Husqvarna FS 450 2017 Repair Manual
  1. Manuals
  2. Brands
  3. Husqvarna Manuals
  4. Motorcycle
  5. FS 450 2017
  6. Repair manual

Husqvarna FS 450 2017 Repair Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
PIONEERING SINCE 1903
REPAIR MANUAL2017
FS 450
®
Husqvarna
Art. no. 3403050en
MOTORCYCLES

Advertisement

Table of Contents
loading

Related Manuals for Husqvarna FS 450 2017

Summary of Contents for Husqvarna FS 450 2017

  • Page 1 PIONEERING SINCE 1903 REPAIR MANUAL2017 FS 450 ® Husqvarna Art. no. 3403050en MOTORCYCLES...
  • Page 3 Husqvarna accepts no liability for delivery options, deviations from figures and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 6.15 Disassembling the shock absorber MEANS OF REPRESENTATION ......7 cartridge ..........26 Symbols used ........7 6.16 Checking the fork legs ......28 1 .2 Formats used ........7 6.17 Assembling the shock absorber cartridge ..........29 SAFETY ADVICE ..........
  • Page 5 TABLE OF CONTENTS 12.8 9.10 Installing the shock absorber ....60 Installing the fuel tank ....... 103 9.11 Checking the shock absorber 12.9 Checking the fuel pressure ....105 linkage ..........62 12.10 Changing the fuel pump ....106 9.12 Servicing the shock absorber .....
  • Page 6 TABLE OF CONTENTS 15.9 Checking the capacitor ..... 141 17.3.22 Removing the torque limiter ..183 15.10 Checking the starter relay ....142 17.3.23 Removing the starter idler gear ..183 17.3.24 Removing the force pump .... 183 BRAKE SYSTEM ........... 144 17.3.25 Removing the shift shaft ....
  • Page 7 TABLE OF CONTENTS 17.4.20 Measuring the piston/cylinder 17 .5.12 Installing the force pump ....227 mounting clearance ...... 201 17 .5.13 Installing the starter idler gear ..228 17.4.21 Checking the oil pumps ....202 17 .5.14 Installing the torque limiter ... 229 17.4.22 Disassembling the 17 .5.15...
  • Page 8 TABLE OF CONTENTS IGNITION SYSTEM ........259 29.3 Page 3 of 3 ........288 21.1 SUBSTANCES ..........290 Ignition coil - checking the secondary winding ......259 AUXILIARY SUBSTANCES ......292 21.2 Checking the spark plug connector .......... 259 SPECIAL TOOLS ........... 294 21.3 Changing the spark plug ....

  • Page 9: Means Of Representation 1

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

  • Page 10: Safety Advice

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

  • Page 11: Important Notes 3

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

  • Page 12: Serial Numbers

    4 SERIAL NUMBERS Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 401945-10 e label The type label is fixed to the front of the steering head. 401946-10 En ine number The engine number is stamped on the left side of the engine.

  • Page 13: Shock Absorber Article Number

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

  • Page 14: Motorcycle

    5 MOTORCYCLE Raising the motorcycle with a lift stand Note The parked vehicle can roll away or fall over. Danger of damage Park the vehicle on a firm and level surface. Raise the motorcycle at the frame underneath the engine. I Lift stand (80329955100) p.

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

    MOTORCYCLE 5 Remove plug-in stand Shift the transmission to neutral position. 402001-10 Condition Ambient temperature: < 20 °C (< 68 °F) Push the cold start button in all the way. Press the electric starter button 0. Info Press the electric starter button for a maximum of 5 seconds.

  • Page 16: Fork, Triple Clamp

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

  • Page 17: Adjusting The Fork Air Pressure

    Info This is due to the volume of the hose and not due to a defect in the fork airpump or the fork. Read the accompanying instructions for Husqvarna Motorcycles accessories. Adjust the air pressure as specified. Guideline Air pressure 11.0 bar (160 psi)

  • Page 18: Adjusting The Compression Damping Of The Fork

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

  • Page 19: Bleeding The Fork Legs

    FORK, TRIPLE CLAMP 6 Guideline Rebound damping Comfort 15 clicks Standard 12 clicks Sport 9 clicks • Info Turn clockwise to increase damping; turn counter­ clockwise to reduce damping. Mount protection cap Bleeding the fork le s Preparatory work Raise the motorcycle with a lift stand. p.

  • Page 20: Removing The Fork Legs

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

  • Page 21: Installing The Fork Legs

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

  • Page 22: Installing The Fork Protector

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

  • Page 23: Disassembling The Fork Legs

    FORK, TRIPLE CLAMP 6 6.13 Disassembling the fork legs Caution Disassembling pressurized parts can cause injuries. Danger of accidents The fork is filled with compressed air. Please follow the description provided. Condition The fork legs have been removed. • Left fork leg Clamp the fork leg in the area of the lower triple clamp .
  • Page 24 6 FORK, TRIPLE CLAMP Remove dust boot Remove lock ring • Info The lock ring has a beveled end where a screw­ driver can be applied. Warm up the outside fork tube in area of the lower slide bearing. Guideline (122 °F) Pull the outside fork tube off the inside fork tube with a jerk.
  • Page 25 FORK, TRIPLE CLAMP 6 Right fork leg Remove protection cap Make a note of the present state of rebound compression damping@. Open the adjusters of the rebound and compression damping completely. Clamp the fork leg in the area of the lower triple clamp. I Clamping stand (T1403S) (ll!:!I p.
  • Page 26 6 FORK, TRIPLE CLAMP Clamp the fork leg with the axle clamp. Guideline Use soft jaws. Remove rebound adjuster Remove the cartridge. 803536-10 Remove dust boot (D. Remove lock ring@. Info The lock ring has a beveled end where a screw­ driver can be applied.

  • Page 27: Disassembling The Air Cartridge

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

  • Page 28: Disassembling The Shock Absorber Cartridge

    6 FORK, TRIPLE CLAMP Remove the piston rod with the seal ring retainer. B03553-10 Degrease and clamp the top of the piston rod. I Clamping stand (T14016S) p. 310) Heat up the thread area of the piston. Guideline I 50 °C (122 °F) Remove piston (D.
  • Page 29 FORK, TRIPLE CLAMP 6 Drain the shock absorber cartridge. Turn the shock absorber cartridge, degrease and clamp at the bottom. Clamping stand (T14072) p. 311) Remove lock ring Remove fluid barrier Heat up thread area of shock absorber cartridge f). Guideline (122 °F) Loosen seal ring retainer 0).

  • Page 30: Checking The Fork Legs

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

  • Page 31: Assembling The Shock Absorber Cartridge

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

  • Page 33: Assembling The Air Cartridge

    FORK, TRIPLE CLAMP 6 Position fluid barrier Mount lock ring Gi). Turn the shock absorber cartridge around and clamp at top. Clamping stand (T14016S) p. 310) Fill with fork oil. Oil capacity, right 380 ml Fork oil (SAE 4) cartridge (12.85 fl.
  • Page 34 6 FORK, TRIPLE CLAMP Push spring guide and spring guide @t onto spring (D. Mount the spring. ✓ The narrow spring guide is located at the top. ✓ The wide spring guide is located at the bottom. Slot end stop @ onto the piston rod. ✓...

  • Page 35: Assembling The Fork Legs

    FORK, TRIPLE CLAMP 6 48 . Mount and tighten valve core Fill the cartridge with air . Guideline Minimum air pressure 7 bar (1 02 psi) Maximum air pressure 15 bar (218 psi) Adjust air pressure with special tool 41) as per specifications. Guideline Air pressure 111.0 bar (160 psi)
  • Page 36 6 FORK, TRIPLE CLAMP Info Without using a tool, pull the stack slightly apart by hand. Warm up the outside fork tube in area of the lower slide bearings. Guideline (122 °F) Hold the lower slide bearing with the longer side of the special tool.
  • Page 37 FORK, TRIPLE CLAMP 6 Assemble the individual components that belong together. • Info Air cartridge (left fork leg): cartridge with blue adapter (9, axle clamp with brake mount and outside fork tube with warning label screw cartridge@. T02861-10 Slide the air cartridge into the inside fork tube. 803524-10 Lubricate O-ring I Lubricant (T1 58)
  • Page 38 6 FORK, TRIPLE CLAMP Tighten air cartridge Guideline M51x1 .5 50 Nm (36.9 lbf ft) Damper cartridge on outer tube Ring wrench (T14017) (ral p. 310) Right fork leg Clamp the inside fork tube using the axle clamp. Guideline Use soft jaws. Mount the special tool.
  • Page 39 FORK, TRIPLE CLAMP 6 Warm up the outside fork tube in area of the lower slide bearings. Guideline (122 °F) Hold the lower slide bearing with the longer side of the special tool. I Mounting tool (T14040S) (ll!:!l p. 311) Slide on the outside fork tube.
  • Page 40 6 FORK, TRIPLE CLAMP Slide the shock absorber cartridge into the inside fork tube. B03536-10 Lubricate O-ring @ on the rebound adjuster. Lubricant (T158) p. 292) Mount and tighten the rebound adjuster. Guideline Rebound adjuster M20x1 45 Nm (33.2 lbf ft) on the axle clamp Clamp the left fork leg vertically.

  • Page 41: Lubricating The Steering Head Bearing

    FORK, TRIPLE CLAMP 6 Condition Value not determined on removal: � Turn compression adjusting screw � and rebound adjusting screw clockwise all the way. Turn counterclockwise by the number of clicks corre­ sponding to the fork type. Guideline Compression damping Comfort 15 clicks Standard...

  • Page 42: Installing The Lower Triple Clamp

    6 FORK, TRIPLE CLAMP Main work Remove indicator lamp holder. Open cable holder on the left and detach the wiring har- ness. Remove screw Remove screw Take off the upper triple clamp with the handlebar and place to one side. Info Cover the components to protect them against dam­...
  • Page 43 FORK, TRIPLE CLAMP 6 Position the upper triple clamp with the handlebar. Mount screw but do not tighten yet. Guideline Screw, top steering M20x1 .5 12 Nm (8.9 lbf ft) head Position the fork legs. ✓ Air bleeder screw of the right fork leg is positioned to the front.

  • Page 44: Checking Steering Head Bearing Play

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

  • Page 45: Changing The Steering Head Bearing

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

  • Page 46: Adjusting Steering Head Bearing Play

    6 FORK, TRIPLE CLAMP Remove upper bearing ring with special tool Tool bracket (58429089000) (i!!ll p. 297) Pressing tool (58429092000) p. 298) Press the new bearing ring up to the stop with special tool@). Tool bracket (58429089000) (i!!ll p. 297) Pressing tool (58429091000) (i!!ll p.
  • Page 47 FORK, TRIPLE CLAMP 6 Main work Loosen screws Remove screw Loosen and retighten screw Guideline Screw, top steering M20x1 .5 12 Nm (8.9 lbf ft) head Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses. Mount and tighten screw @.

  • Page 48: 7 Handlebar,Controls

    7 HANDLEBAR,CONTROLS Handlebar �osition On the upper triple clamp, there are 2 holes at a distance of to each other. I Hole distance A 15 mm (0.59 in) The holes on the handlebar supports are placed at a distance of G) from the center. Hole distance B 3.5 mm (0.138 in) The handlebar can be mounted in four different positions.

  • Page 49: Clutch Lever

    HANDLEBAR,CONTROLS 7 Tighten screws evenly. Guideline 20 Nm (14.8 lbf ft) Screw, handlebar clamp Finishing work Mount the handlebar cushion. 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.

  • Page 50: Checking Throttle Cable Routing

    7 HANDLEBAR,CONTROLS Checking throttle cable routing Preparatory work Remove the right side cover. p. 100) Remove the air filter box cover. p. 96) Remove the seat. p. 100) Remove the fuel tank. p. 102) Main work Check throttle cable routing. Both throttle cables must be routed, side by side, on the back of the handlebars and above the fuel tank bracket, to the throttle valve body.

  • Page 51: Adjusting Throttle Cable Play

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

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

    7 HANDLEBAR,CONTROLS Finishing work Check throttle cable play. p. 48) 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. A guide plate with a different characteristic map is supplied. Main work Push back sleeve Remove screws...
  • Page 53 HANDLEBAR,CONTROLS 7 Position half-shells 6), 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 throttle cable play. p. 48)

  • Page 54: Frame

    Change the frame. Info Always replace a frame that has been damaged due to a mechanical impact. Repair of the frame is not authorized by Husqvarna F00435-01 Motorcycles. Changing the footrests Info The procedures are the same on both footrests.
  • Page 55 FRAME 8 Position spring as shown. (!). ✓ Spring G) engages in area ✓ Press the spring with special tool Footrest spring plier (79029083000) (ll!:!I p. 304) ✓ The special tool is applied to area on the footrest. Mount pin Mount the washer and splint D02603-10...

  • Page 56: Shock Absorber, Link Fork

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

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

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

  • Page 58: Measuring The Rear Wheel Dimension Unloaded

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

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

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

  • Page 60: Adjusting The Riding Sag

    9 SHOCK ABSORBER, LINK FORK Main work Loosen screw Turn adjusting ring @ until the spring is no longer under ten- sion. I Hook wrench (90129051000) (iell p. 307) Measure the overall spring length while the spring is not under tension. Tighten the spring by turning adjusting ring to specified measurement...

  • Page 61: Removing The Shock Absorber

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

  • Page 62: Installing The Shock Absorber

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

  • Page 64: Checking The Shock Absorber Linkage

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

  • Page 66: Servicing The Shock Absorber

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

  • Page 67: Removing The Spring

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

  • Page 68: Disassembling The Damper

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

  • Page 69: Disassembling The Piston Rod

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

  • Page 70: Disassembling The Seal Ring Retainer

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

  • Page 71: Changing The Pilot Bushing

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

  • Page 72: Checking The Damper

    9 SHOCK ABSORBER, LINK FORK Slide the new pilot bushing onto the special tool. I Pressing tool (T1504) p. 312) Position the pilot bushing in the seal ring retainer using the special tool. I Pressing tool (T1504) (!Sl p. 312) Support seal ring retainer with sleeve of the special...

  • Page 73: Removing The Heim Joint

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

  • Page 74: Installing The Heim Joint

    9 SHOCK ABSORBER, LINK FORK Place special tool underneath and press out heim joint using special tool I Pressing tool (T1207S) (IOI p. 309) B04391-10 Position new heim joint and the special tool in the bench vise. Guideline I Use soft jaws. I Pressing tool (T1206) (IOI p.

  • Page 75: Assembling The Seal Ring Retainer

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

  • Page 77: Assembling The Damper

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

  • Page 79: Bleeding And Filling The Damper

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

  • Page 82: Filling Damper With Nitrogen

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

  • Page 83: Installing The Spring

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

  • Page 84: Checking The Link Fork

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

  • Page 85: Removing The Link Fork

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

  • Page 86: Installing The Link Fork

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

  • Page 88: Changing The Fork Bearing

    9 SHOCK ABSORBER, LINK FORK Position the brake line in the guide. Finishing work Install the air filter box cover. p. 96) Install the rear wheel. p. 125) Remove the motorcycle from the lift stand. p. 12) 9.31 Changing the fork bearing Preparatory work Raise the motorcycle with a lift stand.
  • Page 89 SHOCK ABSORBER, LINK FORK 9 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 the stop disks Press in shaft seal rings (D. Mount bushing@.
  • Page 90 9 SHOCK ABSORBER, LINK FORK 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 Press in shaft seal rings Mount bushing @. R02761-10 Grease the shaft seal rings.

  • Page 91: Checking The Heim Joint For Play

    SHOCK ABSORBER, LINK FORK 9 9.32 Checking the heim joint for Ria� Preparatory work Raise the motorcycle with a lift stand. (ra:!l p. 12) Place a load on the front of the vehicle. ✓ The rear wheel is not in contact with the ground. Main work Move the link fork up and down.
  • Page 92 9 SHOCK ABSORBER, LINK FORK Place special tool underneath and press out heim joint using special tool I Pressing tool (T1207S) (IOI p. 309) B04391-10 Position the new heim joint and the special tool. Guideline I Use soft jaws. I Pressing tool (T1206) p.

  • Page 93: Exhaust System

    EXHAUST SYSTEM Removing the manifold 10.1 Preparatory work Raise the motorcycle with a lift stand. (ra:!l p. 12) Remove the right side cover. p. 100) Remove the main silencer. p. 93) Main work Remove screw Remove fitting Info Raise the link fork slightly to be able to remove the screws more easily.

  • Page 94: Installing The Manifold

    10 EXHAUST SYSTEM Lift the link fork. 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) shock absorber...

  • Page 95: Removing The Main Silencer

    EXHAUST SYSTEM Guideline Remaining screws, 25 Nm (18.4 lbf ft) chassis Lower the link fork. Position the angle lever and linkage lever. Mount and tighten fitting Guideline Nut, linkage lever to M14x1 .5 80 Nm (59 lbf ft) angle lever •...

  • Page 96: Installing The Main Silencer

    10 EXHAUST SYSTEM Main work Detach spring I Spring hook (5030501700004) (ll!:!l p. 307) Remove screws with the washers and take off the main silencer. 10.4 Main work Mount main silencer. Mount screws with the washers, but do not tighten yet. Attach spring I Spring hook (5030501700004) p.
  • Page 97 EXHAUST SYSTEM Main work Remove all the screws on the main silencer. Take off silencer cap Take off outer tube (!}. Remove glass fiber yarn filling from the inner tube with connecting cape. Clean the parts that need to be reinstalled and check for damage.

  • Page 98: 11 Air Filter

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

  • Page 99: Installing The Air Filter

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

  • Page 100: Sealing The Air Filter Box

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

  • Page 101: Fuel Tank, Seat, Trim

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

  • Page 102: Removing The Right Side Cover

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

  • Page 103: Mounting The Seat

    FUEL TANK, SEAT, TRIM Main work Remove screw Pull seat back and lift it off. 12.6 Mountin 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 104: Removing The Fuel Tank

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

  • Page 105: Installing The Fuel Tank

    FUEL TANK, SEAT, TRIM Remove screws Remove screw with the rubber bushing. Pull both spoilers laterally off the radiator and take off the fuel tank upwards. 12.8 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
  • Page 106 12 FUEL TANK, SEAT, TRIM Main work Check throttle cable routing. p. 48) Position the fuel tank and fit the two spoilers laterally to the radiator. Make sure that no cables or throttle cables are trapped or damaged. Attach the fuel tank breather hose to the fuel tank lid. Mount and tighten screw with the rubber bushing.

  • Page 107: Checking The Fuel Pressure

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

  • Page 108: Changing The Fuel Pump

    12 FUEL TANK, SEAT, TRIM Guideline Maximum duration of the 3 min actuator test Check the fuel pressure with the fuel tank filler cap closed. Fuel pressure When the fuel pump is 3.3 ... 3. 7 bar (48 ... 54 psi) active If the specification is not reached: Open fuel tank filler cap.
  • Page 109 FUEL TANK, SEAT, TRIM Note Environmental hazard Improper handling of fuel is a danger to the environment. Do not allow fuel to enter the groundwater, the soil, or the sewage system. Preparatory work Drain the fuel from the fuel tank into a suitable container. Remove the right side cover.
  • Page 110 12 FUEL TANK, SEAT, TRIM Position the new fuel pump. Mount nut with gasket, but do not tighten yet. Pull out the fuel pump. ✓ The fuel filter remains in the fuel tank. • Info Make sure that the fuel filter is not pulled out too far. Keep the fuel pump with hose tensioned, turn clockwise and position.

  • Page 111: Changing The Fuel Filter

    FUEL TANK, SEAT, TRIM Install the air filter box cover. p. 96) Install the right side cover. p. 100) 12.11 Changing the fuel filter Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
  • Page 112 12 FUEL TANK, SEAT, TRIM Remove screws R00449-10 Remove the fuel pump. Remove hose clamps Remove fuel filter Ci). R00450-11 Press locking mechanism Q). Pull back fuel pump housing 305317-10 Change fuel screen Mount the fuel pump housing.
  • Page 113 FUEL TANK, SEAT, TRIM Mount the new fuel filter ✓ Arrow points away from the fuel pump. Mount hose clamps Hose clamp plier (60029057000) (� p. 300) R00451-10 Position the fuel pump. Mount nut with gasket, but do not tighten yet. Pull out the fuel pump.

  • Page 114: Changing The Fuel Screen

    12 FUEL TANK, SEAT, TRIM Mount fuel connection with the gasket but do not tighten yet. Tighten nut Guideline Nut, fuel pump fas­ M12x1.75 15 Nm (11 .1 lbf ft) tener Tighten fuel connection Guideline Fuel connection on M8x1 .25 10 Nm (7.4 lbf ft) fuel tank Finishing work...
  • 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 and fj. 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

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

  • Page 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 pressure of the tires all have a major impact on the handling characteristic of the motorcycle.

  • 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: Checking The Rim Run-Out

    WHEELS 14 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 kit (58429094000) (� p. 298) Checking the rim run-out Warning Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary damage.

  • Page 122: Front Wheel

    14 WHEELS Front wheel 14.7 14.7.1 Removing the front wheel Preparatory work Raise the motorcycle with a lift stand. p. 12) Main work Remove screws with washers Press back the brake linings by slightly tilting the brake caliper laterally on the brake disc. Pull the brake caliper carefully back from the brake disc and hang to the side loosely.

  • Page 123: Installing The Front Wheel

    WHEELS 14 14.7.2 Installing the front wheel Warning Oil or grease on the brake discs reduces the braking effect. Danger of accidents Always keep the brake discs free of oil and grease. Clean the brake discs with brake cleaner when necessary. Check the wheel bearing for damage and wear.

  • Page 124: Changing The Front Brake Disc

    14 WHEELS Remove the motorcycle from the lift stand. p. 12) Operate the front brake and compress the fork a few times firmly. ✓ The fork legs straighten. Tighten screws Guideline I Screw, fork stub Nm (11.1 lbf ft) Changing the front brake disc 14.7.3 Info If the brake discs are changed, the brake linings must also be changed.
  • Page 125 WHEELS 14 Press out bearing using a suitable tool. • Info Spacing tube can be pushed aside. Remove the spacing tube. Press out bearing using a suitable tool. Press in new bearing all the way using a suitable tool. Info Only press the bearing in via the outer bearing race otherwise the bearing will be damaged when it is pressed in.

  • Page 126: Rear Wheel

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

  • Page 127: Installing The Rear Wheel

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

  • Page 128: Changing The Rear Brake Disc

    14 WHEELS 14.8.3 Changing the rear brake disc Info If the brake discs are changed, the brake linings must also be changed. Preparatory work Raise the motorcycle with a lift stand. p. 12) Remove the rear wheel. p. 124) Main work Remove screws Remove the brake disc.

  • Page 129: Adjusting The Chain Tension

    WHEELS 14 14.8.5 Adjusting the chain tension Warning Incorrect chain tension damages components and results in accidents. Danger of accidents If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.
  • Page 130 14 WHEELS Main work Shift the transmission to neutral position. Check the chain, rear sprocket and engine sprocket for wear. If the chain, rear sprocket or engine sprocket is worn: Change the drivetrain kit.(� p. 131) Info The engine sprocket, rear sprocket and chain should always be replaced together.
  • Page 131 WHEELS 14 Check the chain sliding guard for wear. If the lower edge of the chain pins is in line with, or below, the chain sliding guard: Change the chain sliding guard. Check that the chain sliding guard is firmly seated. If the chain sliding guard is loose: Tighten the screws on the chain sliding guard.

  • Page 132: Checking For Chain Dirt Accumulation

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

  • Page 133: Changing The Drivetrain Kit

    WHEELS 14 Main work Rinse off loose dirt with a soft jet of water. Remove old grease residue with chain cleaner. Chain cleaner (!el p. 292) After drying, apply chain spray. Off-road chain spray (!el p. 293) 400725-01 Finishing work Remove the motorcycle from the lift stand.
  • Page 134 14 WHEELS Remove engine sprocket Remove fittings 0). Take off the rear sprocket. Position the new rear sprocket. Mount and tighten the fit­ tings. Guideline Nut, rear 35 Nm (25.8 lbf ft) ® Loctite 2701 sprocket screw Slide new engine sprocket onto the countershaft.

  • Page 135: Changing The Rear Wheel Bearing

    WHEELS 14 Position the engine sprocket cover. Mount and tighten screw with the washer. Guideline Screw, clutch slave 10 Nm (7.4 lbf ft) cylinder Mount and tighten screw @. Guideline Remaining screws, 25 Nm (18.4 lbf ft) chassis Finishing work Remove the motorcycle from the lift stand.
  • Page 136 14 WHEELS Using a suitable tool, press bearing out from the inside to the outside. Check spacer washer @ for damage and wear. If the spacer washer is damaged or worn: Replace the spacer washer. Position spacer washer @. Press new bearing all the way in from the outside to the inside.

  • Page 137: Wiring Harness, Battery 15

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

  • Page 138: Of The 12 V Battery

    15 WIRING HARNESS, BATTERY 15.2 Disconnecting the negative cable of the 12 V batterY Preparatory work Press and hold the kill switch � while the engine is idling until the engine stops. Remove the air filter box cover. p. 96) Remove the seat.

  • Page 139: Removing The 12 V Battery

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

  • Page 140: Installing The 12 V Battery

    15 WIRING HARNESS, BATTERY Installing the 12 V batte� Main work Position the 12 V battery in the battery compartment with the terminals facing forward, and secure with holding bracket 112 V battery (C22S) p. 274) Mount and tighten screw Guideline Screw, battery sup­...

  • Page 141: Charging The 12 V Battery

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

  • Page 142: Checking The Charging Voltage

    15 WIRING HARNESS, BATTERY Alternative 2 UK battery charger XCharge-professional (00029095052) p. 295) Alternative 3 CH battery charger XCharge-professional (00029095053) p. 295) • Info Follow the instructions of the charger and the manual. Disconnect the battery charger after charging the 12 V bat­ tery.

  • Page 143: Checking The Open-Circuit Current

    WIRING HARNESS, BATTERY 15 Install the air filter box cover. p. 96) 15.8 Checking the open-circuit current Preparatory work Press and hold the kill switch � while the engine is idling until the engine stops. Remove the air filter box cover. p.

  • Page 144: Checking The Starter Relay

    15 WIRING HARNESS, BATTERY Discharge the capacitor with a 12 V test lamp, as shown in the figure. Info As the capacitor charge decreases, the test lamp becomes dimmer. » The bulb lights up for: 0.5 ... 2.0 s The capacitor is OK. »...
  • Page 145 WIRING HARNESS, BATTERY 15 Connect cables to the starter relay. Plug in connector Mount the starter relay onto the holder and route the cables. Finishing work Connect the negative cable of the 12 V battery. p. 136) Mount the seat. p.

  • Page 146: 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 147 BRAKE SYSTEM 16 Remove screws with washers Press back the brake linings by slightly tilting the brake caliper laterally on the brake disc. Pull the brake caliper carefully back from the brake disc and hang to the side. Info Do not operate the hand brake lever if the brake caliper has been removed.

  • Page 148: Adjusting The Basic Position Of The

    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 149: Checking The Front Brake Fluid Level

    BRAKE SYSTEM 16 Checking the front brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail. If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.

  • Page 150: Changing The Front Brake Fluid

    16 BRAKE SYSTEM Note 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 151 BRAKE SYSTEM 16 Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container.

  • Page 152: Checking The Brake Linings Of The Rear Brake

    16 BRAKE SYSTEM • Info Overfilling the brake fluid reservoir is prevented. Tighten the bleeder screw. Remove the bleeder bottle hose. Attach the protection cap. Disconnect the bleeding device. Remove the bleeder cover. Fill brake fluid up to the MAX marking. I Brake fluid DOT 4 / DOT 5.1 (ll!:!I p.
  • Page 153 BRAKE SYSTEM 16 Warning Brake fluid causes skin irritation. Skin irritation Keep brake fluid out of the reach of children. Wear suitable protective clothing and safety glasses. Do not allow brake fluid to come into contact with the skin, the eyes or clothing. Consult a doctor immediately if brake fluid has been swallowed.

  • Page 154: Checking The Free Travel Of Foot

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

  • Page 155: Adjusting The Basic Position Of The Foot Brake Lever

    BRAKE SYSTEM 16 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 156: Adding Rear Brake Fluid

    16 BRAKE SYSTEM Preparatory work Check the brake linings of the rear brake. p. 150) 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. p.

  • Page 157: Changing The Rear Brake Fluid

    BRAKE SYSTEM 16 Main work Stand the vehicle upright. Remove screw cap with membrane f!} and the O-ring. Add brake fluid to level f). Brake fluid DOT 4 / DOT 5.1 p. 290) Mount and tighten the screw cap with the membrane and O­ ring.
  • Page 158 16 BRAKE SYSTEM Mount bleeder cover I Bleeder cover (00029013006) p. 294) Connect the bleeding device. I Bleeding device (00029013100) p. 294) Open shut-off valve • Info Follow the instructions in the Owner's Manual of the bleeding device. Ensure that the inflation pressure is set on pressure gauge Correct the inflation pressure on pressure regulator G) if necessary.
  • Page 159 BRAKE SYSTEM 16 Check the foot brake lever for a firm pressure point.

  • Page 160: 17 Engine

    17 ENGINE 17.1 Removing the engine Preparatory work Raise the motorcycle with a lift stand. p. 12) Drain the coolant. p. 250) Remove the right side cover. p. 100) Remove the air filter box cover. p. 96) Remove the seat. p.
  • Page 161 ENGINE 17 @» 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 the subframe up and secure it. Remove screw Pivot the shock absorber toward the rear and twist it slightly.
  • Page 162 17 ENGINE Remove springs 41). I Spring hook (5030501700004) p. 307) Remove screw with the washer. Remove screws Take off the engine braces. Take off the manifold. Disconnect plug-in connector 41). Disconnect plug-in connectors...
  • Page 163 ENGINE 17 Disconnect plug-in connector Remove the cable tie. Remove the cable clamps and expose the cable. Push back protection cap (0. Unplug the connector. Loosen hose clip Pull off the radiator hose. Loosen hose clips G). Pull off the radiator hoses.
  • Page 164 17 ENGINE Pull capacitor off of the holder and hang to one side. @'!). Disconnect 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 165 ENGINE 17 Remove connecting link � of the chain. Take off the chain. Info Cover the components to protect them against dam­ age. Remove screw ... Take off the engine sprocket. Remove screw Ci) with the washers. Take off the shift lever. Loosen hose clip �.
  • Page 166 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 link fork back, and secure it.

  • Page 167: Installing The Engine

    ENGINE 17 Remove screws Lift out the engine sideways. • Info The help of an assistant is useful in this step. Make sure that the engine is sufficiently secured against falling over. Cover the components to protect them against dam­ age.
  • Page 168 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 169 ENGINE 17 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 170 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 10 Nm (7.4 lbf ft) Screw, clutch slave cylinder Mount and tighten screw 41).
  • Page 171 ENGINE 17 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. Join plug-in connector @!) of the gear position sensor. Join plug-in connector @D of the crankshaft speed sensor.
  • Page 172 17 ENGINE Position the manifold. Position the engine braces. Mount and tighten screws Guideline Screw, engine 25 Nm (18.4 lbf ft) ® brace Loctite 2701 Tighten screws Guideline Engine carrying 60 Nm (44.3 lbf ft) screw Mount screw with the washer but do not tighten yet. Guideline Remaining screws, 25 Nm (18.4 lbf ft)
  • Page 173 ENGINE 17 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 174 17 ENGINE Position and tighten hose clip Connect negative cable G). Guideline Screw, battery termi- 2.5 Nm (1.84 lbf ft) • Info The contact disk must be mounted under the screw and the cable lug @ with the claws facing down.

  • Page 175: Engine Disassembly

    Refill the coolant. p. 250) Perform the initialization run. p. 268) 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. (�...

  • Page 176: 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 177: Removing The Starter Motor

    ENGINE 17 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. 303) 17.3.7 Removing the valve cover Remove screws Take off the valve cover with the valve cover seal.

  • Page 178: Positioning The Engine At Ignition Top Dead Center

    17 ENGINE Take off alternator cover gasket 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) p. 295) 17.3.10 Removing the timing chain tensioner Remove screw...

  • Page 179: Removing The Camshaft

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

  • Page 180: 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 181: Removing The Timing Chain

    ENGINE 17 Mount special tool on the rotor. Extractor (79229032044) p. 304) 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 182: 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 183: Removing The Clutch Cover

    ENGINE 17 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 fs). 17 .3.20 Removing the clutch discs Clamp the antihopping clutch with special tool...

  • Page 184: Removing The Clutch Basket

    17 ENGINE Hold the clutch basket using special tool and remove nut @ with the lock washer. I Gear segment (80029004000) p. 306) Remove clutch disc pack entirely. 17.3.21 Removing the clutch basket Take off washer Info The washer usually sticks to the inner clutch hub. Lock the clutch basket and primary gear wheel using special tool I Gear segment (80029004000)

  • Page 185: Removing The Torque Limiter

    ENGINE 17 0) . Take off both needle bearings and collar bushing 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...

  • Page 186: Removing The Shift Shaft

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

  • Page 187: Removing The Shift Drum Locating Unit

    ENGINE 17 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 188: 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) (ral p. 304) • 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 189: Removing The Shift Rails

    ENGINE 17 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 190: 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 191 ENGINE 17 Main work Remove all remaining dowels. Remove oil nozzle Remove screws and take off the bearing retainers. Remove the bearing retainer from main shaft bearing countershaft bearing and shift drum bearing Remove any remnants of sealing compound and clean the section of the engine case thoroughly.

  • Page 192: Working On The Left Section Of The Engine Case

    17 ENGINE Guideline Oil nozzle, pis­ 2 Nm (1.5 lbf ft) ton cooling ® Loctite ™ Blow compressed air through all oil channels and check that they are clear. 401797-01 Finishing work Install the oil pressure control valve. p. 192) 17.4.2 Working on the left section of the engine case Remove all remaining dowels.

  • Page 193: Oil Pressure Control Valve, Removing

    ENGINE 17 Info When pressing the bearing in, ensure that the engine case section is level to prevent damage. Only press the bearings in via the outer bearing race; otherwise, the bearings will be damaged when they are pressed in. After the engine case section has cooled, check that the bearings are firmly seated.

  • Page 194: Spring Length Of The Oil Pressure Control Valve, Checking

    17 ENGINE 17.4.4 spring length of the oil pressure control valve, checking Preparatory work Remove the oil pressure control valve. p. 191) Main work Measure the spring length of the oil pressure control valve. Oil pressure control valve Minimum length of pres- 22.1 mm (0.87 in) sure spring If the measured value does not meet specifications:...

  • Page 195: Installing The Water Pump

    ENGINE 17 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 196: Removing The Timing Chain

    17 ENGINE Mount special tool on the water pump shaft. I Protection cap (90129005000) p. 307) Mount balancer shaft • Info Be careful not to damage the shaft seal rings. Remove the special tool. I Protection cap (90129005000) p. 307) Mount water pump impeller Mount and tighten nut (D.

  • Page 197: Removing The Crankshaft Bearing Inner Race

    ENGINE 17 Warm up new timing chain sprocket and immediately push it onto the crankshaft. Guideline 1180 °c (356 °F) 17.4.11 Removing the crankshaft bearing inner race Fix the crankshaft in the vise. Guideline Use soft jaws. Warm up special tool Guideline 1150 °c (302 °F) Puller (58429037043)

  • Page 198: Changing The Connecting Rod, Conrod Bearing, And Crank Pin

    17 ENGINE Info After replacing the crankshaft bearings, the crankshaft end play must be measured. Finishing work Measure the crankshaft end play. p. 198) 17.4.13 Changing the connecting rod, conrod bearing, and crank pin Main work Position the crankshaft with special tool in the press.
  • Page 199 ENGINE 17 Mount new connecting rod (D. Info Thoroughly lubricate the bearing. 310044-10 Position special tools @ and on the press. Crankshaft pressing tool (75029047000) p. 301) Insert for crankshaft pressing tool (79429008000) p. 305) Insert the crankweb with the connecting rod and bearing. Position the second crankweb.

  • Page 200: Checking Crankshaft Run-Out At Bearing Pin

    17 ENGINE 17.4.14 Checking crankshaft run-out at bearing pin Position the crankshaft on a roller block. Turn the crankshaft slowly. Check the crankshaft run-out on both bearing pins. Crankshaft - run-out on � 0.03 mm (� 0.0012 in) bearing pin If the crankshaft run-out at the bearing pin is larger than the specification: Align the crankshaft.

  • Page 201: Cylinder - Nikasil ® - Coating

    ENGINE 17 17.4.16 Cylinder - Nikasil ® - coating ® Nikasil is a surface protection layer for a coating procedure developed by Mahle. The name is derived from the two materials used in this procedure - a layer of nickel into which is embedded the particularly hard silicone carbide.

  • Page 202: Checking/Measuring The Piston

    17 ENGINE 17.4.18 Checking/measuring the piston Use the special tool to measure clearance of the piston rings in the piston ring groove. e -' ­ Guideline Piston ring - groove clear­ :S 0.08 mm (:S 0.0031 in) ance I Feeler gauge (59029041100) (IUI p.

  • Page 203: Checking The Piston Ring End Gap

    ENGINE 17 Measure the piston at the piston skirt, at right angles to the piston pin, at a distance f) . Guideline Distance f) 7 mm (0.28 in) Piston - diameter Size I 94.93 ... 94.96 mm (3.7374 ... 3.7386 in) Size II 94.94 ...

  • Page 204: 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) 17.4.21 Checking the oil pumps Info The following steps apply to both oil pumps. Use special tool to measure the play between the exter­...

  • Page 205: 17 .4.23 Assembling The Autodecompressor

    ENGINE 17 Pull autodecompression shaft 4!} out of the camshaft. 304674-10 ·� Release and remove autodecompression spring fi). Info Autodecompression weight cannot be taken off. 304675-10 17 .4.23 Assembling the autodecompressor Insert long flange of the autodecompression spring in the hole, push the autodecompression spring over bearing bolt 4!} and hook it into autodecompression weight fi).

  • Page 206: Checking Camshaft

    17 ENGINE 17.4.24 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 207: Removing The Rocker Arm

    ENGINE 17 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 208: Changing The Camshaft Bearing

    17 ENGINE •• Mark the valves corresponding to their installation position. Info £'SI £ v -.ii • Place the valves in a box corresponding to their instal­ • lation position and label them. 200189-10 17.4.28 Changing the camshaft bearing Condition The valves are removed and the exhaust flange is removed.

  • Page 209: Checking The Valves

    ENGINE 17 Press the small camshaft bearing in until flush using special tool Pressing tool (75029044020) (IUI p. 301) Press the large camshaft bearing in all the way using special tool Pressing tool (75029044010) (IUI p. 301) 17 .4.29 Checking the valves Info The valve stem is hard-chrome plated;...

  • Page 210: Checking Valve Springs

    17 ENGINE 17.4.30 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 211: Checking The Rocker Arm Shafts

    ENGINE 17 Check the sealing area of the cylinder for distortion using a straight edge and the special tool. Feeler gauge (59029041100) p. 299) 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 212: Installing The Rocker Arm

    17 ENGINE Pretension the valve springs using the special tool. Valve spring mounter (59029019000) p. 298) Insert for valve spring lever (77029041200) p. 302) Mount the valve keys. Info When mounting the valve keys, check that they are seated correctly; preferably, fix the valve keys to the valve with a little grease.

  • Page 213: Disassembling The Antihopping Clutch

    ENGINE 17 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 M10x1 .25 Screw plug, rocker 10 Nm (7.4 lbf ft) arm shaft 17.4.36 Disassembling the antihopping clutch Clamp clutch into a vise.

  • Page 214: Preassembling The Antihopping Clutch

    17 ENGINE 17.4.37 Preassembling the antihopping clutch • Thoroughly oil the clutch facing discs. Mount the sleeves. ✓ Recess engages in edge G). •• '•11 '., . ·- . - � 306630-10 Beginning with an intermediate clutch disc, alternately position all other clutch facing discs and intermediate clutch discs.

  • Page 215: Checking The Clutch

    ENGINE 17 17 .4.38 Checking the clutch 306625-10 Check clutch throw-out for damage and wear. If there is damage or wear: Change the clutch push rod. Place the clutch push rod on a flat surface and check for run-out. If there is run-out: Change the clutch push rod.

  • Page 216: 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 � and collar bushing for damage and wear. If there is damage or wear: Change the needle bearing and collar bushing.

  • Page 217: Preassembling The Shift Shaft

    ENGINE 17 If the shift drum is not seated correctly: Change the shift drum and/or the bearing. Check bearing 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 218: Disassembling The Main Shaft

    17 ENGINE Mount stop disk (3. 17.4.41 Disassembling the main shaft 310083-10 Secure the main shaft in the vise with the gear teeth facing downward. Guideline 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 (3 and stop disk Remove fifth-gear idler gear (D.

  • Page 219: Disassembling The Countershaft

    ENGINE 17 17 .4.42 Disassembling the countershaft 310089-10 Secure the countershaft in the bench vise with the toothed end facing downward. Guideline I Use soft jaws. Remove stop disk and first-gear idler gear Remove needle bearing and stop disk Remove the fifth-gear sliding gear and lock ring (D.
  • Page 220 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 for damage and wear. If there is damage or wear: Change the main shaft and/or countershaft. Check the tooth profiles of main shaft and countershaft for damage and wear.

  • Page 221: 17.4.44 Assembling The Main Shaft

    ENGINE 17 Check stop disks @ for damage and wear. If there is damage or wear: Change the stop disks. Use new lock rings in every repair. Check distance sleeve� for damage and wear. If there is damage or wear: Change the distance sleeves.

  • Page 222: 17.4.45 Assembling The Countershaft

    17 ENGINE 17.4.45 Assembling the countershaft Info Use new lock rings with every repair. Preparatory work Lubricate all parts carefully before assembling. Check the transmission. p. 217) Main work 310090-10 Secure the countershaft in the bench vise with the toothed end facing downward. Guideline Use soft jaws.

  • Page 223: Checking The Starter Drive

    ENGINE 17 17.4.46 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. If there is damage or wear: Change the torque limiter.

  • Page 224: Checking The Freewheel

    17 ENGINE 17.4.47 Checking the freewheel Insert freewheel gear into primary gear wheel turning the primary gear wheel clockwise; do not wedge! Check the locking action of freewheel gear The primary gear wheel cannot be turned clockwise or does not lock counterclockwise: Change the freewheel.

  • Page 225: Engine Assembly

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

  • Page 226: 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 227: Installing The Shift Drum

    ENGINE 17 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 228: 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 229: Installing The Locking Lever

    ENGINE 17 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) ® lever Loctite ™ 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 230: Installing The Starter Idler Gear

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

  • Page 231: Installing The Torque Limiter

    ENGINE 17 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) ® Loctite ™ bolt, torque lim- iter 17 .5.15 Installing the clutch basket Mount collar bushing and both needle bearings@.

  • Page 232: Installing The Clutch Discs

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

  • Page 233: Installing The Clutch Cover

    ENGINE 17 17 .5.17 Installing the clutch cover Position the balancer shaft with special tool Locking screw (78129032000) (il!:!I p. 303) ✓ Marking and the special tool are aligned. Mount dowels and position the clutch cover gasket@). Mount the clutch cover. Mount screws but do not tighten yet.

  • Page 234: Installing The Water Pump Cover

    17 ENGINE 17.5.18 Installing the water pump cover Put the water pump cover seal in place. Mount the water pump cover. Mount screw with the sealing washer but do not tighten yet. Guideline M6x25 10 Nm (7.4 lbf ft) Screw, water pump cover Mount screw @} but do not tighten yet.

  • Page 235: Installing The Timing Chain

    ENGINE 17 Mount internal rotor and external rotor ✓ The rounded sides of the external rotor face the engine case. Position oil pump cover (D. Mount and tighten screws@. Guideline Screw, suction 6 Nm (4.4 lbf ft) ® Loctite ™ pump cover 17.5.21 Installing the timing chain...

  • Page 236: Installing The Rotor

    17 ENGINE 17.5.22 Installing the rotor Mount the woodruff key. Mount the rotor. Mount and tighten nut with the spring washer. Guideline Nut, rotor M12x1 60 Nm (44.3 lbf ft) Thread, oiled with engine oil/cone degreased 17.5.23 Installing the piston Move the joints of the compression ring and oil scraper ring so they are offset by 180 °...
  • Page 237 ENGINE 17 Mount timing chain guide rail from above. ✓ The holding lug engages in the recess (I. ✓ The timing chain guide rail engages in recess 6). Info This step is illustrated with the rotor removed for a clearer view. Mount cylinder base gasket Info Ensure that locating pins...

  • Page 238: Installing The Cylinder Head

    17 ENGINE Position the piston ring lock. Insert the special tool and press it with force towards the pis­ ton. Turn the special tool clockwise, thereby pushing the piston ring lock into the groove. I Insertion for piston ring lock (773290301 00) p.

  • Page 239: Installing The Camshaft

    ENGINE 17 Put the cylinder head in place. Mount screws with the washers and tighten them in a crisscross pattern. Guideline Screw, cylinder M10x1 .25 1st stage 10 Nm (7.4 lbf ft) head 2nd stage 30 Nm (22.1 lbf ft) 3rd stage 50 Nm (36.9 lbf ft) Collar and thread oiled...

  • Page 240: 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 241: 17.5.28 Adjusting The Valve Clearance

    ENGINE 17 Remove the special tool. Locking screw (113080802) p. 295) Mount and tighten screw @ with washer. Guideline Screw plug, locking 10 Nm (7.4 lbf ft) screw 17.5.28 Adjusting the valve clearance Main work Remove the timing chain tensioner. p.

  • Page 242: 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 Nm (7.4 lbf ft) Installing the spark plug 17.5.31 Mount and tighten the spark plug using the special tool. Guideline Spark plug M10x1...

  • Page 243: Installing The Clutch Push Rod

    ENGINE 17 Lubricate 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 and the O-ring.

  • Page 244: 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. I Holder and fitting for work stand (79429002000) (�...

  • Page 245: Clutch

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

  • Page 246: 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 247: Anti Hopping Clutch

    CLUTCH Now press the fluid into the system until it emerges from the 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 248: 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 antiho��ing clutch Note Environmental hazard Hazardous substances cause environmental damage. Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.
  • Page 249 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 250: 19 Water Pump, Cooling System

    19 WATER PUMP, COOLING SYSTEM Cooling s�stem 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 251: Checking The Coolant Level

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

  • Page 252: 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 253 WATER PUMP, COOLING SYSTEM 19 Make sure that screw is tightened. Position the motorcycle upright. Pour coolant in up to measurement above the radiator fins. Guideline 10 mm (0.39 in) Dimension over the radi- ator fins Coolant 1.20 I Coolant p.

  • Page 254: Lubrication System

    LUBRICATION SYSTEM 20.1 Oil circuit 401628-60 Oil screen Force pump Oil pressure control valve Oil filter Oil nozzle for conrod bearing lubrication Oil nozzles for 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 255: 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 and the upper edge of the level viewer If the engine oil does not reach the middle of level viewer Add engine oil.
  • Page 256 LUBRICATION SYSTEM Remove screw plug @ with the short oil screen and the O­ rings. Info Do not remove screws 6). 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 257 LUBRICATION SYSTEM Remove screws Remove the oil filter cover with the O­ ring. Pull oil filter (3 out of the oil filter housing. Lock ring plier (51012011000) p. 297) Completely drain the engine oil. Thoroughly clean the parts and sealing surface. Lay the motorcycle on its side and fill the oil filter housing to about ½...

  • Page 258: Adding Engine Oil

    LUBRICATION SYSTEM Finishing work Check the engine oil level. p. 252) Adding engine oil Info Too little engine oil or poor-quality engine oil will result in premature wear of the engine. Main work Remove filler plug with the O-ring. �-- Fill engine oil to the middle of the level viewer.

  • Page 259: Checking The Oil Pressure

    LUBRICATION SYSTEM Position special tool with the O-ring. Mount and tighten the screws. Guideline Screw, oil filter cover 10 Nm (7.4 lbf ft) Oil pressure adapter (79429094000) p. 306) Connect the pressure testing tool to the special tool without the T-plate. Pressure testing tool (61029094000) p.
  • Page 260 LUBRICATION SYSTEM Finishing work Check the engine oil level. p. 252)

  • Page 261: Ignition System

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

  • Page 262: Winding

    IGNITION SYSTEM Remove the spark plug with special tool I Spark plug wrench with link (77229172000) p. 303) Mount and tighten the new spark plug using the special tool. Guideline Spark plug M10x1 10 ... 12 Nm (7.4 ... 8.9 lbf ft) I Spark plug wrench with link (77229172000) p.

  • Page 263: 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. 21.5 Removing the stator Condition The alternator cover has been removed.

  • Page 264: 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. 100) Remove the air filter box cover. p. 96) Remove the seat. p. 1 00) Remove the fuel tank.
  • Page 265 CYLINDER HEAD 22 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 266: Adjusting The Valve Clearance

    22 CYLINDER HEAD Position the valve cover with the gasket. Mount and tighten screws Guideline 10 Nm (7.4 lbf ft) Screw, valve cover Mount the vent hose and hose clamp Mount and tighten the spark plug using the special tool. Guideline Spark plug M10x1...
  • Page 267 CYLINDER HEAD 22 Main work Remove screw plugs with the O-rings. Remove screws of the rocker arm shafts. Screw a suitable screw into rocker arm shafts Pull out rocker arm shafts Take off rocker arm (D. Remove shims @ and set them down according to the installation position.
  • Page 268 22 CYLINDER HEAD Finishing work Check the valve clearance. p. 262) Install the fuel tank. p. 103) Mount the seat. p. 101) Install the air filter box cover. p. 96) Install the right side cover. p. 100) Remove the motorcycle from the lift stand. p.

  • Page 269: Electric Starter System

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

  • Page 270: 24 Throttle Valve Body

    24 THROTTLE VALVE BODY Adjusting the idle s�eed Warning The engine may go out spontaneously if the idle speed is set too low. Danger of accidents 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 271 THROTTLE VALVE BODY Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. Always make sure there is sufficient ventilation when running the engine. Use effective exhaust extraction when starting or running the engine in an enclosed space. Start the engine without operating the throttle grip.

  • Page 272: 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 273: Tolerance, Engine Wear Limits

    TECHNICAL DATA 25 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) 40.7 mm (1.602 in) Exhaust minimum length (without valve spring 40.
  • Page 274 25 TECHNICAL DATA Screw, b earing 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 275: Capacities

    TECHNICAL DATA 25 Spark plug M10x1 10 ... 12 Nm (7.4 ... 8.9 lbf ft) Coolant temperature sensor 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 1st stage 10 Nm (7.4 lbf ft) 2nd stage 30 Nm (22.1 lbf ft)

  • Page 276: Electrical System

    Rear tire 125/600 R 16.5 TL 165/630 R 17 TL Bridgestone Battlax Supermoto BM01 Z Bridgestone Battlax Racing R02Z 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 277: Fork

    TECHNICAL DATA 25 25.8 Fork 34.15.8Q.08 Fork article number Fork WP Suspension Upside down AER 48 Compression damping Comfort 15 clicks Standard 12 clicks Sport 9 clicks Rebound damping Comfort 15 clicks Standard 12 clicks Sport 9 clicks Air pressure 11.0 bar (160 psi) Fork length 920 mm (36.22 in)

  • Page 278: Chassis Tightening Torques

    25 TECHNICAL DATA 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) Gas pressure 1 0 bar (145 psi) 20 mm (0.
  • Page 279 TECHNICAL DATA 25 Screw, bottom triple clamp 12 Nm (8.9 lbf ft} Screw, chain sliding piece 15 Nm (11.1 lbf ft} 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...

  • Page 280: 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 281 CLEANING/PROTECTIVE TREATMENT After the motorcycle has cooled down, lubricate all moving parts and pivot points. Clean the chain. (ll!:!I p. 130) Treat bare metal (except for brake discs and the exhaust sys­ tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber (ll!:!I p.

  • Page 282: 27 Storage

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

  • Page 283: Preparing For Use After Storage

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

  • Page 284: 28 Service Schedule

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

  • Page 285: Recommended Work

    • • • Final check: Check the vehicle for safe operation and take a test ride. • Read out the fault memory after the test ride using the Husqvarna Motorcycles diagnostics • • tool. • Make the service entry in Husqvarna Motorcycles Dealer.net...
  • Page 286 t : : 1 «! . ·X16 u , , "E "E " " " " " " { } rn "E "E -" "" lB j-x1 N fC/2 N A F/4 �l EB /4 1•N -C10 -521 -M10 -G10 �- 1 1' "...

  • Page 287: Wiring Diagram 29

    WIRING DIAGRAM 29 Components: A 11 EFI control unit Capacitor 12 V battery Alternator Starter relay with main fuse Power relay Electric starter system Voltage regulator E-tip switch X295 Diagnostics connector...
  • Page 288 HY/33 HY/33 HY/33 HY/33 HY/33 �HY/33 HY/33 ·X16 ·X16 1·X16 · X16 ·X16 ·X16 ·X16 � ��i � is� �I .0.0 " ��; � - a l. x2 . x s GA/ 3 f 1 , 2 -BF/1 i CX/2 f r 1 2 A/ 1 -520...
  • Page 289 WIRING DIAGRAM 29 Components: A 11 EFI control unit Fuel pump Injection valve Malfunction indicator lamp CAN bus terminating resistor Kill switch X295 Diagnostics connector...
  • Page 290 �1 1 ·X16 1 ·X16 1 ·X16 1·X16 1·X16 1·X16 1 ·X16 1·X16 ·X16 �{ � "' { HY/33 HY/33 HY/33 HY/33 HY/33 HY/33 HY/33 HY/33 HY/33 HY/33 l! f � n.,, · . H U : , �f l.x2 0 - X11 �! l C R/1...
  • Page 291 WIRING DIAGRAM 29 Components: A 11 EFI control unit Intake air temperature sensor Coolant temperature sensor Rollover sensor Gear position sensor Crankshaft speed sensor Induction manifold pressure sensor Throttle valve position sensor Ignition coil Map select switch Cable colors: Black Brown Blue Green...

  • Page 292: Ignition Coil - Checking The 30 Substances

    30 SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification Guideline Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol REACT PERFORMANCE DOT 4 ® MOTOREX Brake Fluid DOT 5.1 Coolant...
  • Page 293 SUBSTANCES 30 Fork oil {SAE 4) {48601166S1 Standard/classification SAE(� p. 313) (SAE 4) Guideline Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Shock absorber fluid {SAE 2.5) {50180751S1) Standard/classification p.

  • Page 294: Auxiliary Substances

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

  • Page 296: 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 297 SPECIAL TOOLS 32 US batterY charger XCharge-�rofessional Art. no.: 00029095051 Feature US plug Nominal voltage 120 V Mains fuse 32 A Power cable length 5 m (16 ft) approx. Charger cable 5 m (16 ft) H01065-01 length approx. e-professional Art. no.: 00029095052 Feature UK safety plug Nominal voltage...
  • Page 298 32 SPECIAL TOOLS 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 ringe Art. no.: 50329050000 £&...
  • Page 299 SPECIAL TOOLS 32 Lock ring �lier Art. no.: 51012011000 51012011000 H00572-01 Puller Art. no.: 58429037043 Feature Inside diameter 43.9 mm (1. 728 in) 58429037043 H00598-01 Tool bracket Art. no.: 58429089000 2x£ 58429089000 H00603-01 Pressing tool Art. no.: 58429091000 58429091000 H00604-01...
  • Page 300 32 SPECIAL TOOLS Pressing tool Art. no.: 58429092000 58429092000 H00605-01 Torgue wrench kit Art. no.: 58429094000 Feature Torque 3 ... 15 Nm (2.2 ... 11 .1 lbf ft) Open ended bit 3.9 mm (0.154 in) ..)P.,P� Open ended bit 4.9 mm (0.193 in) ��...
  • Page 301 SPECIAL TOOLS 32 Feeler gauge & Art. no.: 59029041100 Feature piece 0.10 ... 0.25 mm (0.0039 ... 0.0098 in) 59029041100 H00616-01 Piston ring com�ressor && Art. no.: 60029015000 Feature Height 80 mm (3.15 in) Diameter 57 ... 125 mm (2.24 ... 4.92 in) 60029015000 H00628-01 Puller...
  • Page 302 32 SPECIAL TOOLS Hose clamQ Qlier 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 303 SPECIAL TOOLS 32 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 Art. no.: 75029047000 75029047000 H00714-01...
  • Page 304 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 305 SPECIAL TOOLS 32 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 Locking screw Art.
  • Page 306 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 Art. no.: 79412966000 Feature Maximum pressure 20 bar (290 psi) Display Digital pressure gauge Valve connection Schrader valve Units bar, psi and kg/cm Material...
  • Page 307 SPECIAL TOOLS 32 Holder and fitting for work stand Art. no.: 79429002000 2x££ 79429002000 H01081-01 Pressing tool Art. no.: 79429006000 79429006000 H01018-01 Insert for crankshaft �ressing tool Art. no.: 79429008000 79428008000 H01169-01 Art. no.: 79429009000 79429009000 H00812-01...
  • Page 308 32 SPECIAL TOOLS Oil ressure ada�ter Art. no.: 79429094000 79429094000 H01045-01 Gear segment Art. no.: 80029004000 80029004000 H00813-01 Engine assembl)' stand Art. no.: 80329001000 80329001000 H01047-01 Lift stand Art. no.: 80329955100 Feature Hei g ht 260 ... 370 mm ( 10.24 ... 14.57 in ) Load �...
  • Page 309 SPECIAL TOOLS 32 Protection ca� Art. no.: 90129005000 90129005000 H00816-01 Hook wrench Art. no.: 90129051000 90129051000 H00831-01 S�ring hook Art. no.: 5030501700004 5030501700004 H00973-01 De th micrometer Art. no.: T107S T107S H00842-01...
  • Page 310 32 SPECIAL TOOLS Drift Art. no.: T120 Feature I Diameter 8 mm (0.31 in) T120 H00844-01 Mounting sleeve Art. no.: T1204 Feature I Diameter 25.5 ... 30.5 mm (1 .004 ... 1 .201 in) T1204 H00878-01 Calibrating unit Art. no.: T1205 Feature I Diameter 1 18 mm (0.71 in)
  • Page 311 SPECIAL TOOLS 32 Pressing tool Art. no.: T1207S &.&. �� T1207S H00881-01 Pressing tool Art. no.: T1216 Feature Diameter ... 49 mm (1.5 ... 1.9 3 in) 1 3 8 T1216 H00887-01 Vacuum um� Art. no.: T1240S � T1240S H00890-01 Filling ada ter Art.
  • Page 312 32 SPECIAL TOOLS Protecting sleeve Art. no.: T1401 Feature I Diameter 48 mm (1.89 in) T1401 H00894-01 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 Clam ing stand...
  • Page 313 SPECIAL TOOLS 32 Mounting tool Art. no.: T14040S Feature Diameter 48 mm (1 .89 in) T14040S H00922-01 Clam�ing stand Art. no.: T14072 Feature Diameter 37 mm (1 .46 in) T14072 H00928-01 Protecting sleeve Art. no.: T14073 Feature Diameter 111.5 mm (0.453 in) T14073 H00929-01 ecial socket...
  • Page 314 32 SPECIAL TOOLS Pressing tool Art. no.: T1504 Feature I Diameter 118 mm (0.71 in) T1504 H00899-01 Mounting tool Art. no.: T150S T150S H00852-01 Mounting sleeve Art. no.: T1515 Feature I Diameter 118 mm (0.71 in) T1515 H00900-01 Filling tool Art.

  • Page 315: Standards

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

  • Page 316: 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 317: Index

    INDEX front brake, checking ....144 of rear brake, changing ....150 rear brake, checking .
  • Page 318 INDEX camshaft, checking ....204 water pump, installing crankshaft run-out at the bearing pin, checking 198 Engine assembly oil pumps, checking ....202 alternator cover, installing .
  • Page 319 INDEX dust boots, cleaning ....17 freewheel gear, removing ... . . 185 gear position sensor, removing .
  • Page 320 INDEX Open-circuit current checking ......141 Idle speed adjusting Ignition coil Preparing for use secondary winding, checking ..259 after storage .
  • Page 321 INDEX seal ring retainer, assembling ... 72 fork ......275 seal ring retainer, disassembling ..68 shock absorber ....275 shock absorber, servicing .
  • Page 322 I 1 1 11 1 11 1 1 1 1 11 1 1 1 111 1 11 1 1 1 1 111 1 111 1 1 1 111 1 1 1 I I I I I I II I I II 3403050en 07/2018 ® Husqvarna Husqvarna Motorcycles GmbH StallhofnerstraBe 3 5230 Mattighofen Austria � LZZa" www.husqvarna-motorcycles.com ..

This manual is also suitable for:

F2303q0

Table of Contents