Husqvarna FE 450 2014 Repair Manual
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Husqvarna FE 450 2014 Repair Manual

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PIONEERING SINCE 1903
REPAIR MANUAL2014
FE 450
FE 501
®
Husqvarna
Art. no. 3403003en
MOTORCYCLES

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Summary of Contents for Husqvarna FE 450 2014

  • Page 1 PIONEERING SINCE 1903 REPAIR MANUAL2014 FE 450 FE 501 ® Husqvarna Art. no. 3403003en 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 6.17 Disassembling the seal ring MEANS OF REPRESENTATION ......7 retainer ..........26 Symbols used ........7 6.18 Checking the fork legs ......26 1 .2 Formats used ........7 6.19 Assembling the seal ring retainer ..28 SAFETY ADVICE ..........
  • Page 5 TABLE OF CONTENTS Adjusting the riding sag ...... 52 12.7 Removing the fuel tank ....... 92 Removing the shock absorber .... 53 12.8 Installing the fuel tank ......93 9.10 Installing the shock absorber ....54 12.9 Changing the fuel screen ....95 9.11 Checking the shock absorber 12.10 Changing the fuel filter ......

  • Page 6: Removing The Shift Rails

    TABLE OF CONTENTS 15.6 18.3.11 Removing the camshaft ....163 Recharging the battery ..... 126 15. 7 Checking the charging voltage ..128 18.3.12 Removing the cylinder head ..164 15.8 Checking the open-circuit current..128 18.3.13 Removing the piston ....164 18.3.14 Removing the rotor .......
  • Page 7 TABLE OF CONTENTS 18.4. 7 18.5 Engine assembly ....... 207 Installing the crankshaft seal ring in the clutch cover ....180 18.5.1 Installing the crankshaft ....207 18.4.8 Removing the water pump ... 180 18.5.2 Installing the transmission 18.4.9...
  • Page 8 TABLE OF CONTENTS CLUTCH ............228 25.10 Chassis tightening torques ....253 19.1 CLEANING, CARE ......... 255 Checking/correcting the fluid level of the hydraulic clutch ...... 228 26.1 Cleaning the motorcycle ....255 19.2 Changing the hydraulic clutch 26.2 Checks and maintenance steps for fluid ...........

  • Page 9: Means Of Representation

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

  • Page 10: Safety Advice

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

  • Page 11: Important Notes

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

  • Page 12: Serial Numbers

    4 SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right. 401945-10 e label (FE EU/ AU The type label is fixed to the front of the steering head. 401946-10 Key number (FE EU/ AU} The key number for the steering lock is stamped onto the key connector.

  • Page 13: Fork Part Number

    4 SERIAL NUMBERS Fork �art number The fork part number is stamped on the inner side of the fork stub. 401947-10 Shock absorber article number 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 Danger of damage over. Park the vehicle on a firm and level surface. Raise the motorcycle at the frame underneath the engine. I Lift stand (81329955100) (!;,!I p.

  • Page 15: Starting The Motorcycle For A Check

    5 MOTORCYCLE Raise the motorcycle off of the stand and secure the stand with the rubber band Shift transmission to neutral. (FE AU) Turn the emergency OFF switch to the position 0. Condition Ambient temperature: < 20 °C (< 68 °F) Pull the idle speed adjusting screw all the way out.

  • Page 16: Fork, Triple Clamp

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

  • Page 17: Bleeding The Fork Legs

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

  • Page 18: Loosening The Fork Protector

    6 FORK, TRIPLE CLAMP Finishing work Position the fork protector. (� p. 16) Remove the motorcycle from the lift stand. (l!!ll p. 12) Loosening the fork �rotector Remove screws and remove the clamp. Remove screws on the left fork leg. Push the fork protec- tor downwards.

  • Page 19: Installing The Fork Legs

    6 FORK, TRIPLE CLAMP Loosen screws (5) . Take out the left fork leg. Loosen screws Take out the right fork leg. Main work Position the fork legs. ✓ Bleeder screws are positioned toward the front. Info The compression damping is located in left fork COMP (white adjusting screw).

  • Page 20: Removing The Fork Protector

    6 FORK, TRIPLE CLAMP Removing the fork �rotector Preparatory work Switch off all the power consumers and the engine. Remove the headlight mask with the headlight. p. 103) Raise the motorcycle with a lift stand. (!,Jl p. 12) Remove the front wheel. (!,Jl p.
  • Page 21 6 FORK, TRIPLE CLAMP Disassemble the fork legs. (ll!;!J p. 19) Remove the spring. (ll!;!J p. 21) Disassemble the cartridge. p. 22) Disassemble the piston rod. p. 24) Disassemble the hydrostop unit. p. 25) Disassemble the seal ring retainer. p. 26) Check the fork legs.
  • Page 22 6 FORK, TRIPLE CLAMP Loosen the screw cover Mounting tool (T1404 7) (I!!;,! p. 324) Info The cartridge cannot be taken off yet. Unclamp the fork leg. Slide the outer tube down. Drain the fork oil. Clamp the fork leg with the axle clamp. Release hydrostop unit and remove it.

  • Page 23: Removing The Spring

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

  • Page 24: Disassembling The Cartridge

    6 FORK, TRIPLE CLAMP Main work Pull the spring downward. Mount the open end wrench on the hexagonal part. 201722-11 Clamp the open end wrench in the vise. Release screw but do not remove it yet. I Mounting tool (T1404 7) (il.) p.
  • Page 25 6 FORK, TRIPLE CLAMP Remove spring seat Pull the piston rod out of the cartridge. 201726-12 Degrease the cartridge and clamp it with the special tool. Clamping stand (T14049S) (� p. 325) Release seal ring retainer and remove with the washer. 202481-10 Remove lock ring (D.

  • Page 26: Disassembling The Piston Rod

    6 FORK, TRIPLE CLAMP Disassembling the iston rod Info The steps are identical for both fork legs, except for the hydrostop needle and valve. Preparatory work Disassemble the fork legs. (� p. 19) Remove the spring.(� p. 21) Disassemble the cartridge. (�...

  • Page 27: Disassembling The Hydrostop Unit

    6 FORK, TRIPLE CLAMP • Remove adapter with spring @ and washer . Remove spring (D. 201788-10 Remove valve needle Q) from the piston rod. Info The adjusting tube can be used for this. 201789-10 Disassembling the h unit Info The steps are identical for both fork legs.

  • Page 28: Disassembling The Seal Ring Retainer

    6 FORK, TRIPLE CLAMP Remove shim stack (D. Remove washer @. Remove O-ring Disassemblin the seal rin retainer Info The steps are identical for both fork legs. Preparatory work Disassemble the fork legs. (!!:,!I p. 19) Remove the spring. (!!:,!I p.
  • Page 29 6 FORK, TRIPLE CLAMP Measure the outside diameter at multiple locations of the inner tube. Outside diameter of inner 47.975 ... 48.005 mm (1 .88878 ... 1.88996 in) tube If the measured value is smaller than the specified value: Change the inner tube. Measure the run-out of the inner tube.

  • Page 30: Assembling The Seal Ring Retainer

    6 FORK, TRIPLE CLAMP Assembling the seal ring retainer Info The steps are identical for both fork legs. Mount and grease seal ring I Lubricant (T158) (l!!l p. 308) Mount and grease O-ring I Lubricant (T158) (l!!l p. 308) Position pilot bushing support Assembling the hydrostop unit Info The steps are identical for both fork legs.

  • Page 31: Assembling The Piston Rod

    6 FORK, TRIPLE CLAMP Check distance and total length G) of the hydrostop. Guideline Hydrostop distance � 1 .5 mm (� 0.059 in) 108.5 ... 109.5 mm (4.272 Hydrostop length ... 4.311 in) If the dimensions are out of tolerance: Add or remove washers 201975-10 Assemblin...

  • Page 32: Assembling The Cartridge

    6 FORK, TRIPLE CLAMP Grind the piston on both sides on a surfacing plate using 1200 grit sandpaper. Clean the piston. Lubricate the piston ring. I Fork oil (SAE 4) (48601166S1) (11\:! p. 306) Mount the piston with chamfer facing down. Mount rebound shim stack with the smaller shims facing upward.
  • Page 33 6 FORK, TRIPLE CLAMP Main work Mount and grease seal rings and O-ring @. Lubricant (T158) (� p. 308) Mount and lubricate pilot bushings Fork oil (SAE 4) (48601166S1) (� p. 306) Check the length of the reservoir spring. Guideline Reservoir spring length with 46 mm (1.81 in) preload spacer...

  • Page 34: Assembling The Fork Legs

    6 FORK, TRIPLE CLAMP Clamp piston rod with the special tool. I Clamping stand (T14049S) (I!!,! p. 325) Mount spring guide � all the way on. Info The nut must be firmly tightened against the stop by hand. Do not use a tool. Mount adjusting tube 202480-11 Unclamp the piston rod.
  • Page 35 6 FORK, TRIPLE CLAMP Sand the edges of the sliding bushings with 600 grit sandpa­ per; then clean and grease the bushings. Fork oil (SAE 4) (48601166S1) (llill p. 306) 201715-10 Push on lower sliding bushing Mount upper sliding bushing Q). Info Without using a tool, pull the stack slightly apart by hand.
  • Page 36 6 FORK, TRIPLE CLAMP Mount dust boot Mount fork protector ring G). Grease the O-ring. I Fork oil (SAE 4) (48601166S1) (ll!:!l p. 306) Slide the cartridge all the way into the fork leg. Turn the fork. Have the entire filling quantity of fork oil avail­ able.
  • Page 37 6 FORK, TRIPLE CLAMP Pull out the piston rod and push it back in numerous times while pressing it to one side slightly. ✓ Air bubbles emerge and the cartridge is bled. Keep bleeding until no more air bubbles emerge. ✓...

  • Page 38: Lubricating The Steering Head Bearing

    6 FORK, TRIPLE CLAMP Alternative 1 Turn the adjuster of compression damping Gi) (mark and the adjuster of rebound damping COMP) (mark REB) all the way clockwise. Guideline Rebound damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks Compression damping Comfort 15 clicks Standard...

  • Page 39: Removing The Lower Triple Clamp

    6 FORK, TRIPLE CLAMP 6.25 Removing the lower tri�le clam� Preparatory work Switch off all the power consumers and the engine. Remove the headlight mask with the headlight. (!!;!I p. 103) Raise the motorcycle with a lift stand. (!!;!I p. 12) Remove the front wheel.

  • Page 40: Installing The Lower Triple Clamp

    6 FORK, TRIPLE CLAMP 6.26 Installing the lower tri�le clam� Main work Clean the bearing and sealing elements, check for damage, and grease. I High viscosity grease (I!!:! p. 308) Position the lower triple clamp with the steering stem. Mount the upper steering head bearing.
  • Page 41 6 FORK, TRIPLE CLAMP Tighten screws (D. Guideline Screw, bottom triple 15 Nm (11.1 lbf ft) clamp Tighten screw Guideline Screw, top steering M20x1 .5 12 Nm (8.9 lbf ft) head Mount and tighten screw @. Guideline Screw, top 17 Nm (12.5 lbf ft) ®...

  • Page 42: Checking The Play Of The Steering Head Bearing

    6 FORK, TRIPLE CLAMP Check that the wiring harness, throttle cables, and brake and clutch lines can move freely and are routed correctly. Check the play of the steering head bearing. (ll!.:! p. 40) Remove the motorcycle from the lift stand. (ll!.:! p.
  • Page 43 6 FORK, TRIPLE CLAMP Main work Remove the lower bearing race using a suitable tool. Press in the new bearing race all the way using a suitable tool. Remove the upper bearing race using a suitable tool. Press in the new bearing race all the way using a suitable tool.

  • Page 44: Adjusting The Steering Head Bearing Play

    6 FORK, TRIPLE CLAMP Install the front wheel. p. 109) Install the headlight mask with the headlight. p. 103) Check that the wiring harness, throttle cables, and brake and clutch lines can move freely and are routed correctly. Check the play of the steering head bearing. p.

  • Page 45: 7 Handlebar,Controls

    7 HANDLEBAR,CONTROLS Handlebar �osition On the upper triple clamp, there are two holes at a distance to each other. 1 15 mm (0.59 in) Hole distance The holes on the handlebar supports are placed at a distance from the center. I 3.5 mm (0.138 in) Hole distance The handlebar supports can be mounted in four different posi­...

  • Page 46: Adjusting The Basic Position Of The Clutch Lever

    7 HANDLEBAR,CONTROLS Info Make sure the gap width is even. 7 .3 Adjustin the basic position of the clutch lever Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar.

  • Page 47: Checking The Play In The Throttle Cable

    7 HANDLEBAR,CONTROLS Checking the �lay in the throttle cable Check the throttle grip for smooth operation. Move the handlebar to the straight-ahead position. Move the throttle grip back and forth slightly to ascertain play in the throttle cable. Play in throttle cable 3 ...
  • Page 48 7 HANDLEBAR,CONTROLS Main work Move the handlebar to the straight-ahead position. Push back sleeves Loosen nut@. Turn adjusting screw@) in as far as possi- ble. Loosen nut Turn adjusting screw @t so that there is play in the throttle cable at the throttle grip. Guideline I Play in throttle cable I 3 ...

  • Page 49: 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 mechanical impact. Repair of the frame is not authorized by Husqvarna 401799-01 Motorcycles.

  • Page 50: Shock Absorber, Swingarm

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

  • Page 51: Adjusting The Rebound Damping Of The Shock Absorber

    9 SHOCK ABSORBER, SWINGARM Turn adjusting screw clockwise with a screwdriver up to the last perceptible click. Info Do not loosen nut Turn counterclockwise by the number of clicks correspond­ ing to the shock absorber type. Guideline Compression damping, low-speed Comfort 20 clicks Standard...

  • Page 52: Measuring Rear Wheel Sag Unloaded

    9 SHOCK ABSORBER, SWINGARM Measuring rear wheel sag unloaded Preparatory work Raise the motorcycle with a lift stand. (� p. 12) Main work Measure the distance - as vertically as possible - between the rear axle and a fixed point such as a mark on the side cover.

  • Page 53: Checking The Riding Sag Of The Shock Absorber

    9 SHOCK ABSORBER, SWINGARM Checking the riding sag of the shock absorber Measure distance of rear wheel unloaded. (ta:!! p. 50) 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 54: Adjusting The Riding Sag

    9 SHOCK ABSORBER, SWINGARM Main work Loosen screw Turn adjusting ring until the spring is no longer under ten- sion. I Hook wrench (T106S) (ia:! p. 321) Measure the overall spring length while the spring is not under tension. Tighten the spring by turning adjusting ring to measure­...

  • Page 55: Removing The Shock Absorber

    9 SHOCK ABSORBER, SWINGARM Main work Choose and mount a suitable spring. Guideline Spring rate Weight of rider: 65 ... 54 N/mm (308 lb/in) 75 kg (143 ... 165 lb.) Weight of rider: 75 ... 57 N/mm (325 lb/in) 85 kg (165 ... 187 lb.) Weight of rider: 85 ...

  • Page 56: Installing The Shock Absorber

    9 SHOCK ABSORBER, SWINGARM Main work Carefully position the shock absorber into the vehicle from above. Finishing work Install the manifold. (� p. 83) Mount the seat. (� p. 91) Install the main silencer. (� p. 85) Install the right side cover. (!lll p.
  • Page 57 9 SHOCK ABSORBER, SWINGARM •- -• 303096-10 Check needle bearings for damage and wear. If there is damage or wear: Change the needle bearings. Check spacers (3 and @ for damage and wear. If there is damage or wear: Change the spacers. Check the shaft seal rings for damage and wear.

  • Page 58: Servicing The Shock Absorber

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

  • Page 59: Removing The Spring

    9 SHOCK ABSORBER, SWINGARM Remove the spring. (ll!:! p. 57) Disassemble the damper. (ll!:! p. 58) Disassemble the piston rod. (� p. 59) Disassemble the seal ring retainer. (� p. 60) Check the damper. p. 62) Remove the heim joint. p.

  • Page 60: Disassembling The Damper

    9 SHOCK ABSORBER, SWINGARM 9.14 Disassembling the dam�er Preparatory work Remove the spring. (� p. 57) Main work Note down the current state of rebound damping compression damping Completely open the adjusters of the rebound and compres­ sion damping. Remove rubber cap of the reservoir.

  • Page 61: Disassembling The Piston Rod

    9 SHOCK ABSORBER, SWINGARM Remove the piston rod. Remove adjusting ring with the intermediate washer. Drain the oil. Remove compression adjuster Remove the spring and piston. 9.15 Disassembling the piston rod Preparatory work Remove the spring. p. 57) Disassemble the damper. p.

  • Page 62: Disassembling The Seal Ring Retainer

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

  • Page 63: Changing The Pilot Bushing

    9 SHOCK ABSORBER, SWINGARM Remove centering disk Remove seal ring 201406-10 Remove washer for seal ring Remove washer Remove dust boot. 201407-10 9.17 Changing the �ilot bushing Preparatory work Remove the spring. (� p. 57) Disassemble the damper. (� p. 58) Disassemble the piston rod.

  • Page 64: Checking The Damper

    9 SHOCK ABSORBER, SWINGARM Lubricate the special tool. Shock absorber fluid (SAE 2.5) (50180751 S1) (l!t! p. 307) Calibrating unit (T1205) (� p. 322) Support seal ring retainer with sleeve of the special tool. I Mounting tool (T150S) (� p. 325) Press the special tool through the new pilot bushing.

  • Page 65: Removing The Heim Joint

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

  • Page 66: Installing The Heim Joint

    9 SHOCK ABSORBER, SWINGARM Installing the heim joint Position the new heim joint and the special tool into a vise as shown. Guideline I Use soft jaws. I Pressing tool (T1206) p. 322) Press the heim joint all the way in. Press the heim joint against the lock ring using the special tool.

  • Page 67: Assembling The Piston Rod

    9 SHOCK ABSORBER, SWINGARM Mount washer @. Position washer (Don seal ring 201409-10 Grease seal ring and mount with the washer facing down­ ward. Lubricant (T14034) p. 308) Mount centering disk 201410-10 Mount rebound rubber (D. Grease the 0-ring groove. Lubricant (T158) p.
  • Page 68 9 SHOCK ABSORBER, SWINGARM Mount rebound washer with the cut-out facing down­ ward. Mount the compression shim stack with the smaller shims facing downward. 201418-10 Sand both sides of piston (3 on a surface plate using 1200- grit sandpaper. Clean the piston. Assemble the piston.

  • Page 69: Assembling The Damper

    9 SHOCK ABSORBER, SWINGARM Grease the thread of the piston rod. Lubricant (T152) (I!!;! p. 308) Mount and tighten nut Guideline Nut, piston rod I M16x1 I 45 Nm (33.2 lbf ft) 201422-10 9.23 Assemblin the damper Preparatory work Assemble the seal ring retainer. (!ill p.
  • Page 70 9 SHOCK ABSORBER, SWINGARM Install the seal ring bearer and push it under the ring groove. Mount lock ring • Info Do not scratch the inner surface. Pull out the piston rod so that the seal ring retainer rests against the lock ring. Mount locking cap of the damper cartridge.

  • Page 71: Bleeding And Filling The Damper

    9 SHOCK ABSORBER, SWINGARM Turn counterclockwise by the number of clicks corre­ sponding to the shock absorber type. Guideline Rebound damping Comfort 20 clicks Standard 18 clicks Sport 16 clicks Alternative 2 Warning Danger of accident Modifications to the sus­ pension setting may seriously alter the handling characteristic.
  • Page 72 9 SHOCK ABSORBER, SWINGARM Clamp the control lever as shown in the figure. ✓ The control lever is External tank Closed, Damper on Vacuum, Oil reservoir on Vacuum. Operate the switch (D. On/Off ✓ The vacuum pump process starts. ✓ Pressure gauge @ drops to the specified value. I <...
  • Page 73 9 SHOCK ABSORBER, SWINGARM When the pressure gauge reaches the specified value, turn Oil reservoir control lever to Vacuum. Guideline 0 bar ✓ The vacuum gauge falls to the specified value. 8 mbar When the vacuum pressure gauge reaches the specified value, turn the control lever Oil reservoir...

  • Page 74: Filling Damper With Nitrogen

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

  • Page 75: Installing The Spring

    9 SHOCK ABSORBER, SWINGARM 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 76: Checking The Swingarm

    9 SHOCK ABSORBER, SWINGARM Alternative 2 Warning Modifications to the sus­ Danger of accident 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 77: Removing The Swingarm

    9 SHOCK ABSORBER, SWINGARM Main work Move the swingarm up and down. If there is detectable play: Change the swingarm bearing. (� p. 78) Move the swingarm from one side to the other. If there is detectable play: Change the swingarm bearing. (�...

  • Page 78: Installing The Swingarm

    9 SHOCK ABSORBER, SWINGARM Remove connecting link of the chain. Info Cover the components to protect them against dam­ age. Take off the chain. Remove fitting Lower the swingarm. Remove nut Remove the swingarm pivot. Take off the swingarm. Main work Position the swingarm.
  • Page 79 9 SHOCK ABSORBER, SWINGARM Mount the chain. Connect the chain with connecting link (D. Guideline The closed side of the chain joint lock must face in the direction of travel. Position the engine sprocket cover and mount in the holder. Mount and tighten screws Guideline Screw, clutch slave...

  • Page 80: Changing The Swingarm Bearing

    9 SHOCK ABSORBER, SWINGARM Changing the swingarm bearing Info These operations are the same on both swingarm bearings. Preparatory work Raise the motorcycle with a lift stand. (� p. 12) Remove the rear wheel. (� p. 111) Remove the swingarm. (�...
  • Page 81 9 SHOCK ABSORBER, SWINGARM 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 Ci). Mount bushing @. G01814-10 Grease the shaft seal rings. Long-life grease (lll:!I p.
  • Page 82 9 SHOCK ABSORBER, SWINGARM Remove the motorcycle from the lift stand. (� p. 12)

  • Page 83: Exhaust

    EXHAUST Removing the manifold 10.1 Preparatory work Raise the motorcycle with a lift stand. p. 12) Remove the seat. p. 91) Remove the right side cover. (!,JI p. 91) Remove the main silencer. (!i.,!I p. 84) Main work Remove fitting Remove screw @.
  • Page 84 10 EXHAUST Remove screw @. Raise the rear frame slightly and lower the shock absorber. (FE EU) Remove the fuel tank. (� p. 92) Disconnect plug-in connector of the lambda sensor and remove the cable binder. Remove springs I Spring hook (50305017000) (�...

  • Page 85: Installing The Manifold

    EXHAUST Main work Position the manifold and mount springs Spring hook (50305017000) p. 312) Mount and tighten screw Guideline 25 Nm (18.4 lbf ft) Remaining screws, chassis (FE EU) Connect plug-in connector of the lambda sensor, route the cable without tension, and secure with a new cable binder.

  • Page 86: Removing The Main Silencer

    10 EXHAUST Lower the swingarm. Position the angle lever and linkage lever. Mount and tighten fitting @. Guideline Nut, linkage lever on M 14x1 .5 80 Nm (59 lbf ft) angle lever Mount and tighten screw@). Guideline 60 Nm (44.3 lbf ft) Screw, bottom ®...

  • Page 87: Installing The Main Silencer

    EXHAUST Installing the main silencer Main work Mount the main silencer. Mount screws but do not tighten yet. Attach spring Spring hook (50305017000) (!i.,!I p. 312) Tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis Finishing work Install the right side cover. (!i.,!I p.
  • Page 88 10 EXHAUST (FE 501 US) Remove screws of connecting cap Remove connecting cap with the perforated pipe, O- ring and glass fiber yarn filling Remove screws and silencer cap with O-ring Remove screws and insert Q) together with insulat- ing pad�- Remove the insulating pad from the insert.

  • Page 89: 11 Air Filter

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

  • Page 90: Installing The Air Filter

    11 AIR FILTER 11.4 Installing the air filter Main work Mount the clean air filter on the air filter support. Grease the air filter in area t). I Long-life grease (� p. 308) Insert both parts together, position them, and secure them using air filter holder in area G).

  • Page 91: Sealing The Air Filter Box

    11 AIR FILTER Finishing work Install the air filter. (� p. 88) Install the air filter box cover. (!1ll p. 87) 11.6 Sealing the air filter box Preparatory work Remove the air filter box cover. (!1ll p. 87) Main work Seal the air filter box in the marked area f).

  • Page 92: 12 Fuel Tank, Seat, Trim

    12 FUEL TANK, SEAT, TRIM 12.1 O�ening 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 93: Removing The Right Side Cover

    FUEL TANK, SEAT, TRIM Removing the right side cover Remove screw Pull off the side cover in area 6) sideways and remove it toward the rear. Installing the right side cover Position the side cover and engage in area 6) . Mount and tighten screw Guideline Remaining screws,...

  • Page 94: 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 95: Installing The Fuel Tank

    FUEL TANK, SEAT, TRIM (FE EU/AU) Disconnect the connector of the horn. Remove screws (i) with the collar bushings and horn. (FE 501 US) Remove screws (i) with the collar bushings. Remove screw with the rubber bushing. Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank.
  • Page 96 12 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 97: Changing The Fuel Screen

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

  • Page 98: Changing The Fuel Filter

    12 FUEL TANK, SEAT, TRIM Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. Always make sure there is sufficient ventilation when running the engine. Use an effective exhaust extraction system when starting or running the engine in an enclosed space.
  • Page 99 FUEL TANK, SEAT, TRIM Main work Remove nut with the gasket. Remove fuel connection @ with the gasket. 305313-10 Remove screws Pull out the fuel pump. 305314-10 Remove hose clamps Remove fuel filter 305315-10 Press lock Pull back fuel pump housing@. 305317-10 Change fuel screen Mount the fuel pump housing.

  • Page 100: Changing The Fuel Pump

    12 FUEL TANK, SEAT, TRIM Mount fuel filter ✓ Arrow points away from the fuel pump. Mount hose clamps I Hose clamp plier (60029057000) (ll!:!l p. 315) 305316-10 Position the fuel pump. Mount fuel connection with the gasket but do not tighten yet.
  • Page 101 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 102: Checking The Fuel Pressure

    12 FUEL TANK, SEAT, TRIM Guideline Fuel connection on 10 Nm (7.4 lbf ft) fuel pump Mount and tighten screws Guideline I Screw, fuel pump 3 Nm (2.2 lbf ft) EJOT PT ® 305314-10 12.12 Checking the fuel �ressure Danger Fuel is highly flammable.
  • Page 103 FUEL TANK, SEAT, TRIM Info Remaining fuel may flow out of the fuel hose. Mount special tool@. Pressure testing tool (61029094000) (� p. 315) Mount special tool with nozzle label 0,60. Testing hose (61029093000) (� p. 315) Position the hose end in a fuel cannister. Guideline Minimum size of fuel cannis- 10 I (2.6 US gal)

  • Page 104: 13 Mask, Fender

    13 MASK, FENDER 13.1 Removing front fender Preparatory work Switch off all the power consumers and the engine. Remove the headlight mask with the headlight. p. 103) Main work Disconnect plug-in connectors of the turn signals. Remove screws Take the brake line and wiring harness out of the brake line guide.

  • Page 105: Removing The Headlight Mask With The Headlight

    13 MASK, FENDER 13.3 Removing the headlight mask with the headlight Preparatory work Switch off all the power consumers and the engine. Main work Open rubber bands on the fork legs. Tilt the headlight mask forward and detach at catch Disconnect connector Take off the headlight mask with headlight.

  • Page 106: 14 Wheels

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

  • Page 107: 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 108: 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 109: Checking The Rim Run-Out

    14 WHEELS Guideline Spoke nipple, front M4.5 6 Nm (4.4 lbf ft} wheel Spoke nipple, rear M4.5 6 Nm (4.4 lbf ft) wheel Torque wrench set (58429094000) (!!;! p. 313) Checking the rim run-out Warning Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary damage.

  • Page 110: Front Wheel

    14 WHEELS Front wheel 14.7 14.7.1 Removing the front wheel Preparatory work Raise the motorcycle with a lift stand. (!:Jl p. 12) Main work Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. •...

  • Page 111: Installing The Front Wheel

    14 WHEELS 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 112: Lnstalling The Front Brake Disc

    14 WHEELS 14.7.4 Installing the front brake disc Main work Clean the contact surface of the brake disc. Position the brake disc with the label facing outward. Mount and tighten screws Guideline Screw, front 14 Nm (10.3 lbf ft) ® brake disc Loctite 243™...

  • Page 113: Rear Wheel

    14 WHEELS Position spacing tube 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. Grease new shaft seal rings and press in until they are flush.

  • Page 114: Installing The Rear Wheel

    14 WHEELS Holding the rear wheel, withdraw the wheel spindle. Take the rear wheel out of the swingarm. Info Do not operate the foot brake lever when the rear wheel is removed. Remove spacers 14.8.2 Installing the rear wheel Warning Oil or grease on the brake discs reduces the braking effect.

  • Page 115: Removing The Rear Brake Disc

    14 WHEELS Position chain adjuster Mount nut but do not tighten it yet. Make sure that chain adjusters are fitted correctly on adjusting screws Check the chain tension. p. 114) Tighten nut Guideline Nut, rear wheel spin- M20x1 .5 80 Nm (59 lbf ft) •...

  • Page 116: Checking The Chain Tension

    14 WHEELS 14.8.5 Checking the chain tension Warning Incorrect chain tension damages components and results in accidents. Danger of accidents If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.

  • Page 117: Checking The Chain, Rear Sprocket, Motor Sprocket, And Chain Guide

    14 WHEELS Main work Loosen nut Loosen nuts Adjust the chain tension by turning adjusting screws (D left and right. Guideline Chain tension 55 ... 58 mm (2.17 ... 2.28 in) Turn adjusting screws (D on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks 6).
  • Page 118 14 WHEELS Pull at the top part of the chain with the specified weight fj. Guideline Weight of chain wear mea­ 10 ... 15 kg (22 ... 33 lb.) surement Measure the distance of 18 chain links in the lower chain section.
  • Page 119 14 WHEELS Check the chain sliding piece for wear. If the lower edge of the chain pins is in line with or below the chain sliding piece: Change the chain sliding piece. Check that the chain sliding piece is firmly seated. If the chain sliding piece is loose: Tighten the chain sliding piece.

  • Page 120: Checking For Chain Dirt Accumulation

    14 WHEELS 14.8.8 Checking for chain dirt accumulation Check the chain for coarse dirt accumulation. If the chain is very dirty: Clean the chain. p. 118) 400678-01 14.8.9 Cleaning the chain Warning Oil or grease on the tires reduces the road grip. Danger of accidents Remove the lubricant from the tires using a suitable cleaning agent.
  • Page 121 14 WHEELS Main work Remove screws Take off the engine sprocket cover. Have an assistant operate the rear brake. Remove screw with the washer. Remove the rear wheel. p. 111) Remove connecting link of the chain. Info Cover the components to protect them against dam­ age.

  • Page 122: Changing The Rear Wheel Bearing

    14 WHEELS Slide new engine sprocket onto the countershaft. Mount the new chain. Connect the chain with connecting link Guideline The closed side of the chain joint lock must face in the direction of travel. Install the rear wheel. (l!!l p.
  • Page 123 14 WHEELS Main work Remove shaft seal ring Remove lock ring Remove shaft seal ring Using a suitable tool, press bearing out from the inside to the outside. Remove spacing tube Using a suitable tool, press bearing Q) out from the inside to the outside.
  • Page 124 14 WHEELS Clean, grease, and mount spacing tube @t. I Long-life grease (!!:!I p. 308) Press new bearing all the way in from the outside to the inside. Info Only press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in. Grease new shaft seal ring and press it in until it is flush.

  • Page 125: 15 Wiring Harness, Battery

    15 WIRING HARNESS, BATTERY Changing the fuses of individual �ower consumers Info The fuse box containing the fuses of individual power consumers is located under the seat. Preparatory work Switch off all power consumers and switch off the engine. Remove the seat. (llill p.

  • Page 126: Changing The Main Fuse

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

  • Page 127: Removing The Battery

    15 WIRING HARNESS, BATTERY Main work Disconnect the negative cable of the battery. Pull the starter relay off of the bracket. Pull off connector Disconnect cables on the starter relay. Connect the starter relay to a 12 V power supply as per the figure.

  • Page 128: Installing The Battery

    Warning Batteries contain environmentally-hazardous materials. Environmental hazard Do not dispose of batteries as household waste. Return batteries to your authorized Husqvarna Motorcycles dealer or dispose of them at a collection point for used batteries.
  • Page 129 15 WIRING HARNESS, BATTERY 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. 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.

  • Page 130: Checking The Charging Voltage

    15 WIRING HARNESS, BATTERY 15.7 Checking the charging voltage Condition The battery must be fully functional and completely charged. Preparatory work Remove the seat. p. 91) Main work Carry out the start procedure. p. 12) Measure the voltage between the specified points. (+) - Measuring point Measuring point Plus...

  • Page 131: Brake System

    BRAKE SYSTEM Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. Ensure that worn-out brake linings are replaced immediately. Check the brake linings for minimum thickness f) . I � Minimum thickness f) 1 mm (�...
  • Page 132 Brake linings which have not been approved alter the braking efficiency. Danger of accidents Not all brake linings are tested and approved for Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.

  • Page 133: Checking The Free Travel Of The Hand Brake Lever

    BRAKE SYSTEM Insert the new brake linings, insert pin and mount cotter pinsC,. • Info Always change the brake linings in pairs. 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 134: Adjusting The Basic Position Of The Hand Brake Lever (Fe 501 Us)

    16 BRAKE SYSTEM (FE 501 US) Push the hand brake lever forward and check free travel 6). � 3 mm(� 0.12 in) Free travel of hand brake lever If the free travel does not match the specification: Adjust the basic position of the hand brake lever. (�...

  • Page 135: Checking The Front Brake Fluid Level

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

  • Page 136: Changing The Front Brake Fluid

    16 BRAKE SYSTEM 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. 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 137 BRAKE SYSTEM Info Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container. Move the brake fluid reservoir mounted on the handlebar to a horizontal position. Cover the painted parts. Remove screws Remove cover with membrane.

  • Page 138: Checking The Rear Brake Linings

    16 BRAKE SYSTEM • Info This prevents overfilling of the brake fluid reservoir. Tighten the bleeder screw. Remove the hose of the bleeder bottle. Mount the protection cap. Disconnect the bleeding device. Remove the bleeder cover. Add brake fluid to level Guideline I Measurement of I 5 mm (0.2 in)
  • Page 139 Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 140 16 BRAKE SYSTEM Stand the vehicle upright. Remove screw cap with membrane @ and the 0-ring. Press the brake caliper onto the brake disc by hand in order to push back the brake piston and ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suction if it does.

  • Page 141: Brake Lever

    BRAKE SYSTEM Add brake fluid to level f). Brake fluid DOT 4 (!!ll p. 306) Mount screw cap with membrane @ and 0-ring. Info Clean up overflowed or spilled brake fluid immediately with water. Checkin the free travel of foot brake lever Warning Danger of accidents The brake system fails in the event of overheating.

  • Page 142: Adjusting The Basic Position Of The Foot Brake Lever

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

  • Page 143: Adding Rear Brake Fluid

    BRAKE SYSTEM Stand the vehicle upright. Check the brake fluid level in level viewer lf the brake fluid level has dropped below marking 6): Add rear brake fluid. (I!!;!! p. 141) Addin 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 144: Changing The Rear Brake Fluid

    16 BRAKE SYSTEM Main work Stand the vehicle upright. Remove screw cap with membrane and the 0-ring. Add brake fluid to level f). I Brake fluid DOT 4 (l!!ll p. 306) Mount the screw cap with the membrane and the 0-ring. Info Clean up overflowed or spilled brake fluid immediately with water.
  • Page 145 BRAKE SYSTEM Cover the painted parts. Remove screw cap with membrane and the O-ring. Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid. Syringe (50329050000) (� p. 312) Brake fluid DOT 4 (�...
  • Page 146 16 BRAKE SYSTEM Stand the vehicle upright. Correct the brake fluid up to marking (!). I Brake fluid DOT 4 (� p. 306) Fit and tighten plug with oil screen and O-ring. Info Clean up overflowed or spilt brake fluid immediately with water.

  • Page 147: 17 Lighting System, Instruments

    17 LIGHTING SYSTEM, INSTRUMENTS 17.1 Adjusting the combination instrument Condition The motorcycle is stationary. Press and hold both buttons for 3 - 5 seconds. ✓ The Setup menu is displayed. The UNIT display flashes. Press one of the buttons to select UNIT for the speed in kilo­...

  • Page 148: Adjusting The Kilometers Or Miles

    LIGHTING SYSTEM, INSTRUMENTS Switching off the service interval display Press and hold the left button. ✓ appears on the display. 401914-01 Adjustin the kilometers or miles Info If the unit is changed, the value ODO is retained and converted accordingly. Condition The motorcycle is stationary.

  • Page 149: Setting The Wheel Circumference

    17 LIGHTING SYSTEM, INSTRUMENTS 17.4 Setting the wheel circumference Condition The motorcycle is stationary. Preparatory work Disconnect speedometer connector Main work Press both buttons for 3 - 5 seconds. ----,�-1 - �-- ✓ The Setup menu is displayed. The UNIT display flashes. -um �- ,,,,,, / I\' KM/H...

  • Page 150: Checking The Headlight Setting

    LIGHTING SYSTEM, INSTRUMENTS Switching off the service interval display Press and hold the left button. ✓ appears on the display. 401914-01 Checkin the headli Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight.

  • Page 151: 18 Engine

    18 ENGINE 18.1 Removing the engine Preparatory work Remove the engine guard. p. 47) Drain the coolant. p. 232) Raise the motorcycle with a lift stand. p. 12) Remove the right side cover. (Ii.,! p. 91) Remove the main silencer. (Ii.,! p.
  • Page 152 18 ENGINE Remove screws (D. Loosen screw @. Repeat these steps on the opposite side. Pivot up the subframe and secure it. Remove screw @. Swing the shock absorber to the rear. Remove springs C!). I Spring hook (50305017000) p. 312)
  • Page 153 18 ENGINE Remove screw Ci). Take off the manifold. Push back the cover. «D­ Remove nut Take off the cable. Loosen hose clips �. Pull off the radiator hoses. Detach spring Pull back the protection cap. Unplug connector Disconnect the spark plug connector.
  • Page 154 18 ENGINE Remove screw �. Remove screw Ci). Take off the engine sprocket cover. Remove the connecting link of the chain. Take off the chain. Remove the cable ties. Remove screws Take off the slave cylinder of the clutch and hang it to one side.
  • Page 155 18 ENGINE Remove fittings fl!). Take off the engine braces. Unplug connector @D. Unplug connector�- Remove nut Remove the swingarm pivot. Pull the swingarm slightly toward the rear. 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.

  • Page 156: Installing The Engine

    18 ENGINE Main work Position the engine in the frame. 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. Mount screws but do not tighten yet.
  • Page 157 18 ENGINE Mount the radiator hose. Position and tighten hose clip 0). Mount the throttle valve body. Position and tighten hose clip @. Position the clutch slave cylinder with the gasket. Mount and tighten screws Guideline Screw, clutch slave 10 Nm (7.4 lbf ft) cylinder Mount the chain.
  • Page 158 18 ENGINE 48 . Plug in connector Position the protection cap. Plug in the spark plug connectors. Mount spring G). Mount the radiator hoses. 4D . Position and tighten hose clips Position the cable. Mount and tighten nut Position the cover. Position the manifold and mount springs�­...
  • Page 159 18 ENGINE Mount and tighten screw Guideline 25 Nm (18.4 lbf ft) Remaining screws, chassis Position the shock absorber. Gs,. Mount and tighten screw Guideline Screw, top 60 Nm (44.3 lbf ft) ® Loctite 2701 shock absorber Remove the locking piece and position the subframe. Info Watch out for the intake flange.
  • Page 160 18 ENGINE Position the intake air temperature sensor. Mount and tighten screws�- Guideline Screw, intake air 2 Nm (1.5 lbf ft) temperature sensor Plug in connector fJ). Position the protection cap. Position and tighten hose clip ... Connect negative cable � of the battery. Guideline Screw, battery termi- 2.5 Nm (1.84 lbf ft)

  • Page 161: Engine Disassembly

    231) Execute the initialization run. (l!!,!I p. 244) Finishing work Take a test ride. Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. Check the engine for leak tightness. Check the engine oil level. (l!!,!I p. 234) Check the coolant level.

  • Page 162: Removing The Clutch Push Rod

    18 ENGINE Remove engine oil screen plug@. Completely drain the engine oil. Remove engine oil screen Remove engine oil screen plug Removing the clutch push rod 18.3.3 Remove clutch push rod 18.3.4 Removing the oil filter Remove screws Remove oil filter cover with the O­...

  • Page 163: Removing The Starter Motor

    18 ENGINE Pull oil filter out of the oil filter housing. Lock ring plier (51012011000) (i!!,!l p. 313) 18.3.5 Removing the starter motor Remove screws and take off the starter motor. 18.3.6 Removing the spark plug Remove the spark plug using the special tool. Spark plug wrench with link (77229172000) (�...

  • Page 164: Removing The Alternator Cover

    18 ENGINE 18.3.8 Removing the alternator cover Remove screws Remove the alternator cover. Remove centering pins Take off the alternator cover gas­ ket@). 18.3.9 Positioning the engine at ignition top dead center Turn the crankshaft counterclockwise until the markings are flush with the marking on the cylinder head.

  • Page 165: Removing The Timing Chain Tensioner

    18 ENGINE 18.3.10 Removing the timing chain tensioner Remove screw Remove screw Take off the chain adjuster with the gasket. 18.3.11 Removing the camshaft Remove screw Remove the camshaft support plate Pull the camshaft out of the bearing seats. Take the timing chain off the camshaft gear.

  • Page 166: Removing The Cylinder Head

    18 ENGINE 18.3.12 Removing the cylinder head Remove screw Unscrew screws @ in a crisscross pattern and remove. Remove the cylinder head. Take off the dowels. Remove the cylinder head gasket. 18.3.13 Removing the piston Push the cylinder upward. Info Only push the cylinder as far up as necessary to take the piston pin out.

  • Page 167: Removing The Timing Chain Guide Rail

    18 ENGINE Attach special tool to the rotor. Hold it tight using the special tool and pull off the rotor by turning the screw in. Puller (58012009000) (ll!:!l p. 313) Remove the woodruff key. 18.3.15 Removing the timing chain guide rail Remove screw Take off timing chain guide rail toward the top.

  • Page 168: Removing The Timing Chain

    18 ENGINE 18.3.18 Removing the timing chain Take off the timing chain. Info Identify the direction of travel. 18.3.19 Removing the ignition pulse generator Remove screws Pull the cable support sleeve from the engine case. Take off the crankshaft position sensor. Removing the suction pump 18.3.20 Remove screws...

  • Page 169: Removing The Water Pump Cover

    18 ENGINE @) . Take off pin Remove pin upward. Remove O-ring 18.3.21 Removing the water pump cover Remove screws Take off the water pump cover. Take off the water pump cover seal. 18.3.22 Removing the clutch cover Remove screws Take off the clutch cover.

  • Page 170: Removing The Clutch Discs

    18 ENGINE 18.3.23 Removing the clutch discs Remove screws Take off spring retainer@. Take off spring washer@). Take off pretension ring Take off pressure cap Completely remove clutch disc pack (D. Remove clutch pressure piece@.

  • Page 171: Removing The Primary Gear Nut

    18 ENGINE 18.3.24 Removing the primary gear nut Remove the special tool. Locking screw (113080802) (� p. 311) Lock the outer clutch hub and primary gear using special tool Gear segment (80029004000) (� p. 320) • Info LH thread Remove nut. 18.3.25 Removing the outer clutch hub Bend up the lock washer.

  • Page 172: Removing The Torque Limiter

    18 ENGINE 18.3.26 Removing the torque limiter Remove the screw with the washer. Remove torque limiter Remove the washer. 18.3.27 Removing the starter idler gear Remove the lock ring. Take off the washer. Take off starter idler gear Removing the shift shaft 18.3.28 Push sliding plate away from the shift drum locating unit.

  • Page 173: Removing The Locking Lever

    18 ENGINE 18.3.30 Removing the locking lever Unscrew and remove together with locking lever@, washer, sleeve and spring. 18.3.31 Removing the oil pump gear wheels Remove lock ring Take off washer@. Remove oil pump idler gear (s). Remove lock washer Take off washer@).

  • Page 174: Removing The Force Pump

    18 ENGINE 18.3.32 Removing the force pump 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. 18.3.33 Removing the primary gear Insert special tool...

  • Page 175: Removing The Left Section Of The Engine Case

    18 ENGINE 18.3.35 Removing the left section of the engine case Remove screws Mount special tool with suitable screws. Puller (90129048100) (� p. 321) Info • Use the drill hole with marking 781. Tilt the left section of the engine case upward and remove the fitting of the engine fixing arm.

  • Page 176: Removing The Shift Drum

    18 ENGINE 18.3.36 Removing the shift rails Remove shift rails together with upper springs the lower springs. 18.3.37 Removing the shift drum Tilt shift forks to the side. Info Do not misplace the shift rollers. Remove shift drum@. Removing the shift forks 18.3.38 Take shift forks out of the shift grooves.

  • Page 177: Removing The Crankshaft

    18 ENGINE Secure the engine in an upright position. Remove lock ring Pull out both transmission shafts together from the bearing seats. Info Do not lose the washers. 18.3.40 Removing the crankshaft Attach the special tool to the crankshaft. Protection cap (75029090000) (�...
  • Page 178 18 ENGINE Main work Remove all remaining dowels. Remove oil jets Remove the bearing retainer of main shaft bearing (D, of countershaft bearing and of shift drum bearing Remove any sealing mass remnants and clean the engine case section thoroughly. Warm the engine case section in an oven.

  • Page 179: Working On The Left Section Of The Engine Case

    18 ENGINE Guideline Screw, bearing 6 Nm (4.4 lbf ft) ® Loctite 2701 retainer Mount and tighten oil jet Guideline Oil jet, piston 2 Nm (1.5 lbf ft) ® Loctite cooling ™ Mount and tighten oil jet Guideline Oil nozzle for con rod M6x0.
  • Page 180 18 ENGINE Info Any bearings that remain in the section of the engine case must be removed using a suitable tool. Press out the crankshaft shaft seal ring @ from the inside toward the outside. Press in the shaft seal ring from the outside toward the inside, with the open side facing outward.

  • Page 181: Removing The Oil Pressure Regulator Valve

    18 ENGINE Guideline Screw, oil spray 5 Nm (3. 7 lbf ft) tube ® Loctite ™ Mount the dowels. Blow compressed air through all oil channels and check that they are clear. 18.4.3 Removing the oil pressure regulator valve Remove screw plug with sealing washer Remove pressure spring and ball...

  • Page 182: Installing The Oil Pressure Regulator Valve

    18 ENGINE 18.4.5 Installing the oil pressure regulator valve Install ball and pressure spring Mount and tighten plug@} with sealing washer �-­ Guideline Oil pressure control M12x1.5 20 Nm (14.8 lbf ft) e " - • valve plug •-· "-:) "- 304671-11 Removing the crankshaft seal ring in the clutch cover...

  • Page 183: Installing The Water Pump

    18 ENGINE Remove balancer shaft Remove shaft seal ring Press out water pump shaft bearing toward the inside with an appropriate tool. Info Suitably support the clutch cover while pressing it out. 18.4.9 Installing the water pump Press water pump shaft bearing in until it is flush using the appropriate tool.

  • Page 184: Removing The Timing Chain

    18 ENGINE Mount special tool on the water pump shaft. I Protection cap (90129005000) (I!!,! p. 321) 304714-10 Mount balancer shaft • Info Be careful not to damage the shaft seal rings. Remove the special tool. I Protection cap (90129005000) (I!!,! p.

  • Page 185: Changing The Connecting Rod, Conrod Bearing And Crank Pin

    18 ENGINE Warm up the new timing chain sprocket and immediately push it onto the crankshaft. Guideline c (356 °F) 304701-10 18.4.12 Changing the connecting rod, conrod bearing and crank pin Main work Position the crankshaft with special tool in the press. Separator plate (78029009100) (ll!:!l p.
  • Page 186 18 ENGINE Place the crankweb onto special tool I Crankshaft pressing tool insert (78029008000) (l!!,!I p. 319) • Info The special tool must be positioned with the flat sur­ face facing downward. Press in new crank pin all the way. ✓...

  • Page 187: Checking Crankshaft Run-Out At Bearing Pin

    18 ENGINE Measure axial play between the connecting rod and the crankwebs using the special tool. Feeler gauge (59029041100) (I!!:! p. 314) Connecting rod - end play 0.20 ... 0.45 mm (0.0079 ... of lower conrod bearing 0.0177 in) If the measured value is less than the specification: Correct it so the dimension is equal to the specified value.

  • Page 188: Checking/Measuring The Piston

    18 ENGINE The cylinder size is labeled on the side of the cylinder. 304689-10 Using a straightedge and the special tool, check the sealing area of the cylinder head for distortion. I Feeler gauge (59029041100) (I!!;! p. 314) :5 0.10 mm (:5 0.0039 in) Cylinder/cylinder head sealing area distortion If the measured value does not meet specifications:...

  • Page 189: Checking The Piston Ring End Gap

    18 ENGINE Measure the piston at the piston skirt, parallel to the gudgeon pin.at a distance of 6). Guideline 7 mm (0.28 in) Distance Piston - diameter Size I 94.93 ... 94.96 mm (3.7374 ... 3.7386 in) Size II 94.94 ... 94.97 mm (3.7378 ...

  • Page 190: Checking The Oil Pumps

    18 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) 18.4.19 Checking the oil pumps Info The following steps apply to both oil pumps. Use special tool to measure the play between the exter­...

  • Page 191: Assembling The Autodecompressor

    18 ENGINE Pull autodecompression shaft out of the camshaft. 304674-10 ·� Release and remove autodecompression spring Info Autodecompression weight cannot be taken off. 304675-10 18.4.21 Assembling the autodecompressor Insert long flange of the autodecompression spring in the hole, push the autodecompression spring over bearing bolt and hook it into autodecompression weight 304675-11...

  • Page 192: Checking Camshaft

    18 ENGINE 18.4.22 Checking camshaft Check the camshaft for damage and wear. If there is damage or wear: Change the camshaft. If the camshaft surface is damaged, check the oil supply of the camshaft and the rocker arm. Measure the cams of the camshaft. Camshaft - cam height Exhaust 33.10 ...

  • Page 193: Removing The Rocker Arm

    18 ENGINE If there is damage or wear: Replace the timing chain guide rail. Check the timing chain securing guide for damage and wear. If there is damage or wear: Replace the timing chain securing guide. Check timing chain for damage and wear. If there is damage or wear: Replace the timing chain.

  • Page 194: Changing The Camshaft

    18 ENGINE Remove valve spring retainer @ and the valve spring. Pull the valve out of the valve guide from below and remove valve stem seal@) and valve spring seat •• 304686-10 Mark the valves corresponding to their installation position. Info !:'II EV�...

  • Page 195: Checking The Valves

    18 ENGINE Press the large camshaft bearing in all the way using special tool@). Pressing tool (7502904401 0) p. 316) 18.4.27 Checking the valves Info The valve shaft is hard-chrome plated; wear generally appears at the valve guide. Check the run-out at the valve plate. Valve Run-out at valve plate ::;...

  • Page 196: Checking Valve Spring Seat

    18 ENGINE 40. 7 mm (1 .602 in) Exhaust minimum length (without valve spring seat) If the measured value does not meet specifications: Change the valve spring. 18.4.29 Checking valve spring seat Check the valve spring seat for breakage and wear (visual check).

  • Page 197: Checking The Rocker Arm Shafts

    18 ENGINE Check sealing seat of the valves. Valve Intake sealing seat width 2.00 mm (0.0787 in) Valve Exhaust sealing seat 2.00 mm (0.0787 in) width If the measured value does not meet specifications: Rework the valve seat. 302808-10 Blow compressed air through all oil channels and check that they are clear.

  • Page 198: Installing The Rocker Arm

    18 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.

  • Page 199: Checking The Clutch

    18 ENGINE 18.4.34 Checking the clutch 304690-10 Check clutch push rod for damage and wear. If there is damage or wear: Change the clutch push rod. Place clutch push rod @} on a flat surface and check for run-out. If there is run-out: Change the clutch push rod.

  • Page 200: Checking The Shift Mechanism

    18 ENGINE If there is damage or wear: Change the clutch facing discs and the clutch basket. Check needle bearings and collar bushing for damage and wear. If there is damage or wear: Change the needle bearings and collar bushing. Check intermediate clutch discs G) for damage and wear.

  • Page 201: Preassembling The Shift Shaft

    18 ENGINE Check grooved ball bearing for smooth operation and wear. If the grooved ball bearing does not move easily or is worn: Change the grooved ball bearing. Check shift rollers for surface damage and cracking. If the shift roller exhibits surface damage or cracking: Change the shift drum.

  • Page 202: Disassembling The Main Shaft

    18 ENGINE 18.4.37 Disassembling the main shaft 304684-10 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 6th-gear idler gear (D. Remove the split needle bearing and stop disk @t.
  • Page 203 18 ENGINE 304684-11 Main work Secure the main shaft in the vise with the gear teeth facing downward. Guideline I Use soft jaws. Mount the divided needle bearing and attach the fifth-gear idler gear with the shift dogs facing up. Mount stop disk@) and lock ring Push on the third/fourth-gear sliding gear with the small gear wheel facing downward and mount lock...

  • Page 204: Disassembling The Countershaft

    18 ENGINE 18.4.39 Disassembling the countershaft @ c, � i 304685-10 Secure the countershaft in the bench vise with the toothed end facing downward. Guideline Use soft jaws. Remove stop disk and first-gear idler gear Remove needle bearing and stop disk Remove the fifth-gear sliding gear and lock ring (D.

  • Page 205: Checking The Transmission

    18 ENGINE • 0 (;) 0 6D • • e • • J � 304685-11 Main work Secure the countershaft in the bench vise with the toothed end facing downward. Guideline I Use soft jaws. Mount needle bearing and second-gear idler gear onto the countershaft with the protruding collar facing downward.
  • Page 206 18 ENGINE 304691-10 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 207: Checking The Starter Drive

    18 ENGINE Use new lock rings with every repair. 18.4.42 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 208: Removing The Freewheel

    18 ENGINE 18.4.43 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 18.4.44 Checking the freewheel Insert freewheel gear into primary gear@, turning the primary gear clockwise; do not wedge! Check the locking action of freewheel gear If the primary gear does not turn clockwise or if it does not lock counterclockwise:...

  • Page 209: Engine Assembly

    18 ENGINE Mount spreader ring @. 304705-10 Ensure that all lugs of the spreader ring pass through slots of the freewheel and engage in groove of the primary gear. 18.5 Engine assembl}' 18.5.1 Installing the crankshaft Tighten the right section of the engine case in the engine assembly stand.

  • Page 210: Installing The Shift Forks

    18 ENGINE Mount lock ring Installing the shift forks 18.5.3 Thoroughly oil all parts. Shift fork has a smaller inside diameter; mount this in the shift groove of the main shaft. Mount shift fork in the lower shift groove of the counter­ shaft.

  • Page 211: Installing The Shift Rails

    18 ENGINE 18.5.5 Installing the shift rails Install shift rails together with upper springs @ and lower springs. Info Fix the springs in the shift rails with grease. 18.5.6 Installing the left engine case Mount dowels onto the left section of the engine case. Grease the sealing surfaces.

  • Page 212: Installing The Freewheel Gear

    18 ENGINE Mount the 0-ring on the countershaft. Lightly grease and mount spacer @. 18.5.7 Installing the freewheel gear Mount freewheel gear 18.5.8 Installing the primary gear Mount woodruff key Degrease the cone and thinly apply thread locker to it. I Loctite ®...

  • Page 213: Installing The Oil Pump Gear Wheels

    18 ENGINE Position oil pump cover Mount and tighten screws Guideline 10 Nm (7.4 lbf ft) Screw, oil pump ® Loctite ™ cover 18.5.10 Installing the oil pump gear wheels Insert pin Position oil pump gear wheel @. Position washers (D. Mount lock washer Mount oil pump idler gear Mount washer...

  • Page 214: Installing The Shift Drum Locating Unit

    18 ENGINE 18.5.12 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.

  • Page 215: Installing The Outer Clutch Hub

    18 ENGINE 18.5.16 Installing the outer clutch hub Mount collar bushing and both needle bearings@. Slide clutch basket onto the gearbox main shaft. Turn oil pump gear wheel until the gear teeth of the clutch basket engage. Slide on washer and inner clutch hub (3.

  • Page 216: Installing The Clutch Discs

    18 ENGINE Position the crankshaft at top dead center (TDC) and block using the special tool. I Locking screw (113080802) (llill p. 311) 18.5.18 Installing the clutch discs Thoroughly oil the clutch facing discs. Beginning with an intermediate clutch disc, alternately insert all other clutch facing discs and intermediate clutch discs into the clutch basket.
  • Page 217 18 ENGINE Position spring retainer with marking I. Mount screws and tighten in a crisscross pattern. Guideline Screw, clutch spring 6 Nm (4.4 lbf ft) retainer Using a straightedge and the special tool, check the spring washer for distortion. Feeler gauge (59029041100) (�...

  • Page 218: Installing The Clutch Cover

    18 ENGINE 18.5.19 Installing the clutch cover Position the balancer shaft with special tool I Marking mandrel (78129032000) p. 320) ✓ Marking and the special tool are aligned. Mount dowels Put the new clutch cover gasket place. Mount the clutch cover. Mount screws and tighten once all of the clutch cover screws have been mounted.

  • Page 219: Installing The Suction Pump

    18 ENGINE Guideline Screw, water pump M6x25 10 Nm (7.4 lbf ft) cover Mount screw and tighten all screws in a crisscross pat­ tern. Guideline 10 Nm (7.4 lbf ft) Screw, water pump M6x55 cover 18.5.21 Installing the suction pump Oil the internal rotor and external rotor before mounting.

  • Page 220: Installing The Timing Chain

    18 ENGINE Position the cable and insert the cable sleeve into the engine • case. 18.5.23 Installing the timing chain Thread in the timing chain and place it over the timing chain sprocket. Info • If the timing chain was used before, ensure it is run­ ning in the correct direction.

  • Page 221: Installing The Rotor

    18 ENGINE 18.5.27 Installing the rotor Mount the woodruff key. Mount the rotor. Mount the spring washer and nut. Tighten the nut. Guideline Nut, rotor I M12x1 I 60 Nm (44.3 lbf ft) 18.5.28 Installing the piston Move the joints of the compression ring and oil scraper ring so they are offset by 1 80 °...
  • Page 222 18 ENGINE Ensure that piston mark faces toward the exhaust side. 304606-10 Cover the engine case opening with a cloth. Thread the tim­ ing chain through the chain shaft. Mount the piston pin. • Info In order to present them more clearly, the following steps are shown with a removed piston.

  • Page 223: Installing The Cylinder Head

    18 ENGINE 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 for piston ring lock (77329030100) (!1ll p. 318) Ensure that the piston pin retainer is seated properly on both sides.

  • Page 224: Installing The Camshaft

    18 ENGINE Guideline Screw, cylinder head 110 Nm (7.4 lbf ft) 18.5.30 Installing the camshaft Place the timing chain over the camshaft gear. Push the camshaft into the bearing seats. ✓ The markings on the camshaft and of the cylinder head are lined up with each other.

  • Page 225: Checking The Valve Clearance

    18 ENGINE Mount and tighten screw plug @ with washer spring Guideline Plug, timing chain M8x1 8 Nm (5.9 lbf ft} tensioner 18.5.32 Checking the valve clearance Remove special tool Locking screw (113080802) p. 311) Crank the engine several times. Position the engine at ignition top dead center.

  • Page 226: Installing The Alternator Cover

    18 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 suitable shims. Install the camshaft. p. 222) Install the timing chain tensioner.

  • Page 227: Installing The Spark Plug

    18 ENGINE 18.5.36 Installing the spark plug Mount and tighten the spark plug using the special tool. Guideline Spark plug M12x1 .25 15 ... 20 Nm (11.1 ... 14.8 lbf ft) Spark plug wrench with link (77229172000) (� p. 318) 309224-10 Installing the starter motor 18.5.37...

  • Page 228: Installing The Clutch Push Rod

    18 ENGINE 18.5.39 Installing the clutch push rod Mount clutch push rod 18.5.40 Installing the oil screen Mount and tighten engine oil screen plug with the O-ring. Guideline Screw plug, engine M20x1.5 15 Nm (11 .1 lbf ft) oil screen Push the oil screen with O-rings onto a pin wrench.

  • Page 229: Removing The Engine From The Engine Assembly Stand

    18 ENGINE 18.5.41 Removing the engine from the engine assembly stand Remove the fitting from the special tool. Holder and fitting for work stand (78029002000) (� p. 319) Remove the engine from the engine assembly stand. • Info Work with an assistant or a motorized hoist.

  • Page 230: 19 Clutch

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

  • Page 231: Changing The Hydraulic Clutch Fluid

    19 CLUTCH 19.2 Changing the h�draulic clutch fluid 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. Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 232: 20 Water Pump, Cooling System

    20 WATER PUMP, COOLING SYSTEM 20.1 Cooling s�stem Water pump in the engine circulates the coolant. The water flow through the radiator is controlled as a function of the coolant temperature. The cooling system is divided into two circuits. In the warming-up phase of the engine, the coolant flows through the small cooling circuit.

  • Page 233: Checking The Coolant Level

    20 WATER PUMP, COOLING SYSTEM 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 234: Draining The Coolant

    20 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 235 20 WATER PUMP, COOLING SYSTEM Main work Make sure that the screw is tightened. Stand the vehicle upright. Pour coolant in up to measurement above the radiator fins. Guideline 10 mm (0.39 in) Coolant 11.2 I (1 .3 qt.) I Coolant (�...

  • Page 236: Lubrication System

    LUBRICATION SYSTEM 21.1 Oil circuit 305159-10 Engine oil screen Force pump Oil pressure regulator valve Oil filter Oil nozzle, piston cooling Suction pump 21.2 Checking the engine oil level Condition The engine is at operating temperature. Preparatory work Stand the motorcycle upright on a horizontal surface. Main work Check the engine oil level.

  • Page 237: 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 Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden. Wear suitable protective clothing and safety gloves. In the event of scalding, rinse the area affected immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 238 LUBRICATION SYSTEM Mount and tighten screw plug @ with the gear oil screen and the O-rings. Guideline Screw plug, gear oil M20x1.5 15 Nm (11.1 lbf ft) screen Position oil screen with the O-rings on a pin wrench. Insert the pin wrench through the drill hole of the screw plug and into the engine case on the opposite side.

  • Page 239: Adding Engine Oil

    LUBRICATION SYSTEM Lay the motorcycle on its side and fill the oil filter housing to about½ full with engine oil. Insert the oil filter into the oil filter housing. Oil the O-ring of the oil filter cover and mount it with the oil filter cover @.

  • Page 240: Checking The Engine Oil Pressure

    LUBRICATION SYSTEM Main work Remove oil filler plug with the O-ring from the clutch cover. Fill engine oil to the middle of the level viewer. I Engine oil (SAE 1 0W/50) (!!:,!I p. 306) • Info For optimal performance of the engine oil, do not mix different types of engine oil.
  • Page 241 LUBRICATION SYSTEM Danger Exhaust gases are toxic and Danger of poisoning inhaling them may result in unconsciousness and death. Always make sure there is sufficient ventilation when running the engine. Use an effective exhaust extraction system when starting or running the engine in an enclosed space.

  • Page 242: 22 Ignition System

    22 IGNITION SYSTEM 22.1 winding Ignition coil - checking the seconda Condition Ignition coil cylinder 1 is disconnected. Spark plug connector cylinder 1 has been removed. Ignition coil cylinder 1 - check the secondary winding resistance Measure the resistance between the specified points. Ignition coil cylinder 1 pin (-) - Ignition coil cylin­...

  • Page 243: Removing The Stator

    22 IGNITION SYSTEM Stator winding, measurement II - check the resistance Measure the resistance between the specified points. Stator, connector pin 1 - Stator, connector Alternator Resistance of stator 0.368 ... 0.552 Q winding at: 20 °c (68 °F) If the value displayed does not meet specifications: Change the stator.

  • Page 244: Installing The Stator

    22 IGNITION SYSTEM Installing the stator Position the stator in the alternator cover. Mount and tighten screws Guideline Screw, stator 6 Nm (4.4 lbf ft) ® Loctite ™ Position cable support sleeve in the alternator case. Position the cable holder. Mount and tighten screw Guideline 700079-11 4 Nm (3 lbf ft)

  • Page 245: 23 Electric Starter

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

  • Page 246: Throttle Valve Body

    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. Danger Exhaust gases are toxic and Danger of poisoning inhaling them may result in unconsciousness and death.
  • Page 247 24 THROTTLE VALVE BODY Start the engine without operating the throttle grip. Guideline Coolant temperature < 25 °C (< 77 °F) Let the engine idle until it reaches the specified temperature. Guideline Coolant temperature so ... 90 °c (176 ... 194 °F) •...

  • Page 248: 25 Technical Data

    25 TECHNICAL DATA 25.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement (all 450 models) 449.3 cm (27.418 cu in) Displacement (all 501 models) 510.4 cm (31.147 cu in) Stroke (all 450 models) 63.4 mm (2.496 in) Stroke (all 501 models) 72 mm (2.83 in) Bore 95 mm (3.74 in)

  • Page 249: Tolerance, Engine Wear Limits

    25 TECHNICAL DATA 25.2 Tolerance, engine wear limits Camshaft - cam height Exhaust 33.10 ... 33.30 mm (1.3031 ... 1.311 in) Camshaft - cam height (all 450 models) Intake 33.90 ... 34.10 mm (1.3346 ... 1.3425 in) Camshaft - cam height (all 501 models) Intake 34.40 ...

  • Page 250: Engine Tightening Torques

    25 TECHNICAL DATA 25.3 Engine tightening tor ues Oil jet, piston cooling 2 Nm (1 .5 lbf ft) ® Loctite ™ Screw, cab le holder in alternator 4 Nm (3 lbf ft) Loctite ® ™ cover Oil jet, piston cooling 2 Nm (1 .5 lbf ft) ®...
  • Page 251 25 TECHNICAL DATA Screw, starter motor 10 Nm (7.4 lbf ft) Screw, timing chain guide rail 10 Nm (7.4 lbf ft) ® Loctite ™ Screw, timing chain securing 10 Nm (7.4 lbf ft) ® Loctite ™ guide Screw, timing chain tensioner 10 Nm (7.4 lbf ft) Screw, timing chain tensioning rail 10 Nm (7.4 lbf ft)

  • Page 252: Capacities

    25 TECHNICAL DATA Nut, primary gear M20LHx1.5 100 Nm (73.8 lbf ft) ® Loctite ™ Screw plug, engine oil screen M20x1.5 15 Nm (11.1 lbf ft) Screw plug, gear oil screen M20x1.5 15 Nm (11.1 lbf ft) 25.4 Ca�acities 25.4.1 Engine oil 11.50 I (1.59 qt.) I Engine oil...

  • Page 253: Electrical System

    80/100 - 21 M/C 51M TT 110/100 - 18 M/C 64M TT Dunlop GEOM AX MX51 F A Dunlop GEOM AX MX51 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 254: Fork

    25 TECHNICAL DATA Fork 25.8 Fork part number 24.18. 7N.69 Fork WP Suspension Up Side Down 4860 4CS Compression damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks Rebound damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks Spring length with preload spacer(s) 472 mm (18.58 in) Spring rate...

  • Page 255: Chassis Tightening Torques

    25 TECHNICAL DATA Riding sag 105 mm (4.13 in) Fitted length 490 mm (19.29 in) Shock absorber oil Shock absorber fluid (SAE 2.5) (50180751 S1) (� p. 307) 25.10 Chassis tightening tor�ues Spoke nipple, front wheel M4.5 6 Nm (4.4 lbf ft) Spoke nipple, rear wheel M4.5 6 Nm (4.4 lbf ft)
  • Page 256 25 TECHNICAL DATA Engine attachment bolt 60 Nm (44.3 lbf ft) Remaining nuts, chassis 45 Nm (33.2 lbf ft) Remaining screws, chassis 45 Nm (33.2 lbf ft) 60 Nm (44.3 lbf ft) Screw, bottom shock absorber 2701 TM ® Loctite Screw, handlebar holder 40 Nm (29.5 lbf ft) ®...

  • Page 257: 26 Cleaning, Care

    26 CLEANING, CARE 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 258: Checks And Maintenance Steps For Winter Operation

    26 CLEANING, CARE Treat bare metal (except for brake discs and the exhaust sys­ tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p. 309 ) � Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

  • Page 259: 27 Storage

    0 ... 35 °C (32 ... 95 °F) tery without direct sunshine Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info Husqvarna Motorcycles recommends raising the motorcycle. Raise the motorcycle with a lift stand. (� p. 12) Preferably cover the vehicle with a tarp or similar cover that is permeable to air.

  • Page 260: Preparing For Use After Storage

    27 STORAGE 27.2 Pre�aring for use after storage Remove the motorcycle from the lift stand. (� p. 12) Install the battery. (� p. 126) Perform checks and maintenance measures when preparing for use. Take a test ride. 401059-01...

  • Page 261: 28 Service Schedule

    Every 30 operating hours/after every race Every 15 operating hours Once after 1 operating hour • • Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. • • Check that the electrical equipment is functioning properly. • •...

  • Page 262: Service Work (As Additional Order)

    Final check: Check the vehicle for roadworthiness 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 and in the Service and War- ranty Booklet.
  • Page 263 28 SERVICE SCHEDULE...

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  • Page 265: 29 Wiring Diagram

    29 WIRING DIAGRAM Components: Battery Starter relay with main fuse Starter motor Electric starter button...

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  • Page 267 29 WIRING DIAGRAM Components: A 11 EFI control unit Radiator fan temperature switch Fuse Fuse Fuse Alternator Light relay Power relay Radiator fan Voltage regulator X295 Diagnostics connector...

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  • Page 269 29 WIRING DIAGRAM Components: A 11 EFI control unit Low beam, high beam Speedometer Horn Parking light Light switch, horn button, kill switch...

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  • Page 271 29 WIRING DIAGRAM Components: Front brake light switch Rear brake light switch License plate lamp Brake/tail light...

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  • Page 273 29 WIRING DIAGRAM Components: Turn signal relay Turn signal indicator light Left front turn signal Right front turn signal Left rear turn signal Right rear turn signal S2 5 Turn signal switch...

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  • Page 275 29 WIRING DIAGRAM Components: A 11 EFI control unit Fuel level sensor Lambda sensor (cylinder 1) Fuse Speedometer...

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  • Page 277 29 WIRING DIAGRAM Components: A 11 EFI control unit Front wheel speed sensor Fuel pump Injection valve (cylinder 1) CAN-bus terminating resistor 1 Speedometer X295 Diagnostics connector...

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  • Page 279 29 WIRING DIAGRAM Components: A 11 EFI control unit Throttle position sensor circuit A Intake air temperature sensor 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 for basic position (optional) Cable colors:...

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  • Page 281 29 WIRING DIAGRAM Components: Battery Starter relay with main fuse Starter motor S2 3 Emergency OFF switch, electric starter button...

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  • Page 283 29 WIRING DIAGRAM Components: A 11 EFI control unit Radiator fan temperature switch Fuse Fuse Fuse Alternator Light relay Power relay Radiator fan Voltage regulator X295 Diagnostics connector...

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  • Page 285 29 WIRING DIAGRAM Components: A 11 EFI control unit Low beam, high beam Speedometer Horn Parking light Light switch, horn button, kill switch Emergency OFF switch, electric starter button...

  • Page 286: Fe Au)

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  • Page 287 29 WIRING DIAGRAM Components: Front brake light switch Rear brake light switch License plate lamp Brake/tail light...

  • Page 288: Fe Au)

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  • Page 289 29 WIRING DIAGRAM Components: Turn signal relay Turn signal indicator light Left front turn signal Right front turn signal Left rear turn signal Right rear turn signal S2 5 Turn signal switch...

  • Page 290: Fe Au)

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  • Page 291 29 WIRING DIAGRAM Components: A 11 EFI control unit Fuel level sensor Fuse Speedometer...

  • Page 292: Fe Au)

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  • Page 293 29 WIRING DIAGRAM Components: A 11 EFI control unit Front wheel speed sensor Fuel pump Injection valve (cylinder 1) CAN-bus terminating resistor 1 Speedometer X295 Diagnostics connector...

  • Page 294: Fe Au)

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  • Page 295 29 WIRING DIAGRAM Components: A 11 EFI control unit Throttle position sensor circuit A Intake air temperature sensor 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 for basic position (optional) Cable colors:...

  • Page 296: Fe 501 Us)

    29 WIRING DIAGRAM 29.17 Page 1 of 6 (FE 501 US) � ► -�© �- l:l-® � oo-ro� 4 IJd[ >---1--- "�,, - � � �wh-ro wh-rd- � �� �� � :3---• 9?1,i,i,i,111-iP � � ..-wh-rd,wh-rd ..£i oo<d� c>----2-•...
  • Page 297 29 WIRING DIAGRAM Components: Battery Starter relay with main fuse Starter motor Electric starter button...

  • Page 298: Fe 501 Us)

    ; 1 : 1 � DT/36 �DT/36 :;;; ---------------------------------)1!-nl-c>c /4.B1 j" j " t 1 0 1 t3 i . x s ± J /2 ± J /2 ± J /2 -B33 i E B/ 4 E B/ 4 ri:Jl BG/3 "'ij l+JJ...
  • Page 299 29 WIRING DIAGRAM Components: A 11 EFI control unit Radiator fan temperature switch (optional) Fuse Fuse Fuse Alternator Light relay Power relay Radiator fan (optional) Voltage regulator X295 Diagnostics connector...

  • Page 300: Fe 501 Us)

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  • Page 301 29 WIRING DIAGRAM Components: A 11 EFI control unit Low beam Parking light Tail light Kill switch Light switch...

  • Page 302: Fe 501 Us)

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  • Page 303 29 WIRING DIAGRAM Components: A 11 EFI control unit Fuel tank sensor Fuse Speedometer...

  • Page 304: Fe 501 Us)

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  • Page 305 29 WIRING DIAGRAM Components: A 11 EFI control unit Front wheel speed sensor Fuel pump Injection valve (cylinder 1) Speedometer CAN-bus terminating resistor 1 X295 Diagnostics connector...

  • Page 306: Fe 501 Us)

    -A11 1 " "" 1 " '" 1 " '" '" -© 1° ' " " 1''" " 1'"" 1 " 1''"" -X15 -X15 - X15 -X15 -X15 -X15 -X15 -X15 -X15 � " " � � � � · �...
  • Page 307 29 WIRING DIAGRAM Components: A 11 EFI control unit Throttle position sensor circuit A Intake air temperature sensor 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 for basic position (optional) Cable colors:...

  • Page 308: 30 Substances

    30 SUBSTANCES Brake fluid DOT 4 Standard/classification Guideline Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corresponding properties. Recommended supplier ® Bel-Ray Super DOT 4 Brake Fluid Coolant Guideline Only use high-grade, silicate-free coolant with corrosion inhibitor additive for aluminum motors.
  • Page 309 30 SUBSTANCES Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification p. 327) (SAE 2.5) Guideline Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification DIN EN 228 (ROZ 95/RON 95/PON 91) Guideline...

  • Page 310: Auxiliary Substances

    AUXILIARY SUBSTANCES Air filter cleaning agent Recommended supplier ® Bel-Ray Foam Filter Cleaner & Degreaser High viscosi't}f grease Recommended supplier ® LGHB 2 Long-life grease Recommended supplier ® Bel-Ray Waterproof Grease Lubricant (I158) Recommended supplier Lubcon ® ® Turmogrease PP 300 Lubricant 14034 Recommended supplier...
  • Page 311 31 AUXILIARY SUBSTANCES Oil for foam air filter Recommended supplier ® Bel-Ray Foam Filter Oil Preserving materials for �aints metal and rubber Recommended supplier ® Bel-Ray Silicone Detailer & Protectant Spray Universal oil s�ra}! Recommended supplier ® Bel-Ray 6 in 1...

  • Page 312: 32 Special Tools

    32 SPECIAL TOOLS Bleeder cover Art. no.: 00029013005 00029013005 H00504-01 Bleeder cover Art. no.: 00029013006 00029013006 H00505-01 Bleeding device Art. no.: 00029013100 00029013100 H00518-01 EU batte charger XCharge- rofessional Art. no.: 00029095050 Feature EU safety plug Nominal voltage 230 V Mains fuse Power cable length 5 m (16 ft)
  • Page 313 32 SPECIAL TOOLS US batterY charger XCharge-�rofessional Art. no.: 00029095051 Feature US plug Nominal voltage 120 V Mains fuse 32 A Power cable length 5 m (16 ft) approx. Charger cable 5 m (16 ft) H01065-01 length approx. e-professional Art. no.: 00029095052 Feature UK safety plug Nominal voltage...
  • Page 314 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 S ring hook Art. no.: 50305017000 50305017000 H00973-01 ringe Art. no.: 50329050000 £&...
  • Page 315 32 SPECIAL TOOLS Lock ring �lier Art. no.: 51012011000 51012011000 H00572-01 Holding wrench Art. no.: 51129003000 51129003000 H00575-01 Puller Art. no.: 58012009000 58012009000 H00592-01 Tor ue wrench set Art. no.: 58429094000 Feature Torque 3 ... 15 Nm (2.2 ... 11.1 lbf ft) Open ended bit 3.9 mm (0.154 in) Open ended bit...
  • Page 316 32 SPECIAL TOOLS Valve s�ring mounter Art. no.: 59029019000 59029019000 H00610-01 Limit �lug gauge Art. no.: 59029026006 Feature I Diameter 6.05 mm (0.2382 in) 59029026006 H00612-01 Feeler gauge Art. no.: 59029041100 Feature s piece 0.10 ... 0.25 mm (0.0039 ... 0.0098 in) 59029041100 H00616-01 Piston ring mountin tool...
  • Page 317 32 SPECIAL TOOLS Puller Art. no.: 60029033000 2x£ 60029033000 H00633-01 Hose clamR Rlier Art. no.: 60029057000 60029057000 H00650-01 Testing hose Art. no.: 61029093000 � 61029093000 H00659-01 Pressure testin tool Art. no.: 61029094000 £. 61029094000 H00660-01...
  • Page 318 32 SPECIAL TOOLS Puller Art. no.: 75029021000 75029021000 H00707-01 Pressing tool Art. no.: 75029044010 75029044010 H00712-01 Pressing tool Art. no.: 75029044020 75029044020 H00713-01 Crankshaft ressing tool Art. no.: 75029047000 75029047000 H00714-01...
  • Page 319 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 Oil ressure ada ter Art. no.: 75029094000 � 75029094000 H00728-01...
  • Page 320 32 SPECIAL TOOLS Limit �lug gauge Art. no.: 77029026000 Feature I Diameter 5.05 mm (0.1988 in) 77029026000 H00741-01 Insert for valve s�ring lever Art. no.: 77029041200 77029041200 H00746-01 S ark �lug wrench with link Art. no.: 77229172000 Feature Drive 3/8 in Hexagonal part 14 mm (0.55 in) Length...
  • Page 321 32 SPECIAL TOOLS Holder and fitting for work stand Art. no.: 78029002000 78029002000 H00783-01 Protection ca� Art. no.: 78029005000 78029005000 H00784-01 Crankshaft ressing tool insert Art. no.: 78029008000 78029008000 H00786-01 Art. no.: 78029009100 78029009100 H01174-01...
  • Page 322 32 SPECIAL TOOLS Marking mandrel Art. no.: 78129032000 78129032000 H00796-01 Gear segment Art. no.: 80029004000 80029004000 H00813-01 Engine work stand Art. no.: 80329001000 80329001000 H01047-01 Lift stand Art. no.: 81329955100 Feature 315 ... 425 mm ( 12.4 ... 16.73 in) Height ::;...
  • Page 323 32 SPECIAL TOOLS Protection ca� Art. no.: 90129005000 90129005000 H00816-01 Puller Art. no.: 90129048100 90129048100 H00828-01 Hook wrench Art. no.: T106S Feature Diameter I 68 ... 75 mm (2.68 ... 2.95 in) T106S H00841-01 De th micrometer Art. no.: T107S T107S H00842-01...
  • Page 324 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 325 32 SPECIAL TOOLS Pressing tool Art. no.: T1207S T1207S H00881-01 Mounting sleeve Art. no.: T1215 Feature Diameter 1 1 8 mm (0.71 in) T1215 H00886-01 Pressing tool Art. no.: T1216 Feature Diameter 138 ... 49 mm (1.5 ... 1.9 3 in) T1216 H00887-01 Vacuum...
  • Page 326 32 SPECIAL TOOLS Protecting sleeve Art. no.: T1401 & Feature I Diameter 48 mm (1.89 in) T1401 H00894-01 Clam�ing stand Art. no.: T1403S .&. Feature Diameter 48 mm (1.89 in) Diameter 60 mm (2.36 in) tpP� T1403S H00896-01 Mounting tool Art.
  • Page 327 32 SPECIAL TOOLS Clam�ing stand Art. no.: T14049S Feature Diameter 8 mm (0.31 in) Diameter 24.8 mm (0.976 in) T14049S H00924-01 Pressing tool Art. no.: T14051 Feature Diameter I 50 mm (1 .97 in) T14051 H00926-01 Pressing tool Art. no.: T1504 Feature Diameter 118 mm (0.71 in)
  • Page 328 32 SPECIAL TOOLS Filling tool Art. no.: T170S1 £ £ T170S1 H00855-01...

  • Page 329: Standards

    STANDARDS JASOT903MA Different technical development directions required a separate specification for motorcycles - the JASO T903 MA standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 330: 34 List Of Abbreviations

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

  • Page 331: Index

    INDEX engine oil ....158, 237, 250 Cartridge Accessories ......9 of fork legs, disassembling .
  • Page 332 INDEX main shaft, assembling ....rocker arm, installing ....Engine valves, installing ....installing valves, removing ....191 removing ......149 water pump, removing .
  • Page 333 INDEX clutch push rod, removing ... . . 160 Foot brake lever crankshaft, removing ....175 basic position, adjusting cylinder head, removing .
  • Page 334 INDEX removing from lift stand ....12 Hand brake lever basic position, adjusting Oil circuit free travel, adjusting Oil filter free travel, checking ....131 changing .
  • Page 335 INDEX Servicing the shock absorber ... . 56 Swingarm checking ......74 Shock absorber installing ......76 damper, assembling .
  • Page 336 INDEX Page 6 of 8 ....272, 288 Page 7 of 8 ....274, 290 Page 8 of 8 ....276, 292 Work rules ......8...
  • Page 337 I 1 1 11 1 11 1 1 1 1 11 1 1 1 111 1 11 1 1 1 1 111 1 1 111 1 11 1 1 1 1 1 1 1 1 1 1 1 II I I II 3403003en 07/2017 ® Husqvarna Husqvarna Motorcycles GmbH StallhofnerstraBe 3 5230 Mattighofen Austria Photo: Mitterbauer, www.husqvarna-motorcycles.com MOTORCYCLES...

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Fe 501 2014

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