Husqvarna FE 250 AU 2014 Manuals

Manuals and User Guides for Husqvarna FE 250 AU 2014. We have 1 Husqvarna FE 250 AU 2014 manual available for free PDF download: Repair Manual

Husqvarna FE 250 AU 2014 Repair Manual (286 pages)

Brand: Husqvarna | Category: Motorcycle | Size: 74.65 MB

Table of Contents
4
Consumers
5
Means of Representation
8
Symbols Used
8
Formats Used
8
Safety Advice
9
Repair Manual
9
Degrees of Risk and Symbols
9
Work Rules
9
Important Notes
10
Manufacturer and Implied Warranty
10
Operating and Auxiliary Substances
10
Spare Parts, Accessories
10
Figures
10
Serial Numbers
11
Chassis Number
11
Type Label (FE EU/AU)
11
Key Number (FE EU/AU)
11
Engine Number
11
Fork Part Number
11
Shock Absorber Article Number
12
Motorcycle
13
Raising the Motorcycle with a Lift Stand
13
Removing the Motorcycle from the Lift Stand
13
Starting
13
Starting the Motorcycle for a Check
14
Fork, Triple Clamp
15
Adjusting the Compression Damping of the 9.11 Fork
15
Adjusting the Rebound Damping of the Fork
15
Bleeding the Fork Legs
15
Cleaning the Dust Boots of the Fork Legs
16
Loosening the Fork Protector
16
Positioning the Fork Protector
17
Removing the Fork Legs
17
Installing the Fork Legs
17
Removing the Fork Protector
18
Installing the Fork Protector
18
Performing a Fork Service
19
Disassembling the Fork Legs
19
Removing the Spring
21
Disassembling the Cartridge
22
Disassembling the Piston Rod
23
Disassembling the Hydrostop Unit
24
Disassembling the Seal Ring Retainer
24
Checking the Fork Legs
25
Assembling the Seal Ring Retainer
26
Assembling the Hydrostop Unit
26
Assembling the Piston Rod
27
Assembling the Cartridge
28
Assembling the Fork Legs
29
Lubricating the Steering Head Bearing
33
Removing the Lower Triple Clamp
33
Installing the Lower Triple Clamp
34
Adjusting the Steering Head Bearing Play
36
Bearing
37
Changing the Steering Head Bearing
37
Handlebar,Controls
39
Handlebar Position
39
Adjusting the Handlebar Position
39
Adjusting the Basic Position of the Clutch Lever
39
Checking the Routing of the Throttle Cable
40
Checking the Play in the Throttle Cable
40
Adjusting the Play in the Throttle Cable
41
Frame
42
Removing the Engine Guard
42
Installing the Engine Guard
42
Checking the Frame
42
Shock Absorber, Swingarm
43
Adjusting the High-Speed Compression Damping of the Shock Absorber
43
Adjusting the Low-Speed Compression Damping of the Shock Absorber
43
Adjusting the Rebound Damping of the Shock Absorber
44
Measuring Rear Wheel Sag Unloaded
44
Checking the Static Sag of the Shock Absorber
44
Checking the Riding Sag of the Shock Absorber
45
Adjusting the Spring Preload of the Shock Absorber
45
Adjusting the Riding Sag
46
Removing the Shock Absorber
47
Installing the Shock Absorber
47
Checking the Shock Absorber Linkage
47
Servicing the Shock Absorber
49
Removing the Spring
50
Disassembling the Damper
50
Disassembling the Piston Rod
51
Disassembling the Seal Ring Retainer
52
Changing the Pilot Bushing
53
Checking the Damper
54
Removing the Heim Joint
54
Installing the Heim Joint
55
Assembling the Seal Ring Retainer
56
Assembling the Piston Rod
57
Assembling the Damper
58
Clearance
58
Bleeding and Filling the Damper
60
Filling the Damper with Nitrogen
62
Installing the Spring
63
Checking the Swingarm
64
Removing the Swingarm
64
Installing the Swingarm
65
Changing the Swingarm Bearing
66
Exhaust
69
Removing the Manifold
69
Installing the Manifold
70
Removing the Main Silencer
71
Installing the Main Silencer
72
Changing the Glass Fiber Yarn Filling in the Main Silencer
72
Cleaning the Spark Arrestor (FE US)
73
Air Filter
75
Removing the Air Filter Box Cover
75
Installing the Air Filter Box Cover
75
Removing the Air Filter
75
Installing the Air Filter
75
Cleaning the Air Filter and Air Filter Box
76
Sealing the Air Filter Box
76
Fuel Tank, Seat, Trim
77
Opening Filler Cap
77
Closing Filler Cap
77
Removing the Right Side Cover
77
Installing the Right Side Cover
78
Removing the Seat
78
Mounting the Seat
78
Removing the Fuel Tank
79
Installing the Fuel Tank
80
Changing the Fuel Screen
81
Changing the Fuel Filter
82
Changing the Fuel Pump
84
Checking the Fuel Pressure
85
Mask, Fender
88
Removing the Front Fender
88
Installing the Front Fender
88
Removing the Headlight Mask with the Headlight
89
Installing the Headlight Mask with the Headlight
89
Wheels
90
Checking the Tire Air Pressure
90
Checking the Tire Condition
90
Checking the Brake Discs
91
Checking Spoke Tension
91
Checking the Rim Run-Out
92
Front Wheel
92
Removing the Front Wheel
92
Installing the Front Wheel
93
Removing the Front Brake Disc
93
Installing the Front Brake Disc
94
Changing the Front Wheel Bearing
94
Rear Wheel
95
Removing the Rear Wheel
95
Installing the Rear Wheel
96
Removing the Rear Brake Disc
97
Installing the Rear Brake Disc
97
Checking the Chain Tension
97
Adjusting the Chain Tension
98
Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide
98
Checking for Chain Dirt Accumulation
100
Cleaning the Chain
100
Changing the Drivetrain Kit
101
Changing the Rear Wheel Bearing
102
Wiring Harness, Battery
105
Changing the Main Fuse
105
Changing the Fuses of Individual Power
105
Checking the Starter Relay
106
Removing the Battery
107
Installing the Battery
107
Recharging the Battery
108
Checking the Charging Voltage
109
Checking the Quiescent Current
109
Brake System
110
Checking the Front Brake Linings
110
Changing the Front Brake Linings
110
Checking Free Travel of Hand Brake Lever
112
(Fe Eu/Au)
112
Checking the Front Brake Fluid Level
113
Adding Front Brake Fluid
113
Changing the Front Brake Fluid
114
Checking the Rear Brake Linings
116
Changing the Rear Brake Linings
116
Checking the Free Travel of Foot Brake Lever
118
Adjusting the Basic Position of the Foot Brake Lever
118
Checking the Rear Brake Fluid Level
119
Adding Rear Brake Fluid
119
Changing the Rear Brake Fluid
120
Lighting System, Instruments
123
Setting the Speedometer
123
Setting the Kilometers or Miles
124
Setting the Clock
124
Setting the Wheel Circumference
124
Setting the Service Display
125
Checking the Headlight Setting
125
Adjusting the Headlight Range
126
Engine
127
Removing the Engine
127
Installing the Engine
131
Engine Disassembly
135
Preparations
135
Removing the Clutch Push Rod
136
Removing the Spacer
136
Draining the Engine Oil
136
Removing the Oil Filter
137
Removing the Spark Plug
137
Removing the Valve Cover
137
Removing the Alternator Cover
138
Removing the Torque Limiter
138
Positioning the Engine at Ignition Top Dead Center
138
Removing the Timing Chain Tensioner
139
Removing the Camshaft
139
Removing the Cylinder Head
140
Removing the Piston
140
Removing the Starter Drive
141
Removing the Suction Pump
142
Removing the Water Pump Wheel
143
Removing the Clutch Cover
143
Removing the Clutch Discs
143
Removing the Clutch Basket
144
Removing the Shift Shaft
145
Removing the Shift Drum Locating Unit
145
Removing the Locking Lever
145
Removing the Force Pump
145
Removing the Primary Gear
146
Removing the Timing Chain
146
Removing the Spacer
147
Removing the Left Section of the Engine Case
147
Removing the Shift Rails
147
Removing the Shift Drum
148
Removing the Shift Forks
148
Removing the Transmission Shafts
148
Removing the Crankshaft
148
Working on Individual Parts
149
Work on the Right Section of the Engine Case
149
Work on the Left Section of the Engine Case
150
Work on the Clutch Cover
151
Checking the Oil Pressure Regulator Valve
152
Checking the Lubrication System
153
Removing the Crankshaft Bearing Inner Race
153
Installing the Crankshaft Bearing Inner Race
154
Changing the Connecting Rod, Conrod Bearing, and Crank Pin
154
Checking the Crankshaft Run-Out at the Bearing Pin
156
Measuring the Crankshaft End Play
156
Removing the Drive Wheel of the Balancer Shaft
156
Installing the Drive Wheel of the Balancer Shaft
157
Cylinder - Nikasil ® Coating
157
Checking/Measuring the Cylinder
157
Checking/Measuring the Piston
158
Measuring the Piston/Cylinder Mounting
158
Checking the Piston Ring End Gap
159
Checking the Camshafts
159
Work on the Intake Camshaft
159
Checking the Pivot Points of the Camshafts
160
Removing the Valves
161
Checking the Valves
162
Checking the Valve Springs
162
Checking the Valve Spring Seat
162
Checking the Cam Levers
163
Checking the Cylinder Head
163
Installing the Valves
163
Checking the Freewheel
164
Removing the Freewheel
165
Installing the Freewheel
165
Checking the Electric Starter Drive
166
Checking the Timing Assembly
167
Preparing the Timing Chain Tensioner for Installation
168
Checking the Clutch
168
Checking the Shift Mechanism
170
Preassembling the Shift Shaft
171
Disassembling the Main Shaft
171
Disassembling the Countershaft
172
Checking the Transmission
172
Assembling the Main Shaft
173
Assembling the Countershaft
174
Engine Assembly
175
Installing the Crankshaft
175
Installing the Shift Rails
177
Installing the Left Engine Case
177
Installing the Spacer
178
Installing the Timing Chain
178
Installing the Primary Gear
178
Installing the Force Pump
179
Installing the Suction Pump
179
Installing the Locking Lever
180
Installing the Shift Drum Locating Unit
180
Installing the Shift Shaft
181
Installing the Clutch Basket
181
Installing the Clutch Discs
182
Installing the Clutch Cover
183
Installing the Water Pump Cover
184
Installing the Starter Drive
184
Installing the Piston
185
Installing the Cylinder Head
187
Installing the Camshafts
188
Installing the Timing Chain Tensioner
188
Checking the Valve Clearance
189
18.5.25 Adjusting the Valve Clearance
190
Installing the Torque Limiter
190
Installing the Alternator Cover
190
Installing the Valve Cover
191
Installing the Spark Plug
191
Installing the Oil Filter
192
Installing the Oil Screen
192
Installing the Spacer
193
Installing the Clutch Push Rod
193
Removing the Engine from the Engine Assembly Stand
193
Clutch
194
Checking/Correcting the Fluid Level of the Hydraulic Clutch
194
Changing the Hydraulic Clutch Fluid
194
Water Pump, Cooling System
196
Cooling System
196
Checking the Antifreeze and Coolant Level
196
Checking the Coolant Level
197
Draining the Coolant
197
Refilling Coolant
198
Lubrication System
199
Oil Circuit
199
Checking the Engine Oil Level
199
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen
200
Adding Engine Oil
202
Checking the Engine Oil Pressure
202
Ignition System
204
Ignition Coil - Checking the Secondary
204
Winding
204
Checking the Spark Plug Connector
204
Alternator - Checking the Stator Winding
204
Removing the Stator and Ignition Pulse Generator
205
Installing the Stator and Ignition Pulse Generator
205
Electric Starter
206
Checking the Starter Motor
206
Throttle Valve Body
207
Adjusting the Idle Speed
207
Executing the Initialization Run
207
Technical Data
208
Engine
208
Tolerance, Engine Wear Limits
208
Engine Tightening Torques
209
Capacities
210
Engine Oil
210
Coolant
210
Fuel
210
Chassis
211
Electrical System
211
Tires
212
Fork
212
Shock Absorber
212
Chassis Tightening Torques
213
Cleaning, Care
215
Cleaning the Motorcycle
215
Checks and Maintenance Steps for Winter Operation
216
Storage
217
Preparing for Use after Storage
217
Service Schedule
218
Service Work as Additional Order
219
Fe Eu)
220
Wiring Diagram
221
Fe Eu)
222
Fe Eu)
224
Fe Eu)
226
Fe Eu)
228
Fe Eu)
230
Fe Eu)
232
Fe Eu)
234
Fe Au)
236
Fe Au)
238
Fe Au)
240
Fe Au)
242
Fe Au)
244
Fe Au)
246
Fe Au)
248
Fe Au)
250
Fe Us)
252
Fe Us)
254
Fe Us)
256
Fe Us)
258
Fe Us)
260
Fe Us)
262
Substances
264
Auxiliary Substances
266
Special Tools
268
Standards
280
Index
281

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Husqvarna FE 250 AU 2014 Repair Manual (286 pages)

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