Husqvarna FC 350 2016 Manuals

Manuals and User Guides for Husqvarna FC 350 2016. We have 1 Husqvarna FC 350 2016 manual available for free PDF download: Repair Manual

Husqvarna FC 350 2016 Repair Manual (310 pages)

Brand: Husqvarna | Category: Motorcycle | Size: 79.03 MB

Table of Contents
4
Means of Representation
9
Symbols Used
9
Formats Used
9
Safety Advice
10
Repair Manual
10
Degrees of Risk and Symbols
10
Work Rules
10
Important Notes
11
Manufacturer and Implied Warranty
11
Operating and Auxiliary Substances
11
Spare Parts, Accessories
11
Figures
11
Serial Numbers
12
Chassis Number
12
Type Label
12
Engine Number
12
Fork Part Number
12
Shock Absorber Article Number
13
Motorcycle
14
Raising the Motorcycle with a Lift Stand
14
Removing the Motorcycle from the Lift Stand
14
Starting
14
Starting the Motorcycle to Check the Function
15
Fork, Triple Clamp
16
Adjusting the Compression Damping of the Fork
16
Adjusting the Rebound Damping of the Fork
16
Bleeding the Fork Legs
17
Cleaning the Dust Boots of the Fork Legs
17
Removing the Fork Legs
18
Installing the Fork Legs
18
Removing the Fork Protector
19
Installing the Fork Protector
19
Performing a Fork Service
20
Disassembling the Fork Legs
20
Removing the Spring
22
Disassembling the Cartridge
23
Disassembling the Piston Rod
24
Disassembling the Hydrostop Unit
26
Disassembling the Seal Ring Retainer
26
Checking the Fork Legs
27
Assembling the Seal Ring Retainer
28
Assembling the Hydrostop Unit
29
Piston Rod, Assembling
29
Cartridge, Assembling
31
Assembling the Fork Legs
32
Lubricating the Steering Head Bearing
37
Removing the Lower Triple Clamp
37
Installing the Lower Triple Clamp
38
Checking the Steering Head Bearing Play
40
Changing the Steering Head Bearing
41
Adjusting the Steering Head Bearing Play
42
7 Handlebar,Controls
44
Handlebar Position
44
Adjusting the Handlebar Position
44
Adjusting the Basic Position of the Clutch Lever
45
Checking the Rubber Grips
45
Checking the Throttle Cable Routing
45
Checking the Play in the Throttle Cable
46
Adjusting the Play in the Throttle Cable
47
Setting the Characteristic Map of the Throttle Response
48
Frame
50
Checking the Frame
50
Changing the Footrests
50
Shock Absorber, Swingarm
52
Adjusting the High-Speed Compression Damping of the Shock Absorber
52
Adjusting the Low-Speed Compression Damping of the Shock Absorber
52
Adjusting the Rebound Damping of the Shock Absorber
53
Measuring the Rear Wheel Dimension Unloaded
54
Checking the Static Sag of the Shock Absorber
54
Checking the Riding Sag of the Shock Absorber
55
Shock Absorber
55
Adjusting the Riding Sag
56
Removing the Shock Absorber
57
Installing the Shock Absorber
59
Checking the Shock Absorber Linkage
60
Servicing the Shock Absorber
62
Removing the Spring
63
Disassembling the Damper
64
Disassembling the Piston Rod
65
Disassembling the Seal Ring Retainer
66
Changing the Pilot Bushing
67
Checking the Damper
68
Removing the Heim Joint
69
Installing the Heim Joint
70
Assembling Seal Ring Retainer
71
Assembling the Piston Rod
71
Assembling the Damper
73
Bleeding and Filling the Damper
75
Filling the Damper with Nitrogen
79
Installing the Spring
80
Checking the Swingarm
81
Checking the Swingarm Bearing for 14.6.1 Play
81
Removing the Swingarm
82
Installing the Swingarm
83
Changing the Swingarm Bearing
85
10 Exhaust
88
Removing the Manifold
88
Installing the Manifold
89
Removing the Main Silencer
90
Installing the Main Silencer
90
Changing the Glass Fiber Yarn Filling of the Main Silencer
91
11 Air Filter
92
Removing the Air Filter Box Cover
92
Installing the Air Filter Box Cover
92
Removing the Air Filter
92
Installing the Air Filter
93
Cleaning the Air Filter and Air Filter Box
93
Sealing the Air Filter Box
94
Fuel Tank, Seat, Trim
95
Opening the Filler Cap
95
Closing the Filler Cap
95
Removing the Right Side Cover
96
Installing the Right Side Cover
96
Removing the Seat
96
Mounting the Seat
97
Removing the Fuel Tank
98
Installing the Fuel Tank
99
Checking the Fuel Pressure
101
Changing the Fuel Pump
102
Changing the Fuel Filter
104
Changing the Fuel Screen
108
13 Mask, Fender
110
Removing Front Fender
110
Installing Front Fender
110
Removing the Start Number Plate
111
Installing the Start Number Plate
111
14 Wheels
112
Checking the Tire Air Pressure
112
Checking the Tire Condition
112
Checking the Wheel Bearing for Play
113
Checking the Brake Discs
113
Checking Spoke Tension
114
Front Wheel
114
Removing the Front Wheel
114
Installing the Front Wheel
115
Changing the Front Brake Disc
116
Changing Front Wheel Bearing
117
Rear Wheel
118
Removing the Rear Wheel
118
Installing the Rear Wheel
119
Changing the Rear Brake Disc
120
Checking the Chain Tension
121
Adjusting the Chain Tension
121
Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide
122
Checking for Chain Dirt Accumulation
125
Cleaning the Chain
125
Changing the Drivetrain Kit
125
Changing the Rear Wheel Bearing
127
15 Wiring Harness, Battery
130
Changing the Main Fuse
130
Removing the Battery
131
Installing the Battery
132
Recharging the Battery
132
Checking the Charging Voltage
134
Checking the Open-Circuit Current
134
Checking the Capacitor
135
Checking the Starter Relay
136
16 Brake System
138
Checking the Front Brake Linings
138
Changing the Front Brake Linings
138
Checking the Free Travel of the
140
Hand Brake Lever
140
Checking the Brake Fluid Level of
141
The Front Brake
141
Adding Front Brake Fluid
142
Changing the Front Brake Fluid
143
Checking the Brake Linings of the Rear Brake
145
Changing the Rear Brake Linings
145
Brake Lever
147
Adjusting the Basic Position of the Foot Brake Lever
148
Checking the Rear Brake Fluid Level
148
Adding Rear Brake Fluid
149
Changing the Rear Brake Fluid
150
17 Engine
152
Removing the Engine
152
Installing the Engine
159
Engine Disassembly
167
Preparations
167
Removing the Clutch Push Rod
167
Draining the Engine Oil
167
Removing the Oil Filter
168
Removing the Gear Position Sensor
169
Removing the Spark Plug
169
Removing the Valve Cover
169
Removing the Starter Motor
170
Positioning the Engine at Ignition Top Dead Center
171
Removing the Timing Chain Tensioner
171
Removing the Camshafts
172
Removing the Cylinder Head
172
Removing the Piston
173
Removing the Rotor
173
Removing the Starter Drive
174
Removing the Suction Pump
174
Removing the Water Pump Impeller
175
Removing the Clutch Cover
176
Removing the Clutch Discs
176
Removing the Clutch Basket
177
Removing the Primary Gear
178
Removing the Timing Chain
178
Removing the Force Pump
178
Removing the Locking Lever
179
Removing the Shift Drum Locating Unit
180
Removing the Shift Shaft
180
Removing the Spacer
180
Removing the Left Engine Case
180
Removing the Shift Rails
181
Removing the Shift Drum
181
Removing the Shift Forks
182
Removing the Transmission Shafts
182
Removing the Crankshaft
182
Working on Individual Parts
183
Working on the Right Section of the Engine Case
183
Work on the Left Section of the Engine Case
185
Work on the Clutch Cover
186
Checking the Oil Pressure Regulator Valve
188
Checking the Lubrication System
189
Removing the Crankshaft Bearing Inner Race
189
Changing the Connecting Rod, Conrod Bearing, and Crank Pin
190
Checking the Crankshaft Run-Out at the Bearing Pin
192
Installing the Crankshaft Bearing Inner Race
192
Measuring the Crankshaft End Play
193
Removing the Drive Wheel of the Balancer Shaft
193
Installing the Drive Wheel of the Balancer Shaft
194
Cylinder - Nikasil ® Coating
194
Checking/Measuring the Cylinder
194
Checking/Measuring the Piston
195
Measuring the Piston/Cylinder Mounting Clearance
196
Checking the Piston Ring End Gap
196
Changing the Camshaft
197
Bearing
197
Checking the Camshafts
197
Checking the Pivot Points of the Camshafts
198
Removing the Valves
199
Checking the Valves
200
Checking the Valve Springs
200
Checking the Valve Spring Seat
201
Checking the Cam Levers
201
Checking the Cylinder Head
201
Installing the Valves
202
Checking the Freewheel
203
Removing the Freewheel
203
Installing the Freewheel
204
Checking the Electric Starter Drive
205
Checking the Timing Assembly
206
Preparing the Timing Chain Tensioner for Installation
207
Checking the Clutch
208
Checking the Shift Mechanism
209
Preassembling the Shift Shaft
210
Disassembling the Main Shaft
211
Disassembling the Countershaft
212
Checking the Transmission
212
Assembling the Main Shaft
214
Assembling the Countershaft
215
Engine Assembly
216
Installing the Crankshaft
216
Installing the Transmission Shafts
216
Installing the Shift Forks
217
Installing the Shift Drum
217
Installing the Shift Rails
217
Installing the Left Engine Case
218
Installing the Spacer
219
Installing the Shift Shaft
219
Installing the Shift Drum Locating Unit
219
Installing the Locking Lever
219
Installing the Force Pump
220
Installing the Timing Chain
221
Installing the Primary Gear
221
Installing the Suction Pump
222
Installing the Clutch Basket
223
Installing the Clutch Discs
224
Installing the Clutch Cover
224
Installing the Water Pump Cover
225
Installing the Starter Drive
226
Installing the Rotor and Ignition Pulse Generator
226
Installing the Piston
227
Installing the Cylinder Head
228
Installing the Camshafts
229
Installing the Timing Chain Tensioner
230
Checking the Valve Clearance
231
17.5.26 Adjusting the Valve Clearance
231
17.5.27 Installing the Starter Motor
232
Installing the Valve Cover
233
Installing the Spark Plug
234
Installing the Gear Position Sensor
234
Installing the Oil Filter
234
Installing the Oil Screen
235
Installing the Clutch Push Rod
236
Removing the Engine from the Engine Assembly Stand
236
18 Clutch
237
Checking/Correcting the Fluid Level of the Hydraulic Clutch
237
Changing the Hydraulic Clutch Fluid
238
19 Water Pump, Cooling System
240
Cooling System
240
Checking the Antifreeze and Coolant Level
240
Checking the Coolant Level
241
Draining the Coolant
242
Refilling Coolant
242
Lubrication System
244
Oil Circuit
244
Checking the Engine Oil Level
244
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen
245
Adding Engine Oil
248
Checking the Engine Oil Pressure
248
Ignition System
251
Ignition Coil - Checking the Secondary Winding
251
Checking the Spark Plug Connector
251
Alternator - Checking the Stator Winding
251
Removing the Stator and Crankshaft Position Sensor
252
Installing the Stator and Ignition Pulse Generator
252
22 Cylinder Head
254
Checking the Valve Clearance
254
Adjusting the Valve Clearance
257
23 Throttle Valve Body
258
Adjusting the Idle Speed
258
Executing the Initialization Run
258
24 Technical Data
260
Engine
260
Tolerance, Engine Wear Limits
261
Engine Tightening Torques
262
Capacities
264
Engine Oil
264
Coolant
264
Fuel
264
Chassis
264
Electrical System
265
Tires
265
Fork
265
Shock Absorber
266
Chassis Tightening Torques
266
25 Cleaning
269
Cleaning the Motorcycle
269
26 Storage
271
Preparing for Use after Storage
272
27 Service Schedule
273
Additional Information
273
Required Work
273
Recommended Work
274
28 Wiring Diagram
277
29 Substances
282
30 Auxiliary Substances
284
Special Tools
286
32 Standards
303
33 List of Abbreviations
304
Index
305

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Husqvarna FC 350 2016 Repair Manual (310 pages)

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