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Husqvarna FE 250 Owner's Manual

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OWNER'S MANUAL 2020
FE 250
Art. no. 3402340en

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Summary of Contents for Husqvarna FE 250

  • Page 1 OWNER'S MANUAL 2020 FE 250 Art. no. 3402340en...
  • 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 that will continue giving you pleasure for a long time if you maintain it properly.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS 6.15 Idle speed adjusting screw ....20 MEANS OF REPRESENTATION......5 6.16 Shift lever ..........21 Symbols used ........5 6.17 Foot brake lever ........21 Formats used ........5 6.18 Side stand........... 21 SAFETY ADVICE ..........
  • Page 5 TABLE OF CONTENTS SERVICE SCHEDULE........40 12.11 Checking steering head bearing play ............. 59 10.1 Additional information......40 12.12 Adjusting steering head bearing 10.2 Required work........40 play ..........60 10.3 Recommended work......41 12.13 Lubricating the steering head bearing ..........
  • Page 6 TABLE OF CONTENTS 13.5 Checking the front brake linings ..88 17.5 Adjusting the idle speed ....122 13.6 Changing the front brake linings ..89 17.6 Teaching the throttle valve position ..........123 13.7 Checking the free travel of foot brake lever ..........

  • Page 7: Means Of Representation 1

    MEANS OF REPRESENTATION 1 Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). All work marked with this symbol requires specialist knowledge and technical understand- ing.

  • Page 8: Safety Advice

    2 SAFETY ADVICE 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 9: Tampering Warning

    The vehicle should only be used by trained persons. An appropriate driver's license is needed to drive the vehi- cle on public roads. Have malfunctions that impair safety immediately eliminated by an authorized Husqvarna Motorcycles work- shop. Adhere to the information and warning labels on the vehicle.

  • Page 10: Protective Clothing

    – 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. Work rules Special tools are necessary for certain tasks.
  • Page 11 SAFETY ADVICE 2 The Owner's Manual is also available for download from your authorized Husqvarna Motorcycles dealer and on the Husqvarna Motorcycles website. International Husqvarna Motorcycles website: www.husqvarna-motorcycles.com...

  • Page 12: Important Notes

    3 IMPORTANT NOTES Manufacturer and 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 13: 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 14: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) S03544-10 Hand brake lever ( p. 16) Clutch lever ( p. 16) Fuel tank filler cap Air filter box cover Side stand ( p. 21) Engine number ( p. 14) Shift lever ( p.

  • Page 15: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) S03545-10 Fork compression adjuster Switch-off button ( p. 16) Horn button ( p. 17) Light switch ( p. 17) Turn signal switch ( p. 17) Start button ( p. 18) Emergency OFF switch ( p.

  • Page 16: 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. 401946-10 Key number Key number for the steering lock is stamped on a tag on the key ring.

  • Page 17: Fork Part Number

    SERIAL NUMBERS 5 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. H02222-10...

  • Page 18: 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. F00257-10 Hand brake lever The hand brake lever is fitted on the right side of the handle- bar.

  • Page 19: Horn Button

    CONTROLS 6 Horn button Horn button is fitted on the left side of the handlebar. Possible states • The horn button is in the basic position is pressed – The horn is operated in this • The horn button position. F00260-11 Light switch Light switch...

  • Page 20: Start Button

    – 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 21: Opening Fuel Tank Filler Cap

    CONTROLS 6 Turn signal indicator lamp flashes green – The turn signal is switched on. 6.12 Opening fuel tank filler cap Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. –...

  • Page 22: Cold Start Button

    6 CONTROLS 6.14 Cold start button The cold start button is fitted to the bottom of the throttle valve body. The electronic fuel injection system extends the injection time if the engine is cold and the ambient temperature is low. To help the engine burn the increased fuel quantity, it must be supplied with additional oxygen by pushing the cold start button.

  • Page 23: Shift Lever

    CONTROLS 6 6.16 Shift lever Shift lever is mounted on the left of the engine. 401950-10 The gear positions can be seen in the figure. The neutral or idle position is between the first and second gears. 401950-11 6.17 Foot brake lever Foot brake lever is located in front of the right footrest.

  • Page 24: Steering Lock

    6 CONTROLS The side stand is used for parking the motorcycle. Info When you are riding, side stand must be folded up and secured with rubber strap 401944-10 6.19 Steering lock Steering lock is fitted on the left side of the steering head. The steering lock is used to lock the steering.

  • Page 25: Unlocking The Steering

    CONTROLS 6 6.21 Unlocking the steering – Insert the key for the steering lock into thesteering lock p. 22), turn it to the left, pull it out, pull it out, and turn it to the right. Pull out the key for the steering lock. The handlebar can now be moved again.

  • Page 26: Combination Instrument

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

  • Page 27: Adjusting The Kilometers Or Miles

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

  • Page 28: Adjusting The Clock

    7 COMBINATION INSTRUMENT – 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 Adjusting the clock Condition...

  • Page 29: Speed, Time, And Dst Distance 1

    COMBINATION INSTRUMENT 7 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 30: Avg Average Speed, Art Operating Hours, And Odo Total Distance Covered

    7 COMBINATION INSTRUMENT 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 31: Preparing For Use 8

    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 32: Running-In The Engine

    8 PREPARING FOR USE – Adjust the basic position of the hand brake lever. ( p. 86) – Adjust the basic position of the foot brake lever. p. 92) – Adjust the basic position of the shift lever. p. 124) –...

  • Page 33: Starting Power Of Lithium-Ion Batteries At Low Temperatures

    Riding at low temperatures and in snow. ( p. 33) 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 34: Preparing The Vehicle For Riding On Wet Sand

    8 PREPARING FOR USE – 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 35: Preparing Vehicle For High Temperatures Or Slow Riding

    Straighten bent radiator fins carefully. – Check the coolant level. ( p. 117) 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 36: Riding Instructions

    9 RIDING INSTRUCTIONS 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 37: Activating Traction Control

    RIDING INSTRUCTIONS 9 – Take the motorcycle off side stand and secure the side stand with rubber strap – Shift the transmission into neutral. – Turn the emergency OFF switch to the position Condition Ambient temperature: < 20 °C (< 68 °F) –...

  • Page 38: Starting Off

    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.)

  • Page 39: Stopping, Parking

    RIDING INSTRUCTIONS 9 Warning Danger of accidents Moisture and dirt impair the brake system. – Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs. – On sandy, wet or slippery surfaces, use the rear brake. –...

  • Page 40: Transporting

    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.)
  • Page 41 RIDING INSTRUCTIONS 9 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. – Switch off engine. – Open fuel tank filler cap. ( p.

  • Page 42: 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 43: 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 diag- nostics tool. ○ ● ● ● ● Make a service entry in Husqvarna Motorcycles Dealer.net.
  • Page 44 10 SERVICE SCHEDULE Every 135 operating hours Every 70 operating hours when used for motorsports After 20 operating hours After 10 operating hours every 12 months ● ● 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 45: 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 46: 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 fast compression of the shock absorber.

  • Page 47: 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 48: Checking The Static Sag Of The Shock Absorber

    11 TUNING THE CHASSIS Finishing work – Remove the motorcycle from the lift stand. ( p. 53) 11.7 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 45) – Hold the motorcycle upright with aid of an assistant. –...

  • Page 49: 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 50: Adjusting The Riding Sag

    11 TUNING THE CHASSIS 11.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 53) – Remove the shock absorber. p. 62) – After removing the shock absorber, clean it thoroughly. Main work –...

  • Page 51: 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 52: 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 53: Handlebar Position

    TUNING THE CHASSIS 11 11.15 Handlebar position On the upper triple clamp, there are two holes at a distance to each other. 15 mm (0.59 in) Hole distance The holes on the handlebar supports are placed at a distance from the center. 3.5 mm (0.138 in) Hole distance The handlebar supports can be mounted in four different posi-...
  • Page 54 11 TUNING THE CHASSIS Info Make sure the gap width is even.

  • Page 55: Service Work On The Chassis 12

    SERVICE WORK ON THE CHASSIS 12 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 56: Cleaning The Dust Boots Of The Fork Legs

    12 SERVICE WORK ON THE CHASSIS 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 53) – Remove the fork protector. ( p. 54) Main work – Push dust boots of both fork legs downward.

  • Page 57: Installing The Fork Protector

    SERVICE WORK ON THE CHASSIS 12 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 58: Installing The Fork Legs

    12 SERVICE WORK ON THE CHASSIS 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 COM (white adjusting screw). The rebound damping is located in right fork leg REB (red adjusting screw).

  • Page 59: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 12 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 60 12 SERVICE WORK ON THE CHASSIS – 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 61: Checking 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 62: Adjusting Steering Head Bearing Play

    12 SERVICE WORK ON THE CHASSIS 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 63: Lubricating The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS 12 12.13 Lubricating the steering head bearing – Remove the lower triple clamp. p. 56) – Install the lower triple clamp. p. 57) H02387-01 12.14 Removing front fender Preparatory work – Remove the headlight mask with the headlight. ( p.

  • Page 64: Installing Front Fender

    12 SERVICE WORK ON THE CHASSIS 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 65 SERVICE WORK ON THE CHASSIS 12 – Press angle lever toward the rear. – Press linkage lever downward. H03694-10 – Disconnect the plug-in connector of the brake light switch. S03556-10 – Remove screws – Pull off foot brake cylinder from the push rod. S03557-10 –...

  • Page 66: Installing The Shock Absorber

    12 SERVICE WORK ON THE CHASSIS – Hold the shock absorber and remove screw – Remove the shock absorber carefully at the bottom. H03699-10 12.17 Installing the shock absorber Main work – Carefully position the shock absorber into the vehicle from the bottom.

  • Page 67: Removing The Seat

    SERVICE WORK ON THE CHASSIS 12 – 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 F02307-10 –...

  • Page 68: Mounting The Seat

    12 SERVICE WORK ON THE CHASSIS 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 69: Removing The Air Filter Box Cover

    SERVICE WORK ON THE CHASSIS 12 12.20 Removing the air filter box cover – Pull off the air filter box cover sideways in areas , and remove toward the front. F02311-10 12.21 Installing the air filter box cover – Attach catch of the air filter box in area and push for- ward.

  • Page 70: Installing The Air Filter

    12 SERVICE WORK ON THE CHASSIS Main work – Detach retaining tab . Remove air filter with air filter sup- port. – Remove air filter from air filter support. F02313-10 12.23 Installing the air filter Main work – Mount the clean air filter on the air filter support. –...

  • Page 71: Removing The Right Side Cover

    SERVICE WORK ON THE CHASSIS 12 Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 147) Info Only press the air filter to dry it, never wring it out. –...

  • Page 72: Installing The Right Side Cover

    12 SERVICE WORK ON THE CHASSIS 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 H03701-10 Finishing work – Mount the seat. ( p.

  • Page 73: Installing The Main Silencer

    SERVICE WORK ON THE CHASSIS 12 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 74: Removing The Fuel Tank

    12 SERVICE WORK ON THE CHASSIS Main work – Remove all the screws on the main silencer. – Take off silencer cap with O-ring – Remove glass fiber yarn filling from main silencer – Clean the parts that need to be reinstalled and check for damage.
  • Page 75 SERVICE WORK ON THE CHASSIS 12 – Remove the seat. ( p. 65) – Remove the right side cover. ( p. 69) Main work – Unplug connector of the fuel pump. – Clean plug-in connection of the fuel line thoroughly with compressed air.

  • Page 76: Installing The Fuel Tank

    12 SERVICE WORK ON THE CHASSIS 12.31 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 77: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS 12 – Position the horn with the horn bracket. – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis H03705-11 – Plug in connector for the fuel pump. – Remove the wash cap set. –...

  • Page 78: Cleaning The Chain

    12 SERVICE WORK ON THE CHASSIS 12.33 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip. – Remove lubricants from the tires using a suitable cleaning agent. Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. –...

  • Page 79: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 12 Main work – Pull the chain at the end of the chain sliding piece upward to measure chain tension Info Lower chain section must be taut. When the chain guard is mounted, it must be possi- ble to pull up the chain at least to the point where it makes contact with chain guard Chain wear is not always even, so you should repeat...

  • Page 80: 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 81 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 82 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 83: Checking The Frame

    – Change the frame. Info Always replace a frame that has been damaged due to a mechanical impact. Repair of the frame is not authorized by Husqvarna F00255-01 Motorcycles. 12.38 Checking the link fork – Check the link fork for damage, cracking, and deformation.

  • Page 84: Checking The Rubber Grip

    12 SERVICE WORK ON THE CHASSIS Main work – Check throttle cable routing. Both throttle cables must be routed, side by side, on the back of the handlebars and above the fuel tank bracket, to the throttle valve body. Both throttle cables must be secured behind the rubber strap of the fuel tank support.

  • Page 85: Adjusting The Basic Position Of The Clutch Lever

    SERVICE WORK ON THE CHASSIS 12 12.41 Adjusting the basic position of the clutch lever – Adjust basic position of the clutch lever to your hand size by turning adjusting screw Info When the adjusting screw is turned clockwise, the clutch lever moves closer to the handlebar.

  • Page 86: Changing The Hydraulic Clutch Fluid

    12 SERVICE WORK ON THE CHASSIS Brake fluid DOT 4 / DOT 5.1 ( p. 145) – Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilled brake fluid immediately with water. 12.43 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation.

  • Page 87: Removing The Engine Guard

    SERVICE WORK ON THE CHASSIS 12 – Fill bleeding syringe with the appropriate hydraulic fluid. Syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p. 145) – On the clutch slave cylinder, remove bleeder screw mount bleeding syringe S02086-10 –...

  • Page 88: 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 89: 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 reservoir mounted on the handlebar to a hori- zontal position.

  • Page 90: 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 91: Changing The Front 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 92 13 BRAKE SYSTEM – Move the brake reservoir mounted on the handlebar to a hori- zontal position. – Remove screws – Take off cover with membrane H03720-10 – 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, if necessary extract excess.

  • Page 93: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM 13 – Correct the brake fluid quantity to level Guideline 5 mm (0.2 in) Level (brake fluid level below reservoir rim) Brake fluid DOT 4 / DOT 5.1 ( p. 145) – Position cover with membrane – Mount and tighten screws Info Clean up overflowed or spilled brake fluid immediately with water.

  • Page 94: Adjusting The Basic Position Of The Foot Brake Lever

    Warning 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.)

  • Page 95: Adding Rear Brake Fluid

    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.) Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 96: 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 97 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 98 13 BRAKE SYSTEM – Take out the brake linings. – Clean the brake caliper and brake caliper bracket. – Check that spring plate in the brake caliper and sliding plate in the brake caliper bracket are seated correctly. H02369-10 – Insert the new brake linings.

  • Page 99: Wheels, Tires 14

    WHEELS, TIRES 14 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 53) 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 100: 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 101: 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 102 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 surface of the spacers. Long-life grease ( p.

  • Page 103: 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 104: 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 105: 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 106 15 ELECTRICAL SYSTEM – Remove starter relay and fuse box from the holding bracket and hang to the side. S03578-10 – Detach wiring harness , disconnect relays and hang them to the side. S03579-10 – Remove screw and unhook the holding bracket. –...

  • Page 107: Installing The 12-V Battery

    ELECTRICAL SYSTEM 15 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) ( p. 141) – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft)

  • Page 108: Charging The 12-V Battery

    15 ELECTRICAL SYSTEM – Connect positive cable to the 12-V battery. Guideline Screw, battery termi- 2.5 Nm (1.84 lbf ft) Info Contact disk must be mounted under screw and cable lug with the claws toward the battery terminal. – Slide the positive terminal cover over the positive terminal. –...
  • Page 109 ELECTRICAL SYSTEM 15 Info Even if there is no load on the 12-V battery, it discharges each day. The charging level and the method of charging are very important for the service life of the 12-V battery. Rapid recharging with a high charging current shortens the service life of the battery. If the charging current or charging voltage are exceeded, the 12 V battery will be destroyed.

  • Page 110: Changing The Main Fuse

    15 ELECTRICAL SYSTEM This battery charger is only suitable for lithium iron phosphate batteries. Read the accompanying instruc- tions for Husqvarna Motorcycles accessories. Info Never remove cover – Switch off the battery charger after charging and dis- connect it from the 12-V battery.

  • Page 111: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM 15 – 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. – Install a new main fuse. Fuse (58011109120) ( p.

  • Page 112: Removing The Headlight Mask With The Headlight

    15 ELECTRICAL SYSTEM Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. – Insert spare fuse with the correct rating. Fuse (75011088010) ( p. 141) Fuse (75011088005) ( p.

  • Page 113: Installing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM 15 – Detach plug-in connectors and take off the headlight mask with the headlight. H03750-10 15.7 Installing the headlight mask with the headlight Main work – Join plug-in connectors H03750-11 – Position the brake line and the wiring harness in the cable guide.

  • Page 114: Changing The Headlight Bulb

    15 ELECTRICAL SYSTEM Finishing work – Check the headlight setting. ( p. 113) 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 115: Checking The Headlight Setting

    ELECTRICAL SYSTEM 15 Main work – Remove the screw on the rear of the turn signal housing. – Carefully remove turn signal glass – Lightly squeeze orange cap in the area of the holding lugs and take it off. – Press the turn signal bulb lightly into the socket, turn it coun- terclockwise by about 30°, and pull it out of the socket.

  • Page 116: Adjust The Headlight Range

    15 ELECTRICAL SYSTEM 15.11 Adjust the headlight range. Preparatory work – Check the headlight setting. ( p. 113) Main work – Loosen screw – Adjust the headlight range by pivoting the headlight. Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with rider (instructions on how to apply the mark: Checking the headlight setting).

  • Page 117: Diagnostics Connector

    ELECTRICAL SYSTEM 15 Finishing work – Install the headlight mask with the headlight. ( p. 111) – Check the headlight setting. ( p. 113) – Set the combination instrument. ( p. 24) 15.13 Diagnostics connector Diagnostics connector is located under the seat below the EFI control unit.

  • Page 118: 16 Cooling System

    16 COOLING SYSTEM 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 119: Checking The Coolant Level

    COOLING SYSTEM 16 Coolant ( p. 145) – 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 120: Refilling Coolant

    16 COOLING SYSTEM 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 121: Tuning The Engine 17

    TUNING THE ENGINE 17 17.1 Checking the throttle cable play – 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 Throttle cable play 3 …...

  • Page 122: 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 123 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 124: Changing The Mapping

    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.)

  • Page 125: Teaching The Throttle Valve Position

    TUNING THE ENGINE 17 – Run the engine until warm. The cold start button is deactivated – The cold start but- ton is in its basic position. ( p. 20) Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.

  • Page 126: Checking The Basic Position Of The Shift Lever

    17 TUNING THE ENGINE 17.7 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the rider's boot when in the basic position. When the shift lever keeps touching the boot, the transmission will be subject to an excessive load. –...

  • Page 127: 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 refuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 128: Checking The Engine Oil Level

    18 SERVICE WORK ON THE ENGINE – Start the engine and check the response. 18.2 Checking the engine oil level Preparatory work – Stand the motorcycle upright on a horizontal surface. Condition The engine is cold. – Check the engine oil level. The engine oil reaches the lower edge of level viewer »...
  • Page 129 SERVICE WORK ON THE ENGINE 18 Main work – Place an appropriate container under the engine. – Remove oil drain plug with the magnet and seal ring. Info Do not remove screws V01393-10 – Remove screw plug with oil screen and the O-rings.
  • Page 130 18 SERVICE WORK ON THE ENGINE – Pull oil filter out of the oil filter housing. Lock ring plier (51012011000) – Allow the engine oil to drain completely. – Thoroughly clean the parts and the sealing surface. V01398-10 – Lay the motorcycle on its side and fill the oil filter housing to about ⅓...

  • Page 131: Adding Engine Oil

    SERVICE WORK ON THE ENGINE 18 18.4 Adding engine oil Info Too little engine oil or poor-quality engine oil will result in premature wear of the engine. Main work – Remove filler plug with the O-ring. – Fill engine oil to the middle of the level viewer.

  • Page 132: 19 Cleaning, Care

    19 CLEANING, CARE 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 133: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE 19 – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p. 147) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

  • Page 134: 20 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. 53) –...

  • Page 135: Preparing For Use After Storage

    STORAGE 20 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 136: 21 Troubleshooting

    Check the electrical system. faulty – 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 137 Check wiring for damage and electri- lights up or flashes cal plug-in connectors for corrosion and damage. – 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 138 21 TROUBLESHOOTING Faults Possible cause Action – The high beam, low beam, tail Fuse 2 blown Change the fuses of individual power light, position light, and license consumers. ( p. 109) plate lamp are not working – Combination instrument, horn, Fuse 3 blown Change the fuses of individual power brake light, turn signal, and...

  • Page 139: Technical Data 22

    TECHNICAL DATA 22 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 249.91 cm³ (15.2505 cu in) Stroke 52.3 mm (2.059 in) Bore 78 mm (3.07 in) Compression ratio 13.8:1 Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 32.5 mm (1.28 in) Valve diameter, exhaust...

  • Page 140: Engine Tightening Torques

    22 TECHNICAL DATA 22.2 Engine tightening torques Nozzle, crank chamber ventilation 2 Nm (1.5 lbf ft) ® Loctite 243™ Oil nozzle for alternator cooling 2 Nm (1.5 lbf ft) ® Loctite 243™ Oil nozzle for balancer shaft lubri- 2 Nm (1.5 lbf ft) ®...
  • Page 141 TECHNICAL DATA 22 Screw, shift drum locating 10 Nm (7.4 lbf ft) ® Loctite 243™ Screw, shift lever 14 Nm (10.3 lbf ft) ® Loctite 243™ Screw, starter motor 10 Nm (7.4 lbf ft) Screw, timing chain failure protec- 10 Nm (7.4 lbf ft) ®...

  • Page 142: Capacities

    22 TECHNICAL DATA Plug, timing chain tensioner M24x1.5 40 Nm (29.5 lbf ft) Screw, alternator cover M24x1.5 18 Nm (13.3 lbf ft) 22.3 Capacities 22.3.1 Engine oil Engine oil 1.0 l (1.1 qt.) Engine oil (SAE 10W/50) ( p. 145) 22.3.2 Coolant Coolant...

  • Page 143: Electrical System

    140/80 - 18 M/C 70M M+S TT Metzeler MCE 6 Days Extreme Metzeler MCE 6 Days Extreme 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 14.15.8T.63...

  • Page 144: Shock Absorber

    22 TECHNICAL DATA Standard Sport Spring length with preload spacer(s) 474 mm (18.66 in) Spring rate Weight of rider: 65 … 75 kg (143 … 165 lb.) 4.0 N/mm (22.8 lb/in) Weight of rider: 75 … 85 kg (165 … 187 lb.) 4.2 N/mm (24 lb/in) Weight of rider: 85 …...

  • Page 145: Chassis Tightening Torques

    TECHNICAL DATA 22 22.9 Chassis tightening torques ® Remaining screws, chassis EJOT PT K60x25‑Z 2.0 Nm (1.48 lbf ft) ® Screw, combination switch EJOT PT K50x18 2 Nm (1.5 lbf ft) ® Screw, intake air temperature sen- EJOT PT K45x12 0.7 Nm (0.52 lbf ft) Screw, fixed grip 5 Nm (3.7 lbf ft)
  • Page 146 22 TECHNICAL DATA Screw, subframe M8x30 30 Nm (22.1 lbf ft) ® Loctite 2701™ Screw, top steering stem 17 Nm (12.5 lbf ft) ® Loctite 243™ Screw, top triple clamp 17 Nm (12.5 lbf ft) Engine attachment bolt 60 Nm (44.3 lbf ft) Remaining nuts, chassis 45 Nm (33.2 lbf ft) Remaining screws, chassis...

  • Page 147: Substances 23

    SUBSTANCES 23 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 148 23 SUBSTANCES Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 148) (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 149: Auxiliary Substances 24

    AUXILIARY SUBSTANCES 24 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 150: 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 151: 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 152: 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 153: 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 154: Index

    INDEX INDEX Chain tension adjusting ......77 checking ......76 12-V battery charging .
  • Page 155 INDEX Engine oil adding ......129 Hand brake lever ..... . 16 changing .
  • Page 156 INDEX Motorcycle removing ......62 cleaning ......130 riding sag, checking .
  • Page 157 INDEX Troubleshooting ....134-136 Turn signal bulb changing ......112 Turn signal switch .
  • Page 158 *3402340en* 3402340en 05/2019 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria Photo: Mitterbauer/KISKA, www.husqvarna-motorcycles.com Husqvarna Motorcycles GmbH...

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