Husqvarna FS 450 2015 Repair Manual
  1. Manuals
  2. Brands
  3. Husqvarna Manuals
  4. Motorcycle
  5. FS 450 2015
  6. Repair manual

Husqvarna FS 450 2015 Repair Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
PIONEERING SINCE 1903
REPAIR MANUAL2015
FS 450
®
Husqvarna
Art. no. 3403022en
MOTORCYCLES

Advertisement

Table of Contents
loading

Related Manuals for Husqvarna FS 450 2015

Summary of Contents for Husqvarna FS 450 2015

  • Page 1 PIONEERING SINCE 1903 REPAIR MANUAL2015 FS 450 ® Husqvarna Art. no. 3403022en MOTORCYCLES...
  • Page 3 Husqvarna accepts no lia­ bility for delivery options, deviations from illustrations 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 HANDLEBAR, CONTROLS ..........42 MEANS OF REPRESENTATION ........6 Handlebar position ..........42 Symbols used ............6 Adjusting the handlebar position ......42 1 .2 Formats used ............6 Adjusting the basic position of the clutch SAFETY ADVICE ...............
  • Page 5 TABLE OF CONTENTS 11.6 Sealing the air filter box ........78 16.5 Adding front brake fluid ........FUEL TANK, SEAT, TRIM ..........79 16.6 Changing the front brake fluid ......114 12.1 Opening the filler cap .......... 79 16.7 Checking the rear brake linings ......12.2 Closing the filler cap ...........

  • Page 6: Removing The Manifold

    TABLE OF CONTENTS 17.4.6 Changing the crankshaft seal ring in the 17.5.15 Installing the outer clutch hub ...... 176 clutch cover..........148 17.5.16 Installing the clutch discs ......177 17.4.7 Removing the water pump ......148 17.5.17 Installing the clutch cover ......178 17.4.8 Installing the water pump ......
  • Page 7 TABLE OF CONTENTS 24.4.2 Coolant............207 24.4.3 Fuel ............... 207 24.5 Chassis ............. 207 24.6 Electrical system ..........208 24. 7 Tires ..............208 24.8 Fork ..............208 24.9 Shock absorber ..........209 24.10 Chassis tightening torques ....... 209 CLEANING/PROTECTIVE TREATMENT ....... 211 25.1 Cleaning the motorcycle ........

  • Page 8: Means Of Representation

    MEANS OF REPRESENTATION S mbols 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 9: Safety Advice

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

  • Page 10: Important Notes

    IMPORTANT NOTES Manufacturer and im lied warran The work prescribed in the service schedule must be carried out by an authorized Husqvarna Motorcycles workshop only and con­ firmed both in the customer's Service & Warranty Booklet and in the Husqvarna Motorcycles Dealer.net;...

  • Page 11: Serial Numbers

    SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. 401945-10 The type label is fixed to the front of the steering head. 401946-10 The engine number is stamped on the left side of the engine under the engine sprocket.

  • Page 12: Motorcycle

    MOTORCYCLE Raising the motorc cle with a lift stand Note Danger of damage The parked vehicle can roll away or fall over. Park the vehicle on a firm and level surface. Raise the motorcycle at the frame underneath the engine. Lift stand (81329955000) (�...

  • Page 13: Starting The Motorcycle For A Check

    MOTORCYCLE Press the electric starter button CD. • Info Press the electric starter button for at most 5 seconds. Wait for a least 5 seconds before trying again. When starting Fl warning lamp lights up briefly as a function check. 400733-01 Starting the motorc cle for a check Danger...

  • Page 14: Fork, Triple Clamp

    FORK, TRIPLE CLAMP Ad"ustin in of the fork Info The hydraulic compression damping determines the fork suspension behavior. Turn adjusting screws clockwise all the way. • Info Adjusting screws are located at the top end of the fork legs. Make the same adjustment on both fork legs. Turn back counterclockwise by the number of clicks corresponding to the fork type.

  • Page 15: Bleeding The Fork Legs

    FORK, TRIPLE CLAMP Bleedin the fork le s Preparatory work Raise the motorcycle with a lift stand. (!:JI p. 10) Main work Release bleeder screws ✓ Any excess pressure escapes from the interior of the fork. Tighten the bleeder screws. Finishing work Remove the motorcycle from the lift stand.

  • Page 16: Installing The Fork Legs

    FORK, TRIPLE CLAMP Release screws @ .Take out the left fork leg. Release screws Take out the right fork leg. Installing the fork legs Main work Position the fork legs. ✓ Bleeder screws are positioned toward the front. • Info Grooves are milled into the side of the upper end of the fork legs.

  • Page 17: Installing The Fork Protector

    FORK, TRIPLE CLAMP rotector Position the fork protector on the left fork leg. Mount and tighten screws Guideline Remaining screws, chassis 1 10 Nm (7.4 lbf ft) Position the brake line and clamp. Mount and tighten screws Position the fork protector on the right fork leg. Mount and tighten screws fi). Guideline Remaining screws, chassis 1 10 Nm (7.4 lbf ft)

  • Page 18: Disassembling The Fork Legs

    FORK, TRIPLE CLAMP Disassemble the fork legs. p. 16) Check the fork legs - during a minor fork service. p. 25) Assemble the fork legs. p. 31) 200978-01 Disassembling the fork legs Info The steps are identical for both fork legs. Condition The fork legs are disassembled.
  • Page 19 FORK, TRIPLE CLAMP Loosen cartridge Ring wrench (T14017) (llt!l p. 238) Info The cartridge cannot be taken off yet. Unclamp the fork leg. Push the outer tube down. Drain the fork oil. 201361-10 Clamp the fork leg with the axle clamp. Guideline Use soft jaws.

  • Page 20: Disassembling The Cartridge

    FORK, TRIPLE CLAMP Remove dust boot Remove fork protection ring • Info The fork protection ring does not necessarily need to be removed for repair work. Remove lock ring • Info The lock ring has a ground end against which a screwdriver can be posi­ tioned.
  • Page 21 FORK, TRIPLE CLAMP Main work Remove adjusting tube and nut 200835-10 Clamp the cartridge into a vise. Info Use soft jaws. 200836-10 Remove filling screw (D. Pierce the membrane with the needle of the special tool. Nitrogen charging tool (T14019) p.

  • Page 22: Disassembling The Piston Rod

    FORK, TRIPLE CLAMP Reclamp the cartridge upside down. Guideline Use soft jaws. Heat the cartridge in area of pilot bushing Guideline 0�­ 1100 °C (212 °F) Loosen the screw sleeve and remove the piston rod. Remove spring guide and ring@. Remove guide ring@).
  • Page 23 FORK, TRIPLE CLAMP Main work Remove screw sleeve and washer from the piston rod. 200856-10 Degrease the piston rod. Clamp the piston rod with the special tool as far up as possible. Clamping stand (T14016S) p. 237) Remove nut@). Remove rebound shim stack Remove rebound piston Remove the piston ring from the piston.

  • Page 24: Disassembling The Screw Cap With The Membrane Holder

    FORK, TRIPLE CLAMP Remove the valve with the spring from tap rebound Remove the 0-rings. 200862-10 Disassembling the screw ca with the membrane holder Info The steps are identical for both fork legs. Preparatory work Disassemble the fork legs. (� p.

  • Page 25: Disassembling The Screw Sleeve

    FORK, TRIPLE CLAMP Remove compression shim stack@). Remove 0-ring Gi). 200872-10 Disassembling the screw sleeve Info The steps are identical for both fork legs. Preparatory work Disassemble the fork legs. (� p. 16) Disassemble the cartridge. (l!t!I p. 18) Disassemble the piston rod. (l!t!J p.
  • Page 26 FORK, TRIPLE CLAMP Measure the outside diameter of the inner tube at several locations. Outside diameter of the inner tube 47.975 ... 48.005 mm (1.88878 ... 1.88996 in) If the measured value is less than the specified value: Change the inner tube. Measure the run-out of the inner tube.

  • Page 27: Checking The Fork Legs - During A Minor Fork Service

    FORK, TRIPLE CLAMP Check the piston rod for damage. If there is damage: Replace the piston rod. Measure the outside diameter of the piston rod at several locations. I � Outside diameter of the piston rod 11.965 mm (� 0.4 7106 in) If the measured value is less than the specified value: Replace the piston rod.

  • Page 28: Changing The Pilot Bushing

    FORK, TRIPLE CLAMP Check the surface of the sliding bushing. If the bronze-colored layer under the sliding layer is visible or the sur­ face is rough: Replace the sliding bushing. � 200665-10 Check the spring length. Guideline Spring length with preload spacer(s) 482 mm (18.98 in) If the measured value is greater than the specified value: Reduce the thickness of the preload spacers.

  • Page 29: Assembling The Screw Sleeve

    FORK, TRIPLE CLAMP Assembling the screw sleeve Info The steps are identical for both fork legs. Mount and lubricate O-ring Lubricant (T158) (� p. 224) Mount ring Mount lock ring 6). Info The seal ring is mounted when the piston rod is assembled. 200866-11 Assembling the screw cap with the membrane holder Info...

  • Page 30: Assembling The Piston Rod

    FORK, TRIPLE CLAMP @) . Mount and grease O-ring Lubricant (T158) p. 224) Clamp the screw cap with the membrane holder and the special tool into a vise. Pin wrench (T103) (� p. 235) Info Only tighten the vise lightly. Mount membrane Mount and tighten compression holder Ci).

  • Page 31: Assembling The Cartridge

    FORK, TRIPLE CLAMP Grind the rebound piston on both sides on a surface plate with 1200 grit sandpa- per. Clean the rebound piston. Wrap the piston ring around the shaft of a screwdriver before mounting. Mount the piston ring. Lubricate the piston ring. Fork oil (SAE 4) (48601166S1) p.
  • Page 32 FORK, TRIPLE CLAMP Mount guide ring Mount spring guide and ring 200884-10 Clamp the cartridge in a bench vise. Guideline Use soft jaws. Push the piston rod into the cartridge. Info • Check that the piston ring is correctly seated. Slide washer onto the piston rod with the open side forward.

  • Page 33: Assembling The Fork Legs

    FORK, TRIPLE CLAMP Mount the screw cap with the membrane holder and tighten with the special tool. Guideline Screw cap on the cartridge M41x1 30 Nm (22.1 lbf ft) Pin wrench (T103) (!1ll p. 235) Bleed and fill the cartridge. (!1ll p.
  • Page 34 FORK, TRIPLE CLAMP Roughen, clean and lubricate the edges of the sliding bushings using 600 grit sandpaper. Fork oil (SAE 4) (48601166S1) (� p. 222) 200670-10 Slide on lower sliding bushing Mount upper sliding bushing (D . Info Gently pull them apart without using a tool. Slide on the outer tube.
  • Page 35 FORK, TRIPLE CLAMP Mount the preload spacers and spring. Guideline Spring rate Weight of rider: 65 ... 75 kg (143 ... 4.6 N/mm (26.3 lb/in) 165 lb.) 4.8 N/mm (27.4 lb/in) Weight of rider: 75 ... 85 kg (165 ... 187 lb.) Push the cartridge into the fork leg.

  • Page 36: Bleeding And Filling The Cartridge

    FORK, TRIPLE CLAMP Tighten the cartridge. Guideline Cartridge on the outer tube M51x1.5 50 Nm (36.9 lbf ft) Ring wrench (T14017) (� p. 238) Mount adjuster � of the compression damping. Mount and tighten the screw. Guideline Screw, compression adjuster M4x0.5 1.5 Nm (1 .11 lbf ft)
  • Page 37 FORK, TRIPLE CLAMP Info Hand-tighten only without using a tool. Connect adapter @ to special tool Connect adapter@ to the filling port of vacuum pump G). laiN1· Vacuum pump (T1240S) p. 237) Clamp the control lever as shown in the figure. ✓...

  • Page 38: Filling The Cartridge With Nitrogen

    FORK, TRIPLE CLAMP Disconnect the vacuum pump. Remove the special tool. • Info The filling port must be positioned at the highest point. Mount and tighten the filling screw with the O-ring. Guideline Cartridge filling screw M4x0.5 I 2 Nm (1.5 lbf ft) 200889-10 Clamp the cartridge in a vise using soft jaws.

  • Page 39: Removing The Lower Triple Clamp

    FORK, TRIPLE CLAMP 6.27 Removin the lower tri Preparatory work Raise the motorcycle with a lift stand. (!:JI p. 10) Remove the handlebar cushion. Remove the front wheel. (!:JI p. 93) Remove the fork legs. (!:JI p. 13) Remove the start number plate. (�...
  • Page 40 FORK, TRIPLE CLAMP Position the fork legs. ✓ Bleeder screws are positioned toward the front. • Info Grooves are milled into the side of the upper end of the fork legs. The sec­ ond milled groove (from the top) must be flush with the top edge of the upper triple clamp.

  • Page 41: Checking The Steering Head Bearing Play

    FORK, TRIPLE CLAMP Checkin the steerin head bearing la Warning Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components. Correct incorrect steering head bearing play immediately. Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam­ aged over time.

  • Page 42: Adjusting The Steering Head Bearing Play

    FORK, TRIPLE CLAMP Remove the upper bearing race @ using a suitable tool. Press in the new bearing race all the way using a suitable tool. Pull off bearing@. Remove seal ring retainer. Remove O-ring. Grease the new O-ring and mount with seal ring retainer. Press on the new bearing with a suitable tube as far as it will go.
  • Page 43 FORK, TRIPLE CLAMP Tighten screws Guideline Screw, top triple clamp Nm (12.5 lbf ft) Check the steering head bearing play. (I!!:! p. 39) Finishing work Mount the handlebar cushion. Remove the motorcycle from the lift stand. (I!!:! p. 10)

  • Page 44: Handlebar,Controls

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

  • Page 45: Checking The Throttle Cable Routing

    HANDLEBAR,CONTROLS Checkin the throttle cable routin Preparatory work Remove the seat. (!ill p. 80) Remove the fuel tank. (!ill p. 80) Main work Check the throttle cable routing. Both throttle cables must be routed to the throttle valve body side by side behind the handlebars and above the fuel tank bracket.

  • Page 46: Adjusting The Play In The Throttle Cable

    HANDLEBAR,CONTROLS in the throttle cable Preparatory work Remove the seat. (� p. 80) Remove the fuel tank. (� p. 80) Check the throttle cable routing. (� p. 43) Main work Move the handlebar to the straight-ahead position. Push back sleeves Loosen nut @.

  • Page 47: Frame

    If the frame exhibits cracks or deformation due to a mechanical impact: Change the frame. • Info Always replace a frame that has been damaged due to a mechan­ ical impact. Repair of the frame is not authorized by Husqvarna Motorcycles.

  • Page 48: Shock Absorber, Swingarm

    SHOCK ABSORBER, SWINGARM Ad"ustin Caution Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly. The shock absorber is filled with highly compressed nitrogen. Please follow the description provided. Info The high-speed setting can be seen during the fast compression of the shock absorber. Turn adjusting screw all the way clockwise with a socket wrench.

  • Page 49: Adjusting The Rebound Damping Of The Shock Absorber

    SHOCK ABSORBER, SWINGARM Ad"ustin the rebound dam in of the shock absorber Caution Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly. Risk of injury The shock absorber is filled with highly compressed nitrogen. Please follow the description provided.

  • Page 50: Checking The Riding Sag Of The Shock Absorber

    SHOCK ABSORBER, SWINGARM sag of the shock absorber Measure distance of rear wheel unloaded. p. 47) With another person holding the motorcycle, the rider, wearing full protective clothing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down a few times.

  • Page 51: Adjusting The Riding Sag

    SHOCK ABSORBER, SWINGARM Main work Loosen screw Turn adjusting ring @ until the spring is no longer under tension. Hook wrench (T1 06S) (I!!:! p. 235) Measure the overall spring length while the spring is not under tension. Tighten the spring by turning adjusting ring @ to measurement f). Guideline Spring preload 19 mm (0.75 in)

  • Page 52: Removing The Shock Absorber

    SHOCK ABSORBER, SWINGARM Adjust the rebound damping of the shock absorber. p. 47) Remove the motorcycle from the stand. p. 10) lift Removing the shock absorber Preparatory work Raise the motorcycle with a lift stand. (� p. 10) Remove the seat. (�...

  • Page 53: Installing The Shock Absorber

    SHOCK ABSORBER, SWINGARM Main work Raise the rear frame slightly and insert the shock absorber from above. Position the shock absorber. Mount and tighten screw Guideline Screw, top shock 60 Nm Loctite ® 2701 absorber (44.3 lbf ft) Position the rear frame. Mount and tighten screws on both sides.
  • Page 54 SHOCK ABSORBER, SWINGARM Main work Remove screw Remove screw connection Info Raise the wheel slightly to make it easier to remove the screws. Remove screw connection Take off the angle lever. •- -• 303096-10 Check needle bearing for damage and wear. If there is damage or wear: Change the needle bearing.

  • Page 55: Servicing The Shock Absorber

    SHOCK ABSORBER, SWINGARM Position the angle lever. Mount screw connection but do not tighten yet. Guideline Nut, linkage lever on swingarm M14x1.5 I 80 Nm (59 lbf ft) Mount screw but do not tighten yet. Guideline Screw, bottom shock 60 Nm Loctite ®...

  • Page 56: Removing The Spring

    SHOCK ABSORBER, SWINGARM Remove the spring. p. 54) Disassemble the damper. p. 54) Disassemble the piston rod. p. 56) Disassemble the seal ring retainer. p. 57) Check the damper. p. 58) Remove the heim joint. (l!lll p. 59) Install the heim joint. (il!l p.
  • Page 57 SHOCK ABSORBER, SWINGARM Remove rubber cap of the reservoir. Open screw slowly. ✓ The pressurized nitrogen escapes. Remove locking cap Press in seal ring retainer using the special tool. Disassembly tool (T1216) (I!!.:! p. 237) Remove lock ring @. Info Do not scratch the inner surface.

  • Page 58: Disassembling The Piston Rod

    SHOCK ABSORBER, SWINGARM Remove compression adjuster@). Remove the spring and piston. 9.15 Disassembling the �iston rod Preparatory work Remove the spring. (I!!;,! p. 54) Disassemble the damper. (I!!;,! p. 54) Main work Clamp the piston rod with the fork in a vise. Guideline Use soft jaws.

  • Page 59: Disassembling The Seal Ring Retainer

    SHOCK ABSORBER, SWINGARM 9.16 Disassemblin the seal rin retainer Preparatory work Remove the spring. (I!!) p. 54) Disassemble the damper. (I!!) p. 54) Disassemble the piston rod. (I!!) p. 56) Main work Remove spring Remove O-ring @. Remove rebound rubber@). 201405-10 Remove centering disk Remove seal ring...

  • Page 60: Checking The Damper

    SHOCK ABSORBER, SWINGARM Slide the new pilot bushing onto the special tool. Press drift (T1504) (� p. 240) Position the pilot bushing in the seal ring retainer using the special tool. Press drift (T1504) (l!l:! p. 240) Support seal ring retainer @ with sleeve f) of the special tool. Press the pilot bushing all the way in.

  • Page 61: Removing The Heim Joint

    SHOCK ABSORBER, SWINGARM Check the piston rings for damage and wear. If damage or a bronze-colored surface is visible: Change the piston. 201404-10 Removing the heim joint 9.19 Condition The shock absorber has been removed. Clamp the shock absorber in the vise using soft jaws for protection. Remove the collar bushing of the heim joint.

  • Page 62: Installing The Heim Joint

    SHOCK ABSORBER, SWINGARM Installing the heim "oint Position the new heim joint and the special tool into a vise as shown. Guideline Use soft jaws. Pressing tool (T1206) (� p. 236) Press the heim joint all the way in. Press the heim joint against the lock ring using the special tool. Pressing tool (T1 207S) p.

  • Page 63: Assembling The Piston Rod

    SHOCK ABSORBER, SWINGARM Mount washer@. Position washer (Don seal ring 201409-10 Grease seal ring and mount with the washer facing downward. Lubricant (T511) (IOJ p. 224) Mount centering disk 201410-10 Mount rebound rubber (D. Lubricate the groove of the O-ring. Lubricant (T158) (�...

  • Page 64: Assembling The Damper

    SHOCK ABSORBER, SWINGARM Mount the compression shim stack with the smaller shims facing downward. 201418-10 Sand both sides of piston on a surface plate using 1200-grit sandpaper. Clean the piston. Assemble the piston. Guideline Piston from above View6) Piston from below ViewC, Mount the rebound shim stack @ with the smaller shims facing upward.
  • Page 65 SHOCK ABSORBER, SWINGARM Main work Lubricate the O-rings of the compression adjuster. Lubricant (T158) (l!lJJ p. 224) Lubricate the threads. Lubricant (T159) (!!l p. 224) Mount the piston with the spring. Mount and tighten the compression adjuster Guideline Compression adjuster M31x1 45 Nm (33.2 lbf ft) Clamp the damper in a bench vise.

  • Page 66: Bleeding And Filling The Damper

    SHOCK ABSORBER, SWINGARM Alternative 1 Turn adjusting screw clockwise with a screwdriver up to the last percepti­ ble click. Turn counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Compression damping, low-speed Comfort 21 clicks Standard 18 clicks Sport 15 clicks...
  • Page 67 SHOCK ABSORBER, SWINGARM Info Clamp the damper only lightly. The filling port must be at the highest point. The piston rod slides in and out during filling - do not hold it tight with your hand! Clamp the control lever as shown in the figure. ✓...
  • Page 68 SHOCK ABSORBER, SWINGARM When the pressure gauge reaches the specified value, turn the Oil reservoir control lever to Vacuum. Guideline Pressure Vacuum 0 bar ✓ The vacuum gauge falls to the specified value. Equallza pressure 8 mbar When the vacuum pressure gauge reaches the specified value, turn the Oil reser­...

  • Page 69: Filling The Damper With Nitrogen

    SHOCK ABSORBER, SWINGARM @> Remove adapter from connection of the vacuum pump. • Info Hold the damper so that the filling port is at the highest point. Remove the adapter. Mount and tighten screw Q). Guideline Screw, filling port M10x1 14 Nm (10.3 lbf ft) 9.25 Filling the dam er with nitrogen...

  • Page 70: Installing The Spring

    SHOCK ABSORBER, SWINGARM 9.26 Installing the s ring Ensure that adjusting ring is screwed on with the intermediate washer. Measure the overall spring length while the spring is not under tension. Position spring. Guideline Spring rate Weight of rider: 65 ... 75 kg (143 ... 54 N/mm (308 lb/in) 165 lb.) Weight of rider: 75 ...

  • Page 71: Checking The Swingarm

    If the swingarm shows signs of damage, cracking, or deformation: Change the swingarm. • Info Always change a damaged swingarm. Repair of the swingarm is not authorized by Husqvarna Motorcycles. 9.28 Removin Preparatory work Raise the motorcycle with a lift stand.

  • Page 72: Installing The Swingarm

    SHOCK ABSORBER, SWINGARM Remove fitting Lower the swingarm. Remove nut Remove the swingarm pivot. Remove the swingarm. Main work Position the swingarm. Mount the swingarm pivot. Mount and tighten nut Guideline Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) Lift the swingarm.

  • Page 73: Changing The Swingarm Bearing

    SHOCK ABSORBER, SWINGARM Position the brake caliper and pull it back. Position the brake line in the guide. Finishing work Install the rear wheel. (ilill p. 97) Remove the motorcycle from the lift stand. (ilill p. 10) Changing the swingarm bearing Info These operations are the same on both swingarm bearings.
  • Page 74 SHOCK ABSORBER, SWINGARM Remove bushing @ . G01814-10 Remove shaft seal rings (D using a suitable tool. Press out the bearing with a suitable tool. Press in the new bearing until it is flush using a suitable tool. Press in shaft seal rings (D . Mount bushing @ .
  • Page 75 SHOCK ABSORBER, SWINGARM Grease the shaft seal rings. Long-life grease p. 224) Position collar bushings with the shoulder facing inward. G01819-10 Finishing work Install the swingarm. (� p. 70) Install the rear wheel. (� p. 97) Remove the motorcycle from the lift stand. p.

  • Page 76: Exhaust

    EXHAUST Detach springs Spring hook (50305017000) (� p. 228) Remove screw @ . Take off manifold. Position the manifold. Mount screw but do not tighten yet. Guideline Screw, manifold holder 1 15 Nm (11.1 lbf ft) Attach springs @ . Spring hook (50305017000) (�...

  • Page 77: Removing The Main Silencer

    EXHAUST Removin the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. Allow the exhaust system to cool down before performing any work on the vehicle. Preparatory work Remove the right side cover. (I!!.:! p.
  • Page 78 EXHAUST Main work Remove all screws on the main silencer. Take off silencer cap and O-ring @. Take off outer tube and O-ring Pull glass fiber yarn filling off of inner tube (D. Clean the parts that need to be reinstalled and check for damage. Mount new glass fiber yarn filling on inner tube (D.

  • Page 79: Air Filter

    AIR FILTER Release catch pull off the air filter box lid sideways in areas f) and G), and remove toward the rear. Position the air filter box lid and tab Engage the air filter box lid in areas f) and G). Engage tab 11.3 Removin the air filter...

  • Page 80: Cleaning The Air Filter And Air Filter Box

    AIR FILTER Insert both parts together, position them, and fasten them using air filter holder in area ✓ The arrow of marking faces upward. • Info If the air filter is not correctly mounted, dust and dirt can enter the engine and cause damage.

  • Page 81: Fuel Tank, Seat, Trim

    FUEL TANK, SEAT, TRIM 12.1 0 ening the filler ca Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. Switch off the engine for refueling.

  • Page 82: Installing The Right Side Cover

    FUEL TANK, SEAT, TRIM Position the side cover and engage in area f). Mount and tighten screw Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 12.5 Removin the seat Remove screws Lift up the seat at the rear, pull it back and then remove it from above. 12.6 Mountin the seat Hook in the front of the seat at the collar bushing of the fuel tank, lower it at the...

  • Page 83: Installing The Fuel Tank

    FUEL TANK, SEAT, TRIM Main work Unplug connector of the fuel pump. Pull the fuel tank breather hose off the tank lid. Thoroughly clean plug-in connection of the fuel line 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.
  • Page 84 FUEL TANK, SEAT, TRIM Warning Fuel is poisonous and a health hazard. Danger of poisoning Avoid skin, eye and clothing contact with fuel. Immediately consult a doctor if you swallow fuel. Do not inhale fuel vapors. In case of skin contact, rinse the affected area with plenty of water. Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.

  • Page 85: Checking The Fuel Pressure

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

  • Page 86: Changing The Fuel Pump

    FUEL TANK, SEAT, TRIM Check the fuel pressure with the filler cap open. Fuel pressure When the fuel pump is active 3.3 ... 3. 7 bar (48 ... 54 psi) If the specification is not reached: Check that the fuel line is clear. Change the fuel filter.
  • Page 87 FUEL TANK, SEAT, TRIM · , � Remove screws � � - - � ,�1' G01785-10 Pull out the fuel pump. G01786-10 Position the fuel pump. Mount fuel connection with the gasket but do not tighten yet. Mount and tighten nut with the gasket.

  • Page 88: Changing The Fuel Filter

    FUEL TANK, SEAT, TRIM 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. Switch off the engine for refueling.
  • Page 89 FUEL TANK, SEAT, TRIM Pull out the fuel pump. Remove hose clamps Remove fuel filter Press locking mechanism (D. Pull back fuel pump housing Change fuel screen Mount the fuel pump housing. Mount fuel filter ✓ Arrow points away from the fuel pump. Mount hose clamps Hose clamp pliers (60029057000) (�...

  • Page 90: Changing The Fuel Screen

    FUEL TANK, SEAT, TRIM Position the fuel pump. Mount fuel connection fj with the gasket but do not tighten yet. Mount and tighten nut with the gasket. Guideline Nut, fuel pump fastener M12x1.75 15 Nm (11.1 lbf ft) Tighten fuel connection fj. Guideline Fuel connection on fuel tank M8x1 .25...
  • Page 91 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. •...

  • Page 92: Mask, Fender

    MASK, FENDER 13.1 Removin the front fender Preparatory work Remove the start number plate. (!,Jl p. 90) Main work Remove screws Remove the front fender. Ensure that the spacers remain in position. 13.2 Installing the front fender Main work Ensure that the spacers are mounted in the fender. Position the front fender.

  • Page 93: Wheels

    Husqvarna Motorcycles recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear. the tires are more than 5 years old:...

  • Page 94: Checking The Brake Discs

    WHEELS Checkin the brake discs Warning Danger of accidents Worn-out brake discs reduce the braking effect. Make sure that worn-out brake discs are replaced immediately. Check the thickness of the front and rear brake discs at multiple points on each brake disc to ensure it is at least thickness f).

  • Page 95: Checking The Rim Run-Out

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

  • Page 96: Installing The Front Wheel

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

  • Page 97: Removing The Brake Disc Of The Front Brake

    WHEELS Remove the fixation of the hand brake lever. Remove the motorcycle from the lift stand. p. 10) Operate the front brake and compress the fork a few times firmly. ✓ The fork legs straighten. Tighten screws Guideline Screw, fork stub Nm (11.1 lbf ft) 14.6.3 Removing the brake disc of the front brake...

  • Page 98: Rear Wheel

    WHEELS Press out bearing using a suitable tool. Info • Spacing tube can be pushed aside. Remove the spacing tube. Press out bearing using a suitable tool. Press in new bearing all the way using a suitable tool. • Info Only press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in.

  • Page 99: Installing The Rear Wheel

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

  • Page 100: Removing The Brake Disc Of The Rear Brake

    WHEELS Position the rear wheel and insert wheel spindle ✓ The brake linings are correctly positioned. Mount the chain. Position chain adjuster (D. Mount nut but do not tighten it yet. Make sure that chain adjusters (D are fitted correctly on adjusting screws Check the chain tension.

  • Page 101: Checking The Chain Tension

    WHEELS 14.7.5 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.

  • Page 102: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    WHEELS Main work Loosen nut Loosen nuts@. Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 55 ... 58 mm (2.17 ... 2.28 in) Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks The rear wheel is then correctly aligned.
  • Page 103 WHEELS Check the chain sliding guard for wear. If the lower edge of the chain pins is in line with or below the chain sliding guard: Change the chain sliding guard. Check that the chain sliding guard is firmly seated. If the chain sliding guard is loose: Tighten the screws on the chain sliding guard.

  • Page 104: Checking For Chain Dirt Accumulation

    WHEELS 14.7.8 Checking for chain dirt accumulation Check the chain for coarse dirt accumulation. If the chain is very dirty: Clean the chain. p. 1 02) 400678-01 14.7.9 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces the road grip. Remove the lubricant from the tires using a suitable cleaning agent.
  • Page 105 WHEELS Have an assistant operate the rear brake. Remove screw with the washer. Remove the rear wheel. (I!!) p. 96) Remove connecting link of the chain. • Info Cover the components to protect them against damage. Take off the chain. Remove engine sprocket@).

  • Page 106: Changing The Rear Wheel Bearing

    WHEELS Have an assistant operate the rear brake. Mount and tighten screw with the washer. Guideline 60 Nm Screw, engine sprocket Loctite ® 2701 (44.3 lbf ft) Position the engine sprocket cover. Mount and tighten screw Guideline Screw, clutch slave cylinder 10 Nm (7.4 lbf ft) Mount and tighten screw Guideline...
  • Page 107 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 108: Wiring Harness, Battery

    WIRING HARNESS, BATTERY Changing the main fuse Warning Fire hazard Incorrect fuses overload the electrical system. Only use fuses with the required ampere value. Do not bypass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the air filter box lid. Preparatory work Switch off all power consumers and switch off the engine.

  • Page 109: Installing The Battery

    Warning Environmental hazard Batteries contain environmentally-hazardous materials. Do not dispose of batteries as household waste. Return batteries to your authorized Husqvarna Motorcycles dealer or dispose of them at a collection point for used bat- teries. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 110: Checking The Charging Voltage

    WIRING HARNESS, BATTERY Info Even when there is no load on the battery, it discharges steadily. The charging level and the method of charging are very important for the service life of the battery. Rapid recharging with a high charging current shortens the service life of the battery. If the charging current, charging voltage, and charging time are exceeded, the battery will be destroyed.

  • Page 111: Checking The Open-Circuit Current

    WIRING HARNESS, BATTERY 15.6 en-circuit current Preparatory work Switch off all power consumers and switch off the engine. Remove the seat. (il!l p. 80) Main work Disconnect the negative cable of the battery. Measure the current between battery ground (-) and the negative cable. •...

  • Page 112: Checking The Starter Relay

    WIRING HARNESS, BATTERY 15.8 Checkin the starter rela Preparatory work Switch off all power consumers and switch off the engine. Remove the seat. (il!l p. 80) Remove the air filter box lid. (il!l p. 77) Main work Disconnect the negative cable of the battery. Pull off connector Pull back the cover.

  • Page 113: Brake System

    BRAKE SYSTEM Checkin the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. Ensure that worn-out brake linings are replaced immediately. Check the brake linings for minimum thickness 6) . Minimum thickness 6) <'= 1 mm (<'= 0.04 in) If the minimum thickness is less than specified: Change the front brake linings.
  • Page 114 BRAKE SYSTEM Move the brake fluid reservoir mounted on the handlebar to a horizontal position. Remove screws Remove cover with membrane Press the brake piston back into the basic position and ensure that brake fluid does not flow out of the brake fluid reservoir, sucking it away if necessary. Press together brake linings (D and remove them from the brake caliper.

  • Page 115: Brake Lever

    BRAKE SYSTEM Remove the locking piece of the hand brake lever. Adjust the basic position of the hand brake lever to your hand size by turning adjusting wheel • Info Push the hand brake lever forward and turn the adjusting wheel. Turn the adjusting wheel clockwise to increase the distance between the hand brake lever and the handlebar.

  • Page 116: Changing The Front Brake Fluid

    BRAKE SYSTEM Warning Old brake fluid reduces the braking effect. Danger of accidents Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. Warning Environmental hazard Hazardous substances cause environmental damage. Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.
  • Page 117 BRAKE SYSTEM Move the brake fluid reservoir mounted on the handlebar to a horizontal position. Cover the painted parts. Remove screws Remove cover with the membrane. Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid.

  • Page 118: Checking The Rear Brake Linings

    BRAKE SYSTEM Check the hand brake lever for a firm pressure point. Checking the rear brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. Ensure that worn-out brake linings are replaced immediately. Check the brake linings for minimum thickness 6) . I ;:: Minimum thickness 6) 1 mm (<:: 0.04 in)

  • Page 119: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM Manually press the brake caliper to the brake disc to push back the brake piston. Ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suction if it does. Info • Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.

  • Page 120: Adjusting The Basic Position Of The Foot Brake Lever

    BRAKE SYSTEM Ad"ustin 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. Set the free travel on the foot brake lever in accordance with the specification.

  • Page 121: Adding Rear Brake Fluid

    BRAKE SYSTEM Adding rear brake fluid Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail. If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.
  • Page 122 BRAKE SYSTEM Warning Hazardous substances cause environmental damage. Environmental hazard Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container.
  • Page 123 BRAKE SYSTEM Stand the vehicle upright. Correct the brake fluid up to marking (9. Brake fluid DOT 4 p. 222) Mount and tighten the screw cap with the membrane and 0-ring. Info • Clean up overflowed or spilt brake fluid immediately with water. Check the foot brake lever for a firm pressure point.

  • Page 124: Engine

    ENGINE 17.1 Removin the engine Preparatory work Raise the motorcycle with a lift stand. (!:JI p. 10) Drain the coolant. (!:JI p. 193) Remove the seat. (!:JI p. 80) Remove the fuel tank. (il!JJ p. 80) Remove the right side cover. (il!ll p.
  • Page 125 ENGINE C&. Remove screw Loosen screws Repeat these steps on the opposite side. Lift the subframe. Push back hose clamp Pull off the bleeder hose. Pivot up the subframe and secure it. Remove screw Pivot the shock absorber toward the rear and twist it slightly. Remove springs Spring hook (50305017000) (�...
  • Page 126 ENGINE Loosen hose clips Remove the radiator hose. Pull back the protection cap. Remove nut Qi). Remove screw Remove screw Ci). Take off the engine sprocket cover. Remove screws •. Remove the cable tie(s). Remove cable holder �. Take off the slave cylinder of the clutch and hang it to one side. •...
  • Page 127 ENGINE Remove screw �. Take off the shift lever. Pull back the protection cap. Unplug connector�- Disconnect spark plug connector @,. Loosen hose clip �- Pull the throttle valve body out of the intake flange toward the rear and hang it to one side.

  • Page 128: Installing The Engine

    ENGINE Remove screws �. Lift out the engine sideways. • Info The help of an assistant is useful in this step. Make sure that the engine is sufficiently secured against falling over. Protect the frame and attachments against damage. Main work Position the engine in the frame.
  • Page 129 ENGINE Position the engine braces. Mount and tighten fittings Guideline Screw, engine brace 33 Nm Loctite ® 2701 (24.3 lbf ft) Mount the vent hose. Position the throttle valve body. Tighten hose clip Plug in connector (3 . Position the protection cap. Plug in spark plug connector @ .
  • Page 130 ENGINE Position the engine sprocket cover. Mount and tighten screw 41). Guideline Screw, clutch slave cylinder 10 Nm (7.4 lbf ft) 4D . Mount and tighten screw Guideline Remaining screws, chassis 25 Nm (18.4 lbf ft) Position the positive cable on the starter motor. 48 .
  • Page 131 ENGINE Mount springs �. Spring hook (50305017000) p. 228) Tighten screw G). Guideline Screw, manifold holder 15 Nm (11.1 lbf ft) Position the shock absorber. Mount and tighten screw �- Guideline Screw, top shock 60 Nm Loctite 2701 ® (44.3 lbf ft) absorber Remove the fixation and lower the subframe.
  • Page 132 Remove the motorcycle from the lift stand. (l!ill p. 10) Refill the coolant. (l!ill p. 194) Execute the initialization run. (� p. 203) Go for a short test ride. Read out the fault memory using the Husqvarna Motorcycles diagnostics tool.

  • Page 133: Engine Disassembly

    ENGINE Check the engine for leak tightness. Check the engine oil level. p. 195) Check the coolant level. p. 193) 17.3 En ine disassembly 17.3.1 Preparations Mount the special tool on the engine assembly stand. Engine fixing arm (78029002000) p. 233) Engine assembly stand (61229001000) p.

  • Page 134: Removing The Clutch Push Rod

    ENGINE Removing the clutch push rod 17.3.3 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. Circlip pliers reverse (51012011000) (!,JI p.

  • Page 135: Removing The Valve Cover

    ENGINE 17.3.7 Removing the valve cover Remove screws Take off the valve cover with the valve cover seal. 17.3.8 Removing the alternator cover Remove screws Take off the alternator cover. Remove locating pins Take off the alternator cover gasket 17.3.9 Positioning the engine at ignition top dead center Turn the crankshaft counterclockwise until the markings are flush with the...

  • Page 136: Removing The Timing Chain Tensioner

    ENGINE Screw in special tool Locking screw (113080802) p. 227) 17.3.10 Removing the timing chain tensioner Remove screw with the washer and spring. Remove screws Take off the chain adjuster with the gasket. 17.3.11 Removing the camshaft Remove screw Remove the camshaft support plate@. Pull the camshaft out of the bearing seats.

  • Page 137: Removing The Cylinder Head

    ENGINE 17 .3.12 Removing the cylinder head Remove screw Unscrew screws in a crisscross pattern and remove. Remove the cylinder head. Take off dowels@). Remove cylinder head gasket 17 .3.13 Removing the piston Push the cylinder upward. • Info Only push the cylinder as far up as necessary to take the piston pin out. Remove the piston pin retainer Remove the piston pin.

  • Page 138: Removing The Rotor

    ENGINE 17 .3.14 Removing the rotor Remove nut with the spring washer. Mount special tool @ on the rotor. Extractor (58012009000) (� p. 228) Hold it tight using the special tool and pull off the rotor by turning the screw in. Remove the woodruff key.

  • Page 139: Removing The Ignition Pulse Generator

    ENGINE 17.3.16 Removing the ignition pulse generator Remove screws Pull the cable sleeve out of the engine case. Take off the crankshaft position sensor. 17.3.17 Removing the suction pump Remove screws Take off oil pump cover of the suction pump. Remove external rotor @ and internal rotor Take off pin Remove pin...

  • Page 140: Removing The Clutch Cover

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

  • Page 141: Removing The Outer Clutch Hub

    ENGINE Hold the clutch cage using the special tool G) and remove nut @ with the lock washer. Gear segment (80029004000) (!ill p. 234) Completely remove clutch disc pack 17 .3.21 Removing the outer clutch hub Take off washer Info The washer usually sticks to the inner clutch hub.

  • Page 142: Removing The Torque Limiter

    ENGINE 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 Remove the lock ring and washer. Take off starter idler gear 17 .3.24 Removing the shift shaft �...

  • Page 143: Removing The Force Pump

    ENGINE 17.3.27 Removing the force pump Remove lock ring Take washer Remove oil pump idler gear Remove lock washer Take washer Take oil pump gear wheel 0). Remove pin@. Remove screws @. Take oil pump cover@). Remove internal rotor � and external rotor Remove the pin.

  • Page 144: Removing The Primary Gear

    ENGINE 17 .3.28 Removing the primary gear Insert special tool in the crankshaft. Protection cap (75029090000) p. 232) Install special tool Extractor (75029021000) (ll!:!l p. 231) Hold it using the special tool and pull off the primary gear by turning the screw in. Remove the special tools.

  • Page 145: Removing The Shift Rails

    ENGINE Remove dowels 17 .3.31 Removing the shift rails together with upper springs @ and lower springs. Remove shift rails 17 .3.32 Removing the shift drum Swing shift forks to one side. • Info Do not misplace the shift rollers. Remove shift drum @ .

  • Page 146: Removing The Crankshaft

    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 Attach the special tool to the crankshaft. Protection cap (75029090000) p.
  • Page 147 ENGINE Warm the engine case section again. Guideline (302 °F) Insert the new cold bearings into the bearing seats of the hot engine case section and, if necessary, use a suitable press drift to push the bearing from the inside to the outside, all the way to the stop or so it is flush.

  • Page 148: Work On The Left Section Of The Engine Case

    ENGINE 17.4.2 Work on the left section of the engine case Remove all remaining dowels. Remove screw Remove oil spray tube@. Remove screws Remove membrane support plate and the membrane. Remove shaft seal ring of the countershaft and shaft seal ring of the shift shaft.

  • Page 149: Removing The Oil Pressure Regulator Valve

    ENGINE Guideline Screw, membrane 1.5 Nm Loctite ® ™ (1 .11 lbf ft) Position membrane support plate together with the membrane. Mount and tighten screws Guideline Screw, membrane 1.5 Nm Loctite ® ™ (1 .11 lbf ft) Position oil spray tube Mount and tighten screw Guideline Screw, oil spray tube...

  • Page 150: Installing The Oil Pressure Regulator Valve

    ENGINE 17.4.5 Installing the oil pressure regulator valve Install ball and pressure spring Mount and tighten plug fs) with sealing washer Guideline Plug, oil pressure regulator valve M12x1.5 20 Nm (14.8 lbf ft) 304671-11 17.4.6 Changing the crankshaft seal ring in the clutch cover Remove crankshaft seal ring Press the new crankshaft seal ring into the clutch cover with the open side facing inward until it is flush.

  • Page 151: Installing The Water Pump

    ENGINE Press out water pump bearing toward the inside with an appropriate tool. Info Provide suitable support for the clutch cover while pressing out. 17.4.8 Installing the water pump Press water pump shaft bearing in until it is flush using the appropriate tool. Info Support the clutch cover sufficiently when pressing in.

  • Page 152: Removing The Timing Chain Sprocket

    ENGINE 17.4.9 Removing the timing chain sprocket Warm up the timing chain sprocket with a blow-dryer. Pull off the timing chain sprocket with the special tool. Puller, 2-arm (60029033000) (� p. 230) • Info The timing chain sprocket is usually damaged by the disassembly and must be replaced.
  • Page 153 ENGINE Place the crank web onto special tool Insert for crankshaft pressing tool (78929008000) p. 234) Info The special tool must be positioned with the flat surface facing downward. Press the new crank pin all the way in. ✓ Oil channel is aligned with oil channel G).

  • Page 154: Checking Crankshaft Run-Out At Bearing Pin

    ENGINE 17.4.12 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 bearing pin :5 0.04 mm (:5 0.0016 in) If the crankshaft run-out at the bearing pin is larger than the specification: Align the crankshaft.

  • Page 155: Checking/Measuring The Piston

    ENGINE 17.4.15 Checking/measuring the piston Check the piston sliding surface for damage. If the piston sliding surface is damaged: Replace the piston and, if necessary, the cylinder. Check that the piston rings move easily in the piston ring grooves. If the piston ring is stiff: Clean the piston ring groove.

  • Page 156: Measuring The Piston/Cylinder Mounting Clearance

    ENGINE 17.4.17 Measuring the piston/cylinder mounting clearance Check/measure the cylinder. (� p. 152) Check/measure the piston. (� p. 153) The smallest piston/cylinder mounting clearance equals the smallest cylinder bore diameter minus the largest piston diameter. The largest piston/cylinder mount- ing clearance equals the largest cylinder bore diameter minus the smallest piston diameter.

  • Page 157: Assembling The Autodecompressor

    ENGINE Pull autodecompression shaft out of the camshaft. 304674-10 Release and remove autodecompression spring Info e� Autodecompression weight cannot be taken off. 304675-10 17.4.20 Assembling the autodecompressor Insert long flange of the autodecompression spring in the hole, push the autodecompression spring over bearing bolt @ and hook it into autodecompression weight Mount autodecompression shaft in the camshaft.

  • Page 158: Checking Camshaft

    ENGINE 17.4.21 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 159: Removing The Rocker Arm

    ENGINE Replace the timing chain. 17 .4.23 Removing the rocker arm Remove screws of the rocker arm shafts. Remove plugs with the O-rings. 306606-10 Screw appropriate screw into the rocker arm shafts. Pull out rocker arm shafts Take off rocker arm (D. 306607-10 17 .4.24 Removing the valves...

  • Page 160: Changing Camshaft Bearing

    ENGINE 17.4.25 Changing camshaft bearing Mount the cylinder head. Clamping plate (75029050000) p. 232) Remove the large camshaft bearing using the special tool. Push-out drift (75029051000) p. 232) Remove the small camshaft bearing using the special tool. Bearing puller (15112017000) p.

  • Page 161: Checking Valve Springs

    ENGINE Check sealing seat on the valve. Valve Intake sealing seat width 2.00 mm (0.0787 in) Valve Exhaust sealing seat width 2.00 mm (0.0787 in) If the sealing area is not in the center of the valve seat or deviates from the specified value: Rework the valve seat.

  • Page 162: Checking The Rocker Arm Shafts

    ENGINE Using a straightedge and the special tool, check the sealing area of the cylinder for distortion. Feeler gauge (590290411 00) (� p. 229) Cylinder/cylinder head - sealing area :5 0.10 mm (:5 0.0039 in) distortion If the measured value does not meet specifications: Change the cylinder head.

  • Page 163: Installing The Rocker Arm

    ENGINE 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. Place shims into the valve spring retainers according to the installation position. 17.4.32 Installing the rocker arm Position rocker arm...

  • Page 164: Preassembling The Antihopping Clutch

    ENGINE Take the clutch out of the vise and place it on a clean workbench with the outside inner clutch hub facing downward. Take the inside inner clutch hub and release springs @t out of the outer inner clutch hub. 306628-10 Remove clutch facing discs from the outer inner clutch hub.

  • Page 165: Checking The Clutch

    ENGINE Info Apply the special tool by hand only; do not use another tool. Only tighten the special tool to the point where the clutch facing discs cannot be shifted relative to each other; they will need to be aligned when they are mounted in the clutch basket.

  • Page 166: Checking The Shift Mechanism

    ENGINE If the contact surface exhibits significant 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. Check clutch facing discs for discoloration and scoring.

  • Page 167: Preassembling The Shift Shaft

    ENGINE Change the shift drum. Check springs of the shift rails for damage and wear. If the spring is damaged or worn: Change the spring of the shift rail. Check shift rails (3 on a flat surface for run-out. If there is run-out: Change the shift rail.

  • Page 168: Disassembling The Main Shaft

    ENGINE 17.4.38 Disassembling the main shaft 306610-10 Secure the main shaft with the toothed end facing downward in the vise. Guideline Use soft jaws. Remove stop disk and 2nd-gear fixed gear Remove lock ring Remove needle bearing and distance sleeve@). Remove 3rd/4th-gear sliding gear (D.

  • Page 169: Checking The Transmission

    ENGINE Remove stop disk and 1st-gear idler gear Remove needle bearing and stop disk Remove 5th-gear sliding gear and lock ring 0). Remove stop disk@ and 3rd-gear idler gear@. Remove needle bearing and 4th-gear idler gear Gi). Remove needle bearing and stop disk Remove lock ring�...

  • Page 170: Assembling The Main Shaft

    ENGINE Change the gear wheel pair. Check sliding gear for smooth operation in the profile of main shaft @}. If the sliding gear does not move freely: Change the sliding gear or the main shaft. Check shift collar for damage and wear. If there is damage or wear: Change the shift collar.

  • Page 171: Assembling The Countershaft

    ENGINE Mount lock ring Mount 2nd-gear fixed gear with the collar facing downward and stop disk �. Finally, check all gear wheels for smooth operation. 17.4.42 Assembling the countershaft • Info Use new lock rings with every repair. Preparatory work Carefully grease all parts before assembling.

  • Page 172: Checking The Starter Drive

    ENGINE 17.4.43 Checking the starter drive 304688-10 Check the gear mesh and bearing of starter idler gear for damage and wear. If there is damage or wear: Change the starter idler gear. Check the gear mesh and bearing of torque limiter for damage and wear.

  • Page 173: Removing The Freewheel

    ENGINE 17 .4.45 Removing the freewheel Press expansion ring together with suitable pliers and take off. 304703-10 Take the freewheel @ out of the primary gear. 304704-10 17.4.46 Installing the freewheel Thoroughly oil all parts. Push the freewheel into the primary gear. Info Note the direction of rotation.

  • Page 174: Engine Assembly

    ENGINE 17.5 Engine assembl 17.5.1 Installing the crankshaft Tighten the right section of the engine case in the engine assembly stand. Heat the crankshaft bearing. Guideline (176 °F) Info • Do not damage the seal ring. Mount the special tool on the clutch end of the crankshaft. Mounting sleeve (78029005100) p.

  • Page 175: Installing The Shift Drum

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

  • Page 176: Installing The Force Pump

    ENGINE Guideline Screw, engine case M6x75 1 10 Nm (7.4 lbf ft) Mount screw but do not tighten yet. Guideline Screw, engine case M6x80 1 10 Nm (7.4 lbf ft) Mount screw and tighten all screws in a crisscross pattern. Guideline Screw, engine case M6x85...

  • Page 177: Installing The Locking Lever

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

  • Page 178: Installing The Shift Drum Locating Unit

    ENGINE 17.5.11 Installing the shift drum locating unit Push away locking lever from the shift drum locating unit and position the shift drum locating unit • Info The flat areas of the shift drum locating unit are not symmetric. Relieve tension from the locking lever. Mount and tighten screw Guideline Screw, shift drum locating...

  • Page 179: Installing The Clutch Discs

    ENGINE Slide the outer clutch hub onto the gearbox main shaft. Turn oil pump gear wheel until the gear teeth of the clutch basket engage. Lock the outer clutch hub and primary gear using special tool Gear segment (80029004000) (!!:! p.

  • Page 180: Installing The Clutch Cover

    ENGINE Insert pressure piece Set the crankshaft to top dead center and lock it with special tool Locking screw (113080802) (� p. 227) Position pressure cap (D. Mount and tighten screws @ with the spring retainers and clutch springs. Guideline Screw, clutch spring retainer I 6 Nm (4.4 lbf ft) Remove special tool (D.

  • Page 181: Installing The Water Pump Cover

    ENGINE Mount screw (D and tighten all screws in a crisscross pattern. Guideline Screw, clutch cover M6x30 10 Nm (7.4 lbf ft) Remove the special tool. Fixing drift (78129032000) (� p. 234) 17.5.18 Installing the water pump cover Put the water pump cover seal in place. Mount the water pump cover.

  • Page 182: Installing The Ignition Pulse Generator

    ENGINE 17.5.20 Installing the ignition pulse generator Position the ignition pulse generator. • Info Use the middle drill hole pair. Mount and tighten screws Guideline Screw, crankshaft posi­ Loctite ® ™ tion sensor (4.4 lbf ft) Position the cable and insert the cable sleeve into the engine case. 17.5.21 Installing the timing chain Thread in the timing chain and place it over the timing chain sprocket.

  • Page 183: Installing The Piston

    ENGINE 17.5.23 Installing the piston Move the joints of the compression ring and oil scraper ring so they are offset by ° Place the oiled piston on the cylinder. Compress the piston rings using the special tool. Piston ring mounting tool (60029015000) (l!!ll p.

  • Page 184: Installing The Cylinder Head

    ENGINE Position the piston pin retainer. Insert the special tool and press it forcefully to the piston. Turn the special tool counterclockwise, thereby pushing the piston pin retainer into the groove. Insertion tool for piston ring lock (77329030100) p. 233) Ensure that the piston pin retainer is seated properly on both sides.

  • Page 185: Installing The Camshaft

    ENGINE Put the cylinder head in place. Mount screws with the washers and tighten them in a crisscross pattern. Guideline Screw, cylinder head M10x1 .25 Step 1 Lubricated with engine oil 10 Nm (7.4 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 50 Nm...

  • Page 186: Checking The Valve Clearance

    ENGINE Position the timing chain tensioner with the gasket. Mount and tighten screws Guideline Screw, timing chain tensioner 10 Nm (7.4 lbf ft) Mount and tighten screw plug with washer and spring Guideline Plug, timing chain tensioner I 8 Nm (5.9 lbf ft) 17.5.27 Checking the valve clearance Remove special tool...

  • Page 187: Installing The Alternator Cover

    ENGINE Raise rocker arm on the outside. Remove shims and set down in the position in which they were installed. Correct the shims according to the findings from checking the valve clearance. Insert suitab le shims. Install the camsha ft. (llill p.

  • Page 188: Installing The Starter Motor

    ENGINE Installing the starter motor 17.5.32 Grease the O-ring. Mount the starter motor. Mount and tighten screws Guideline Screw, starter motor 1 10 Nm (7.4 lbf ft) 17.5.33 Installing the oil filter Tilt the motorcycle to one side and fill the oil filter housing to about 1 /3 full with engine oil.

  • Page 189: Removing The Engine From The Engine

    ENGINE Place the long oil screen with the O-rings onto a pin wrench. Push the pin wrench through the opening into the drill hole of the opposite engine case wall and push the oil screen as far as possible into the engine case. Mount and tighten screw plug with the O-ring.

  • Page 190: Clutch

    CLUTCH Checkin /correctin 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 191: Antihopping Clutch

    CLUTCH Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. Remove screws Remove cover with membrane@). Fill bleeding syringe with the appropriate hydraulic fluid. Bleed syringe (50329050000) (ll!ll p. 228) Brake fluid DOT 4 (� p. 222) @»...

  • Page 192: Adjusting The Antihopping Clutch

    CLUTCH The antihopping system uses a two-part inner clutch hub. The individual parts are connected via helical gears. � The clutch spring preload can be adjusted if necessary. Low preload, without 0 mm (0 in) washer Moderate preload, with 1.0 mm (0.039 in) �...
  • Page 193 CLUTCH Remove screw • Info Never remove more than one screw at once. Position the required washer. Guideline Low preload, without washer 0 mm (0 in) Moderate preload, with washer (con- 1.0 mm (0.039 in) dition at delivery) High preload, with washer 1.5 mm (0.059 in) Mount and tighten screw Guideline...

  • Page 194: Water Pump, Cooling System

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

  • Page 195: Checking The Coolant Level

    WATER PUMP, COOLING SYSTEM Mount the radiator cap. Checking the coolant level Warning During motorcycle operation, the coolant gets very hot and is under pressure. Danger of scalding 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 196: Refilling Coolant

    WATER PUMP, COOLING SYSTEM Position the motorcycle upright. Place a suitable container under the water pump cover. Remove screw Take off radiator cap fj. Completely drain the coolant. Mount and tighten screw with a new seal ring. Guideline Screw, water pump cover 10 Nm (7.4 lbf ft) Refilling coolant Warning...

  • Page 197: Lubrication System

    LUBRICATION SYSTEM 20.1 Oil circuit 401628-60 Oil screen Force pump Oil pressure regulator valve Oil filter Oil nozzle for conrod bearing lubrication Oil nozzle, piston cooling Oil nozzle for cam follower lubrication Suction pump Oil channel, transmission lubrication 20.2 ine oil level Condition The engine is at operating temperature.

  • Page 198: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens

    LUBRICATION SYSTEM Changing the engine oil and oil filter, cleaning the oil screens Warning Engine and gear oil get very hot when the motorcycle is ridden. Danger of scalding Wear suitable protective clothing and safety gloves. In the event of scalding, rinse the area affected immediately with lukewarm water. Warning Hazardous substances cause environmental damage.
  • Page 199 LUBRICATION SYSTEM Place the long oil screen with the O-rings onto a pin wrench. Position the pin wrench through the drilled hole of the screw plug in the opposite section of the engine case. Push the oil screen all the way into the engine case. Mount and tighten screw plug with the O-ring.

  • Page 200: Adding Engine Oil

    LUBRICATION SYSTEM Danger Exhaust gases are toxic and inhaling them may Danger of poisoning result in unconsciousness and death. Always make sure there is sufficient ventilation when running the engine. Use an effective exhaust extraction system when starting or running the engine in an enclosed space.
  • Page 201 LUBRICATION SYSTEM Danger Exhaust gases are toxic and inhaling them may Danger of poisoning result in unconsciousness and death. Always make sure there is sufficient ventilation when running the engine. Use an effective exhaust extraction system when starting or running the engine in an enclosed space.

  • Page 202: Ignition System

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

  • Page 203: Removing The Stator

    IGNITION SYSTEM 21.4 Removin the stator Condition The alternator cover has been removed. Remove screw and take off the cable holder. Remove cable support sleeve from the alternator case. Remove screws Take the stator out of the alternator cover. 306639-10 21.5 Installing the stator Position the stator in the alternator cover.

  • Page 204: Electric Starter

    ELECTRIC ST ARTER 22.1 Checkin 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 205: Throttle Valve Body

    THROTTLE VALVE BODY 23.1 Ad"ustin the idle s eed Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. Always make sure there is sufficient ventilation when running the engine. Use an effective exhaust extraction system when starting or running the engine in an enclosed space. Warning Danger of accidents The engine may go out spontaneously if the idle speed is set too low.
  • Page 206 THROTTLE VALVE BODY As soon as the specified temperature is reached, switch off the ignition. • Info If the initialization is not completed or the initialization process is inter­ rupted, the entire process must be restarted.

  • Page 207: Technical Data

    TECHNICAL DATA 24.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 449.3 cm (27.418 cu in) Stroke 63.4 mm (2.496 in) Bore 95 mm (3.74 in) Compression ratio 12.6:1 2,250 ... 2,350 rpm Idle speed Control OHC, 4 valves controlled via rocker arm Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust...

  • Page 208: Engine Tightening Torques

    TECHNICAL DATA 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) Piston ring end gap Compression ring s; 1.00 mm (s; 0.0394 in) Oil scraper ring s;...

  • Page 209: Capacities

    TECHNICAL DATA Oil nozzle for conrod bearing lubrica- M6x0.75 4 Nm (3 lbf ft) tion Plug, oil channel 9 Nm (6.6 lbf ft) ® Loctite ™ Screw, rocker arm bearing 15 Nm (11.1 lbf ft) Plug, timing chain tensioner 8 Nm (5.9 lbf ft) Screw plug, crankshaft location 10 Nm (7.4 lbf ft) Plug, oil channel...

  • Page 210: Electrical System

    Metzeler Racetec SM 16.5 125/80 R 420 NHS TL - K1 Metzeler Racetec SM 17 165/55 R 17 M/C NHS TL - K1 The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: www.husqvarna-motorcycles.com Fork 24.8 Fork part number 14.18.

  • Page 211: Shock Absorber

    TECHNICAL DATA Gas pressure 1 .2 bar (17 psi) Fork length 920 mm (36.22 in) Oil capacity per cartridge 195 ml (6.59 fl. oz.) Fork oil (SAE 4) (48601166S1) (� p. 222) Oil capacity fork leg without 380 ml (12.85 fl. oz.) Fork oil (SAE 4) (48601166S1) (�...
  • Page 212 TECHNICAL DATA 5 Nm (3.7 lbf ft) Screw, throttle grip Fuel connection on fuel tank 10 Nm (7.4 lbf ft) Nut, foot brake lever stop 20 Nm (14.8 lbf ft) ® Nut, rear sprocket screw 35 Nm (25.8 lbf ft) Loctite 2701 Nut, rim lock...

  • Page 213: Cleaning/Protective Treatment

    CLEANING/PROTECTIVE TREATMENT 25.1 Cleanin 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 214: Storage

    Store the vehicle in a dry location that is not subject to large fluctuations in tem­ perature. • Info Husqvarna Motorcycles recommends raising the motorcycle. Raise the motorcycle with a lift stand. (� p. 10) Cover the vehicle with a tarp or similar cover that is permeable to air.

  • Page 215: Service Schedule

    Final check: Check the vehicle for safe operation and take a test ride. • • • Read out the fault memory after the test ride using the Husqvarna Motorcycles diagnostics tool. • • • Make the service entry in the Husqvarna Motorcycles Dealer.net...

  • Page 216: Service Work (As Additional Order)

    SERVICE SCHEDULE • Periodic interval 27.2 Service work {as additional order) Annually Every 100 operating hours - corresponds to about 700 liters of fuel (185 US gal) Every 50 operating hours - corresponds to about 350 liters of fuel (92.5 US gal) Every 40 operating hours - corresponds to about 280 liters of fuel (74 US gal) Once after 20 operating hours •...
  • Page 218 ; : : I ◄ �T �DT/36 � X1 6 1 · - � l. x 1 i E B / 4 { E B / 4 -1FC/2 - X7 " .c o < ..� - X302 < � FS 450 2015...

  • Page 219: Wiring Diagram

    WIRING DIAGRAM Components: A 11 EFI control unit Capacitor Battery Alternator Starter relay with main fuse Power relay Starter motor Voltage regulator Electric starter button X295 Diagnostics connector...
  • Page 220 ""® � ::: t -X29 5 � -X301 E - 1 � N � AP/6 �- �- -CW/2 • -CX/2 < DD D � -X300 < ('I) "' � - /1.FB a. /1.FB b. � "' ,df,f FS 450 2015...
  • Page 221 WIRING DIAGRAM Components: A 11 EFI control unit Fuel pump Injection valve (cylinder 1) warning lamp (MIL) CAN bus terminating resistor Kill switch X295 Diagnostics connector...
  • Page 222 -X1 3 � < � < � ('I) �� _-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_ .._,_ _-_-_-_-_-_-_- .+ _ _. ___ -_-_-_-_-_-_-_-_-_ _. ___ -_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_ .._,_ _- .+ _-_-_-_-_-_-_-_-_-<_ ... _-_-_-_-_-_---::'._ __ � ('I) � Ft----��;;��--�----------------------�-----------------------�----�----tF FS 450 2015 KltN : 3/3 ('I)
  • Page 223 WIRING DIAGRAM Components: A 11 EFI control unit Throttle position sensor circuit A Intake air temperature sensor Engine coolant temperature sensor (cylinder 1) Rollover sensor Crankshaft position sensor Manifold absolute pressure sensor (cylinder 1) Ignition coil (cylinder 1) Map-Select switch for ride mode (optional) Map-Select switch (optional) Cable colors:...

  • Page 224: Substances

    SUBSTANCES Brake fluid DOT 4 Standard/classification Guideline Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the cor- responding properties. Recommended supplier ® Bel-Ray Super DOT 4 Brake Fluid Coolant Guideline Only use high-grade, silicate-free coolant with corrosion inhibitor additive for aluminum motors.
  • Page 225 SUBSTANCES Su er unleaded ROZ 95/RON 95/PON 91 Standard/classification DIN EN 228 (ROZ 95/RON 95/PON 91) Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade. Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use. Info use fuel containing methanol (e.

  • Page 226: Auxiliary Substances

    AUXILIARY SUBSTANCES Air filter cleaning agent Recommended supplier ® Bel-Ray Foam Filter Cleaner & Degreaser Hi h viscosity rease Recommended supplier ® LGHB2 rease Recommended supplier ® Bel-Ray Waterproof Grease Lubricant (T158) Recommended supplier ® Lubcon ® Turmogrease PP 300 Lubricant (T511) Recommended supplier ®...
  • Page 227 AUXILIARY SUBSTANCES Preserving materials for aints, metal and rubber Recommended supplier ® Bel-Ray Silicone Detailer & Protectant Spray Universal oil s ray Recommended supplier ® Bel-Ray 6 in 1...

  • Page 228: Special Tools

    SPECIAL TOOLS Bleeder cover Art. no.: 00029013002 00029013002 H00501-01 Bleeder cover Art. no.: 00029013006 00029013006 H00505-01 Bleedin device Art. no.: 00029013100 00029013100 H00518-01 Battery charger XCharge-professional EU Art. no.: 00029095050 H01065-01 Batte� charger XCharge-�rofessional US Art. no.: 00029095051 H01065-01...
  • Page 229 SPECIAL TOOLS Art. no.: 00029095052 H01065-01 Batte rofessional CH Art. no.: 00029095053 H01065-01 Lockin screw Art. no.: 113080802 113080802 H00944-01 Bearing puller 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...
  • Page 230 SPECIAL TOOLS Tachometer Art. no.: 45129075000 45129075000 H00525-01 hook Art. no.: 50305017000 50305017000 H00973-01 Bleed syrin e Art. no.: 50329050000 50329050000 H00565-01 Circlip pliers reverse Art. no.: 51012011000 51012011000 H00572-01 Extractor Art. no.: 58012009000 58012009000 H00592-01...
  • Page 231 SPECIAL TOOLS Tor ue wrench with various accessories in set Art. no.: 58429094000 ..flt#'� �� 58429094000 H00606-01 Valve s Art. no.: 59029019000 2x.£. 59029019000 H00610-01 Limit plu Art. no.: 59029026006 59029026006 H00612-01 Feeler gauge Art. no.: 59029041100 59029041100 H00616-01 Piston ring mounting tool Art.
  • Page 232 SPECIAL TOOLS Puller, 2-arm Art. no.: 60029033000 2x.£. 60029033000 H00633-01 Hose clam liers Art. no.: 60029057000 60029057000 H00650-01 Testin hose Art. no.: 61029093000 61029093000 H00659-01 Pressure tester Art. no.: 61029094000 4x £ 61029094000 H00660-01 Engine assembly stand Art. no.: 61229001000 61229001000 H00662-01...
  • Page 233 SPECIAL TOOLS Extractor Art. no.: 75029021000 75029021000 H00707-01 Assembl screws Art. no.: 75029033000 4x&. � 75029033000 H00708-01 Push-in drift Art. no.: 75029044010 &. (§) 75029044010 H00712-01 Push-in drift Art. no.: 75029044020 75029044020 H00713-01 Pressing tool for crankshaft, com�lete Art. no.: 75029047000 75029047000 H00714-01...
  • Page 234 SPECIAL TOOLS Clam late Art. no.: 75029050000 75029050000 H00719-01 Push-out drift Art. no.: 75029051000 �� 75029051000 H00721-01 Protection cap Art. no.: 75029090000 75029090000 H00726-01 Oil pressure adapter Art. no.: 75029094000 � 75029094000 H00728-01 Insert for valve s�ring lever Art. no.: 77029041200 �...
  • Page 235 SPECIAL TOOLS lug wrench Art. no.: 77229172000 77229172000 H00761-01 Insertion tool for Art. no.: 77329030100 77329030100 H00768-01 Art. no.: 78029002000 2x£ �� 78029002000 H00783-01 Mounting sleeve Art. no.: 78029005100 78029005100 H00785-01 Removal tool Art. no.: 78029049100 2x.£. 78029049100 H00794-01...
  • Page 236 SPECIAL TOOLS Fixing drift Art. no.: 78129032000 78129032000 H00796-01 tool Art. no.: 78929008000 78929008000 H01016-01 Separator plate Art. no.: 78929009000 78929009000 H00799-01 Gear segment Art. no.: 80029004000 80029004000 H00813-01 Lift stand Art. no.: 81329955000 81329955000 H01015-01...
  • Page 237 SPECIAL TOOLS Mounting sleeve Art. no.: 90129005000 90129005000 H00816-01 Case se tool Art. no.: 90129048100 90129048100 H00828-01 Pin wrench Art. no.: T103 T103 H00838-01 Hook wrench Art. no.: T106S T106S H00841-01 De�th micrometer Art. no.: T107S T107S H00842-01...
  • Page 238 SPECIAL TOOLS Art. no.: T120 T120 H00844-01 Mountin sleeve Art. no.: T1204 T1204 H00878-01 Calibration pin Art. no.: T1205 T1205 H00879-01 Pressing tool .& Art. no.: T1206 � T1206 H00880-01 Pressing tool .&.& Art. no.: T1207S �� T1207S H00881-01...
  • Page 239 SPECIAL TOOLS Mounting sleeve Art. no.: T1215 T1215 H00886-01 Disassembl tool Art. no.: T1216 T1216 H00887-01 Vacuum pump Art. no.: T1240S � T1240S H00890-01 Protecting sleeve Art. no.: T1401 T1401 H00894-01 Clam�ing stand Art. no.: T14016S T14016S H01036-01...
  • Page 240 SPECIAL TOOLS Rin wrench Art. no.: T14017 T14017 H00904-01 Nitro tool Art. no.: T14019 T14019 H00906-01 Support tool Art. no.: T14020 T14020 H00907-01 Calibrating unit Art. no.: T14021 T14021 H00908-01 Mounting tool Art. no.: T14022B T14022B H00910-01...
  • Page 241 SPECIAL TOOLS Threaded bushing Art. no.: T14023 T14023 H00911-01 Mountin sleeve Art. no.: T14029 T14029 H00917-01 Fillin adapter Art. no.: T14030 T14030 H00918-01 Tweezers Art. no.: T14033 T14033 H00921-01 Clam�ing stand Art. no.: T1403S 2x.&. T1403S H00896-01...
  • Page 242 SPECIAL TOOLS Mounting tool Art. no.: T14040S T14040S H00922-01 Press drift Art. no.: T1504 T1504 H00899-01 Assembly tool Art. no.: T150S �o && T150S H00852-01 Nitrogen filling tool Art. no.: T170S1 2x£3x£ T170S1 H00855-01...

  • Page 243: Standards

    STANDARDS JASOT903MA Different technical development directions required a separate specification for 4-stroke motorcycles - the JASO T903 MA stan­ dard. Earlier, engine oils from the automobile industry were used for 4-stroke 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 244: Index

    INDEX Cartridge fork legs, assembling ......29 'Accessories ....... . . 8 fork legs, disassembling .
  • Page 245 INDEX ® cylinder - Nikasil coating ....152 spark plug, installing cylinder head, checking ..... 159 starter idler gear, installing cylinder, checking/measuring starter motor, installing .
  • Page 246 INDEX Fuse main fuse, changing ......106 Figures ........8 Filler cap closing ........79 Hand brake lever opening .........
  • Page 247 INDEX Preparing for use Shock absorber linkage after storage ......212 checking ....... . . 51 Spare parts ........
  • Page 248 INDEX Warranty ........8 Wheel bearing of the front wheel , chan g in g ....95 of the rear wheel , chan g in g ....104 Wiring diagram .
  • Page 249 I 1 1 11 1 11 1 1 1 1 11 1 1 1 111 1 11 1 1 1 1 111 1 1 1 1 1 1 1 1 1 1 11 1 I I I I I I II I I II 3403022en 07/2016 ® Husqvarna llmi Husqvarna Motorcycles GmbH StallhofnerstraBe 3 5230 Mattighofen Austria fiiiHiAv � LZZa" ·...

Table of Contents