel Pump

    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 ... 54 psi) active If the specification is not reached: Open the filler cap.
  • Page 110 12 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 111: Changing The Fuel Filter

    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 112 12 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 113 FUEL TANK, SEAT, TRIM Press locking mechanism (D. Pull back fuel pump housing@. 305317-10 Change fuel screen Mount the fuel pump housing. Mount fuel filter ✓ Arrow points away from the fuel pump. Mount hose clamps Hose clamp plier (60029057000) (�...

  • Page 114: Changing The Fuel Screen

    12 FUEL TANK, SEAT, TRIM Mount and tighten screws Guideline I Screw, fuel pump EJOT Nm (1.7 lbf ft) Finishing work Install the fuel tank. p. 104) Mount the seat. (11!.:! p. 1 0 2 ) Install the air filter box cover. (11!.:! p.
  • Page 115 FUEL TANK, SEAT, TRIM Clean plug-in connection of the fuel line thoroughly with compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve! Disconnect the plug-in connection of the fuel line. Info Remaining fuel may flow out of the fuel hose.

  • Page 116: 13 Mask, Fender

    13 MASK, FENDER 13.1 Removing front fender Preparatory work Remove the start number plate. p. 115) 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 117: Removing The Start Number Plate

    13 MASK, FENDER Removing the start number �late Remove screw 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 118: 14 Wheels

    Checkin 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 119: Checking The Wheel Bearing For Play

    DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manufacture. Husqvarna Motorcycles recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear.

  • Page 120: Checking The Brake Discs

    14 WHEELS Checking the brake discs Warning Worn-out brake discs reduce the braking effect. Danger of accidents Make sure that worn-out brake discs are replaced immediately. Check the front and rear brake disc thickness at multiple points for the dimension r �...

  • Page 121: Front Wheel

    14 WHEELS Check the spoke torque. Guideline Spoke nipple, front M4.5 6 Nm (4.4 lbf ft} wheel Spoke nipple, rear M4.5 6 Nm (4.4 lbf ft} wheel Torque wrench set (58429094000) (!!:! p. 294) 14.6 Front wheel 14.6.1 Removing the front wheel Preparatory work Raise the motorcycle with a lift stand.

  • Page 122: Installing The Front Wheel

    14 WHEELS Remove spacers �()( filJ � [ �® �◊) H00934-11 Installing the front wheel 14.6.2 Warning Oil or grease on the brake discs reduces the braking effect. Danger of accidents Always keep the brake discs free of oil and grease. Clean the brake discs with brake cleaner when necessary.

  • Page 123: Changing The Front Brake Disc

    14 WHEELS Remove the motorcycle from the lift stand. (ll!;,! p. 12) Operate the front brake and compress the fork a few times firmly. ✓ The fork legs straighten. Tighten screws Guideline Screw, fork stub Nm (11.1 lbf ft) 14.6.3 Changing the front brake disc Info If the brake discs are changed, the brake linings must also be changed.
  • Page 124 14 WHEELS Press out bearing using a suitable tool. • Info Spacing tube can be pushed aside. Remove the spacing tube. Press out bearing using a suitable tool. Press in new bearing all the way using a suitable tool. Info Only press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in.

  • Page 125: Checking The Rim Run-Out

    14 WHEELS 14.6.5 Checking the rim run-out Warning Incorrectly tensioned spokes impair the handling characteristic and result in Danger of accidents secondary damage. The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes is too low, then lateral and radial run-out will form in the wheel.

  • Page 126: Installing The Rear Wheel

    14 WHEELS Main work Press the brake caliper onto the brake disc by hand in order to push back the brake piston. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes. Remove nut Remove chain adjuster Pull out wheel spindle...

  • Page 127: Changing The Rear Brake Disc

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

  • Page 128: Checking The Chain Tension

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

  • Page 129: Adjusting The Chain Tension

    14 WHEELS 14.7.5 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.
  • Page 130 14 WHEELS Main work Shift the transmission to idle. Check the rear sprocket and engine sprocket for wear. If the rear sprocket or engine sprocket is worn: Change the drivetrain kit. (ll!;!J p. 130) Info The engine sprocket, rear sprocket, and chain should always be replaced together.
  • Page 131 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 132: 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. p. 130) 400678-01 14.7.8 Cleaning the chain Warning Oil or grease on the tires reduces the road grip. Danger of accidents Remove the lubricant from the tires using a suitable cleaning agent.
  • Page 133 WHEELS Main work Remove screws Take off the engine sprocket cover. Have an assistant operate the rear brake. Remove screw with the washer. Remove the rear wheel. p. 123) Remove connecting link of the chain. Info Cover the components to protect them against dam­ age.

  • Page 134: 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. (l!!l p.
  • Page 135 14 WHEELS Main work Remove shaft seal ring Remove lock ring Remove shaft seal ring Using a suitable tool, press bearing out from the inside to the outside. Remove spacing tube Using a suitable tool, press bearing Q) out from the inside to the outside.
  • Page 136 14 WHEELS Clean, grease, and mount spacing tube @t. I Long-life grease (!!:!I p. 288) 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 137: 15 Wiring Harness, Battery

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

  • Page 138: 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 139: Installing The Battery

    15 WIRING HARNESS, BATTERY Installing the battery Main work Position the battery in the battery compartment with the ter­ minals facing forward, and secure with holding bracket Battery (C22S) (l!!ll p. 269) Mount and tighten screw @. Guideline Screw, battery sup­ 10 Nm (7.4 lbf ft) port bracket Connect positive cable...
  • Page 140 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 141: Checking The Charging Voltage

    15 WIRING HARNESS, BATTERY Finishing work Mount the seat. (� p. 102) Install the air filter box cover. (!1ll p. 97) 15.5 Checking the charging voltage Condition The battery must be fully functional and completely charged. Preparatory work Remove the air filter box cover. (!1ll p.

  • Page 142: Checking The Capacitor

    15 WIRING HARNESS, BATTERY imum open-circuit cur- < 1 .0 mA I � �; If the measured value is greater than the specified value: Disconnect the voltage regulator from the wiring har­ ness and perform the measurement again. Check the capacitor. (!:JI p.

  • Page 143: Checking The Starter Relay

    15 WIRING HARNESS, BATTERY 15.8 Checking the starter rela� Preparatory work Press and hold the kill switch Q9 while the engine is idling until the engine stops. Remove the air filter box cover. p. 97) Remove the seat. p. 101) Main work Pull starter relay from the holder.

  • Page 144: 16 Brake System

    16 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 I Minimum thickness I � 1 mm (� 0.04 in) If the minimum thickness is less than specified: Change the front brake linings.
  • Page 145 BRAKE SYSTEM Remove screws with washers Press back the brake linings with a light lateral tilting of the brake caliper on the brake disc. Pull the brake caliper care­ fully back from the brake disc and hang it to one side. •...

  • Page 146: Hand Brake Lever

    16 BRAKE SYSTEM Position the brake caliper. Mount screws with wash­ but do not tighten yet. ✓ The brake linings are correctly positioned. Operate the hand brake lever repeatedly until the brake lin­ ings are in contact with the brake disc and there is a pressure point.

  • Page 147: Checking The Front Brake Fluid Level

    BRAKE SYSTEM Checking the front brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail. If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.

  • Page 148: Changing The Front Brake Fluid

    16 BRAKE SYSTEM Warning Hazardous substances cause environmental damage. Environmental hazard Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.
  • Page 149 BRAKE SYSTEM Info Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container. Move the brake fluid reservoir mounted on the handlebar to a horizontal position. Cover the painted parts. Remove screws Remove cover with the membrane.

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

    16 BRAKE SYSTEM • Info This prevents overfilling of the brake fluid reservoir. Tighten the bleeder screw. Remove the hose of the bleeder bottle. Mount the protection cap. Lock the bleeding device. Remove the bleeder cover. Add brake fluid to level Guideline 5 mm (0.2 in) Level...
  • Page 151 BRAKE SYSTEM Warning Brake fluid causes skin irritation. Skin irritation Keep brake fluid out of the reach of children. Wear suitable protective clothing and safety glasses. Do not allow brake fluid to come into contact with the skin, the eyes or clothing. Consult a doctor immediately if brake fluid has been swallowed.

  • Page 152: Checking The Free Travel Of Foot

    16 BRAKE SYSTEM Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. Info The arrow on the leaf spring points in the rotation direction of the brake disc. Insert the new brake linings, insert pin and mount cotter pins@).

  • Page 153: 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 154: Adding Rear Brake Fluid

    16 BRAKE SYSTEM Preparatory work Check the brake linings of the rear brake. (l!!,!I p. 148) Main work Stand the vehicle upright. Check the brake fluid level in the viewer If the brake fluid level drops below marking f): Add rear brake fluid. (l!l:! p.

  • Page 155: 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. 286) Mount and tighten the screw cap with the membrane and O­ ring.
  • Page 156 16 BRAKE SYSTEM Mount bleeder cover I Bleeder cover (00029013006) (� p. 290) Connect the bleeding device. I Bleeding device (00029013100) (� p. 290) Open shut-off valve • Info Follow the operating instructions of the bleeding device. Ensure that the filling pressure is set on pressure gauge 6). Adjust the filling pressure on pressure regulator G) if neces­...
  • Page 157 BRAKE SYSTEM Check the foot brake lever for a firm pressure point.

  • Page 158: 17 Engine

    17 ENGINE 17.1 Removing the engine Preparatory work Raise the motorcycle with a lift stand. (� p. 12) Drain the coolant. (� p. 24 7) Remove the right side cover. (� p. 101) Remove the air filter box cover. (� p.
  • Page 159 17 ENGINE @» Pull rollover sensor off of the holder and hang to one side. Push back hose clamp and pull off the vent hose. Remove screw @. 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 160 17 ENGINE Remove springs 41). I Spring hook (50305017000) (I!!.:! p. 292) Remove screw with the washer. Take off the manifold. Remove screws Take off the engine brace. Disconnect plug-in connector 41). Disconnect plug-in connectors...
  • Page 161 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. Loosen hose clip Pull off the radiator hose. Loosen hose clips G). Pull off the radiator hoses.
  • Page 162 17 ENGINE Pull capacitor off of the holder and hang to one side. €!). Pull off spark plug connector Remove screw •. 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 163 17 ENGINE Remove connecting link � of the chain. Take off the chain. Remove screw ... Take off the engine sprocket. Remove screw Ci) 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 164 17 ENGINE Remove spring@!). Remove fitting Remove screws Remove the foot brake cylinder and allow it to hang tension­ free to the side. Take the brake line out of the guide. Remove nut Remove the swingarm pivot. Carefully pull the swingarm back, and secure the swingarm.

  • Page 165: 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 166 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 167 17 ENGINE Position the throttle valve body. Tighten hose clip Position the shift lever. Mount and tighten screw with washers. Guideline Screw, shift 14 Nm (10.3 lbf ft) ® Loctite ™ lever Slide on the engine sprocket with the collar facing the engine. Mount screw Ci) with the washer but do not tighten yet.
  • Page 168 17 ENGINE Position the clutch slave cylinder with the gasket. Mount and tighten screws Guideline Screw, clutch slave 10 Nm (7.4 lbf ft) cylinder Position the engine sprocket cover. Mount and tighten screw «I). Guideline Screw, clutch slave 10 Nm (7.4 lbf ft) cylinder Mount and tighten screw Guideline...
  • Page 169 17 ENGINE Mount the radiator hose. Position and tighten hose clip�- Plug in the connector. Mount protection cap Ci). 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 @D of the crankshaft position sensor.
  • Page 170 17 ENGINE Position the engine brace. Mount and tighten screws@). Guideline 25 Nm (18.4 lbf ft) Screw, engine brace ® Loctite 2701 Tighten screws Guideline Engine carrying 60 Nm (44.3 lbf ft) screw Position the manifold. Mount screw with the washer but do not tighten yet. Guideline Remaining screws, 25 Nm (18.4 lbf ft)
  • Page 171 17 ENGINE Remove the locking piece and position the subframe. Info Watch out for the intake flange. Mount and tighten screw �. Guideline Screw, sub­ 30 Nm (22.1 lbf ft) Loctite ® 2701 frame Remove screw �. Mount and tighten screw �. Guideline Screw, sub­...
  • Page 172 17 ENGINE Position and tighten hose clip Connect negative cable 61). 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 173: Engine Disassembly

    24 7) Execute the initialization run. (� p. 263) 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. (!!:!I p. 249) Check the coolant level.

  • Page 174: Removing The Clutch Push Rod

    17 ENGINE Remove the long oil screen@). Remove screw plug with the short oil screen. 17.3.3 Removing the clutch push rod Remove clutch push rod 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 175: Removing The Starter Motor

    17 ENGINE 17.3.5 Removing the starter motor Remove screws and take off the starter motor. 17.3.6 Removing the spark plug Remove the spark plug using the special tool. Spark plug wrench with link (77229172000) (� p. 299) B03785-10 17.3.7 Removing the valve cover Remove screws Take off the valve cover with the valve cover seal.
  • Page 176 17 ENGINE Take off alternator cover gasket (g. 17.3.9 Positioning the engine at ignition top dead center Align camshaft marking with the center of screw the cylinder head. Remove screw with the washer. Screw in special tool Locking screw (113080802) (ilill p.

  • Page 177: Removing The Camshaft

    17 ENGINE Remove screws @. Take off the chain adjuster with the gasket. 17 .3.11 Removing the camshaft Remove screw Remove the camshaft support plate @. Pull the camshaft out of the bearing seats. Take the timing chain off the camshaft gear. Remove the camshaft. 17 .3.12 Removing the cylinder head Remove screw...

  • Page 178: Removing The Piston

    17 ENGINE 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 piston ring lock Remove the piston pin. Take off the cylinder and piston. Push the piston upward out of the cylinder.

  • Page 179: Removing The Timing Chain

    17 ENGINE Mount special tool on the rotor. Extractor (79229032044) (� p. 300) Hold it tight using the special tool and pull off the rotor by turning the screw in. Remove the woodruff key. 17.3.15 Removing the timing chain Remove screw Remove timing chain tensioning rail toward the top.

  • Page 180: Removing The Gear Position Sensor

    17 ENGINE Remove external rotor and internal rotor Take off pin Remove pin upward. Remove O-ring 17.3.17 Removing the gear position sensor Remove screws Take off the gear position sensor. 17.3.18 Removing the water pump cover Remove screws Take off the water pump cover. Take off the water pump cover seal.

  • Page 181: Removing The Clutch Cover

    17 ENGINE 17 .3.19 Removing the clutch cover Remove screws Take off the clutch cover. Info If work is to be performed on the water pump, unscrew the nut of the water pump impeller. Remove dowels Take off clutch cover gasket 17 .3.20 Removing the clutch discs Clamp the anti hopping clutch with special tool...

  • Page 182: Removing The Outer Clutch Hub

    17 ENGINE Hold the clutch basket using special tool and remove nut @ with the lock washer. I Gear segment (80029004000) (l!!ll p. 302) Remove clutch disc pack entirely. 17.3.21 Removing the outer clutch hub Take off washer Info The washer usually sticks to the inner clutch hub. Lock the outer clutch hub and primary gear using special tool@.

  • Page 183: Removing The Torque Limiter

    17 ENGINE Take off both needle bearings and collar bushing 0). 17.3.22 Removing the torque limiter Remove screw with the washer. Take off the torque limiter. 17 .3.23 Removing the starter idler gear Take off starter idler gear 17.3.24 Removing the force pump Remove lock ring Take off washer Remove oil pump idler gear fs).

  • Page 184: Removing The Shift Shaft

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

  • Page 185: Removing The Shift Drum Locating Unit

    17 ENGINE 17.3.26 Removing the shift drum locating unit Remove screw Push away locking lever from shift drum locating unit and remove the shift drum locating unit. Relieve tension from the locking lever. 17 .3.27 Removing the locking lever Unscrew and remove together with locking lever washer, sleeve and spring.

  • Page 186: Removing The Left Engine Case Section

    17 ENGINE 17.3.30 Removing the left engine case section Remove screws Mount special tool with suitable screws. Puller (79229048000) (l!i]l p. 300) Info • Use the 794 drill hole. Tilt the left section of the engine case upward and remove the fitting of the engine fixing arm.

  • Page 187: Removing The Shift Rails

    17 ENGINE 17.3.31 Removing the shift rails Remove shift rails together with upper springs lower springs. 17.3.32 Removing the shift drum Swing shift forks to one side. • Info Do not misplace the shift rollers. Remove shift drum@. 17.3.33 Removing the shift forks Take shift forks out of the shift grooves.

  • Page 188: Removing The Crankshaft

    17 ENGINE Position the engine upright. Remove lock ring@. Pull both transmission shafts out of the bearing seats together. Info Make sure not to misplace the washers. 17.3.35 Removing the crankshaft Remove crankshaft • Info Ensure that washer is not damaged. Take off the right section of the engine case.
  • Page 189 17 ENGINE Main work Remove all remaining dowels. Remove oil nozzle Remove screws @ and take off the bearing retainers. Remove the bearing retainer of main shaft bearing (D, of countershaft bearing and of shift drum bearing Remove any remnants of sealing compound and clean the engine case section thoroughly.

  • Page 190: Working On The Left Section Of The Engine Case

    17 ENGINE Blow compressed air through all oil channels and check that they are clear. 401797-01 Finishing work Install the oil pressure regulator valve. p. 190) 17.4.2 Working on the left section of the engine case Remove all remaining dowels. Remove screw Remove oil spray tube Remove screws...

  • Page 191: Removing The Oil Pressure Regulator Valve

    17 ENGINE After the engine case section has cooled, check that the bearings are firmly seated. Info If the bearings are not firmly seated after cooling, it is likely that they will rotate in the engine case when warm. In this case, the engine case must be renewed. Press in shaft seal ring of the countershaft and shaft seal ring...

  • Page 192: Installing The Oil Pressure Regulator Valve

    17 ENGINE Main work Measure the spring length of the oil pressure regulator valve. Oil pressure regulator valve ;;:: 21.07 mm (;;,: 0.8295 in) Minimum length of pres- sure spring If the measured value does not meet specifications: Change the spring. 306115-10 Finishing work Install the oil pressure regulator valve.

  • Page 193: Installing The Water Pump

    17 ENGINE Remove balancer shaft Remove shaft seal ring Press out water pump shaft bearing toward the inside with an appropriate tool. Info Suitably support the clutch cover while pressing it out. Installing the water pump 17.4.8 Press bearing of the water pump shaft up to the stop with a suitable tool.

  • Page 194: Removing The Crankshaft Bearing Inner Race

    17 ENGINE Mount special tool on the water pump shaft. I Protection cap (90129005000) (I!!,! p. 302) Mount balancer shaft • Info Be careful not to damage the shaft seal rings. Remove the special tool. I Protection cap (90129005000) (I!!,! p.

  • Page 195: Installing The Crankshaft Bearing Inner Race

    17 ENGINE 17 .4.10 Installing the crankshaft bearing inner race Main work Fix the crankshaft in the vise. Info Use soft jaws. Slide on compensating disk Info The compensating disks have a larger diameter than the crankshaft stub. Ensure that the compensating disks are centered and fixed with a small amount of grease.
  • Page 196 17 ENGINE Press crank pin out of the lower crankweb. 310046-10 Place the crankweb onto special tool I Crankshaft pressing tool insert (79429008000) p. 301) Info The special tool must be positioned with the flat sur­ face facing downward. Press in new crank pin all the way.

  • Page 197: Checking Crankshaft Run-Out At Bearing Pin

    17 ENGINE Position special tool with the heel pointing down. Crankshaft pressing tool insert (78929008000) (� p. 299) 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 198: Cylinder - Nikasil ® Coating

    17 ENGINE If the measured value does not meet specifications: Remove the crankshaft. Remove the crankshaft bearing inner race. p. 192) Calculate the thickness of the compensating disks. Add or remove compensating disks equally on both sides. Info If the end play is too small, remove compen­ sating disks.

  • Page 199: Checking/Measuring The Piston

    17 ENGINE Using a straightedge and the special tool, check the sealing area of the cylinder head for distortion. Feeler gauge (59029041100) (llill p. 295) Cylinder/cylinder head - :;; 0.10 mm (:;; 0.0039 in) sealing area distortion If the measured value does not meet specifications: Change the cylinder.

  • Page 200: Checking The Piston Ring End Gap

    17 ENGINE If the piston pin seating has excessive play: Replace the piston and, if necessary, the cylinder and piston pin. Measure the piston at the piston skirt, at right angles to the piston pin, at a distance f). Guideline 7 mm (0.28 in) Distance Piston - diameter...

  • Page 201: Checking The Oil Pumps

    17 ENGINE Guideline Piston/cylinder - mounting clearance Size I 0.040 ... 0.082 mm (0.00157 ... 0.00323 in) Size II 0.043 ... 0.085 mm (0.00169 ... 0.00335 in) Wear limit 0.120 mm (0.00472 in) 17.4.19 Checking the oil pumps Info The following steps apply to both oil pumps. Use special tool to measure the play between the exter­...

  • Page 202: Assembling The Autodecompressor

    17 ENGINE Pull autodecompression shaft out of the camshaft. 304674-10 -� Release and remove autodecompression spring Info Autodecompression weight cannot be taken off. 304675-10 17.4.21 Assembling the autodecompressor Insert long flange of the autodecompression spring in the hole, push the autodecompression spring over bearing bolt and hook it into autodecompression weight 304675-11...

  • Page 203: Checking Camshaft

    17 ENGINE 17 .4.22 Checking camshaft Check the camshaft for damage and wear. If there is damage or wear: Change the camshaft. If the camshaft surface is damaged, check the oil supply of the camshaft and the rocker arm. Measure the cams of the camshaft. Camshaft - cam height Exhaust 33.10 ...

  • Page 204: Removing The Rocker Arm

    17 ENGINE Check timing chain for damage and wear. If there is damage or wear: Replace the timing chain. Check the timing chain links for smooth operation. Let the timing chain hang down freely. The chain links no longer align in a straight line: Replace the timing chain.

  • Page 205: Changing The Camshaft Bearing

    17 ENGINE •• Mark the valves corresponding to their installation position. Info £VI £ 11 '15> Place the valves in a carton corresponding to their • installation position and label them . 200189-10 17.4.26 Changing the camshaft bearing Condition The valves are removed and the exhaust flange is removed. Mount the cylinder head.

  • Page 206: Checking The Valves

    17 ENGINE Press the small camshaft bearing in until flush using special tool I Pressing tool (75029044020) (� p. 297) Press the large camshaft bearing in all the way using special tool@). Pressing tool (75029044010) (!,JI p. 297) 17.4.27 Checking the valves Info The valve stem is hard-chrome plated;...

  • Page 207: Checking Valve Springs

    17 ENGINE 17.4.28 Checking valve springs 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 Intake minimum length 40.

  • Page 208: Checking The Rocker Arm Shafts

    17 ENGINE Using a straightedge and the special tool, check the sealing area of the cylinder for distortion. I Feeler gauge (59029041100) (l!!ll p. 295) Cylinder/cylinder head - ::; 0.10 mm (::; 0.0039 in) sealing area distortion If the measured value does not meet specifications: Change the cylinder head.

  • Page 209: Installing The Rocker Arm

    17 ENGINE Pretension the valve springs using the special tool. Valve spring mounter (59029019000) (� p. 294) Insert for valve spring lever (77029041200) (� p. 298) Mount the valve keys. • Info When mounting the valve keys, check that they are seated correctly;...

  • Page 210: 17.4.34 Disassembling The Antihopping Clutch

    17 ENGINE Mount and tighten screws@. Guideline Screw, rocker arm 15 Nm (11.1 lbf ft) bearing Mount and tighten screw plugs with the O-ring. Guideline Screw plug, rocker M10x1.25 10 Nm (7.4 lbf ft) arm shaft 17.4.34 Disassembling the antihopping clutch Clamp clutch into a vise.

  • Page 211: Preassembling The Antihopping Clutch

    17 ENGINE 17.4.35 Preassembling the antihopping clutch Thoroughly oil the clutch facing discs. Mount the sleeves. ✓ Recess engages in edge 306630-10 Beginning with an intermediate clutch disc, alternately position all other clutch facing discs and intermediate clutch discs. 306631-10 Position release springs in the inside inner clutch hub.

  • Page 212: Checking The Clutch

    17 ENGINE 17.4.36 Checking the clutch 306625-10 Check clutch push rod for damage and wear. If there is damage or wear: Change the clutch push rod. Place clutch push rod on a flat surface and check for run-out. If there is run-out: Change the clutch push rod.

  • Page 213: Checking The Shift Mechanism

    17 ENGINE Thrust surface, clutch facing discs in outer clutch :S 0.5 mm (:S 0.02 in) If the thrust surface exhibits excessive wear: Change the clutch facing discs and the clutch basket. Check needle bearing Gi) and collar bushing for damage and wear. If there is damage or wear: Change the needle bearing and collar bushing.

  • Page 214: Preassembling The Shift Shaft

    17 ENGINE If the shift drum is not seated correctly: Change the shift drum and/or the bearing. Check bearing (D for stiffness and wear. If the bearing is stiff or worn: Change the bearings. Check shift rollers for surface damage and cracking. If the shift roller exhibits surface damage or cracking: Change the shift roller.

  • Page 215: Disassembling The Main Shaft

    17 ENGINE Mount stop disk (D. 17.4.39 Disassembling the main shaft 310083-10 Secure the main shaft in the vise with the gear teeth facing downward. Guideline I Use soft jaws. Remove stop disk and second-gear fixed gear Remove lock ring Remove distance sleeve Remove third/fourth-gear sliding gear Remove lock ring (D and stop disk @.

  • Page 216: Disassembling The Countershaft

    17 ENGINE 17.4.40 Disassembling the countershaft 310089-10 Secure the countershaft in the bench vise with the toothed end facing downward. Guideline Use soft jaws. Remove stop disk and first-gear idler gear Remove needle bearing and stop disk Remove the fifth-gear sliding gear and lock ring (D.
  • Page 217 17 ENGINE 310091-10 Check needle bearings for damage and wear. If there is damage or wear: Change the needle bearings. Check the pivot points of main shaft and countershaft (D for damage and wear. If there is damage or wear: Change the main shaft and/or countershaft.

  • Page 218: Assembling The Main Shaft

    17 ENGINE Check stop disks @ for damage and wear. there is damage or wear: Change the stop disks. Use new lock rings @ with every repair. Check distance sleeves Ci) for damage and wear. there is damage or wear: Change the distance sleeves.

  • Page 219: 17 .4.43 Assembling The Countershaft

    17 ENGINE 17 .4.43 Assembling the countershaft Info Use new lock rings with every repair. Preparatory work Lubricate all parts carefully before assembling. Check the transmission. p. 214) Main work 310090-10 Secure the countershaft in the bench vise with the toothed end facing downward. Guideline I Use soft jaws.

  • Page 220: Checking The Starter Drive

    17 ENGINE 17.4.44 Checking the starter drive 0 - • 310086-10 Check the gear mesh and bearing of starter idler gear for damage and wear. If there is damage or wear: Change the starter idler gear. Check the gear mesh and bearing of torque limiter for damage and wear.

  • Page 221: Checking The Freewheel

    17 ENGINE 17 .4.45 Checking the freewheel Insert freewheel gear into primary gear turning the primary gear clockwise; do not wedge! • Check the locking action of freewheel gear If the primary gear does not turn clockwise or if it does not lock counterclockwise: Change the freewheel.

  • Page 222: Engine Assembly

    17 ENGINE Mount spreader ring 304705-10 Ensure that all lugs of the spreader ring pass through slots of the freewheel and engage in groove of the primary gear. 17.5 Engine assembl)' 17.5.1 Installing the crankshaft Position the right section of the engine case in the engine work stand.

  • Page 223: Installing The Transmission Shafts

    17 ENGINE 17.5.2 Installing the transmission shafts Lubricate all bearings. Slide both transmission shafts into the bearing seats. Info Make sure not to misplace the washers. Mount lock ring 17.5.3 Installing the shift forks Lubricate all parts thoroughly. Mount shift fork in the upper shift groove of the main •- shaft.

  • Page 224: Installing The Shift Drum

    17 ENGINE 17.5.4 Installing the shift drum Push shift drum into the bearing seat. Put shift forks in the shift drum. Info Do not misplace the shift rollers. 17.5.5 Installing the shift rails Install shift rails together with upper springs lower springs.

  • Page 225: Installing The Freewheel Gear

    17 ENGINE Mount the left section of the engine case. If necessary, strike lightly with a rubber mallet. • Info Do not use the screws to pull the two sections of the engine case together. Mount screws but do not tighten yet. Guideline Screw, engine case M6x60...

  • Page 226: Installing The Locking Lever

    17 ENGINE 17.5.9 Installing the locking lever Mount locking lever with the washer, sleeve and spring. Mount and tighten screw @ . Guideline Screw, locking 6 Nm (4.4 lbf ft) ® Loctite lever ™ 17.5.10 Installing the shift drum locating unit Push away locking lever from the shift drum locating unit and position the shift drum locating unit...

  • Page 227: Installing The Starter Idler Gear

    17 ENGINE Position oil pump cover ✓ The marking faces up. Mount and tighten screws@). Guideline 10 Nm (7.4 lbf ft) Screw, pressure ® Loctite pump cover ™ Insert pin (D. Position oil pump gear wheel @. Position washers Mount lock washer Mount oil pump idler gear �.

  • Page 228: Installing The Torque Limiter

    17 ENGINE 17.5.14 Installing the torque limiter Position the washer. Mount the torque limiter. Mount and tighten screw with the washer. Guideline Screw, bearing 10 Nm (7.4 lbf ft) ® bolt, torque lim- Loctite ™ iter 17.5.15 Installing the clutch basket Mount collar bushing and both needle bearings Slide clutch basket...

  • Page 229: Installing The Clutch Discs

    17 ENGINE 17.5.16 Installing the clutch discs Insert clutch pack in the clutch basket. Info If necessary, turn the main shaft a little to ease access. Position the new lock washer and mount nut Lock the clutch basket and primary gear using special tool and tighten the nut.

  • Page 230: Installing The Clutch Cover

    17 ENGINE • 17.5.17 Installing the clutch cover Position the balancer shaft with special tool I Marking mandrel (78129032000) p. 299) ✓ Marking and the special tool are aligned. Mount dowels and position the clutch cover gasket (D. Mount the clutch cover. Mount screws but do not tighten them yet.

  • Page 231: Installing The Gear Position Sensor

    17 ENGINE Mount screw and tighten all screws in a crisscross pat­ tern. Guideline Screw, water pump M6x55 10 Nm (7.4 lbf ft) cover 17 .5.19 Installing the gear position sensor Position the gear position sensor. Mount and tighten screws Guideline Screw, gear 5 Nm (3.

  • Page 232: Installing The Timing Chain

    17 ENGINE 17.5.21 Installing the timing chain Thread in the timing chain and place it over the timing chain sprocket. • Info If the timing chain was used before, ensure it is run­ ning in the correct direction. Position the timing chain securing guide. Mount and tighten screw Guideline Screw, timing...

  • Page 233: Installing The Piston

    17 ENGINE 17.5.23 Installing the piston Move the joints of the compression ring and oil scraper ring so they are offset by 1 80 ° Place the oiled piston on the cylinder. Clamp the piston rings together using the special tool. Piston ring mounting tool (60029015000) (Ill:!! p.
  • Page 234 17 ENGINE Mount cylinder base gasket (5). Info Ensure that locating pins @ are seated properly. Ensure that piston marking faces the exhaust side. 310079-10 Cover the engine case opening with a cloth. Feed the timing chain through the timing chain shaft and mount the piston pin.

  • Page 235: Installing The Cylinder Head

    17 ENGINE Insert the special tool and press it with force towards the pis­ ton. Turn the special tool clockwise, thereby pushing the piston ring lock into the groove. Insertion for piston ring lock (77329030100) (ll,JI p. 299) Ensure that the piston ring lock is in the correct position on both sides.

  • Page 236: Installing The Camshaft

    17 ENGINE Guideline Screw, cylinder M10x1 .25 Step 1 10 Nm (7.4 lbf ft) head Step 2 30 Nm (22.1 lbf ft) Step 3 50 Nm (36.9 lbf ft) Lubricated with engine Mount and tighten screw Guideline Screw, cylinder head 110 Nm (7.4 lbf ft) 17.5.25 Installing the camshaft...

  • Page 237: Checking The Valve Clearance

    17 ENGINE Position the timing chain tensioner with the gasket. Mount and tighten screws Guideline Screw, timing chain 10 Nm (7.4 lbf ft) tensioner Mount and tighten screw plug with washer spring Guideline Plug, timing chain 8 Nm (5.9 lbf ft) tensioner 17 .5.27 Checking the valve clearance...

  • Page 238: 17.5.28 Adjusting The Valve Clearance

    17 ENGINE Remove the special tool. I Locking screw (113080802) (� p. 291) Mount and tighten screw with washer. Guideline Screw plug, 10 Nm (7.4 lbf ft) crankshaft location 17.5.28 Adjusting the valve clearance Main work Remove the timing chain tensioner. (!;!I p.

  • Page 239: Installing The Valve Cover

    17 ENGINE 17.5.30 Installing the valve cover Position the valve cover seal. Position the valve cover. Mount and tighten screws Guideline Screw, valve cover I10Nm(7.41bfft) Installing the spark plug 17 .5.31 Mount and tighten the spark plug using the special tool. Guideline Spark plug M10x1...

  • Page 240: Installing The Clutch Push Rod

    17 ENGINE Oil the O-ring of the oil filter cover. Mount oil filter cover Mount and tighten screws@). Guideline Screw, oil filter cover 110 Nm (7.4 lbf ft) • 17.5.34 Installing the clutch push rod Mount clutch push rod 17.5.35 Installing the oil screens Mount and tighten screw plug with the short oil screen...

  • Page 241: Removing The Engine From The Engine Assembly Stand

    17 ENGINE Mount and tighten oil drain plug with the magnet and a new seal ring. Guideline Oil drain plug with M12x1 .5 20 Nm (14.8 lbf ft) magnet 17 .5.36 Removing the engine from the engine assembly stand Remove the fitting from the special tool. Holder and fitting for work stand (79429002000) (IE.! p.

  • Page 242: 18 Clutch

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

  • Page 243: 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 244: Anti Hopping Clutch

    18 CLUTCH Now inject the fluid into the system until it emerges from drill hole of the master cylinder without bubbles. Now and then, extract fluid from the master cylinder reservoir to prevent overflow. Tighten the bleeder screw and remove the bleeding syringe with the hose.

  • Page 245: Adjusting The Antihopping Clutch

    18 CLUTCH In case of a high level of engine braking effect, short-term slip of the clutch occurs. This prevents rear wheel hopping. 18.4 Adjusting the antihog�ing clutch 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 246 18 CLUTCH Check 0-ring for damage. If the 0-ring is damaged: Change the 0-ring. Lubricate the 0-ring with engine oil and position the clutch cover. Mount screws but do not tighten yet. Guideline Screw, clutch cover M6x25 10 Nm (7.4 lbf ft) Mount screw but do not tighten yet.

  • Page 247: 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 248: 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 249: 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 250 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) Dimension over the radi- ator fins Coolant 1.20 I Coolant (ll!:!l p.

  • Page 251: 20 Lubrication System

    20 LUBRICATION SYSTEM 20.1 Oil circuit 401628-60 Oil screen Force pump Oil pressure regulator valve Oil filter Oil nozzle for conrod bearing lubrication Oil nozzle, piston cooling Oil nozzle for cam follower lubrication Suction pump Oil channel, transmission lubrication Checkin Info The engine oil level can be checked when the engine is cold or warm.

  • Page 252: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens

    LUBRICATION SYSTEM Condition The engine is at operating temperature. Check the engine oil level. Info After switching off the engine, wait one minute before checking the level. The engine oil level is between the middle of the level viewer fj and the upper edge of the level viewer If the engine oil does not reach the middle of level viewer fj : Add engine oil.
  • Page 253 20 LUBRICATION SYSTEM Remove screw plug with the short oil screen and the O­ rings. Info Do not remove screw f). Remove screw plug with the long oil screen and the O-rings. Completely drain the engine oil. Thoroughly clean the parts and sealing surfaces. Mount and tighten screw plug with the short oil screen and the O-rings.
  • Page 254 LUBRICATION SYSTEM Remove screws Remove the oil filter cover with the O­ ring. Pull oil filter out of the oil filter housing. I Lock ring plier (51012011000) (� p. 293) Completely drain the engine oil. Thoroughly clean the parts and sealing area. Lay the motorcycle on its side and fill the oil filter housing to about ½...

  • Page 255: Adding Engine Oil

    20 LUBRICATION SYSTEM Finishing work Check the engine oil level. (� p. 249) 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 0-ring from the clutch iii-0 cover.

  • Page 256: Checking The Engine Oil Pressure

    LUBRICATION SYSTEM Position special tool @ with the O-ring. Mount and tighten the screws. Guideline Screw, oil filter cover 110 Nm (7.4 lbf ft) I Oil pressure adapter (79429094000) (!!ll p. 301) Connect the pressure tester to the special tool without the T­ plate.
  • Page 257 20 LUBRICATION SYSTEM Guideline 0 Nm (7.4 lbf ft) Screw, oil filter cover Finishing work Check the engine oil level. (!!;!I p. 249)

  • Page 258: Ignition System

    IGNITION SYSTEM 21.1 winding Ignition coil - checking the seconda 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 259: Removing The Stator

    IGNITION SYSTEM Stator winding - check the short circuit to ground {terminal 31) Measure the resistance between the specified points. Alternator, connector - Measuring point Ground Resistance If the displayed value does meet specifications: Change the stator. 21.4 Removing the stator Condition The alternator cover has been removed.

  • Page 260: 22 Cylinder Head

    22 CYLINDER HEAD 22.1 Checking the valve clearance Preparatory work Raise the motorcycle with a lift stand. (� p. 12) Remove the right side cover. (� p. 101) Remove the air filter box cover. (� p. 97) Remove the seat. (�...
  • Page 261 22 CYLINDER HEAD Engage the highest gear. Turn the rear wheel until the engine is at ignition top dead center. ✓ The markings on the camshaft and screw G) on the cylinder head are lined up. Info Make sure that the crankshaft is at top dead center. Unscrew and remove screw Remove washer Mount and tighten screw...

  • Page 262: Adjusting The Valve Clearance

    22 CYLINDER HEAD Position the valve cover with the gasket. Mount and tighten screws Guideline Screw, valve cover 110 Nm (7.4 lbf ft) Mount the vent hose and hose clamp Mount and tighten the spark plug using the special tool. Guideline Spark plug M1 0x1...
  • Page 263 22 CYLINDER HEAD Main work Swing up cam lever Correct the shims based on the results of the valve clearance check. Finishing work Install the camshaft. (� p. 234) Install the timing chain tensioner. (I!!:! p. 234) Check the valve clearance. (I!!:! p.

  • Page 264: 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 connector of the starter motor.

  • Page 265: 24 Throttle Valve Body

    24 THROTTLE VALVE BODY Adjusting the idle s�eed Warning Danger of accidents The engine may go out spontaneously if the idle speed is set too low. Set the idle speed to the specified value. Run the engine until warm. ✓ The cold start button is deactivated - The cold start but­ ton is in its basic position.
  • Page 266 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 267: 25 Technical Data

    25 TECHNICAL DATA 25.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 449.9 cm (27.455 cu in) Stroke 63.4 mm (2.496 in) Bore 95 mm (3.74 in) Compression ratio 12.75:1 Idle speed 2,250 ... 2,350 rpm Control OHC, 4 valves controlled via rocker arm Valve diameter, intake 40 mm (1 .57 in) Valve diameter, exhaust...

  • Page 268: Tolerance, Engine Wear Limits

    25 TECHNICAL DATA 25.2 Tolerance, engine wear limits Camshaft - cam height Exhaust 33.10 ... 33.30 mm (1.3031 ... 1.311 in) Intake 33.90 ... 34.10 mm (1.3346 ... 1 .3425 in) Valve spring Intake minimum length (without valve spring seat) 40.
  • Page 269 25 TECHNICAL DATA Screw, bearing retainer 6 Nm (4.4 lbf ft) Loctite ® ™ Screw, clutch spring retainer 8 Nm (5.9 lbf ft) Screw, gear position sensor 5 Nm (3. 7 lbf ft) Loctite ® ™ Screw, locking lever 6 Nm (4.4 lbf ft) ®...

  • Page 270: Capacities

    25 TECHNICAL DATA Spark plug M10x1 10 ... 12 Nm (7.4 ... 8.9 lbf ft} Engine coolant temperature sen- M10x1 .25 12 Nm (8.9 lbf ft} Screw plug, rocker arm shaft M10x1.25 10 Nm (7.4 lbf ft) Screw, cylinder head M10x1.25 Step 1 10 Nm (7.4 lbf ft)

  • Page 271: Electrical System

    Rear tire 125/600 R 16.5 TL 165/630 R 17 TL Bridgestone Battlax Supermoto BM01 Soft Bridgestone Battlax Racing R02Z Medium The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: www.husqvarna-motorcycles.com...

  • Page 272: Fork

    25 TECHNICAL DATA 25.8 Fork 14.15.7P.08 Fork part number Fork WP Performance Systems Up Side Down 4860 MXMACC Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Rebound damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Spring length with preload spacer(s) 482 mm (18.98 in) Spring rate...

  • Page 273: Chassis Tightening Torques

    25 TECHNICAL DATA Weight of rider: 65 ... 75 kg (143 ... 165 lb.) 247 mm (9.72 in) Weight of rider: 75 ... 85 kg (165 ... 187 lb.) 247 mm (9.72 in) Weight of rider: 85 ... 95 kg (187 ... 209 lb.) 252 mm (9.92 in) 1 0 bar (145 psi) Gas pressure...
  • Page 274 25 TECHNICAL DATA Screw, engine brace 25 Nm (18.4 lbf ft) ® Loctite 2701 Screw, fork stub 15 Nm (11.1 lbf ft) Screw, handlebar clamp 20 Nm (14.8 lbf ft) Screw, subframe 30 Nm (22.1 lbf ft) Loctite ® 2701 Screw, top steering stem 20 Nm (14.8 lbf ft) ®...

  • Page 275: 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 276 26 CLEANING/PROTECTIVE TREATMENT Treat bare metal parts (except for brake discs and the exhaust system) with a corrosion inhibitor. Treat all plastic parts and powder-coated parts with a mild cleaning and care agent. Preserving materials for paints, metal and rubber (�...

  • Page 277: 27 Storage

    O ... 35 °C (32 ... 95 °F) tery without direct sunshine 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- able to air.

  • Page 278: Preparing For Use 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 279: 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 280: Recommended Work

    • • • • Final check: Check the vehicle for safe operation and take a test ride. Read out the fault memory after the test ride using the Husqvarna Motorcycles diagnostics • • • tool. Make the service entry in the Husqvarna Motorcycles Dealer.net...
  • Page 281 28 SERVICE SCHEDULE...
  • Page 282 t : : 1 «! . · � 1 " 1 -" . NfC/2 l. x1 9 R / 4 • EB / 4 �S/2 -C10 -M10 -G101 1+ �K/4 ""ij -521 ,'!-, -1FC/2 EB / 4 r BR / 4 �...

  • Page 283: 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 284 � HY/33 HY/33 HY/33 HY/33 HY/33 �HY/33 HY/33 1 ·X16 1·X16 1·X16 1·X16 is� � ��i �I " ��; � - a .0.0 l.x 2 1 . x 1 . x s -BF/1 iCX/2 f 1 , 2 f r 1 2 -520 -P25 - X 295...
  • Page 285 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 286 -© -A11 " ' l " ' 1�, . l" 1 1 " l" l" 1 � m 1 1 � ru 1 � -X16 -X16 -X16 -X16 -X16 -X16 -X16 -X16 -X16 -X16 " 1""' "" • " � i �...
  • Page 287 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) Map-Select switch for ride mode (optional) switch (optional) Map-Select...

  • Page 288: 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 289 30 SUBSTANCES Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification p. 310) (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 290: 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 291 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 292: Special Tools

    32 SPECIAL TOOLS Bleeder cover Art. no.: 00029013002 00029013002 H00501-01 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 293 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 294 32 SPECIAL TOOLS Bearing �uller Art. no.: 15112017000 15112017000 H00520-01 Internal bearing �uller Art. no.: 15112018100 .& Feature 1 18 ... 23 mm (0.71 ... 0.91 in) 15112018100 H00522-01 Tachometer Art. no.: 45129075000 �� 45129075000 H00525-01 ring hook Art. no.: 50305017000 50305017000 H00973-01...
  • Page 295 32 SPECIAL TOOLS S�ringe Art. no.: 50329050000 50329050000 H00565-01 Lock ring �lier Art. no.: 51012011000 51012011000 H00572-01 Puller Art. no.: 58429037043 Feature Inside diameter I 43.9 mm (1.728 in) 58429037043 H00598-01 Tool bracket Art. no.: 58429089000 58429089000 H00603-01...
  • Page 296 32 SPECIAL TOOLS Pressing tool Art. no.: 58429091000 58429091000 H00604-01 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) Open ended bit 4.9 mm (0.193 in) 5.5 mm (0.217 in)
  • Page 297 32 SPECIAL TOOLS Limit �lug gauge Art. no.: 59029026006 Feature Diameter I 6.05 mm (0.2382 in) 59029026006 H00612-01 Feeler gauge Art. no.: 59029041100 Feature piece I 0.10 ... 0.25 mm (0.0039 ... 0.0098 in) 59029041100 H00616-01 Piston ring mounting tool Art.
  • Page 298 32 SPECIAL TOOLS Hose clam� �lier Art. no.: 60029057000 60029057000 H00650-01 Testing hose Art. no.: 61029093000 61029093000 H00659-01 Pressure testing tool Art. no.: 61029094000 .£. 61029094000 H00660-01 Puller Art. no.: 75029021000 75029021000 H00707-01...
  • Page 299 32 SPECIAL TOOLS Assembly screws Art. no.: 75029033000 4x &. 75029033000 H00708-01 Pressing tool Art. no.: 75029044010 75029044010 H00712-01 Pressing tool Art. no.: 75029044020 75029044020 H00713-01 Crankshaft ressing tool Art. no.: 75029047000 75029047000 H00714-01...
  • Page 300 32 SPECIAL TOOLS Clam�ing �late Art. no.: 75029050000 75029050000 H00719-01 Pressing tool Art. no.: 75029051000 75029051000 H00721-01 Protection ca� Art. no.: 75029090000 75029090000 H00726-01 Insert for valve s ring lever Art. no.: 77029041200 77029041200 H00746-01...
  • Page 301 32 SPECIAL TOOLS 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 Insertion for �iston ring lock Art. no.: 77329030100 77329030100 H00768-01 Marking mandrel Art.
  • Page 302 32 SPECIAL TOOLS Footrest s�ring �lier Art. no.: 79029083000 79029083000 H00804-01 Extractor Art. no.: 79229032044 79229032044 H00808-01 Puller Art. no.: 79229048000 79229048000 H00809-01 Holder and fittin for work stand Art. no.: 79429002000 2xffiffi 79429002000 H01081-01...
  • Page 303 32 SPECIAL TOOLS Pressing tool Art. no.: 79429006000 79429006000 H01018-01 Crankshaft �ressing tool insert Art. no.: 79429008000 79428008000 H01169-01 Se�arator late Art. no.: 79429009000 79429009000 H00812-01 Oil ressure ada ter Art. no.: 79429094000 79429094000 H01045-01...
  • Page 304 32 SPECIAL TOOLS Gear segment Art. no.: 80029004000 80029004000 H00813-01 Engine work stand Art. no.: 80329001000 80329001000 H01047-01 Lift stand Art. no.: 80329955100 Feature Height 260 ... 370 mm (10.24 ... 14.57 in) Load � 150 kg(� 331 lb.) 80329955100 H02016-01 Protection ca Art.
  • Page 305 32 SPECIAL TOOLS Pin wrench Art. no.: T103 Feature adjustable Diameter mm (0.16 in) T103 H00838-01 Hook wrench Art. no.: T106S Feature Diameter I 68 ... 75 mm (2.68 ... 2.95 in) T106S H00841-01 De�th micrometer Art. no.: T107S T107S H00842-01 Drift Art.
  • Page 306 32 SPECIAL TOOLS Mounting sleeve Art. no.: T1204 Feature I Diameter 25.5 ... 30.5 mm (1 .004 ... 1 .201 in) T1204 H00878-01 Calibrating unit Art. no.: T1205 Feature I Diameter 1 18 mm (0.71 in) T1205 H00879-01 Pressing tool Art.
  • Page 307 32 SPECIAL TOOLS Mounting sleeve Art. no.: T1215 Feature Diameter 1 18 mm (0.71 in) T1215 H00886-01 Pressing tool Art. no.: T1216 Feature Diameter 13 8 ... 49 mm (1.5 ... 1.9 3 in) T1216 H00887-01 Vacuum um� Art. no.: T1240S �...
  • Page 308 32 SPECIAL TOOLS Clam�ing stand Art. no.: T14016S Feature I Diameter 12 mm(0.47in) T14016S H01036-01 Ring wrench Art. no.: T14017 Feature I Hexagonal part 50 mm (1.97 in) T14017 H00904-01 Filling tool Art. no.: T14019 &2x£ T14019 H00906-01 ort tool Art.
  • Page 309 32 SPECIAL TOOLS Calibrating unit Art. no.: T14021 Feature Diameter 112 mm (0.47 in) T14021 H00908-01 Pressing tool Art. no.: T14022B Feature Diameter 111.95 ... 21.4 mm (0.4705 ... 0.843 in) T14022B H00910-01 Threaded bushing Art. no.: T14023 Feature Diameter I 24.5 mm (0.965 in) T14023 H00911-01...
  • Page 310 32 SPECIAL TOOLS Filling ada�ter Art. no.: T14030 Feature 116 mm (0.63 in) T14030 H00918-01 Tweezers Art. no.: T14033 T14033 H00921-01 Clam�ing stand Art. no.: T1403S £. Feature Diameter 48 mm (1.89 in) Diameter 60 mm (2.36 in) �� T1403S H00896-01 Mounting tool Art.
  • Page 311 32 SPECIAL TOOLS Pressing tool Art. no.: T1504 Feature Diameter 1 18 mm (0.71 in) T1504 H00899-01 Mounting tool Art. no.: T150S �o £& T150S H00852-01 Filling tool Art. no.: T170S1 �, 2x£3x.£. T170S1 H00855-01...

  • Page 312: Standards

    33 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 313: 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 314: Index

    INDEX Capacity coolant ....... 248, 268 ......9 Accessories engine oil ....170, 252, 268 Air filter Cartridge cleaning ......98 fork legs, disassembling .
  • Page 315 INDEX main shaft, disassembling ... . . 213 Engine - work on individual parts antihopping clutch, disassembling water pump, installing antihopping clutch, preassembling Engine assembly autodecompressor, assembling ..200 alternator cover, installing .
  • Page 316 INDEX cartridge, filling with nitrogen ... . 43 freewheel gear, removing ... . . 183 gear position sensor, removing ..178 checking .
  • Page 317 INDEX Handlebar position ....50 Play in throttle cable adjusting ......50 adjusting .
  • Page 318 INDEX piston rod, disassembling ....71 chassis ......268 rebound damping, adjusting .
  • Page 319 I 1 1 11 1 11 1 1 1 1 11 1 1 1 111 1 11 1 1 1 1 111 1 11 1 1 1 1 11 1 11 1 I I I I I I II I I II 3403034en 06/2017 ® Husqvarna llmi Husqvarna Motorcycles GmbH StallhofnerstraBe 3 5230 Mattighofen Austria fiiiHiAv � LZZa" ·...

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