Husqvarna FE 250 2016 Repair Manual
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Husqvarna FE 250 2016 Repair Manual

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PIONEERING SINCE 1903
REPAIR MANUAL2016
FE 250
®
Husqvarna
Art. no. 3403024en
MOTORCYCLES

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Summary of Contents for Husqvarna FE 250 2016

  • Page 1 PIONEERING SINCE 1903 REPAIR MANUAL2016 FE 250 ® Husqvarna Art. no. 3403024en MOTORCYCLES...
  • Page 3 Husqvarna accepts no liability for delivery options, deviations from figures and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 6.16 Checking the fork legs ......25 MEANS OF REPRESENTATION ......7 6.17 Assembling the seal ring retainer ..26 Symbols used ........7 6.18 Assembling the hydrostop unit ... 26 Formats used ........7 6.19 Assembling the piston rod ....27 SAFETY ADVICE ..........
  • Page 5 TABLE OF CONTENTS 9.10 12.8 Installing the shock absorber ....52 Installing the fuel tank ......94 9.11 Checking the shock absorber 12.9 Changing the fuel screen ....96 linkage ..........52 12.10 Changing the fuel filter ......97 9.12 Servicing the shock absorber .....

  • Page 6: Removing The Timing Chain

    TABLE OF CONTENTS BRAKE SYSTEM ........... 132 18.3.14 Removing the piston ....167 18.3.15 Removing the starter drive ... 167 16.1 Checking the front brake linings ..132 18.3.16 Removing the suction pump ..169 16.2 Changing the front brake linings ..132 18.3.17 Removing the water pump 16.3...
  • Page 7 TABLE OF CONTENTS 18.4.16 Measuring the piston/cylinder 18.5.18 Installing the water pump mounting clearance ...... 189 cover ..........219 18.4.17 Checking the piston ring end 18.5.19 Installing the starter drive ..... 220 gap ..........190 18.5.20 Installing the piston ...... 221 18.4.18 Checking the camshafts ....
  • Page 8 TABLE OF CONTENTS 22.5 30.11 Page 3 of 8 (FE AU) ......290 Installing the stator and crankshaft position sensor ......... 246 30.12 Page 4 of 8 (FE AU) ......292 30.13 Page 5 of 8 (FE AU) ......294 CYLINDER HEAD ..........

  • 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 white adjusting screw all the way clockwise. Info Adjusting screw is located at the upper end of the left fork leg.

  • Page 17: Bleeding The Fork Legs

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

  • Page 18: Removing The Fork Legs

    6 FORK, TRIPLE CLAMP Finishing work Install the fork protector. (l!!ll p. 17) Remove the motorcycle from the lift stand. (l!!ll p. 12) Removing the fork legs Preparatory work Remove the headlight mask with the headlight. (l!!ll p. 104) Raise the motorcycle with a lift stand. (l!!ll p.

  • Page 19: Removing The Fork Protector

    6 FORK, TRIPLE CLAMP Tighten screws Guideline Screw, top triple 17 Nm (12.5 lbf ft) clamp Tighten screws @) . Guideline Screw, bottom triple 15 Nm (11.1 lbf ft) clamp Position the brake caliper, and mount and tighten screws with the washers. Guideline Screw, front 25 Nm (18.4 lbf ft)

  • Page 20: Performing A Fork Service

    6 FORK, TRIPLE CLAMP Performing a fork service Condition The fork legs have been removed. Disassemble the fork legs. (� p. 18) Remove the spring. (� p. 20) Disassemble the cartridge.(� p. 21) Disassemble the piston rod. (ll!l p. 22) Disassemble the hydrostop unit.
  • Page 21 6 FORK, TRIPLE CLAMP Loosen the screw cover Mounting tool (T14047) (!!:,!Ip. 332) Info The cartridge cannot be taken off yet. 201701-10 Unclamp the fork leg. Slide the outer tube down. Drain the fork oil. Clamp the fork leg with the axle clamp. Release hydrostop unit and remove it.

  • Page 22: Removing The Spring

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

  • Page 23: Disassembling The Cartridge

    6 FORK, TRIPLE CLAMP Clamp the open end wrench in the vise. Release screw but do not remove it yet. Mounting tool (T14047) p. 332) Pull the spring downward. Remove the open end wrench. Remove the screw cap. Remove the spring with the preload spacer(s). Disassembling the cartridge Info The procedures are the same on both fork legs.

  • Page 24: Disassembling The Piston Rod

    6 FORK, TRIPLE CLAMP Degrease the cartridge and clamp it with the special tool. I Clamping stand (T14049S) (l!!l p. 332) Release seal ring retainer and remove with the washer. Remove lock ring (D. Pull reservoir @ out of the cartridge. Pull sleeve out of the reservoir.
  • Page 25 6 FORK, TRIPLE CLAMP Main work Degrease hydrostop needle and clamp using the special tool. Clamping stand (T1202S) (� p. 329) Release hydrostop needle and remove it from the piston rod. ✓ Valve usually remains in the hydrostop needle. R00038-10 Info f) - silver hydrostop needle on compression damp­...

  • Page 26: Disassembling The Hydrostop Unit

    6 FORK, TRIPLE CLAMP Disassembling the hydrosto� unit Info The procedures are the same on both fork legs. Preparatory work Disassemble the fork legs. (� p. 18) Main work Clamp hydrostop unit using special tool to sleeve loosen. I Clamping stand (T1202S) (@:,!I p.

  • Page 27: Checking The Fork Legs

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

  • Page 28: Assembling The Seal Ring Retainer

    6 FORK, TRIPLE CLAMP Check the surface of the sliding bushings. If the bronze-colored layer under sliding layer G) is visible or the surface is rough: Change the sliding bushings. Check the spring length. Guideline 475 mm (18.7 in) Spring length with preload spacer(s) If the measured value is larger than the specified value: Reduce the thickness of the preload spacers.

  • Page 29: Assembling The Piston Rod

    6 FORK, TRIPLE CLAMP Mount the new O-ring on hub Mount hub Mount and tighten adapter Guideline 6 Nm (4.4 lbf ft) Hydrostop unit M6x0.5 adapter Mount washer and shim stack @. • Info Note the setting list. Mount sleeve Turn hydrostop unit and clamp sleeve 0with special tool.
  • Page 30 6 FORK, TRIPLE CLAMP Position the spring. Mount compression shim stack with the smaller shims facing downward. Info Note the setting list. R00031-10 Grind the piston on both sides on a surfacing plate using 1200 grit sandpaper. Clean the piston. Lubricate the piston ring.

  • Page 31: Assembling The Cartridge

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

  • Page 32: Assembling The Fork Legs

    6 FORK, TRIPLE CLAMP Slide piston rod into the cartridge. • Info Check that the piston ring is correctly seated. =t-=rt==�----�=====- Mount spring seat R00024-10 Clamp piston rod with the special tool. I Clamping stand (T14049S) (� p. 332) Mount spring guide Ci) all the way on. Info The nut must be firmly tightened against the stop by hand.
  • Page 33 6 FORK, TRIPLE CLAMP Info Sealing lip downward, open side upward. Push on support ring Remove the special tool. Sand the edges of the sliding bushings with 600 grit sandpa- per; then clean and grease the bushings. Fork oil (SAE 4) (48601166S1) (la:! p.
  • Page 34 6 FORK, TRIPLE CLAMP Mount lock ring Info The lock ring must engage audibly. Mount dust boot Mount fork protector ring G). Grease the O-ring. I Fork oil (SAE 4) (48601166S1) (� p. 314) Slide the cartridge all the way into the fork leg. Turn the fork.
  • Page 35 6 FORK, TRIPLE CLAMP Clamp the fork vertically. Add the remaining quantity of fork oil. 202091-10 Pull out the piston rod and push it back in numerous times while pressing it to one side slightly. ✓ Air bubbles emerge and the cartridge is bled. Keep bleeding until no more air bubbles emerge.
  • Page 36 6 FORK, TRIPLE CLAMP Mount the adjuster. Mount and tighten screw@). Guideline 2.5 Nm (1.84 lbf ft) I Screw, adjuster M4x0.5 Alternative 1 Turn the adjuster for rebound damping (mark REB) and the adjuster for compression damping (mark clockwise all the way. COMP) Turn counterclockwise by the number of clicks corre­...

  • Page 37: Lubricating The Steering Head Bearing

    6 FORK, TRIPLE CLAMP 6.22 Lubricating the steering head bearing Remove the lower triple clamp. (l!,JI p. 35) Install the lower triple clamp. (l!,JI p. 36) H02387-01 6.23 Removing the lower triQle clam Preparatory work Remove the headlight mask with the headlight. (l!,JI p.

  • Page 38: Installing The Lower Triple Clamp

    6 FORK, TRIPLE CLAMP 6.24 Installing the lower tri�le clam� Main work Clean the bearing and sealing elements, check for damage, and grease. I High viscosity grease (I!!:! p. 316) Position the lower triple clamp with the steering stem. Mount the upper steering head bearing.
  • Page 39 6 FORK, TRIPLE CLAMP Tighten screws (D. Guideline Screw, bottom triple 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 40: 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. 38) Remove the motorcycle from the lift stand. (ll!.:! p.

  • Page 41: Changing The Steering Head Bearing

    6 FORK, TRIPLE CLAMP Main work Loosen screws Remove screw Loosen and retighten screw Guideline Screw, top steering M20x1 .5 12 Nm (8.9 lbf ft) head Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses. Tighten screws Guideline Screw, top triple...
  • Page 42 6 FORK, TRIPLE CLAMP Press the new bearing ring up to the stop with special tool@). Tool bracket (58429089000) p. 321) Pressing tool (58429091000) p. 321) Remove upper bearing ring with special tool@. Tool bracket (58429089000) (ll!l p. 321) Pressing tool (58429092000) (ll!l p.

  • Page 43: 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 44: 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 45: 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 46 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 47: Frame

    If the frame exhibits cracks or deformation due to a mechanical impact: Change the frame. Info Always replace a frame that has been damaged due to a mechanical impact. Repair of the frame is not authorized by Husqvarna 401799-01 Motorcycles.

  • Page 48: 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 49 9 SHOCK ABSORBER, SWINGARM Turn adjusting screw clockwise with a screwdriver up to the last perceptible click. Info Do not loosen fitting Turn counterclockwise by the number of clicks correspond­ ing to the shock absorber type. Guideline Compression damping, low-speed Comfort 20 clicks Standard...

  • Page 50: 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 51: 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. 48) 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 52: Adjusting The Riding Sag

    9 SHOCK ABSORBER, SWINGARM Main work Loosen screw Turn adjusting ring until the spring is no longer under ten- sion. I Hook wrench (T1 06S) (ia:! p. 328) Measure the overall spring length while the spring is not under tension. Tighten the spring by turning adjusting ring to measure­...

  • Page 53: Removing The Shock Absorber

    9 SHOCK ABSORBER, SWINGARM Main work Choose and mount a suitable spring. Guideline Spring rate Weight of rider: 65 ... 51 N/mm (291 lb/in) 75 kg (143 ... 165 lb.) Weight of rider: 75 ... 54 N/mm (308 lb/in) 85 kg (165 ... 187 lb.) Weight of rider: 85 ...

  • Page 54: Installing The Shock Absorber

    9 SHOCK ABSORBER, SWINGARM Installing the shock absorber Main work Carefully position the shock absorber into the vehicle from above. Finishing work Install the manifold.(� p. 81) Mount the seat. (� p. 92) Install the main silencer. (� p. 83) Install the right side cover.
  • Page 55 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 56: 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 57: Removing The Spring

    9 SHOCK ABSORBER, SWINGARM Remove the spring. (ll!:! p. 55) Disassemble the damper. (ll!:! p. 56) Disassemble the piston rod. (� p. 57) Disassemble the seal ring retainer. (� p. 58) Check the damper. p. 60) Remove the heim joint. p.

  • Page 58: Disassembling The Damper

    9 SHOCK ABSORBER, SWINGARM 9.14 Disassembling the dam�er Preparatory work Remove the spring. (� p. 55) 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 59: 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. 55) Disassemble the damper. p.

  • Page 60: Disassembling The Seal Ring 13.1 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 61: 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. 55) Disassemble the damper. (� p. 56) Disassemble the piston rod.

  • Page 62: Checking The Damper

    9 SHOCK ABSORBER, SWINGARM Lubricate the special tool. Shock absorber fluid (SAE 2.5) (50180751 S1) (l!t! p. 315) Calibrating unit (T1205) (� p. 330) Support seal ring retainer with sleeve of the special tool. I Mounting tool (T150S) (� p. 333) Press the special tool through the new pilot bushing.

  • Page 63: 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 64: 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. 330) Press the heim joint all the way in. Press the heim joint against the lock ring using the special tool.

  • Page 65: 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. 316) Mount centering disk 201410-10 Mount rebound rubber (D. Grease the 0-ring groove. Lubricant (T158) p.
  • Page 66 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 67: Assembling The Damper

    9 SHOCK ABSORBER, SWINGARM Grease the thread of the piston rod. Lubricant (T152) (I!!;! p. 316) 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 68 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 69: 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 70 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 71 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 72: Filling The Damper With Nitrogen

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

  • Page 73: Installing The Spring

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

  • Page 74: Checking The Swingarm

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

  • Page 75: 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. 76) Move the swingarm from one side to the other. If there is detectable play: Change the swingarm bearing. p.

  • Page 76: Installing The Swingarm

    9 SHOCK ABSORBER, SWINGARM Remove screws and @. Take off the engine sprocket cover. 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.
  • Page 77 9 SHOCK ABSORBER, SWINGARM Lift the swingarm. Mount and tighten fitting @. Guideline Nut, angle lever on M14x1 .5 80 Nm (59 lbf ft) swingarm Mount the chain. Connect the chain with connecting link Guideline The closed side of the chain joint lock must face in the direction of travel.

  • Page 78: Changing The Swingarm Bearing

    9 SHOCK ABSORBER, SWINGARM 9.31 Changing the swingarm bearing Preparatory work Raise the motorcycle with a lift stand. (� p. 12) Remove the rear wheel. (� p. 114) Remove the swingarm. (� p. 73) Left swingarm bearing Remove collar bushings R02757-10 Remove bushing@.
  • Page 79 9 SHOCK ABSORBER, SWINGARM Mount bushing R02758-10 Grease the shaft seal rings. I Long-life grease (I!!:! p. 316) Position collar bushings with the shoulder facing inward. R02763-10 Right swingarm bearing Remove collar bushings (D. R02760-10 Remove bushing @ . R02761-10...
  • Page 80 9 SHOCK ABSORBER, SWINGARM Remove shaft seal rings using a suitable tool. Press out bearing using a suitable tool. Using a suitable tool, press in new bearing Press in shaft seal rings @. Mount bushing@. R02761-10 Grease the shaft seal rings. Long-life grease (�...

  • Page 81: Exhaust

    EXHAUST Removing the manifold 10.1 Preparatory work Raise the motorcycle with a lift stand. p. 12) Remove the seat. p. 92) Remove the right side cover. (!,JI p. 91) Remove the main silencer. (!i.,!I p. 82) Main work Remove screw cap Remove screw @.
  • Page 82 10 EXHAUST Remove screw @. Raise the rear frame slightly and lower the shock absorber. (FE EU) Remove the fuel tank. (� p. 93) Disconnect plug-in connector of the lambda sensor and remove the cable binder. Remove springs I Spring hook (50305017000) (�...

  • Page 83: Installing The Manifold

    EXHAUST Main work Position the manifold and mount springs Spring hook (50305017000) p. 320) 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 tie.

  • Page 84: Removing The Main Silencer

    10 EXHAUST Lower the swingarm. Position the angle lever and linkage lever. Mount and tighten screw cap@. 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 85: Installing The Main Silencer

    EXHAUST Installing the main silencer Main work (FE EU) Position catalytic converter in the main silencer. Mount the main silencer. Mount screws but do not tighten yet. Attach spring Spring hook (50305017000) (!!,!l p. 320) Tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis Finishing work...
  • Page 86 10 EXHAUST Main work (FE EU/AU) Remove all screws on the main silencer. Take off silencer cap and 0-ring @. Take off outer tube and 0-ring Remove glass fiber yarn filling from inner tube Q). Clean the parts that need to be reinstalled and check for damage.

  • Page 87: Cleaning The Spark Arrestor (Fe Us)

    EXHAUST Guideline Screws on the 7 Nm (5.2 lbf ft) main silencer Mount O-ring @ on the silencer cap. Position the silencer cap with O-ring @ in the outer tube. Mount and tighten screws Guideline Screws on the 7 Nm (5.2 lbf ft) main silencer Finishing work Install the main silencer.
  • Page 88 10 EXHAUST �--0 'iJ' --0 402269-10 Main work and take off silencer cap @ with 0-ring Remove screws Warning Danger to health Soot particles irritate the eyes and mucuous membranes. Wear suitable breathing and eye protection when cleaning the main silencer and carbon screen. Clean main silencer housing and screen of the spark arrestor with compressed air.

  • 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. 316) 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 the filler ca� Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. Switch off the engine for refueling.

  • Page 93: Closing The Filler Cap

    FUEL TANK, SEAT, TRIM (FE EU) Replace the filler cap and turn clockwise until release but­ locks in place. Info Run the fuel tank breather hose @ without kinks. (FE AU, FE US) Replace the filler cap and turn clockwise until release but­ locks in place.

  • Page 94: Removing The Seat

    12 FUEL TANK, SEAT, TRIM 12.5 Removing the seat Remove screws in the recessed grips on the left and right. Raise the rear of the seat, push the seat back, and lift it off. Mounting the seat Mount the front of the seat on the collar bushing of the fuel tank, lower the seat at the rear while pushing it forward.

  • Page 95: Removing The Fuel Tank

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

  • Page 96: Installing The Fuel Tank

    12 FUEL TANK, SEAT, TRIM (FE EU/AU) Disconnect the connector of the horn. Remove screws (D with the collar bushings and horn. -· - .'.a. (FE US) Remove screws (D 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 97 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 98: Changing The Fuel Screen

    12 FUEL TANK, SEAT, TRIM Info Route the cable and fuel line at a safe distance from the exhaust system. Finishing work Mount the seat. (� p. 92) 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.

  • Page 99: Changing The Fuel Filter

    FUEL TANK, SEAT, TRIM Clean plug-in connection of the fuel line thoroughly with compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve! Disconnect the plug-in connection of the fuel line. Info Remaining fuel may flow out of the fuel hose.
  • Page 100 12 FUEL TANK, SEAT, TRIM Warning Environmental hazard Improper handling of fuel is a danger to the environment. Do not allow fuel to enter the groundwater, the soil, or the sewage system. Preparatory work Drain the fuel from the fuel tank into a suitable container. Remove the seat.
  • Page 101 FUEL TANK, SEAT, TRIM Change fuel screen Mount the fuel pump housing. Mount the new fuel filter ✓ Arrow points away from the fuel pump. Mount hose clamps Hose clamp plier (60029057000) (� p. 323) 305316-10 Position the fuel pump. Mount fuel connection with the gasket b ut do not tighten yet.

  • Page 102: Changing The Fuel Pump

    12 FUEL TANK, SEAT, TRIM 12.11 Changing the fuel �um� Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. Switch off the engine for refueling.

  • Page 103: Checking The Fuel Pressure

    FUEL TANK, SEAT, TRIM Position the fuel pump. Mount fuel connection with the gasket but do not tighten yet. Guideline Fuel connection on 10 Nm (7.4 lbf ft) fuel pump Mount and tighten nut with the gasket. Guideline 305313-10 Nut, fuel pump fixa- 15 Nm (11.1 lbf ft) tion Tighten fuel connection...
  • Page 104 12 FUEL TANK, SEAT, TRIM Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve. Press on the small metal plate and disconnect fuel hose con­ nection Info Remaining fuel may flow out of the fuel hose.

  • Page 105: 13 Mask, Fender

    13 MASK, FENDER 13.1 Removing front fender Preparatory work Remove the headlight mask with the headlight. (� p. 104) Main work Remove screws Remove screws@. Take off the front fender. Main work Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis...

  • Page 106: Removing The Headlight Mask With The Headlight

    13 MASK, FENDER 13.3 Removing the headlight mask with the headlight (FE EU/AU) Press and hold the kill switch � while the engine is idling until the engine stops. (FE US) Press and hold the kill switch � while the engine is idling until the engine stops.

  • Page 107: Installing The Headlight Mask With The Headlight

    13 MASK, FENDER 13.4 Installing the headlight mask with the headlight Main work (FE EU/AU) Connect plug-in connectors Position the headlight mask and secure it with rubber bands@. ✓ The holding lugs engage in the fender. Position brake line fi} and wiring harness in the brake line guide.
  • Page 108 13 MASK, FENDER Position brake line and wiring harness in the brake line guide. Finishing work Check the headlight setting. p. 151)

  • Page 109: 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 110: 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 111: Checking The Brake Discs

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

  • Page 112: Checking The Rim Run-Out

    14 WHEELS Check the spoke torque. Guideline Spoke nipple, front M4.5 6 Nm (4.4 lbf ft) wheel Spoke nipple, rear M4.5 6 Nm (4.4 lbf ft) wheel I Torque wrench set (58429094000) (i!!,!l p. 322) Checking the rim run-out Warning Incorrectly tensioned spokes impair the handling characteristic and result in Danger of accidents secondary damage.

  • Page 113: Front Wheel

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

  • Page 114: 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 115: Changing Front Wheel Bearing

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

  • Page 116: 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 117: 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. GO'? Remove spacers f� <>� �()) H00936-10 14.8.2 Installing the rear wheel Warning Danger of accidents...

  • Page 118: Changing The Rear Brake Disc

    14 WHEELS Position chain adjuster (5) . Mount nut but do not tighten it yet. Make sure that chain adjusters (5) are fitted correctly on adjusting screws Check the chain tension. (� p. 117) Tighten nut Guideline M20x1.5 80 Nm (59 lbf ft) Info The wide adjustment range of the chain adjusters (32 mm (1.26 in)) enables different secondary ratios...

  • Page 119: Checking The Chain Tension

    14 WHEELS 14.8.4 Checking the chain tension Warning Incorrect chain tension damages components and results in accidents. Danger of accidents If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.

  • Page 120: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide

    14 WHEELS Main work Loosen nut Loosen nuts Adjust the chain tension by turning adjusting screws (D left and right. Guideline Chain tension 55 ... 58 mm (2.17 ... 2.28 in) Turn adjusting screws (D on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks f).
  • Page 121 14 WHEELS Pull on the upper part of the chain with the specified weight f). Guideline Weight of chain wear mea­ 10 ... 15 kg (22 ... 33 lb.) surement Measure the distance ti) of 18 chain links in the lower chain section.
  • Page 122 14 WHEELS Check the chain sliding piece for wear. If the bottom edge of the chain bolt 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 123: Checking For Chain Dirt Accumulation

    14 WHEELS 14.8.7 Checking for chain dirt accumulation Check the chain for coarse dirt accumulation. If the chain is very dirty: Clean the chain. (!!;!I p. 121) 400678-01 14.8.8 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces the road grip. Remove the lubricant from the tires using a suitable cleaning agent.
  • Page 124 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. (!!;!I p. 114) Remove connecting link of the chain. Info Cover the components to protect them against dam­ age.

  • Page 125: Changing The Rear Wheel Bearing

    14 WHEELS Slide new engine sprocket onto the countershaft. Mount the new chain. Connect the chain with connecting link Guideline The closed side of the chain joint lock must face in the direction of travel. Install the rear wheel. (!ill p.
  • Page 126 14 WHEELS Main work Remove shaft seal ring Remove lock ring@. Remove shaft seal ring (D. Using a suitable tool, press bearing out from the inside to the outside. Remove spacing tube Using a suitable tool, press bearing (D out from the inside to the outside.
  • Page 127 14 WHEELS Clean, grease, and mount spacing tube Long-life grease (� p. 316) 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 128: 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 (FE EU/AU) Press and hold the kill switch (5<:) while the engine is idling until the engine stops.

  • Page 129: Changing The Main Fuse

    15 WIRING HARNESS, BATTERY Finishing work Mount the seat. (� p. 92) Changing the main fuse Warning Fire hazard Incorrect fuses overload the electrical system. Only use fuses with the required ampere value. Do not bypass or repair fuses. Info The main fuse protects all power consumers of the vehicle.

  • Page 130: Checking The Starter Relay

    15 WIRING HARNESS, BATTERY Checking the starter rela� 15.3 Preparatory work (FE EU/AU) Press and hold the kill switch � while the engine is idling until the engine stops. Remove the seat. p. 92) Remove the air filter box cover. p.

  • Page 131: Installing The Battery

    15 WIRING HARNESS, BATTERY Main work Pull back the negative terminal cover and disconnect the negative cable from the battery. Pull back positive terminal cover @ and disconnect the pos­ itive cable from the battery. Detach rubber band at the bottom. Lift the battery up and out.
  • Page 132 Warning Environmental hazard Batteries contain environmentally-hazardous materials. Do not dispose of batteries as household waste. Return batteries to your authorized Husqvarna Motorcycles dealer or dispose of them at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 133: 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. (lit!I p. 92) Main work Carry out the start procedure. (lit!I p. 12) Measure the voltage between the specified points. - Measuring point Measuring point Plus(+)

  • Page 134: 16 Brake System

    16 BRAKE SYSTEM Checking the front brake linings Warning Worn-out brake linings reduce the braking effect. Danger of accidents Ensure that worn-out brake linings are replaced immediately. Check the brake linings for minimum thickness I Minimum thickness I � 1 mm (� 0.04 in) If the minimum thickness is less than specified: Change the front brake linings.
  • Page 135 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 136: Checking The Free Travel Of The Hand Brake Lever

    16 BRAKE SYSTEM Insert the new brake linings, insert pin and mount cotter pins • 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 137: Adjusting The Basic Position Of The

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

  • Page 138: Checking The Front Brake Fluid Level

    16 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 139: Changing The Front Brake Fluid

    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 140 16 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 141: Checking The Rear Brake Linings

    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 (9 . Guideline Measurement of (9 5 mm (0.2 in)
  • Page 142 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 143 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 144: Checking The Free Travel Of Foot

    16 BRAKE SYSTEM Add brake fluid to level f). I Brake fluid DOT 4 (I!\',! p. 314) Mount screw cap with membrane and O-ring. Info Clean up overflowed or spilled brake fluid immediately with water. Checking the free travel of foot brake lever Warning The brake system fails in the event of overheating.

  • Page 145: Adjusting The Basic Position Of The Foot Brake Lever

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

  • Page 146: Adding Rear Brake Fluid

    16 BRAKE SYSTEM Stand the vehicle upright. Check the brake fluid level in level viewer lf the brake fluid level has dropped below marking Add rear brake fluid. (� p. 144) 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 147: Changing The Rear Brake Fluid

    BRAKE SYSTEM Main work Stand the vehicle upright. Remove screw cap with membrane f!} and the 0-ring. Add brake fluid to level fj. Brake fluid DOT 4 (!ill p. 314) Mount the screw cap with the membrane and the 0-ring. Info Clean up overflowed or spilled brake fluid immediately with water.
  • Page 148 16 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. 320) Brake fluid DOT 4 (�...
  • Page 149 BRAKE SYSTEM Stand the vehicle upright. Correct the brake fluid up to marking (!). Brake fluid DOT 4 (Ii!:! p. 314) Fit and tighten plug with oil screen and 0-ring. Info Clean up overflowed or spilt brake fluid immediately with water. Check the foot brake lever for a firm pressure point.

  • Page 150: Lighting System, Instruments

    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 display flashes. UNIT ____ ,�_ I _L Press one of the buttons to select for the speed in kilo­...

  • Page 151: Adjusting The Kilometers Or Miles

    17 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 152: Setting The Wheel Circumference

    LIGHTING SYSTEM, INSTRUMENTS 17.4 Setting the wheel circumference Condition The motorcycle is stationary. Preparatory work Disconnect speedometer connector CZ. Main work Press both buttons for 3 - 5 seconds. ✓ The Setup menu is displayed. The UNIT display flashes. ____ ,�_1_1, . ✓...

  • Page 153: Checking The Headlight Setting

    17 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 154: 18 Engine

    18 ENGINE 18.1 Removing the engine Preparatory work Remove the engine guard.(� p. 45) Drain the coolant. (� p. 236) Raise the motorcycle with a lift stand. (!,Jl p. 12) Remove the right side cover. (!,Jl p. 91) Remove the main silencer. (!,Jl p.
  • Page 155 18 ENGINE Remove screws on both sides. Release screw on both sides. 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 Spring hook (50305017000) (�...
  • Page 156 18 ENGINE Push back the cover. Remove nut Ci). Take off the cable. Loosen hose clip Pull off the radiator hose. Detach spring Remove screw G). Remove screw Take off the engine sprocket cover. Remove the connecting link of the chain. Take off the chain.
  • Page 157 18 ENGINE Remove screws Take off the slave cylinder of the clutch and hang it to one side. • Info Do not kink the clutch line. Do not activate the clutch lever while the slave cylin­ der of the clutch is removed. Gs).

  • Page 158: Installing The Engine

    18 ENGINE 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 159 18 ENGINE Position the swingarm. Mount the swingarm pivot. Mount nut but do not tighten it yet. Guideline Nut, swingarm pivot M16x1 .5 I 100 Nm (73.8 lbf ft) I Position the engine braces. Mount and tighten fittings (D. Guideline Screw, engine 33 Nm (24.3 lbf ft) ®...
  • Page 160 18 ENGINE 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. Connect the chain with connecting link Gi). Guideline The closed side of the chain joint lock must face in the direction of travel.
  • Page 161 18 ENGINE Position the cable. 49 . Mount and tighten nut Position the cover. Position the manifold and mount springs Spring hook (50305017000) p. 320) Mount and tighten screw Guideline Remaining screws, 25 Nm (18.4 lbf ft) chassis Position the shock absorber. G!,.
  • Page 162 18 ENGINE Remove the locking piece and position the subframe. Info Watch out for the intake flange. Mount and tighten screws G). Guideline Screw, sub­ 35 Nm (25.8 lbf ft) Loctite ® 2701 frame Remove screw �. Mount and tighten screw�­ Guideline Screw, sub­...
  • Page 163 235) Execute the initialization run. (� p. 253) 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. (� p. 238) Check the coolant level.

  • Page 164: Engine Disassembly

    18 ENGINE 18.3 Engine disassembl� 18.3.1 Preparations Mount the special tool on the engine assembly stand. Holder and fitting for work stand (77229002000) (� p. 325) Engine work stand (80329001000) p. 328) Mount the engine on the special tool. Info Work with an assistant or a motorized hoist.

  • Page 165: Removing The Oil Filter

    18 ENGINE Remove the oil drain plug with the magnet and seal ring. Remove oil drain plug (D with the O-ring. Completely drain the engine oil. 18.3.5 Removing the oil filter Remove screws Remove the oil filter cover with the O-ring.

  • Page 166: Removing The Valve Cover

    18 ENGINE 18.3.7 Removing the valve cover Remove screws Remove the valve cover with the valve cover seal. Remove gasket Remove spark plug shaft insert (D. 18.3.8 Removing the alternator cover Remove screws Take off the alternator cover. Take off alternator cover gasket (D. ✓...

  • Page 167: Removing The Torque Limiter

    18 ENGINE 18.3.9 Removing the torque limiter Remove torque limiter 18.3.10 Positioning the engine at ignition top dead center Turn the crankshaft counterclockwise until marking flush with the edge of the cylinder head. Remove screw Info Check through the hole whether the position notch of the crankshaft is visible.

  • Page 168: Removing The Camshafts

    18 ENGINE Pull out timing chain tensioner Remove O-ring 18.3.12 Removing the camshafts Loosen and remove screws from the outside to the inside. Take off guide rail@. Take off the camshaft bearing bridge. Info Ensure that the dowel pins remain in place. Take the timing chain from the camshaft gear.

  • Page 169: Removing The Piston

    18 ENGINE Remove cylinder head gasket (5). 18.3.14 Removing the piston Push the cylinder upward. Info Only push the cylinder as far up as necessary to take the piston pin out. Remove the piston pin retainer Remove the piston pin. Take off the cylinder and piston.
  • Page 170 18 ENGINE Insert special tool into the crankshaft. I Protection cap (75029090000) (I!!;! p. 325) 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) (I!!;! p.

  • Page 171: Removing The Suction Pump

    18 ENGINE «D. Remove freewheel gear 18.3.16 Removing the suction pump Remove screws Take off oil pump cover Remove O-ring Take off suction pump Remove needle roller...

  • Page 172: Removing The Water Pump Wheel

    18 ENGINE 18.3.17 Removing the water pump wheel Remove screws Take the water pump cover. Remove nut Take off the two-part water pump impeller@). 18.3.18 Removing the clutch cover Remove screws Take off the clutch cover. Remove the clutch cover seal. 18.3.19 Removing the clutch discs Remove screws...

  • Page 173: Removing The Clutch Basket

    18 ENGINE Take off spring washer Take off pretension ring Take off pressure cap Remove clutch disc pack Q) entirely. Remove clutch pressure piece @. 18.3.20 Removing the clutch basket Bend up the lock washer. Hold the inner clutch hub with the special tool. Loosen Holding wrench (51129003000) (ll!:!I p.

  • Page 174: Removing The Shift Shaft

    18 ENGINE Take off inner clutch hub and washer Info The washer usually sticks to the inner clutch hub. Take off clutch basket Take off needle bearing and collar sleeve (D. 18.3.21 Removing the shift shaft Push sliding plate away from the shift drum locating unit Remove shift shaft with the washer.

  • Page 175: Removing The Locking Lever

    18 ENGINE 18.3.23 Removing the locking lever Unscrew and remove together with locking lever@, washer, sleeve and spring. 18.3.24 Removing the force pump Remove lock ring Take off washer@. Take off oil pump idler gear with the washer. Remove lock ring Take off washer@).

  • Page 176: Removing The Primary Gear

    18 ENGINE 18.3.25 Removing the primary gear Remove nut • Info Left-handed thread! Position the special tool in the crankshaft. I Protection cap (75029090000) p. 325) Pull off primary gear using the special tool. I Puller (46129021000) (� p. 319) Remove screw 18.3.26 Removing the timing chain...

  • Page 177: Removing The Left Section Of The Engine Case

    18 ENGINE 18.3.28 Removing the left section of the engine case Remove screws Tilt the left section of the engine case upward and remove the screw connections of the engine fixing arm. Insert the special tool into the crankshaft. Protection cap (75029090000) (�...

  • Page 178: Removing The Shift Drum

    18 ENGINE 18.3.30 Removing the shift drum Tilt shift forks to the side. Info Do not misplace the shift rollers. Remove shift drum 18.3.31 Removing the shift forks Remove shift forks Info Do not misplace shift rollers Removing the transmission shafts 18.3.32 Remove lock ring Pull both transmission shafts...

  • Page 179: Removing The Crankshaft

    18 ENGINE 18.3.33 Removing the crankshaft Take out crankshaft Take off the right section of the engine case. 18.4 Working on individual �arts 18.4.1 Work on the right section of the engine case Remove all dowels. Remove shaft seal ring of the crankshaft.
  • Page 180 18 ENGINE Info When pressing the bearing in, ensure that the engine case section is level to prevent damage. Only press the bearings in via the outer bearing race; otherwise, the bearings will be damaged when they are pressed in. After the engine case section has cooled, check that the bearings are firmly seated.

  • Page 181: Work On The Left Section Of The Engine Case

    18 ENGINE 18.4.2 Work on the left section of the engine case Remove all dowels. Remove shaft seal ring of the crankshaft, shift shaft countershaft. Remove oil nozzle for clutch lubrication. Remove oil nozzle for piston cooling. Remove screws (D. Remove the bearing retainers. Remove any sealing mass remnants and clean the engine case section thoroughly.

  • Page 182: Work On The Clutch Cover

    18 ENGINE Mount and tighten oil nozzle Guideline 2 Nm (1.5 lbf ft) Oil nozzle, pis­ Loctite ® ™ ton cooling Position all bearing locks. Mount and tighten screws (D. Guideline Locking screw 6 Nm (4.4 lbf ft) Loctite ® for bearing ™...
  • Page 183 18 ENGINE Mount lock ring Press the shaft seal ring all the way in from the inside to the outside with the open side facing in. 309288-10 Press the new bearing all the way in from the inside to the outside using a suitable tool.

  • Page 184: Checking The Oil Pressure Regulator Valve

    18 ENGINE 18.4.4 Checking the oil pressure regulator valve Remove screw plug with sealing washer@. Remove pressure spring (D and ball 308784-10 Measure the spring length of the oil pressure regulator valve. Oil pressure regulator valve 23.5 mm (0.925 in) Minimu ':7 length of pres- sure spring If the measured value does not meet specifications:...

  • Page 185: Checking The Lubrication System

    18 ENGINE 18.4.5 Checking the lubrication system l o � • �, ✓ ✓ 305003-10 Check the internal rotor and external rotor of oil pumps for damage and wear. If there is damage or wear: Change the oil pumps. Check oil pump shaft for damage and wear.

  • Page 186: Installing The Crankshaft Bearing Inner Race

    18 ENGINE 18.4.7 Installing the crankshaft bearing inner race Main work Fix the crankshaft in the vise. Info Use soft jaws. Slide on compensating disk Info The compensating disks have a larger diameter than 306538-10 the crankshaft stub. Ensure that the compensating disks are centered and fixed with a small amount of grease.
  • Page 187 18 ENGINE Press the crank pin out of the lower crank web. Press in the new crank pin as far as possible. ✓ Oil hole is aligned with oil hole G). X If the oil holes are not correctly aligned, the conrod bear­ ing will not be supplied with oil.

  • Page 188: Checking The Crankshaft Run-Out At The Bearing Pin

    18 ENGINE Measure axial play between the connecting rod and the crank webs using the special tool. I Feeler gauge (59029041100) (ra:!l p. 322) Connecting rod - axial play 0.20 ... 0.45 mm (0.0079 ... of lower conrod bearing 0.0177 in) If the specification is not reached: Correct it so the dimension is equal to the specified value.

  • Page 189: Removing The Drive Wheel Of The Balancer Shaft

    18 ENGINE Info If the axial play is too small, remove compen­ sating disks. If the axial play is too large, add compensating disks. Install the crankshaft bearing inner race. (!i.,!I p. 184) 18.4.11 Removing the drive wheel of the balancer shaft Position the balancer shaft in the press with special tool 1 Separator plate (77229032000) (!i.,!I...

  • Page 190: Checking/Measuring The Cylinder

    18 ENGINE 18.4.14 Checking/measuring the cylinder Check the cylinder bearing surface for damage. If the cylinder bearing surface is damaged: Change the cylinder and piston. Measure the cylinder diameter at several locations on using a micrometer to identify oval 0-axes wear.

  • Page 191: Measuring The Piston/Cylinder Mounting Clearance

    18 ENGINE An old piston ring can be used to clean the piston ring groove. Check the piston rings for damage. If the piston ring is damaged: Change the piston ring. • Info Mount the piston ring with the marking facing upward.

  • Page 192: Checking The Piston Ring End Gap

    18 ENGINE 18.4.17 Checking the piston ring end gap Remove the piston ring from the piston. Place the piston ring in the cylinder and align with the piston. Guideline Below the upper edge of the 20 mm (0.79 in) cylinder Measure end gap with a feeler gauge.

  • Page 193: Checking The Pivot Points Of The Camshafts

    18 ENGINE 18.4.20 Checking the pivot points of the camshafts Check the pivot points of the camshafts. If there is damage or wear: Change the cylinder head with the camshaft bearing bridge. 306759-10 Position the camshafts. ✓ The valves are not activated. Insert the Plastigauge clearance gauge in area 6).

  • Page 194: Removing The Valves

    18 ENGINE 18.4.21 Removing the valves Remove screw plugs with the O-ring. Screw appropriate screw into the cam lever shaft. Hold cam levers and remove the cam lever shaft. Info If the cam levers will continue to be used, note down their installation position.

  • Page 195: Checking The Valves

    18 ENGINE 18.4.22 Checking the valves Check the valve plate for run-out. Valve - run-out At the valve plate $ 0.05 mm ($ 0.002 in) If the measured value does not meet specifications: Change the valve. 200193-10 Check sealing seat on the valve.

  • Page 196: Checking The Valve Spring Seat

    18 ENGINE 18.4.24 Checking the valve spring seat Check the valve spring seat for breakage and wear (visual check). If the valve spring seat is broken or worn: Change the valve spring seat. Measure the thickness of the valve spring seat. Valve spring seat - thick­...

  • Page 197: Installing The Valves

    18 ENGINE Check sealing seat of the valves. Valve - sealing seat width Intake 1 .40 mm (0.0551 in) Valve - sealing seat width Exhaust 1 .40 mm (0.0551 in) If the measured value does not meet specifications: Rework the valve seat. 302808-10 Blow compressed air through all oil holes and check that they are clear.

  • Page 198: Checking The Freewheel

    18 ENGINE Position cam levers in the positions they had before they were removed. Mount the cam lever shafts. Remove screw Mount and tighten screw plugs (D. Guideline Screw plug, cam M10x1 10 Nm (7.4 lbf ft) lever axis Place the shims in the valve spring retainers corresponding to their installation position.

  • Page 199: Installing The Freewheel

    18 ENGINE Take freewheel out of the primary gear. 308684-10 18.4.30 Installing the freewheel Thoroughly oil all parts. Slide freewheel into the primary gear. Info Note the direction of rotation. 308684-11 Mount spreader ring Ensure that all lugs of the expansion ring pass through slots of the free wheel and engage in groove of the...

  • Page 200: Checking The Electric Starter Drive

    18 ENGINE 18.4.31 Checking the electric starter drive ·-8 305006-10 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 201: Checking The Timing Assembly

    18 ENGINE 18.4.32 Checking the timing assembly 306753-10 Check timing chain sprocket for damage and wear. If there is damage or wear: Change the timing chain sprocket. Check the timing chain tensioning rail for damage and wear. If there is damage or wear: Replace the timing chain tensioning rail.

  • Page 202: Preparing The Timing Chain Tensioner For Installation

    18 ENGINE 18.4.33 Preparing the timing chain tensioner for installation Press the timing chain tensioner together completely. Info This requires some force, as the oil must be pressed out. Release the timing chain tensioner. ✓ Without pressure, the timing chain tensioner expands fully.

  • Page 203: 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 204: Checking The Shift Mechanism

    18 ENGINE If there is damage or wear: Change the clutch facing discs and the clutch basket. «9 Check needle bearing and collar sleeve for damage and wear. If there is damage or wear: Change the needle bearing and collar sleeve. Check intermediate discs for damage and wear.

  • Page 205: Preassembling The Shift Shaft

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

  • Page 206: Disassembling The Main Shaft

    18 ENGINE 18.4.37 Disassembling the main shaft 306576-10 Secure the main shaft with the toothed end facing downward in the bench vise. Guideline Use soft jaws. Remove stop disk and second-gear fixed gear f!}. Remove sixth-gear idler gear (D. Remove needle bearing and stop disk Remove lock ring (D.

  • Page 207: Disassembling The Countershaft

    18 ENGINE 18.4.38 Disassembling the countershaft 306577-10 Secure the countershaft in the bench vise with the toothed end facing downward. Guideline I Use soft jaws. Remove stop disk and first-gear idler gear@. Remove needle bearing (D and stop disk Remove sixth-gear sliding gear Remove lock ring (D.
  • Page 208 18 ENGINE 306578-10 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 209: Assembling The Main Shaft

    18 ENGINE Use new lock rings with every repair. 18.4.40 Assembling the main shaft Info Use new lock rings with every repair. Preparatory work Check the transmission. (l!!JI p. 205) Carefully lubricate all parts before assembling. Main work 306576-11 Secure the main shaft in the vise with the gear teeth facing downward. Guideline I Use soft jaws.
  • Page 210 18 ENGINE Preparatory work Check the transmission. (llill p. 205) Carefully lubricate all parts before assembling. Main work 306577-11 Secure the countershaft in the bench vise with the toothed end facing downward. Guideline Use soft jaws. Mount needle bearing and second-gear idler gear @ onto the countershaft with the protruding collar facing downward.

  • Page 211: Engine Assembly

    18 ENGINE 18.5 Engine assembly 18.5.1 Installing the crankshaft Position the right section of the engine case in the engine work stand. Oil the bearing. Push crankshaft into the bearing seat. 18.5.2 Installing the transmission shafts Oil the bearing. Slide both transmission shafts into the bearing seats together.

  • Page 212: Installing The Shift Forks

    18 ENGINE 18.5.3 Installing the shift forks Shift fork has a smaller inside diameter; mount this in the shift groove of the main shaft. Mount shift fork in the lower shift groove of the counter­ •- shaft. Mount shift fork in the upper shift groove of the counter­...

  • Page 213: Installing The Left Engine Case

    18 ENGINE Install shift rail together with upper spring 18.5.6 Installing the left engine case Mount the dowels. Degrease the sealing area. Apply the sealing compound to the left section of the engine case. Loctite 5910 ® Mount the left section of the engine case. If necessary, strike it lightly with a rubber mallet and turn the transmission shafts.

  • Page 214: Installing The Spacer

    18 ENGINE 18.5.7 Installing the spacer Grease the shaft seal ring. Mount spacer 18.5.8 Installing the timing chain Mount balancer shaft with the timing chain and timing chain securing guide. Info If the timing chain was used before, ensure it is run­ ning in the correct direction.

  • Page 215: Installing The Primary Gear

    18 ENGINE 18.5.9 Installing the primary gear Position primary gear ✓ Markings and G) are aligned. Set the crankshaft to top dead center and lock it with screw@. Mount and tighten nut (5). Guideline Nut, primary M18LHx1.5 100 Nm (73.8 lbf ft) ®...

  • Page 216: Installing The Suction Pump

    18 ENGINE Mount oil pump idler gear with the washer. Mount washers Ci). Mount lock ring 18.5.11 Installing the suction pump Insert needle roller Position suction pump ✓ The rounded sides of the external rotor face the engine case. Crank the oil pump gear wheel and ensure that it can move easily.

  • Page 217: Installing The Locking Lever

    18 ENGINE 18.5.12 Installing the locking lever Mount locking lever with the washer, sleeve and spring. Mount and tighten screw @ . Guideline Screw, locking 6 Nm (4.4 lbf ft) ® Loctite lever ™ 18.5.13 Installing the shift drum locating unit Push away locking lever from the shift drum locating unit and position the shift drum locating unit @ .

  • Page 218: Installing The Clutch Discs

    18 ENGINE Slide the clutch basket onto the gearbox main shaft. Turn the oil pump gear until the gear teeth of the clutch basket mesh. Slide on washer and inner clutch hub (3. Position the new lock washer and mount nut (D. Tighten the nut, holding the inner clutch hub with a special tool.
  • Page 219 18 ENGINE Mount pretension ring with marking Top facing up. Position spring washer Position spring retainer with marking I. Mount screws and tighten in a crisscross pattern. Guideline Screw, clutch spring I 6 Nm (4.4 lbf ft)

  • Page 220: Installing The Clutch Cover

    18 ENGINE Using a straightedge and the special tool, check the spring washer for distortion. I Feeler gauge (59029041100) (l!!ll p. 322) Spring washer distortion 0 ... 0.10 mm (0 ... 0.0039 in) If the specified value is not reached: Remove screws and mount the spring retainer with marking II.

  • Page 221: Installing The Water Pump Cover

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

  • Page 222: Installing The Starter Drive

    18 ENGINE Guideline Screw, water pump M6x25 10 Nm (7.4 lbf ft) cover 18.5.19 Installing the starter drive £ Position freewheel gear Mount the starter idler gear with the washer. Mount lock ring Grease the O-ring. Position the starter motor. Mount screws (D, but do not tighten yet.

  • Page 223: Installing The Piston

    18 ENGINE Mount and tighten screws@). Guideline Screw, alternator 8 Nm (5.9 lbf ft) cover Tighten screws@). Guideline Screw, starter motor 110 Nm (7.4 lbf ft) Ensure that the woodruff key is seated properly. Mount the rotor. Info To simplify installation, turn the starter idler gear coun­ terclockwise.
  • Page 224 18 ENGINE Position the piston with the special tool on the cylinder. Carefully slide the piston into the cylinder from the top. Info The piston rings should not catch or they will be dam­ aged. Ensure that piston marking faces the exhaust side. Thinly apply sealing compound to area G).

  • Page 225: Installing The Cylinder Head

    18 ENGINE Insert the special tool and press it with force towards the pis­ ton. Turn the special tool clockwise, thereby pushing the piston ring lock into the groove. Insertion for piston ring lock (77729030100) (ll,JI p. 328) Ensure that the piston ring lock is in the correct position on both sides.

  • Page 226: 18.5.22 Installing The Camshafts

    18 ENGINE Guideline Nut, cylinder M10x1 .25 Tightening sequence: Tighten diagonally. head 1st tightening stage 10 Nm (7.4 lbf ft) 2nd tightening stage 30 Nm (22.1 lbf ft) 3rd tightening stage 50 Nm (36.9 lbf ft) Thread, oiled with engine oil/cone greased I Angle disc (60029010000) (�...

  • Page 227: Installing The Timing Chain Tensioner

    18 ENGINE Clean all oil nozzles thoroughly and blow out with compressed air. Mount the camshaft bearing bridge. Info Ensure that the dowel pins are seated properly. Position guide rail Mount screws and tighten from the inside to the outside. Guideline Screw, M7x1...

  • Page 228: Checking The Valve Clearance

    18 ENGINE 18.5.24 Checking the valve clearance Remove screw Crank over the engine repeatedly. Position the engine at ignition top dead center. ✓ Marking are aligned with the edge of the cylinder head. 308708-10 Check the valve clearance at all valves between the camshaft and cam levers.

  • Page 229: Installing The Torque Limiter

    18 ENGINE Raise cam levers Correct the shims according to the findings from checking the valve clearance. Install the camshafts. (!!:! p. 224) Install the timing chain tensioner. (!!:! p. 225) Finishing work Check the valve clearance. p. 226) 18.5.26 Installing the torque limiter Position torque limiter 18.5.27...

  • Page 230: Installing The Valve Cover

    18 ENGINE Guideline Screw, alternator M8x25 6 Nm (4.4 lbf ft) cover 18.5.28 Installing the valve cover Grease O-rings and mount spark plug shaft insert Position gasket Apply a thin layer of sealing compound in area I Loctite 5910 ® Position the valve cover with the gasket.

  • Page 231: Installing The Spark Plug

    18 ENGINE 18.5.29 Installing the spark plug Mount and tighten the spark plug with special tool Guideline Spark plug M10x1 10 ... 12 Nm (7.4 _ ... 8.9 lbf ft) Spark plug wrench with link (77229172000) (� p. 327) 18.5.30 Installing the oil filter Tilt the motorcycle to one side and fill the oil filter housing to about½...

  • Page 232: Installing The Spacer

    18 ENGINE Mount and tighten the oil drain plug with the magnet and the new seal ring. Guideline Oil drain plug with M12x1.5 20 Nm (14.8 lbf ft) magnet Push the oil screen with O-rings onto a pin wrench. Push the pin wrench through the opening into the drill hole of the opposite engine case wall and push the oil screen as far as possible into the engine case.

  • Page 233: Removing The Engine From The Engine Assembly Stand

    18 ENGINE 18.5.34 Removing the engine from the engine assembly stand Remove the screw connection from the special tool. Holder and fitting for work stand (77229002000) (� p. 325) Remove the engine from the engine assembly stand. • Info Work with an assistant or a motorized hoist.

  • Page 234: 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 235: 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 236: 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 237: 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 238: 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 239 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(� p. 314) Refit the radiator cap.

  • Page 240: Lubrication System

    LUBRICATION SYSTEM 21.1 Oil circuit 401362-60 Oil screen Force pump Oil pressure regulator valve Oil filter Oil nozzle, conrod lubrication Oil nozzle for cam follower lubrication Oil nozzle, piston cooling Oil nozzle for alternator cooling Oil nozzle for clutch lubrication �...

  • Page 241: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen

    LUBRICATION SYSTEM Info After switching off the engine, wait one minute before checking the level. The engine oil is at a level between lower edge middle @ of the level viewer. If the engine oil is not at a level between lower edge and middle @ of the level viewer: Add engine oil.
  • Page 242 LUBRICATION SYSTEM Position oil screen with the O-rings on a pin wrench. Position the pin wrench through the drilled hole of the screw plug in the opposite section of the engine case. Push the oil screen all the way into the engine case. Mount and tighten screw plug with the O-ring.

  • Page 243: Adding Engine Oil

    LUBRICATION SYSTEM Remove filler plug @ and 0-ring from the clutch cover and fill up with engine oil. Engine oil 1 .0 I (1 .1 qt.) Engine oil (SAE 1 OW/50) (l,ll p. 314) • Info Too little engine oil or poor-quality engine oil results in premature wear to the engine.

  • Page 244: 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 10W/50) (!!:,!Ip. 314) • Info For optimal performance of the engine oil, do not mix different types of engine oil.
  • Page 245 LUBRICATION SYSTEM 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 246: 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 247: Removing The Stator And Crankshaft Position Sensor

    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 248: Installing The Stator And Crankshaft 30.11 Position Sensor

    22 IGNITION SYSTEM Remove screws Remove the stator and crankshaft position sensor from the alternator cover. 305321-10 22.5 lnstallin the stator and crankshaft position sensor Blow out oil nozzle with compressed air and check that it is clear. Guideline Oil nozzle for 2 Nm (1.5 lbf ft) ®...

  • Page 249: 23 Cylinder Head

    23 CYLINDER HEAD 23.1 Checking the valve clearance Preparatory work Remove the seat. (� p. 92) Remove the fuel tank. (� p. 93) Main work Push back cover disconnect the connector. Disconnect spark plug connector Remove the spark plug with special tool Spark plug wrench with link (77229172000) (�...
  • Page 250 23 CYLINDER HEAD Remove gasket Remove screw Gi). Turn the crankshaft counterclockwise until markings flush with the edge of the cylinder head. Info Make sure that the crankshaft is at top dead center. Remove screw Remove washer Look through the hole to check that the position notch of the crankshaft is visible.
  • Page 251 23 CYLINDER HEAD Remove screw Crank the engine several times. Check the valve clearance and correct it if necessary. Mount and tighten screw with washer Guideline 10 Nm (7.4 lbf ft) Screw plug, crankshaft location Mount and tighten screw Gi). Guideline M24x1 .5 Screw, alternator...

  • Page 252: Adjusting The Valve Clearance

    23 CYLINDER HEAD Position the engine braces. Mount and tighten fittings 0). Guideline Screw, engine 33 Nm (24.3 lbf ft) brace ® Loctite 2701 Position the radiator on the right. Mount and tighten screws Mount right radiator shield Mount and tighten the spark plug with special tool (D. Guideline Spark plug M10x1...
  • Page 253 23 CYLINDER HEAD Main work Swing up cam lever Correct the shims based on the results of the valve clearance check. Finishing work Install the camshafts. p. 224) Install the timing chain tensioner. (I!!:! p. 225) Check the valve clearance. (I!!:! p.

  • Page 254: 24 Electric Starter

    24 ELECTRIC STARTER 24.1 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 255: 25 Throttle Valve Body

    25 THROTTLE VALVE BODY Adjusting the idle s�eed Warning Danger of accidents The engine may go out spontaneously if the idle speed is set too low. Set the idle speed to the specified value. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
  • Page 256 25 THROTTLE VALVE BODY Start the engine without operating the throttle grip. Guideline I Coolant temperature I < 25 °C (< 77 °F) Let the engine idle until it reaches the specified temperature. Guideline I Coolant temperature I so ... 90 °c (176 ... 194 °F) •...

  • Page 257: 26 Technical Data

    26 TECHNICAL DATA 26.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 249.91 cm (15.2505 cu in) Stroke 52.3 mm (2.059 in) Bore 78 mm (3.07 in) Compression ratio 12.8:1 Idle speed 2,050 ... 2,150 rpm Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 32.5 mm (1.28 in)

  • Page 258: Tolerance, Engine Wear Limits

    26 TECHNICAL DATA 26.2 Tolerance, engine wear limits Valve - run-out At the valve plate s; 0.05 mm (s; 0.002 in) Valve spring Minimum length of intake valve 42 mm (1.65 in) Minimum length of exhaust valve 42 mm (1.65 in) Valve - sealing seat width Intake 1 .40 mm (0.0551 in)
  • Page 259 26 TECHNICAL DATA Screw, oil nozzle for piston cool- 2 Nm (1.5 lbf ft) Loctite ® ™ Locking screw for bearing 6 Nm (4.4 lbf ft) Loctite ® ™ Oil channel screw plug in alterna- 1 .2 Nm (0.89 lbf ft) ®...

  • Page 260: Capacities

    26 TECHNICAL DATA Screw, timing chain tensioning rail 15 Nm (11 .1 lbf ft) Loctite ® ™ Screw, engine sprocket 60 Nm (44.3 lbf ft) Loctite ® 2701 ™ Plug, oil channel M10x1 15 Nm (11.1 lbf ft) ® Loctite ™...

  • Page 261: Chassis

    26 TECHNICAL DATA Total fuel tank capacity, approx. (FE US) Super unleaded (ROZ 95/RON 95/PON 91) (� p. 315) 8.5 I (2.25 US gal) Fuel reserve, approx. 1.5 I (1.6 qt.) 26.5 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork Up Side Down 4860...

  • Page 262: Electrical System

    110/100 - 18 64M TT Dunlop GEOMAX AT 81 F Dunlop GEOMAX AT 81 The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: www.husqvarna-motorcycles.com 26.8 Fork Fork part number 24.18.7P.67...

  • Page 263: Shock Absorber

    26 TECHNICAL DATA Weight of rider: 85 ... 95 kg (187 ... 209 lb.) 4.6 N/mm (26.3 lb/in) Fork length 932 mm (36.69 in) Air chamber length 100 mm (3.94 in) Oil capacity per fork leg 630 ml (21.3 fl. oz.) Fork oil (SAE 4) (48601166S1) (�...
  • Page 264 26 TECHNICAL DATA Screw, shock absorber adjusting 5 Nm (3.7 lbf ft} ring Screw, spoiler on fuel tank M5x12 1.5 Nm (1 .11 lbf ft) (FE US) Nut, cable on starter motor 4 Nm (3 lbf ft) Remaining nuts, chassis 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft} Remaining screws, chassis...
  • Page 265 26 TECHNICAL DATA Screw, top shock absorber 60 Nm (44.3 lbf ft) Loctite ® 2701 Nut, fuel pump fixation 15 Nm (11.1 lbf ft) Nut, angle lever on swingarm M14x1.5 80 Nm (59 lbf ft) Nut, frame on linkage lever M14x1 .5 80 Nm (59 lbf ft) Nut, linkage lever on angle lever...

  • Page 266: 27 Cleaning, Care

    27 CLEANING, CARE 27.1 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 267: Checks And Maintenance Steps For Winter Operation

    27 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. 31 7) Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

  • Page 268: Storage

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

  • Page 269: Preparing For Use After Storage

    28 STORAGE 28.2 Pre�aring for use after storage Remove the motorcycle from the lift stand. (illll p. 12) Install the battery. (lillll p. 129) Perform checks and maintenance measures when preparing for use. Take a test ride. 401059-01...

  • Page 270: 29 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 271: 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 272: Wiring Diagram

    � " " " " " " u� " " } x 4 � B A F/4 �l -M10 -K10 � -G10 -521 /""' ...J n � · ,.,. I � ,',!, - X 4 � " -X300 -" 1Wl-rd�a/2.E1 <( ,..
  • Page 273 30 WIRING DIAGRAM Components: Battery Starter relay with main fuse Electric starter system E-tip switch...

  • Page 274: Fe Eu)

    t1 : 1 {HY / 33 X 15 · ---------------------------------ye-<d --i> c /6.B1 " " i . x s r_ X 1 0 E B / 4 i E B / • M 1 - B 33 - X 295 ±...
  • Page 275 30 WIRING DIAGRAM Components: A 11 EFI control unit Radiator fan temperature switch Fuse Fuse Alternator Light relay Power relay Radiator fan Voltage regulator X295 Diagnostics connector...

  • Page 276: Fe Eu)

    30 WIRING DIAGRAM 30.3 Page 3 of 8 (FE EU) -P13 "' I /6.AI /6.A3 «) ww12 ]" � " 1 ™ -X15 � -XSO E 1s lll�t/4.BI " j J }· < C 0 ' �o I ,, J . , t ffl •...
  • Page 277 30 WIRING DIAGRAM Components: A 11 EFI control unit Low beam, high beam Speedometer Horn Parking light Light switch, horn button, kill switch...

  • Page 278: Fe Eu)

    I · � . . . , 1y•bu--1>e /5.B1 � �I _ /3.88 IC>- wh " � � �ic A H /2 A H /2 1 X18 } X13 -D1/2 }x1 9 �"' -X11 -B76 -B77 -P36 � - �- :.1;...
  • Page 279 30 WIRING DIAGRAM Components: Front brake light switch Rear brake light switch License plate lamp Brake/tail light...

  • Page 280: Fe Eu)

    � /4.88 bC>-- t1 /4.88 et:::-ye-00 ._,, " " ._,, J�, H,, . N AJ/3 -C X /2 -C X /2 -C X /2 C X /2 j - X23 AH/2 - NF0/2 j-X25 j -X41 � -X28 -525 -P42 -P46 -P41 -P45...
  • Page 281 30 WIRING DIAGRAM Components: Turn signal relay Turn signal indicator lamp Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right S2 5 Turn signal switch...

  • Page 282: Fe Eu)

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  • Page 283 30 WIRING DIAGRAM Components: A 11 EFI control unit Fuel level sensor Lambda sensor (cylinder 1) Fuse Fuse Fuel pump Speedometer...

  • Page 284: Fe Eu)

    - P 1 -A111 /8. A 1 -© j- tj c TI" ' " m" ' " 1" '" ' 1""' iifY/ -X15 -X15 -X15 -X15 -X52 -B7 0 j � i 5 l5 l5 1515 � � � H H r-- NDQ /2 N AT/2 �...
  • Page 285 30 WIRING DIAGRAM Components: A 11 EFI control unit Front wheel speed sensor Injection valve (cylinder 1) Speedometer CAN-bus terminating resistor 1 X295 Diagnostics connector...

  • Page 286: Fe Eu)

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  • Page 287 30 WIRING DIAGRAM Components: A 11 EFI control unit Throttle position sensor Intake air temperature sensor Coolant temperature sensor (cylinder 1) Rollover sensor Crankshaft position sensor Induction manifold 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 288: Fe Au)

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  • Page 289 30 WIRING DIAGRAM Components: Battery Starter relay with main fuse Electric starter system Emergency OFF switch, tip switch...

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  • Page 291 30 WIRING DIAGRAM Components: A 11 EFI control unit Radiator fan temperature switch Fuse Fuse Alternator Light relay Power relay Radiator fan Voltage regulator X295 Diagnostics connector...

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  • Page 293 30 WIRING DIAGRAM Components: A 11 EFI control unit Low beam, high beam Speedometer Horn Parking light Light switch, horn button, kill switch S2 3 Emergency OFF switch, tip switch...

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  • Page 295 30 WIRING DIAGRAM Components: Front brake light switch Rear brake light switch License plate lamp Brake/tail light...

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  • Page 297 30 WIRING DIAGRAM Components: Turn signal relay Turn signal indicator lamp Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right S2 5 Turn signal switch...

  • Page 298: Fe Au)

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  • Page 299 30 WIRING DIAGRAM Components: A 11 EFI control unit Fuel level sensor Fuse Fuse Fuel pump Speedometer...

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  • Page 301 30 WIRING DIAGRAM Components: A 11 EFI control unit Front wheel speed sensor Injection valve (cylinder 1) Speedometer CAN-bus terminating resistor 1 X295 Diagnostics connector...

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  • Page 303 30 WIRING DIAGRAM Components: A 11 EFI control unit Throttle position sensor Intake air temperature sensor Coolant temperature sensor (cylinder 1) Rollover sensor Crankshaft position sensor Induction manifold 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 305 30 WIRING DIAGRAM Components: Battery Starter relay with main fuse Electric starter system E-tip switch...

  • Page 306: Fe Us)

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  • Page 307 30 WIRING DIAGRAM Components: A 11 EFI control unit Radiator fan temperature switch (optional) Fuse Fuse Alternator Light relay Power relay Radiator fan (optional) Voltage regulator X295 Diagnostics connector...

  • Page 308: Fe Us)

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  • Page 309 30 WIRING DIAGRAM Components: A 11 EFI control unit Low beam Parking light Tail light Kill switch Light switch...

  • Page 310: Fe Us)

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  • Page 311 30 WIRING DIAGRAM Components: A 11 EFI control unit Fuel level sensor Fuse Fuse Fuel pump Speedometer...

  • Page 312: Fe Us)

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  • Page 313 30 WIRING DIAGRAM Components: A 11 EFI control unit Front wheel speed sensor Injection valve (cylinder 1) Speedometer CAN-bus terminating resistor 1 X295 Diagnostics connector...

  • Page 314: Fe Us)

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  • Page 315 30 WIRING DIAGRAM Components: A 11 EFI control unit Throttle position sensor Intake air temperature sensor Coolant temperature sensor (cylinder 1) Rollover sensor Crankshaft position sensor Induction manifold 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 316: Substances

    SUBSTANCES Brake fluid DOT 4 Standard/classification Guideline Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the 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. Low grade and unsuitable antifreeze causes corrosion, deposits and frothing.
  • Page 317 31 SUBSTANCES Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification p. 334) (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 318: 32 Auxiliary Substances

    32 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...
  • Page 319 32 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 320: 33 Special Tools

    33 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 321 33 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 322 33 SPECIAL TOOLS S�ring hook Art. no.: 50305017000 50305017000 H00973-01 S�ringe Art. no.: 50329050000 50329050000 H00565-01 Lock ring lier Art. no.: 51012011000 51012011000 H00572-01 Holding wrench Art. no.: 51129003000 51129003000 H00575-01...
  • Page 323 33 SPECIAL TOOLS Puller Art. no.: 58012009000 58012009000 H00592-01 Puller Art. no.: 58429037037 Feature Inside diameter I 37.5 mm (1.476 in) 58429037037 H00596-01 Tool bracket Art. no.: 58429089000 58429089000 H00603-01 Pressing tool Art. no.: 58429091000 58429091000 H00604-01...
  • Page 324 33 SPECIAL TOOLS Pressing tool Art. no.: 58429092000 58429092000 H00605-01 Torgue wrench set Art. no.: 58429094000 Feature Torque 3 ... 15 Nm (2.2 ... 11 .1 lbf ft) Open ended bit 3.9 mm (0.154 in) ..)P.,P� Open ended bit 4.9 mm (0.193 in) ��...
  • Page 325 33 SPECIAL TOOLS Angle disc Art. no.: 60029010000 2x£ Feature 11/2 in Driver system / tip 60029010000 H00625-01 Plastigauge clearance gauge Art. no.: 60029012000 Feature 0.025 ... 0.175 mm (0.00098 ... 0.00689 in) 60029012000 H00627-01 Piston ring mounting tool Art. no.: 60029015000 Feature Height 80 mm (3.15 in)
  • Page 326 33 SPECIAL TOOLS Testing hose Art. no.: 61029093000 61029093000 H00659-01 Pressure testing tool Art. no.: 61029094000 4x£ 61029094000 H00660-01 Release device for timing chain tensioner Art. no.: 61229021000 61229021000 H00675-01 Crankshaft ressing tool Art. no.: 75029047000 75029047000 H00714-01...
  • Page 327 33 SPECIAL TOOLS Protection ca� Art. no.: 75029090000 75029090000 H00726-01 Crankshaft �ressing tool insert Art. no.: 77029008000 77029008000 H00737-01 Se�arator late Art. no.: 77029009001 77029009001 H00738-01 Holder and fitting for work stand Art. no.: 77229002000 77229002000 H00748-01...
  • Page 328 33 SPECIAL TOOLS Valve stem seals �lier Art. no.: 77229010000 77229010000 H00752-01 Limit �lug gauge Art. no.: 77229026000 Feature 5.55 mm (0.2185 in) I Diameter 77229026000 H00753-01 Protection ca� Art. no.: 77229031000 77229031000 H00755-01 Art. no.: 77229032000 77229032000 H00756-01...
  • Page 329 33 SPECIAL TOOLS Puller Art. no.: 77229048000 77229048000 H00758-01 Insert for valve s�ring lever Art. no.: 77229060000 77229060000 H00760-01 S�ark �lug wrench with link Art. no.: 77229172000 Feature Drive 3/8 in Hexagonal part 14 mm (0.55 in) Length 130 mm (5.12 in) 77229172000 H00761-01 Oil ressure ada ter...
  • Page 330 33 SPECIAL TOOLS Insertion for �iston ring lock Art. no.: 77729030100 77729030100 H01126-01 Engine work stand Art. no.: 80329001000 80329001000 H01047-01 Lift stand Art. no.: 81329955100 Feature Height 315 ... 425 mm (12.4 ... 16.73 in) Load :5 150 kg (:5 331 lb.) 81329955100 H00985-01 Hook wrench...
  • Page 331 33 SPECIAL TOOLS De�th micrometer Art. no.: T107S T107S H00842-01 Drift Art. no.: T120 Feature Diameter I 8 mm (0.31 in) T120 H00844-01 Clam�ing stand Art. no.: T1202S Feature Diameter 10 mm (0.39 in) Diameter 18 mm (0.71 in) T1202S H01149-01 Mounting sleeve Art.
  • Page 332 33 SPECIAL TOOLS Calibrating unit Art. no.: T1205 Feature I Diameter 1 18 mm (0.71 in) T1205 H00879-01 Pressing tool Art. no.: T1206 .& Feature I Diameter 1 15 ... 30 mm (0.59 ... 1.18 in) � T1206 H00880-01 Pressing tool Art.
  • Page 333 33 SPECIAL TOOLS Pressing tool Art. no.: T1216 Feature Diameter 38 ... 49 mm (1.5 ... 1.93 in) T1216 H00887-01 Vacuum �um� Art. no.: T1240S � T1240S H00890-01 Protecting sleeve Art. no.: T1401 Feature Diameter 48 mm (1 .89 in) T1401 H00894-01 Clam ing stand...
  • Page 334 33 SPECIAL TOOLS Mounting tool Art. no.: T14040S Feature 48 mm (1.89 in) I Diameter T14040S H00922-01 Mounting tool Art. no.: T14047 Feature Drive 1/2 in Narrow diameter 34 mm (1.34 in) Wide diameter 42. 7 mm (1.681 in) T14047 H00923-01 Clam�ing stand Art.
  • Page 335 33 SPECIAL TOOLS Pressing tool Art. no.: T1504 Feature 8 mm (0.71 in) Diameter T1504 H00899-01 Mounting tool Art. no.: T150S �o £& T150S H00852-01 Filling tool Art. no.: T170S1 �, 2x£3x.£. T170S1 H00855-01...

  • Page 336: 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 337: 35 List Of Abbreviations

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

  • Page 338: Index

    INDEX of the fork legs, assembling ... . . 29 Chain ......9 Accessories checking Air filter cleaning cleaning ......88 Chain guide installing ......
  • Page 339 INDEX crankshaft end play, measuring ..186 clutch push rod, installing ... . . 230 crankshaft run-out, checking at bearing pin . 186 crankshaft, installing .
  • Page 340 INDEX spring, removing ....20 shift shaft, removing ....172 spacer, removing ....
  • Page 341 INDEX Idle speed Rear sprocket adjusting checking ......Ignition coil Rear wheel secondary winding, checking ..244 installing removing Implied warranty ..... . . 9 Rebound damping Initialization run fork, adjusting .
  • Page 342 INDEX Spare parts ......9 Tire condition checking ......107 Spark plug connector chec�ng ......
  • Page 343 I 1 1 11 1 11 1 1 1 1 11 1 1 1 111 1 11 1 1 1 1 111 1 1 1 1 1 1 1 11 1 11 1 I I I I I I II I I II 3403024en 07/2017 ® Husqvarna llmi Husqvarna Motorcycles GmbH StallhofnerstraBe 3 5230 Mattighofen Austria fiiiHiAv � LZZa" ·...

This manual is also suitable for:

F2103p4F2160p4F2175p4

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