Husqvarna FE 501s 2022 Owner's Manual
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Husqvarna FE 501s 2022 Owner's Manual

Husqvarna FE 501s 2022 Owner's Manual

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OWNER'S MANUAL 2022
FE 501s
Art. no. 3402543en

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Summary of Contents for Husqvarna FE 501s 2022

  • Page 1 OWNER'S MANUAL 2022 FE 501s Art. no. 3402543en...
  • Page 3 DEAR HUSQVARNA MOTORCYCLES CUSTOMER Congratulations on your decision to purchase a Husqvarna motorcycle. You are now the owner of a state-of- DEAR HUSQVARNA MOTORCYCLES CUSTOMER the-art sports vehicle which, with appropriate care, will bring you pleasure for a long time to come.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS Horn button......... 21 MEANS OF REPRESENTATION......6 Light switch......... 21 Symbols used ........6 Turn signal switch ....... 22 Formats used ........6 6.10 Overview of indicator lights ....22 SAFETY ADVICE ..........7 6.11 Opening fuel tank filler cap ....
  • Page 5 TABLE OF CONTENTS Shifting, riding........38 12.6 Installing the fork protector....56 Braking..........39 12.7 Removing the fork legs ....56 Stopping, parking ....... 39 12.8 Installing the fork legs ..... 57 Transporting........40 12.9 Removing the lower triple clamp ..
  • Page 6 TABLE OF CONTENTS BRAKE SYSTEM ..........88 16.5 Refilling with coolant ..... 119 16.6 Changing the coolant ....120 13.1 Adjusting the basic position of the hand brake lever ......... 88 TUNING THE ENGINE ........121 13.2 Checking the brake discs ....88 17.1 Checking the play in the throttle 13.3...
  • Page 7 TABLE OF CONTENTS INDEX OF SPECIAL TERMS ......153 LIST OF ABBREVIATIONS ......154 LIST OF SYMBOLS ........155 28.1 Yellow and orange symbols....155 28.2 Green and blue symbols....155 INDEX ..............156...

  • Page 8: Means Of Representation

    Indicates work that requires expert knowledge and technical understanding. In the interests of your own safety, have these jobs performed by an authorized Husqvarna Motorcycles workshop. Your motorcycle will be cared for there to the highest degree by specially trained experts using the special tools required.

  • Page 9: Safety Advice 2

    SAFETY ADVICE 2 Use definition – intended use This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies with the currently valid regulations and categories of the top international motorsports organizations. Info This vehicle is only authorized for operation on public roads in the homologated (restricted) version.

  • Page 10: Overview Of Labels

    2 SAFETY ADVICE Overview of labels F03567-10 Canada type label Information on noise emission Information on chain tension Information on emissions control USA type label Information on starting up F03384-01 Canada type label...
  • Page 11 SAFETY ADVICE 2 F03386-01 Information on noise emission Information on chain tension F00490-10 Information on emissions control F03385-01 F03387-01 USA type label Information on starting up F00491-10...

  • Page 12: Reporting Safety Defects

    As the owner of the motorcycle, you are responsible for the required maintenance specified in the Owner's Manual. Please note that Husqvarna Motorcycles is entitled to reject warranty claims if your motorcycle or a part fails due to misuse, negligence, an accident, participation in racing or similar events, improper service work, or...

  • Page 13: Operating Noise Warning

    2.10 Consumer rights Warranty claims should be submitted to a Husqvarna Motorcycles workshop. If you are not satisfied, please contact: Husqvarna Motorcycles North America, Inc., c/o KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA Phone: (440) 985–3553...

  • Page 14: Safe Operation

    – Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, Husqvarna Motorcycles recommends that you only operate the vehicle while wearing protective clothing. 2.14...

  • Page 15: Environment

    Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that pertain to the disposal of an end-of-life motorcycle. Your authorized Husqvarna Motor- cycles dealer will be glad to advise you.

  • Page 16: Important Notes

    3 IMPORTANT NOTES Manufacturer warranty, implied warranty The work prescribed in the service schedule must only be carried out in an authorized Husqvarna Motorcy- cles workshop and confirmed in the Husqvarna Motorcycles Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.

  • Page 17: Customer Service

    IMPORTANT NOTES 3 Customer service Your authorized Husqvarna Motorcycles dealer will be happy to answer any questions you may have regarding your vehicle and Husqvarna Motorcycles. A list of authorized Husqvarna Motorcycles dealers can be found on the Husqvarna Motorcycles website.

  • Page 18: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) F03568-10 Hand brake lever ( p. 20) Clutch lever ( p. 20) Fuel tank filler cap Air filter box cover Side stand ( p. 25) Engine number ( p. 19) Shift lever ( p.

  • Page 19: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) F03569-10 Fork compression adjuster Horn button ( p. 21) Light switch ( p. 21) Turn signal switch ( p. 22) Emergency OFF switch ( p. 21) Start button ( p. 21) Throttle grip ( p.

  • Page 20: Serial Numbers

    5 SERIAL NUMBERS Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 401945-10 Type label Type label is fixed to the front of the steering head. The additional type label for Canada is fixed to the front of the chest tube.

  • Page 21: Engine Number

    SERIAL NUMBERS 5 Engine number Engine number is embossed on the left side of the engine behind the shift lever. H00940-01 Fork part 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 22: Controls

    6 CONTROLS Clutch lever Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automati- cally. F03491-10 Hand brake lever The hand brake lever is fitted on the right side of the handle- bar.

  • Page 23: Emergency Off Switch

    CONTROLS 6 Emergency OFF switch The emergency OFF switch is fitted on the right side of the handlebar. Possible states Ignition off – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start. Ignition on –...

  • Page 24: Turn Signal Switch

    – The OBD has detected an error in the vehicle elec- tronics. Come safely to a halt, and contact an autho- rized Husqvarna Motorcycles workshop. The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.

  • Page 25: Closing The Fuel Tank Filler Cap

    CONTROLS 6 Note Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to enter the groundwater, the soil, or the sewage system. – Press release button , turn the fuel tank filler cap counter- clockwise, and lift it off.

  • Page 26: Idle Speed Adjusting Screw

    6 CONTROLS 6.14 Idle speed adjusting screw The idle speed is adjusted using the idle speed adjusting screw Increase the idle speed by turning the idle speed adjusting screw clockwise. Decrease the idle speed by turning the idle speed adjusting screw counterclockwise.

  • Page 27: Foot Brake Lever

    CONTROLS 6 6.16 Foot brake lever Foot brake lever is located in front of the right footrest. The rear brake is engaged with the foot brake lever. 401956-10 6.17 Side stand The side stand is attached to the left side of the vehicle. 401943-10 The side stand is used for parking the motorcycle.

  • Page 28: Locking The Steering

    6 CONTROLS 6.19 Locking the steering Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Park the vehicle. – Turn handlebar as far as possible to the right. –...

  • Page 29: Combination Instrument 7

    Battery voltage of the combination instrument – Bat- tery voltage of the combination instrument is too low. Change combination instrument battery. Service – A service is due. Contact an authorized Husqvarna Motorcycles workshop. 401901-01 Setting the combination instrument Condition The motorcycle is stationary.

  • Page 30: Adjusting The Kilometers Or Miles

    7 COMBINATION INSTRUMENT – Wait for 5 seconds. Combination instrument changes to the next menu item. symbol flashes. – Press one of the buttons to select the 24 h display or 12 h display for the clock. 401911-01 – Wait for 5 seconds. Combination instrument changes to the next menu item.

  • Page 31: Setting The Clock

    COMBINATION INSTRUMENT 7 – Press and hold both buttons for 3 - 5 seconds. The Setup menu is displayed. The UNIT display flashes. – Press one of the buttons to select UNIT for the speed in kilo- meters KM/H or miles M/H. 401909-01 Setting the clock Condition...

  • Page 32: Speed, Time, And Dst Distance 1

    7 COMBINATION INSTRUMENT Switching off the service interval display – Press and hold the left button. off appears in the display. 401914-01 Speed, time, and DST distance 1 – Press one of the buttons until DST appears on the combina- tion instrument.

  • Page 33: Avg Average Speed, Art Operating Hours, And Odo Total Distance Covered

    COMBINATION INSTRUMENT 7 Press the left DST2 can be preset to a value between 0.0 button for 3 – and 39999.9 by pressing the buttons. 5 seconds. Press the Next display mode right button briefly. Press the DST2 is reset to 0.0. right button for 3 –...

  • Page 34: Preparing For Use

    When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-sale inspection work has been carried out by an authorized Husqvarna Motorcycles workshop. You will receive a delivery certificate when the vehicle is handed over.

  • Page 35: Running-In The Engine

    PREPARING FOR USE 8 – Adjust basic position of the hand brake lever. ( p. 88) – Adjust the basic position of the foot brake lever. p. 94) – Adjust the basic position of the shift lever. p. 125) – Get used to the handling characteristics of the motorcycle on a suitable surface before undertaking more challenging trips.

  • Page 36: Starting Power Of Lithium-Ion Batteries At Low Temperatures

    Riding at low temperatures and in snow. ( p. 36) Preparing the vehicle for riding on dry sand – Mount the air filter dust cover. Air filter dust cover (79006920000) Info Read the fitting instructions for Husqvarna Motorcy- cles accessories. 102136-01...

  • Page 37: Preparing The Vehicle For Riding On Wet Sand

    PREPARING FOR USE 8 – Mount the air filter sand cover. Air filter sand cover (79006922000) Info Read the fitting instructions for Husqvarna Motorcy- cles accessories. 102138-01 – Clean the chain. – Mount the steel sprocket. – Grease the chain.

  • Page 38: Preparing Vehicle For High Temperatures Or Slow Riding

    Straighten bent radiator fins carefully. – Check the coolant level. ( p. 118) Preparing the vehicle for low temperatures or snow – Mount the air filter rain cover. Air filter rain cover (79006921000) Info Read the fitting instructions for Husqvarna Motorcy- cles accessories. 102137-01...

  • Page 39: Riding Instructions 9

    RIDING INSTRUCTIONS 9 Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –...

  • Page 40: Starting Off

    Do not change into a low gear at high engine speed. Info If unusual noises occur while riding, stop immediately, switch off the engine, and contact an authorized Husqvarna Motorcycles workshop. First-gear is used for starting off and for steep inclines.

  • Page 41: Braking

    Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Warning Danger of accidents Moisture and dirt impair the brake system.

  • Page 42: Transporting

    9 RIDING INSTRUCTIONS Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. – Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake sys- tem before the vehicle parts have cooled down. –...

  • Page 43: Refueling

    In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Note Environmental hazard Improper handling of fuel is a danger to the environment.

  • Page 44: 10 Service Schedule

    Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up-to- date service schedule can always be found on Husqvarna Motorcycles Dealer.net. Your authorized Husqvarna Motorcycles dealer will be glad to advise you.

  • Page 45: Recommended Work

    ● ● Final check: Check the vehicle is roadworthy and take a test ride. ○ ● ● ● Read out the fault memory after the test ride using the Husqvarna Motorcycles diagnostics tool. Final steps ○ ● ● ● Make a service entry in Husqvarna Motorcycles Dealer.net.
  • Page 46 10 SERVICE SCHEDULE every 48 months every 12 months every 6,750 km (4,185 mi) after 1,000 km (620 mi) after 500 km (310 mi) ● Perform engine service including removing and installing the engine. (Change the spark plug and spark plug connector. Change the piston. Check/measure the cylinder. Check the cylinder head.

  • Page 47: Tuning The Chassis 11

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info The effect of the low-speed compression adjuster can be seen in slow to normal compression of the...

  • Page 48: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info The effect of the high speed compression adjuster can be seen in the fast compression of the shock absorber.

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

    Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incor- rectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) – Turn adjusting screw clockwise up to the last perceptible click.

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

    11 TUNING THE CHASSIS Finishing work – Remove the motorcycle from the lift stand. ( p. 54) 11.7 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 47) – Hold the motorcycle upright with aid of an assistant. –...

  • Page 51: Adjusting The Spring Preload Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the spring length.

  • Page 52: Adjusting The Riding Sag

    11 TUNING THE CHASSIS 11.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 54) – Remove the shock absorber. p. 63) – After removing the shock absorber, clean it thoroughly. Main work –...

  • Page 53: Adjusting The Compression Damping Of The Fork

    TUNING THE CHASSIS 11 11.12 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Turn white adjuster clockwise as far as it will go. Info Adjuster is located at the upper end of the left fork leg.

  • Page 54: Adjusting The Spring Preload Of The Fork

    11 TUNING THE CHASSIS Info Turn clockwise to increase the damping; turn counterclockwise to reduce damping when the shock absorber rebounds. 11.14 Adjusting the spring preload of the fork Preparatory work – Raise the motorcycle with a lift stand. ( p.

  • Page 55: Adjusting The Handlebar Position

    TUNING THE CHASSIS 11 11.16 Adjusting the handlebar position Warning Danger of accidents A repaired handlebar poses a safety risk. If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a result. – Change the handlebar if the handlebar is damaged or bent. –...

  • Page 56: 12 Service Work On The Chassis

    12 SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (81329955100) Neither wheel is in contact with the ground.

  • Page 57: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS 12 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 54) – Remove the fork protector. ( p. 55) Main work – Push dust boots of both fork legs downward.

  • Page 58: Installing The Fork Protector

    12 SERVICE WORK ON THE CHASSIS 12.6 Installing the fork protector – Position the fork protector on the left fork leg. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Position the brake line, wiring harness, and clamp. Mount and tighten screws –...

  • Page 59: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS 12 12.8 Installing the fork legs Main work – Position the fork legs. Bleeder screws are positioned toward the front. Info The compression damping is located in left fork leg COMP (white adjuster). The rebound damping is located in right fork leg REB (red adjuster).

  • Page 60: Installing The Lower Triple Clamp

    12 SERVICE WORK ON THE CHASSIS Main work – Remove screw – Remove screw – Open cable holder in front of the left radiator and detach the clutch line. – Take off the upper triple clamp with the handlebar and set aside.
  • Page 61 SERVICE WORK ON THE CHASSIS 12 – Position the upper triple clamp with the handlebar. – Mount screw , but do not tighten yet. – Mount the clutch line with cable holder S03552-11 – Position the fork legs. Bleeder screws are positioned toward the front.

  • Page 62: Checking The Steering Head Bearing Play

    Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components. – Correct incorrect steering head bearing play immediately. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time.

  • Page 63: Adjusting The Steering Head Bearing Play

    SERVICE WORK ON THE CHASSIS 12 Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. Play should not be detectable on the steering head bear- ing. » If there is detectable play: –...

  • Page 64: Lubricating The Steering Head Bearing

    12 SERVICE WORK ON THE CHASSIS 12.13 Lubricating the steering head bearing – Remove the lower triple clamp. p. 57) – Install the lower triple clamp. p. 58) Info The steering head bearing is cleaned and lubricated in the course of removal and installation of the lower triple clamp.

  • Page 65: Installing Front Fender

    SERVICE WORK ON THE CHASSIS 12 12.15 Installing front fender Main work – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis H03691-10 Finishing work...
  • Page 66 12 SERVICE WORK ON THE CHASSIS – Press angle lever toward the rear. – Press linkage lever downward. H03694-10 – Disconnect the plug-in connector of the brake light switch. F03546-10 – Remove screws – Pull off foot brake cylinder from the push rod. F03547-10 –...

  • Page 67: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 12 – Hold the shock absorber and remove screw – Remove the shock absorber carefully at the bottom. F03469-10 12.17 Installing the shock absorber Main work – Carefully position the shock absorber into the vehicle from the bottom.

  • Page 68: Removing The Seat

    12 SERVICE WORK ON THE CHASSIS – Position the foot brake cylinder. Push rod engages in the foot brake cylinder. The dust boot is correctly positioned. – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis F03550-10 –...

  • Page 69: Mounting The Seat

    SERVICE WORK ON THE CHASSIS 12 Main work – Remove screw with the bushing. – Pull seat back and lift it off. S03559-10 12.19 Mounting the seat Main work – Mount the front of the seat on the collar bushing of the fuel tank and the rear in the bracket.

  • Page 70: Removing The Air Filter Box Cover

    12 SERVICE WORK ON THE CHASSIS 12.20 Removing the air filter box cover – Pull off the air filter box cover sideways in areas and take off toward the rear. F03559-10 12.21 Installing the air filter box cover – Attach catch of the air filter box in area and push for- ward.

  • Page 71: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS 12 Main work – Detach retaining tab . Remove air filter with air filter sup- port. – Remove air filter from air filter support. S03573-10 12.23 Installing the air filter Main work – Mount the clean air filter on the air filter support. –...

  • Page 72: Removing The Right Side Cover

    12 SERVICE WORK ON THE CHASSIS Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 150) Info Only press the air filter to dry it, never wring it out. –...

  • Page 73: Installing The Right Side Cover

    SERVICE WORK ON THE CHASSIS 12 12.26 Installing the right side cover Main work – Attach side cover with the holding lugs from below and push upward. – Engage the side cover in areas F02344-10 Finishing work – Mount the seat. ( p.

  • Page 74: Installing The Main Silencer

    12 SERVICE WORK ON THE CHASSIS 12.28 Installing the main silencer Main work – Position the catalytic converter in the main silencer. S02101-10 – Position the main silencer. – Mount screws , but do not tighten yet. – Attach spring Spring hook (50305017000C1) –...
  • Page 75 SERVICE WORK ON THE CHASSIS 12 S03542-10 Main work – Remove all screws, take off silencer cap with O-ring Info Do not remove the glass fiber yarn filling. Caution 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.

  • Page 76: Changing The Glass Fiber Yarn Filling In The Main Silencer

    12 SERVICE WORK ON THE CHASSIS 12.30 Changing the glass fiber yarn filling in the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. Info Over time, the fibers of the glass fiber yarn filling escape and the damper "burns"...

  • Page 77: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 12 12.31 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 fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 78: Installing The Fuel Tank

    12 SERVICE WORK ON THE CHASSIS – Remove screws – Hang the horn and horn bracket to one side. H03705-10 – Remove screw with the rubber bushing. H03704-10 – Pull both spoilers laterally off the radiator and lift off the fuel tank.
  • Page 79 SERVICE WORK ON THE CHASSIS 12 Main work – Check the throttle cable routing. ( p. 83) – Position the fuel tank and fit the two spoilers to the sides in front of the radiator bracket. – Make sure that no cables or throttle cables are trapped or damaged.

  • Page 80: Checking For Chain Dirt Accumulation

    12 SERVICE WORK ON THE CHASSIS – Install the air filter box cover. ( p. 68) 12.33 Checking for chain dirt accumulation – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p.

  • Page 81: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 12 12.35 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.

  • Page 82: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    12 SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 55 … 58 mm (2.17 … 2.28 in) Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks...
  • Page 83 SERVICE WORK ON THE CHASSIS 12 – Pull on the top section of the chain with the specified weight Guideline Weight of chain wear mea- 10 … 15 kg (22 … 33 lb.) surement – Measure distance of 18 chain rollers in the lower chain section.
  • Page 84 12 SERVICE WORK ON THE CHASSIS – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check that the chain sliding piece is firmly seated.

  • Page 85: Checking The Frame

    If the link fork exhibits damage, cracking, or deformation: – Change the link fork. Info Always replace a damaged link fork. Repair of the link fork is not authorized by Husqvarna Motorcycles. 401520-01 12.40 Checking the throttle cable routing Preparatory work –...

  • Page 86: Checking The Rubber Grip

    12 SERVICE WORK ON THE CHASSIS Finishing work – Install the fuel tank. p. 76) – Install the right side cover. ( p. 71) – Mount the seat. ( p. 67) – Install the air filter box cover. ( p. 68) 12.41 Checking the rubber grip –...

  • Page 87: Checking/Correcting The Fluid Level Of Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS 12 12.43 Checking/correcting the fluid level of hydraulic 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.

  • Page 88: Changing The Hydraulic Clutch Fluid

    12 SERVICE WORK ON THE CHASSIS 12.44 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing. –...

  • Page 89: Removing The Engine Guard

    SERVICE WORK ON THE CHASSIS 12 – Inject the liquid into the system until it escapes from open- ings of the master cylinder without bubbles. – Occasionally extract the fluid from the master cylinder reser- voir to prevent overflowing. – Remove the bleeding syringe.

  • Page 90: 13 Brake System

    Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized Husqvarna Motor- cycles workshop will be glad to help.) – Check the front and rear brake disc thickness at multiple...

  • Page 91: Checking The Front Brake Fluid Level

    – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 92: Checking The Front Brake Linings

    Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized Husqvarna Motorcy- cles workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...

  • Page 93: Changing The Brake Linings Of The Front Brake

    Danger of accidents 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 94 13 BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Take off cover with membrane F03508-10 – Manually press the brake caliper toward the brake disc to push back the brake pistons. Ensure that brake fluid does not flow out of the brake fluid reservoir, extract some if neces- sary.

  • Page 95: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM 13 – Insert the new brake linings. – Mount pin Spring plate engages in the groove on the pin. Info Always change the brake linings in pairs. – Mount cotter pins Guideline Mount the outer cotter pins from the front to the rear. Mount the inner cotter pins from the rear to the front.

  • Page 96: Adjusting The Basic Position Of The Foot Brake Lever

    13 BRAKE SYSTEM – Disconnect spring – Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Guideline Free travel at foot brake 3 … 5 mm (0.12 … 0.2 in) lever »...

  • Page 97: Checking The Rear Brake Fluid Level

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) – Position the vehicle vertically.

  • Page 98: Checking The Rear Brake Linings

    Checking the rear brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized Husqvarna Motorcy- cles workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...

  • Page 99: Changing The Rear Brake Linings

    Danger of accidents 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 100 13 BRAKE SYSTEM – Position the vehicle vertically. – Remove screw cap with membrane F03487-10 – Manually press the brake caliper toward the brake disc to push back the brake piston. Ensure that brake fluid does not flow out of the brake fluid reservoir; extract some if neces- sary.

  • Page 101: Wheels, Tires 14

    WHEELS, TIRES 14 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 54) Main work – Manually press the brake caliper toward the brake disc to push back the brake pistons. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pis- tons.

  • Page 102: Installing The Front Wheel

    14 WHEELS, TIRES 14.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. –...

  • Page 103: Installing The Rear Wheel

    WHEELS, TIRES 14 Main work – Manually press the brake caliper toward the brake disc to push back the brake piston. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pis- ton.
  • Page 104 14 WHEELS, TIRES Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the rear wheel bearing. – Clean and grease shaft seal rings and contact surfaces of the spacers. Long-life grease ( p.

  • Page 105: Checking The Tire Condition

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

  • Page 106: Checking Spoke Tension

    Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) –...

  • Page 107: Electrical System 15

    ELECTRICAL SYSTEM 15 15.1 Removing the 12-V battery Note Environmental hazard 12 V batteries contain environmentally hazardous materials. – Do not dispose of 12 V batteries as household waste. – Dispose of 12 V batteries at a collection point for used batteries. Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 108: Installing The 12-V Battery

    15 ELECTRICAL SYSTEM – Detach wiring harness , disconnect relays and hang them to the side. S03579-10 – Remove screw and unhook the holding bracket. – Lift out the 12-V battery. S03582-10 15.2 Installing the 12-V battery Main work – Insert the 12-V battery into the battery compartment with the terminals facing forward and secure with holding bracket 12-V battery (HJTZ5S-FP-C) (...
  • Page 109 ELECTRICAL SYSTEM 15 – Place the relays on the holding bracket and attach wiring harness S03579-11 – Attach starter relay and fuse box to the holding bracket. S03578-11 – Connect positive cable to the 12-V battery. Guideline Screw, battery termi- 2.5 Nm (1.84 lbf ft) Info Contact disk...

  • Page 110: Charging The 12-V Battery

    15 ELECTRICAL SYSTEM 15.3 Charging the 12-V battery Warning Risk of injury 12 V batteries contain harmful substances. – Keep 12 V batteries out of the reach of children. – Keep sparks and open flames away from 12 V batteries. – Only charge 12 V batteries in well-ventilated rooms.

  • Page 111: Changing Main Fuse

    12-V battery with this battery charger. The charg- ing time may be longer at low temperatures. This battery charger is only suitable for lithium iron phosphate batteries. Read the accompanying instruc- tions for Husqvarna Motorcycles accessories. Info Never remove cover –...

  • Page 112: Changing The Fuses Of Individual Electrical Power Consumers

    15 ELECTRICAL SYSTEM Main work – Pull starter relay from the holder. S03588-10 – Take off protection caps – Remove faulty main fuse Info A faulty fuse has a burned-out fuse wire A spare fuse is located in the starter relay. –...

  • Page 113: Removing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM 15 Guideline Fuse 1 – 10 A – EFI control unit, lambda sensor, combina- tion instrument, electronic fuel injection, diagnostics con- nector, fuel vapor retention system, fuse 4 Fuse 2 ‑ 10 A ‑ high beam, low beam, position light, tail light, license plate lamp Fuse 3 - 10 A - radiator fan, horn, brake light, turn signal Fuse 4 - 5 A - fuel pump...

  • Page 114: Installing The Headlight Mask With The Headlight

    15 ELECTRICAL SYSTEM – Remove screw – Detach the brake line and wiring harness from the headlight mask. – Pivot the headlight mask forwards and place it on the fender. H03748-10 – Detach plug-in connectors and take off the headlight mask with the headlight.

  • Page 115: Changing The Headlight Bulb

    ELECTRICAL SYSTEM 15 – Secure the headlight mask with rubber straps H03749-11 Finishing work – Check the headlight setting. ( p. 114) 15.8 Changing the headlight bulb Note Damage to reflector Grease on the reflector reduces the light intensity. Grease on the bulb will evaporate due to the heat and be deposited on the reflector. –...

  • Page 116: Changing The Turn Signal Bulb

    15 ELECTRICAL SYSTEM 15.9 Changing the turn signal bulb Note Damage to reflector Grease on the reflector reduces the light intensity. Grease on the bulb will evaporate due to the heat and be deposited on the reflector. – Clean and degrease the bulbs before mounting. –...

  • Page 117: Adjusting The Headlight Range

    ELECTRICAL SYSTEM 15 » If the boundary between light and dark does not meet specifications: – Adjust the headlight range. ( p. 115) 15.11 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 114) Main work –...

  • Page 118: Diagnostics Connector

    15 ELECTRICAL SYSTEM – Position protection cap and turn all the way clockwise using a coin. – Press any button on the combination instrument. The combination instrument is activated. – Position the combination instrument in the holder. – Mount and tighten the screws with washers. H03758-10 Finishing work –...

  • Page 119: Cooling System 16

    COOLING SYSTEM 16 16.1 Cooling system Water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operat- ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 120: Checking The Coolant Level

    16 COOLING SYSTEM Coolant ( p. 148) – Mount the radiator cap. 16.3 Checking the coolant level 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 121: Refilling With Coolant

    COOLING SYSTEM 16 Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –...

  • Page 122: Changing The Coolant

    16 COOLING SYSTEM – Install the engine guard. ( p. 87) 16.6 Changing 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 123: Tuning The Engine 17

    TUNING THE ENGINE 17 17.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable Play in throttle cable 3 …...

  • Page 124: Adjusting The Characteristic Map Of The Throttle Response

    17 TUNING THE ENGINE Main work – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen nut – Turn adjusting screw in as far as possible. – Loosen nut – Push cold start button all the way to the stop. –...
  • Page 125 TUNING THE ENGINE 17 – Remove guide plate from handle tube – Position the required guide plate on the grip tube. Guideline The label OUTSIDE must be visible. Marking must be positioned at marking Grey guide plate (79002014000) Alternative 1 Black guide plate (79002014100) Info The gray guide plate opens the throttle valve more...

  • Page 126: Adjusting The Idle Speed

    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. (Your authorized Husqvarna Motorcycles workshop will be glad to help.) – Run the engine until warm.

  • Page 127: Checking The Basic Position Of The Shift Lever

    TUNING THE ENGINE 17 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space.
  • Page 128 17 TUNING THE ENGINE – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage gearing. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle components during the shift procedure.

  • Page 129: Service Work On The Engine 18

    SERVICE WORK ON THE ENGINE 18 18.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 130: Checking The Engine Oil Level

    18 SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space.
  • Page 131 SERVICE WORK ON THE ENGINE 18 Info Drain the engine oil with the engine at operating temperature. Preparatory work – Remove the engine guard. ( p. 87) – Park the motorcycle on a level surface. Main work – Position an appropriate container under the engine. –...
  • Page 132 18 SERVICE WORK ON THE ENGINE – Position long oil screen with the O-rings on a pin wrench. – Position the pin wrench through the drill hole of the screw plug in the opposite section of the engine case. – Push the oil screen all the way into the engine case.

  • Page 133: Adding Engine Oil

    Engine oil (SAE 10W/50) ( p. 148) Info In order to achieve optimal engine oil performance, it is not advisable to mix different engine oils. Husqvarna Motorcycles recommends changing the engine oil. – Mount and tighten the filler plug together with the O-ring. F02360-10...
  • Page 134 18 SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space.

  • Page 135: Cleaning, Care 19

    CLEANING, CARE 19 19.1 Cleaning the motorcycle 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. –...

  • Page 136: Checks And Maintenance Steps For Winter Operation

    19 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. 150) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

  • Page 137: Storage 20

    – 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. 54) –...

  • Page 138: Preparing For Use After Storage

    20 STORAGE Info Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and the exhaust system to rust. 20.2 Preparing for use after storage –...

  • Page 139: Troubleshooting 21

    Check the electrical system. – Error in the electronic fuel Read out the fault memory using the injection Husqvarna Motorcycles diagnostics tool. – Engine does not speed up Error in the electronic fuel Read out the fault memory using the...
  • Page 140 – Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. – High oil consumption Engine vent hose bent Route the vent hose without bends or replace it if necessary.
  • Page 141 TROUBLESHOOTING 21 Faults Possible cause Action – The high beam, low beam, tail Fuse 2 blown Change the fuses of individual electri- light, position light, and license cal power consumers. ( p. 110) plate lamp are not working – The horn, brake light, turn sig- Fuse 3 blown Change the fuses of individual electri- nal, and radiator fan are not...

  • Page 142: 22 Technical Data

    22 TECHNICAL DATA 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 510.9 cm³ (31.177 cu in) Stroke 72 mm (2.83 in) Bore 95 mm (3.74 in) Compression ratio 12.75:1 Idle speed 1,800 … 1,900 rpm Control OHC, 4 valves controlled via rocker arm Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust...

  • Page 143: Engine Tightening Torques

    TECHNICAL DATA 22 22.2 Engine tightening torques Oil jet, piston cooling 2 Nm (1.5 lbf ft) ® Loctite 243™ Crankshaft speed sensor screw 6 Nm (4.4 lbf ft) ® Loctite 243™ and cable retainer Oil nozzle for clutch lubrication 2.5 Nm (1.84 lbf ft) Oil nozzle for piston cooling 2.5 Nm (1.84 lbf ft) Oil nozzle for rocker arm lubrica-...

  • Page 144: Capacities

    22 TECHNICAL DATA Screw, timing chain tensioning rail 10 Nm (7.4 lbf ft) ® Loctite 243™ Screw, torque governor 10 Nm (7.4 lbf ft) ® Loctite 243™ Screw, valve cover 10 Nm (7.4 lbf ft) Screw, water pump cover 10 Nm (7.4 lbf ft) Oil nozzle for conrod bearing M6x0.75 2.5 Nm (1.84 lbf ft)

  • Page 145: Fuel

    TECHNICAL DATA 22 22.3.3 Fuel Total fuel tank capacity, approx. Super unleaded (ROZ 95) ( p. 149) 8.2 l (2.17 US gal) Fuel reserve, approx. 1.5 l (1.6 qt.) 22.4 Chassis Frame Central tube frame made of chrome molybdenum steel tubing WPXPLOR 5548 Fork Suspension travel...

  • Page 146: Electrical System

    120/90 - 18 M/C 65R M+S TT Continental TKC 80 Continental TKC 80 The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: www.husqvarna-motorcycles.com 22.7 Fork Fork article number 0266C169V401000...

  • Page 147: Shock Absorber

    TECHNICAL DATA 22 Weight of rider: 65 … 75 kg (143 … 165 lb.) 4.4 N/mm (25.1 lb/in) Weight of rider: 75 … 85 kg (165 … 187 lb.) 4.6 N/mm (26.3 lb/in) Weight of rider: 85 … 95 kg (187 … 209 lb.) 4.8 N/mm (27.4 lb/in) Fork length 928 mm (36.54 in)
  • Page 148 22 TECHNICAL DATA ® Screw for spoiler attachment EJOT PT K60x23/18 2.5 Nm (1.84 lbf ft) ® EJOT PT Screw, air filter box, on subframe K70x25 5 Nm (3.7 lbf ft) Screw, start button 0.4 Nm (0.3 lbf ft) Screw, fixed grip 5 Nm (3.7 lbf ft) ®...
  • Page 149 TECHNICAL DATA 22 Remaining screws, chassis 25 Nm (18.4 lbf ft) Screw, bottom triple clamp 15 Nm (11.1 lbf ft) Screw, chain sliding piece 15 Nm (11.1 lbf ft) Screw, engine brace M8x15 25 Nm (18.4 lbf ft) ® Loctite 2701™...

  • Page 150: 23 Substances

    23 SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 ®...
  • Page 151 SUBSTANCES 23 Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 152) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification –...

  • Page 152: 24 Auxiliary Substances

    24 AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier ® MOTOREX – Racing Bio Dirt Remover Chain cleaner Recommended supplier ® MOTOREX – Chain Clean High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier ® MOTOREX – Bike Grease 2000 Off-road chain spray Recommended supplier...
  • Page 153 AUXILIARY SUBSTANCES 24 Universal oil spray Recommended supplier ® MOTOREX – Joker 440 Synthetic...

  • Page 154: 25 Standards

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

  • Page 155: Index Of Special Terms 26

    INDEX OF SPECIAL TERMS 26 On-board diagnosis Vehicle system, which monitors the specified param- eters of the vehicle electronics...

  • Page 156: 27 List Of Abbreviations

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

  • Page 157: List Of Symbols 28

    Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an error in the vehicle electronics. Come safely to a halt, and contact an authorized Husqvarna Motorcy- cles workshop. The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.

  • Page 158: Index

    INDEX INDEX Chain guide checking ......80 12-V battery Chain tension charging ......108 adjusting .
  • Page 159 INDEX Engine guard Fuse installing ......87 main fuse, changing ....109 removing .
  • Page 160 INDEX spark arrestor, cleaning ....72 Service schedule ....42-44 Manufacturer warranty .
  • Page 161 INDEX Troubleshooting ....137-139 Turn signal bulb changing ......114 Turn signal switch .
  • Page 162 *3402543en* 3402543en 12/2021 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria Photo: Mitterbauer/KISKA, www.husqvarna-motorcycles.com Husqvarna Motorcycles GmbH...

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