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Husqvarna 2016 FE 250, Owner'S Manual

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Husqvarna 2016 FE 250 Owner'S Manual Download Page 54

12 SERVICE WORK ON THE CHASSIS

52

–

Check the intake flange for damage and looseness.

Finishing work

–

Install the air filter.

(

p. 51)

–

Install the air filter box lid. (

p. 50)

12.25

Sealing the air filter box

Preparatory work

–

Remove the air filter box lid. (

p. 50)

401559-01

Main work

–

Seal the air filter box in the marked area

.

Finishing work

–

Install the air filter box lid. (

p. 50)

12.26

Removing the right side cover

H00186-10

–

Remove screw

.

–

Pull off the side cover in area

sideways and remove it toward the rear.

12.27

Installing the right side cover

H00186-10

–

Position the side cover and engage in area

.

–

Mount and tighten screw

.

Guideline

Remaining screws, chassis

M6

10 Nm (7.4 lbf ft)

12.28

Removing 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. Do not touch hot components.

Preparatory work

–

Remove the right side cover. (

p. 52)

Summary of Contents for 2016 FE 250

Page 1: ...OWNER S MANUAL 2016 FE 250 Art no 3402063en ...

Page 2: ......

Page 3: ...olors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice Husqvarna Motorcy cles accepts no liability for delivery options deviations from illustrations and descriptions as well as misprints and other errors The models portrayed partly contain s...

Page 4: ... 7 6 Setting the clock 23 7 7 Setting the service display 23 7 8 Speed time and DST distance 1 24 7 9 Speed time and DST2 distance 2 24 7 10 AVG average speed ART operating hours and ODO total distance covered 24 8 PREPARING FOR USE 25 8 1 Advice on first use 25 8 2 Running in the engine 26 8 3 Preparing the vehicle for difficult riding conditions 26 8 4 Preparing for rides on dry sand 27 8 5 Prep...

Page 5: ... 13 2 Adjusting free travel of hand brake lever FE EU AU 68 13 3 Adjusting the basic position of the hand brake lever FE US 68 13 4 Checking the brake discs 69 13 5 Checking the front brake fluid level 69 13 6 Adding front brake fluid 69 13 7 Checking the front brake linings 70 13 8 Changing the front brake linings 71 13 9 Checking the free travel of foot brake lever 72 13 10 Adjusting the basic p...

Page 6: ... Coolant 109 23 3 3 Fuel 109 23 4 Chassis 109 23 5 Electrical system 110 23 6 Tires 110 23 7 Fork 110 23 8 Shock absorber 111 23 9 Chassis tightening torques 111 24 SUBSTANCES 113 25 AUXILIARY SUBSTANCES 114 26 STANDARDS 115 27 INDEX OF SPECIAL TERMS 116 28 LIST OF ABBREVIATIONS 117 29 LISY OF SYMBOLS 118 29 1 Yellow and orange symbols 118 29 2 Green and blue symbols 118 INDEX 119 ...

Page 7: ...shop There your motorcycle will be optimally cared for by specially trained experts using the specialist tools required Indicates a page reference more information is provided on the specified page Indicates information with more details or tips Indicates the result of a testing step 1 2 Formats used The typographical formats used in this document are explained below Proprietary name Indicates a p...

Page 8: ...d to at the relevant passages Info The vehicle has various information and warning labels at prominent locations Do not remove information warning labels If they are missing you or others may not recognize dangers and may therefore be injured 2 3 Degrees of risk and symbols Danger Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate m...

Page 9: ...g Warning Risk of injury Missing or poor protective clothing presents an increased safety risk Wear protective clothing helmet boots gloves pants and jacket with protectors every time you ride the vehicle Always wear protective clothing that is in good condition and meets the legal requirements In the interest of your own safety Husqvarna Motorcycles recommends that you only operate the vehicle wh...

Page 10: ... you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury Keep the Owner s Manual in an accessible place to enable you to refer to it as needed If you would like to know more about the vehicle or have questions on the material you read please contact an authorized Husq varna Motorcycles dealer The Owner s Manual is an important component of th...

Page 11: ...sories for your vehicle can be found on the Husqvarna Motorcycles website International Husqvarna Motorcycles website www husqvarna motorcycles com 3 4 Service A prerequisite for perfect operation and prevention of premature wear is that the service care and tuning work on the engine and chassis is properly carried out as described in the Owner s Manual Incorrect adjustment and tuning of the engin...

Page 12: ...4 VIEW OF VEHICLE 10 4 1 View of vehicle front left example H00237 10 1 Filler cap 2 Air filter box lid 3 Side stand p 19 4 Engine number p 12 5 Shift lever p 18 ...

Page 13: ... button p 15 2 Light switch p 15 2 Turn signal switch p 15 3 Emergency OFF switch p 15 3 Electric starter button p 16 4 Throttle grip p 14 5 Fork rebound adjustment 6 Shock absorber rebound adjustment 7 Level viewer for brake fluid rear 8 Shock absorber compression adjustment 9 Level viewer engine oil 10 Foot brake lever p 18 ...

Page 14: ...l is fixed to the front of the steering head 5 3 Key number FE EU AU 402247 10 The key number for the steering lock is stamped onto the key connector 5 4 Engine number 401949 10 The engine number is stamped on the left side of the engine under the engine sprocket 5 5 Fork part number 401947 10 The fork part number is stamped on the inner side of the fork stub ...

Page 15: ...5 SERIAL NUMBERS 13 5 6 Shock absorber article number 0 0 1 1 401948 10 The shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side ...

Page 16: ...is fitted on the left side of the handlebar Possible states Kill switch in basic position the ignition circuit is closed in this position and the engine can be started Kill switch pressed the ignition circuit is open in this position the engine goes out if it was running or does not start if it was off 6 5 Kill switch FE US S00889 10 Kill switch is fitted on the left side of the handlebar Possible...

Page 17: ...ght switch is pressed in up to the stop In this position the light is switched off Light on Light switch is pulled out to the stop In this position the low beam and tail light are switched on 6 9 Turn signal switch FE EU AU H00169 10 Turn signal switch is fitted on the left side of the handlebar Possible states Turn signal light off Turn signal switch is in the central position Turn signal light l...

Page 18: ...p MIL lights up flashes orange The OBD has detected an emission or safety critical fault The low fuel warning lamp lights up orange The fuel level has reached the reserve mark Turn signal indicator light flashes green The turn signal is switched on 6 14 Overview of indicator lamps FE US M00355 12 Possible states FI Warning lamp MIL lights up flashes orange The OBD has detected an emission or safet...

Page 19: ...p away from children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system H00170 10 FE EU Press release button turn the filler cap counterclockwise and lift it off S00909 10 FE AU US Press release button turn the filler cap counterclockwise and lift it off 6 16 Closing the filler cap H00...

Page 20: ...M increase activated Idle speed adjusting screw is pulled out all the way RPM increase deactivated Idle speed adjusting screw is pushed in all the way 6 18 Shift lever 401950 10 Shift lever is mounted on the left side of the engine 401950 11 The gear positions can be seen in the photograph The neutral or idle position is between the first and second gears 6 19 Foot brake lever 401956 10 The foot b...

Page 21: ...is used to lock the steering Steering and therefore riding is no longer possible 6 22 Locking the steering FE EU AU Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 400732 01 Park the vehicle Turn the handlebar as far as possible to the right Grease the steering lock regularly Universal oil spray p 114 Insert the key in the ste...

Page 22: ...ing the steering FE EU AU 400731 01 Insert the key in the steering lock p 19 turn it to the left pull it out and turn it to the right Remove the key You can now steer the bike again Info Never leave the key in the steering lock ...

Page 23: ...meter Battery voltage of the speedometer is too low Change the battery Service A service is due Contact an authorized Husqvarna Motorcy cles workshop 7 4 Setting the speedometer Condition The motorcycle is stationary 401909 01 Press 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 kilometers KM H or miles M H...

Page 24: ...h Shortening the service interval Press the left button The value decreases Extending the service interval Press the right button The value increases 401914 01 Switching off the service interval display Press and hold the left button off appears on the display 7 5 Setting the kilometers or miles Info If the unit is changed the value ODO is retained and converted accordingly Condition The motorcycl...

Page 25: ...value decreases Advancing the time Press the right button The value increases 7 7 Setting the service display Condition The motorcycle is stationary 401913 01 Press both buttons for 3 5 seconds The Setup menu is displayed The UNIT display flashes Wait for the menu of the service display to flash Set the service Guideline One time service after 1 h Service every 15 h Shortening the service interval...

Page 26: ... since the last reset such as between two refueling stops Info If the value of 39999 9 is exceeded DST2 is automatically reset to 0 0 Press the left but ton briefly Next display mode Press the left but ton for 3 5 sec onds DST2 can be preset to a value between 0 0 and 39999 9 by pressing the buttons Press the right button briefly Next display mode Press the right button for 3 5 seconds DST2 is res...

Page 27: ...ag continuously The rear brake may fail due to overheating Take your foot off the foot brake lever when you are not braking Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permissible weight and axle loads Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine is running Secure the vehicle against use by unauthorized p...

Page 28: ...perating hour 7 000 rpm Maximum engine performance During the first 3 operating hours 75 Avoid fully opening the throttle 8 3 Preparing the vehicle for difficult riding conditions Info Use of the vehicle under difficult conditions such as on sand or on wet and muddy surfaces can lead to considerably more rapid wear of components such as the drive train brake system or suspension components For thi...

Page 29: ...rna Motorcycles accessories fitting instructions 600868 01 Clean the chain Fit the steel sprocket Tip Do not grease the chain Clean the radiator fins Straighten bent radiator fins carefully 8 5 Preparing for rides on wet sand B00437 01 Fit a waterproofing device on the air filter Waterproofing device for air filter 77206921100 Info See the Husqvarna Motorcycles accessories fitting instructions 600...

Page 30: ... for rides at high temperature and slow speed 600868 01 Adjust the secondary drive to the road conditions Info The engine oil heats up quickly when the clutch is operated frequently due to an excessively high secondary drive Clean the chain Clean the radiator fins Straighten bent radiator fins carefully Check the coolant level p 91 8 8 Preparing for rides at low temperature or in snow B00437 01 Fi...

Page 31: ...e that they can be operated smoothly Check all screws nuts and hose clamps regularly for tightness Check the fuel supply 9 2 Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exha...

Page 32: ...ses fuel consumption To shift down apply the brakes and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and either open the throttle or shift again Switch off the engine if you expect to be standing for a long time Guideline 2 min Avoid frequent and longer slipping of the clutch This heats the engine oil the engine and the cooli...

Page 33: ...e hazard Some vehicle components become very hot when the vehicle is operated Do not park the vehicle near flammable or explosive substances Do not place objects on the vehicle while it is still warm from being run Always let the vehicle cool first Apply the brakes on the motorcycle Shift transmission to neutral FE EU AU Press and hold the kill switch while the engine is idling until the engine st...

Page 34: ...ntact a physician immediately Change clothing that is contaminated with fuel Note Material damage Premature clogging of the fuel filter In some countries and regions the available fuel quality and cleanliness may not be sufficient This will result in problems with the fuel system Your authorized Husqvarna Motorcycles workshop will be glad to help Only refuel with clean fuel that meets the specifie...

Page 35: ...th operation Check rectify the fluid level of the hydraulic clutch p 66 Check the front brake fluid level p 69 Check the free travel of the hand brake lever p 68 Check the steering head bearing play p 47 Check the valve clearance Check the clutch Change the shaft seal rings of the water pump Change the engine oil and oil filter clean the oil screen p 97 Check all hoses e g fuel cooling bleeding dr...

Page 36: ...FE US Perform a fork service Service the shock absorber Change the spark plug and spark plug connector Change the piston Check measure the cylinder Check the cylinder head Change the valves valve springs and valve spring seats Check camshaft and cam lever Change the connecting rod conrod bearing and crank pin Check the transmission and shift mechanism Check the oil pressure regulator valve Change ...

Page 37: ...el suspension and not to the vehicle speed The high speed setting for example has an effect on the landing after a jump the rear wheel suspension compresses more quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses more slowly These two ranges can be adjusted separately although the transition between high speed and low sp...

Page 38: ...number of turns corresponding to the shock absorber type Guideline Compression damping high speed Comfort 2 5 turns Standard 2 turns Sport 1 5 turns Info Turn clockwise to increase damping turn counterclockwise to reduce damping 11 5 Adjusting the rebound damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with ...

Page 39: ...c sag is the difference between measurements and Check the static sag Static sag 30 mm 1 18 in If the static sag is less or more than the specified value Adjust the spring preload of the shock absorber p 38 11 8 Checking the riding sag of the shock absorber 400990 10 Measure distance of rear wheel unloaded p 37 With another person holding the motorcycle the rider wearing full protective clothing s...

Page 40: ...justing ring until the spring is no longer under tension Hook wrench T106S Measure the overall spring length while the spring is not under tension Tighten the spring by turning adjusting ring to measurement Guideline Spring preload 17 mm 0 67 in Info Depending on the static sag and or the riding sag it may be necessary to increase or decrease the spring preload Tighten screw Guideline Screw shock ...

Page 41: ...st the rebound damping of the shock absorber p 36 11 11 Checking basic setting of fork Info For various reasons no exact riding sag can be determined for the forks 401000 01 As with the shock absorber smaller differences in the rider s weight can be com pensated by the spring preload However if the fork is often overloaded hard end stop on compression harder springs must be fit to avoid damage to ...

Page 42: ...djusting screw Turn counterclockwise by the number of clicks corresponding to the fork type Guideline Rebound damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 11 14 Handlebar position 101859 10 On the upper triple clamp there are two holes at a distance of to each other Hole distance 15 mm 0 59 in The holes...

Page 43: ...r supports Place the handlebar supports in the required position Mount and tighten screws Guideline Screw handlebar holder M10 40 Nm 29 5 lbf ft Loctite 243 Info Position the left and right handlebar holders evenly Position the handlebar Info Make sure the cables and wiring are positioned correctly Position the handlebar clamps Mount and tighten screws evenly Guideline Screw handlebar clamp M8 20 ...

Page 44: ...ss side stand to the ground with your foot and lean the motorcycle on it Info When you are riding the side stand must be folded up and secured with the rubber band 12 3 Bleeding the fork legs Preparatory work Raise the motorcycle with a lift stand p 42 402556 10 Main work Release bleeder screws Any excess pressure escapes from the interior of the fork Tighten the bleeder screws Finishing work Remo...

Page 45: ... the headlight p 85 Raise the motorcycle with a lift stand p 42 Remove the front wheel p 77 H00177 10 Main work Remove screws and take off the clamp Remove the cable tie s Remove screws and take off the brake caliper Allow the brake caliper and brake line to hang tension free to the side H00179 10 Loosen screws Take out the left fork leg Loosen screws Take out the right fork leg 12 6 Installing th...

Page 46: ...ke off the clamp Remove screws on the left fork leg Take off the fork protector Remove screws on the right fork leg Take off the fork protector 12 8 Installing the fork protector S00899 11 Position the fork protector on the left fork leg Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake line wiring harness and clamp Mount and tighten screws Position...

Page 47: ...e clamp with the steering stem Remove the upper steering head bearing 12 10 Installing the lower triple clamp 0 0 1 1 0 0 2 2 0 0 3 3 B01632 10 Main work Clean the bearing and sealing elements check for damage and grease High viscosity grease p 114 Position the lower triple clamp with the steering stem Mount the upper steering head bearing Check whether upper steering head seal is correctly positi...

Page 48: ...ghten screws Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft H00218 10 Tighten screw Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft H00234 10 Mount and tighten screw Guideline Screw top steering stem M8 17 Nm 12 5 lbf ft Loctite 243 H00180 11 Tighten screws Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Secure the wiring harness with cable holder H00178 11 Position the ...

Page 49: ...ection of travel No play should be noticeable in the steering head bearing If there is noticeable play present Adjust the play of the steering head bearing p 47 Move the handlebar to and fro over the entire steering range The handlebar must be able to move easily over the entire steering range No resting locations should be noticeable If click positions are noticeable Adjust the play of the steeri...

Page 50: ...itch off the engine Remove the headlight mask with the headlight p 85 H00235 10 Main work Remove screws Remove screws Remove the front fender 12 15 Installing the front fender H00181 10 Main work Position the front fender Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Ins...

Page 51: ...e shock absorber out of the vehicle toward the top 12 17 Installing the shock absorber H00222 01 Main work Carefully position the shock absorber into the vehicle from above Finishing work Install the manifold p 57 Mount the seat p 50 Install the main silencer p 53 Install the right side cover p 52 Remove the motorcycle from the lift stand p 42 12 18 Removing the seat H00182 10 Remove screws in the...

Page 52: ...and remove toward the rear 12 21 Installing the air filter box lid H00213 10 Position the air filter box lid and tab Engage the air filter box lid in areas and Engage tab 12 22 Removing the air filter Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never operate the vehicle without an air filter as dust and dirt will enter the engine and lead to in...

Page 53: ...y dust and dirt may enter the engine and result in damage Finishing work Install the air filter box lid p 50 12 24 Cleaning the air filter and air filter box Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Do not clean the air filter with fuel or petroleu...

Page 54: ...r box lid p 50 12 26 Removing the right side cover H00186 10 Remove screw Pull off the side cover in area sideways and remove it toward the rear 12 27 Installing the right side cover H00186 10 Position the side cover and engage in area Mount and tighten screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 12 28 Removing the main silencer Warning Danger of burns The exhaust system gets very...

Page 55: ...n screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the right side cover p 52 12 30 Cleaning the spark arrestor FE US Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down Do not touch hot components Info Soot particles accumulate on the screen of the spark arrestor over time This changes the per...

Page 56: ...ap Mount and tighten screws Guideline Screws on the main silencer M5 7 Nm 5 2 lbf ft Finishing work Install the main silencer p 53 Install the right side cover p 52 12 31 Changing the glass fiber yarn filling of 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 Do not touch hot components Info Over time the f...

Page 57: ...screws and silencer cap with O ring Remove screws and insert together with insulating pad Remove the insulating pad from the insert Clean the parts that need to be reinstalled and check for damage Mount the new insulating pad on the insert and fasten with adhesive tape Position the insert with the insulating pad in outer tube Mount and tighten screws Guideline Screws on the main silencer M5 7 Nm 5...

Page 58: ...ve the right side cover p 52 Remove the main silencer p 52 H00185 10 Main work Remove screw cap Remove screw Info Raise the wheel slightly to be able to remove the screws more easily H00223 10 Press angle lever toward the rear Press linkage lever downward H00224 10 Lift the swingarm M00389 10 Remove screws on both sides Loosen screws on both sides ...

Page 59: ...10 FE EU Remove the fuel tank p 59 Disconnect plug in connector of the lambda sensor and remove the cable binder H00239 11 Remove springs Spring hook 50305017000 H00243 10 Remove screw and take off the manifold 12 33 Installing the manifold H00244 10 Main work Position the manifold and mount springs Spring hook 50305017000 ...

Page 60: ...ew top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 Position the rear frame M00389 11 Mount and tighten screws on both sides Guideline Screw subframe M8 35 Nm 25 8 lbf ft Loctite 2701 Remove screws on both sides Mount and tighten screws on both sides Guideline Screw subframe M8 35 Nm 25 8 lbf ft Loctite 2701 H00224 11 Lower the swingarm H00185 11 Position the angle lever and linkage lever Mou...

Page 61: ...ing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that has been contaminated with fuel Store fuel properly in a suitable canister and keep away from children Preparatory work Remove the sea...

Page 62: ...s on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing...

Page 63: ...plug in connection for the fuel line Info Route the cable and fuel line at a safe distance from the exhaust system Finishing work Mount the seat p 50 12 36 Checking for chain dirt accumulation 400678 01 Check the chain for coarse dirt accumulation If the chain is very dirty Clean the chain p 61 12 37 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip Remov...

Page 64: ...the motorcycle with a lift stand p 42 H00191 10 Main work Pull the chain at the end of the chain sliding component upwards to measure chain tension Info The lower chain section must be taut Chain wear is not always even so you should repeat this measurement at different chain positions Chain tension 55 58 mm 2 17 2 28 in If the chain tension does not meet specifications Adjust the chain tension p ...

Page 65: ... 42 12 40 Checking the chain rear sprocket engine sprocket and chain guide Preparatory work Raise the motorcycle with a lift stand p 42 400227 01 Main work Shift gear to neutral Check the rear sprocket and engine sprocket for wear If the rear sprocket or engine sprocket is worn Change the drivetrain kit Info The engine sprocket rear sprocket and chain should always be replaced together 400987 10 P...

Page 66: ... line with or below the chain sliding piece Change the chain sliding piece Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten the chain sliding piece Guideline Screw chain sliding piece M8 15 Nm 11 1 lbf ft 400985 01 Check the chain guide for wear Info Wear is visible on the front of the chain guide If the light part of the chain guide is worn Change th...

Page 67: ...the swingarm shows signs of damage cracking or deformation Change the swingarm Info Always change a damaged swingarm Repair of the swingarm is not authorized by Husqvarna Motorcycles 12 43 Checking the routing of the throttle cable Preparatory work Remove the seat p 49 Remove the fuel tank p 59 H00252 01 Main work Check the routing of the throttle cable Both throttle cables must be routed to the t...

Page 68: ...sting screw clockwise to increase the distance between the clutch lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 12 47 Checking rectifying the fluid level of the hydraulic ...

Page 69: ...eeder screw and mount bleeding syringe H00229 10 Inject the liquid into the system until it escapes from openings of the master cylinder without bubbles To prevent overflow drain fluid occasionally from the master cylinder reservoir Remove the bleeding syringe Mount and tighten the bleeder screw Correct the fluid level of the hydraulic clutch Guideline Fluid level below top edge of con tainer 4 mm...

Page 70: ...ravel of the hand brake lever p 68 Adjust the free travel of the hand brake lever with adjusting screw Info Turn the adjusting screw clockwise to reduce free travel The pressure point moves away from the handlebar Turn the adjusting screw counterclockwise to increase free travel The pressure point moves towards the handlebar The range of adjustment is limited Turn the adjusting screw by hand only ...

Page 71: ...Check the brake system and do not continue riding Your authorized Husqvarna Motorcycles workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized Husqvarna Motor cycles workshop will be glad to help H00214 10 Move the brake fluid reservoir mounted o...

Page 72: ... front brake linings p 70 H00230 10 Main work Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane Add brake fluid to level Guideline Level brake fluid level below con tainer rim 5 mm 0 2 in Brake fluid DOT 4 p 113 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilt brake fluid imme...

Page 73: ...e and friction coefficient of the brake linings and thus their brake power may vary greatly from that of original Husqvarna Motorcycles bake linings If brake linings that differ from the original equipment are used it cannot be guaranteed that these are in keeping with the original homologation In this case the vehicle will not correspond to its condition at delivery and the warranty shall be void...

Page 74: ...ane Mount and tighten screws Info Clean up overflowed or spilt brake fluid immediately with water 13 9 Checking the free travel of foot brake lever Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to overheating Adjust the free travel on foot brake lever according to specific...

Page 75: ...d screw and tighten nut Guideline Nut foot brake lever stop M8 20 Nm 14 8 lbf ft Hold push rod and tighten nut Guideline Remaining nuts chassis M6 10 Nm 7 4 lbf ft Reconnect spring 13 11 Checking the rear brake fluid level Warning Danger of accidents Brake system failure If the brake fluid level drops below the specified marking or the specified value this is an indication that the brake sys tem i...

Page 76: ...ing efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized Husqvarna Motor cycles workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5...

Page 77: ...ake according to the service schedule Your authorized Husqvarna Motor cycles workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accident Reduced braking efficiency due to the use of non approved brake linings...

Page 78: ...caliper support M00414 10 Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated properly The arrow on the leaf spring points in the rotation direction of the brake disc M00413 10 Insert the new brake linings insert pin and mount cotter pins Info Always change the brake linings in pairs Make sure that decoupling plate is mounted on the piston side of ...

Page 79: ...d remove the wheel spindle Take the front wheel out of the fork Info Do not pull the hand brake lever when the front wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged H00934 10 Remove spacers 14 2 Installing the front wheel Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oi...

Page 80: ... work Raise the motorcycle with a lift stand p 42 H00204 10 Main work Press the brake caliper by hand on to the brake disc in order to press back the brake piston Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove nut Remove chain adjuster Withdraw wheel spindle only enough to allow the rear wheel to be pushed forward Push the rear w...

Page 81: ...re fitted correctly on adjusting screws Check the chain tension p 62 Tighten nut Guideline Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm 1 26 in enables different secondary ratios with the same chain length Chain adjusters can be turned by 180 Operate the foot brake lever repeatedly until the brake linings are in contact with the brake d...

Page 82: ...ge the tires 14 6 Checking the tire air pressure Info Low tire air pressure leads to abnormal wear and overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life 400695 01 Remove the protection cap Check the tire air pressure when the tires are cold Tire air pressure off road Front 1 0 bar 15 psi Rear 1 0 bar 15 psi Road tire pressure FE EU AU Fr...

Page 83: ...und frequencies in spokes with the same length and thickness this indicates different spoke tensions You should hear a high note If the spoke tension varies Correct the spoke tension Check the spoke torque Guideline Spoke nipple front wheel M4 5 6 Nm 4 4 lbf ft Spoke nipple rear wheel M4 5 6 Nm 4 4 lbf ft Torque wrench with various accessories in set 58429094000 ...

Page 84: ...erminal cover and disconnect the negative cable from the battery Pull back the positive terminal cover and disconnect the positive cable from the battery Detach rubber band at the bottom Lift the battery up and out 15 2 Installing the battery H00233 10 Main work Insert battery into the battery compartment with the terminals facing to the front Battery YTX5L BS p 110 Reconnect rubber band Info Cont...

Page 85: ...tens the battery s service life If the charging current charging voltage and charging time are exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted from starting the vehicle repeatedly the battery must be charged immediately If the battery is left in a discharged state for an extended period it will become over discharged and sulfate d...

Page 86: ...protection caps Remove the faulty main fuse Info A defective fuse can be identified by the burned out fuse wire A reserve fuse is located in the starter relay Install a new main fuse Fuse 58011109120 p 110 Check that the electrical equipment is functioning properly Tip Insert the spare fuse so that it is available if needed Mount the protection caps Finishing work Install the air filter box lid p ...

Page 87: ...with the correct rating only Fuse 75011088010 p 110 Tip Replace the spare fuse in the fuse box so that it is available if needed Check that the power consumer is functioning properly Close the fuse box cover Finishing work Mount the seat p 50 15 6 Removing the headlight mask with the headlight Preparatory work Switch off all power consumers and switch off the engine S00513 10 Main work FE EU AU De...

Page 88: ...Main work FE EU AU Connect plug in connectors H00221 10 Position the headlight mask and secure it with rubber bands The holding lugs engage in the fender H00208 10 Position brake line and wiring harness in the brake line guide S00893 11 FE US Connect plug in connector S00509 11 Position the headlight mask and secure it with rubber bands The holding lugs engage in the fender ...

Page 89: ...n cap together with the underlying bulb socket counter clockwise all the way and remove it Pull bulb socket of the parking light out of the reflector M00433 10 FE US Turn protection cap together with the underlying bulb socket counter clockwise all the way and remove it Pull bulb socket of the parking light out of the reflector B01563 10 Pull out headlight bulb Insert the new headlight bulb Headli...

Page 90: ...rn signal R10W socket BA15s p 110 Mount the orange cap Position the diffuser Insert the screw and turn it counterclockwise first until it engages in the thread with a light jerk Tighten the screw slightly Finishing work Check that the turn signal system is functioning properly 15 10 Checking the headlight setting 400726 10 Position the vehicle upright on a horizontal surface in front of a light wa...

Page 91: ...tch off the engine Remove the headlight mask with the headlight p 85 S00505 10 Main work Remove screws Pull the speedometer upward out of the holder B01644 10 Using a coin turn protection cap all the way counterclockwise and remove it Remove speedometer battery Insert the new battery with the label facing outward Speedometer battery CR 2032 p 110 Check the O ring of the protection cap for correct ...

Page 92: ...d cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed co...

Page 93: ...s 10 mm 0 39 in If the coolant level does not match the specified value Correct the coolant level Coolant p 113 Mount the radiator cap 16 4 Draining the coolant Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling sys...

Page 94: ... contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children B01780 10 Main work Make sure that the screw is tightened Stand the vehicle upright Pour coolant in up to measurement above the radiator fins Guideline 10 mm 0 39 in Coolant 1 2 l 1 3 qt Coolant p 113 Refit ...

Page 95: ...n idle Move the handlebar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust the play in the throttle cable p 93 17 2 Adjusting the play in the throttle cable Preparatory work Remove the seat p 49 Remove the fuel tank p 59 Check the routing of the throttle cable p 65 C00588 10 Main work Move the handlebar to the straight ahead position Push ba...

Page 96: ...usting screw Guideline Idle speed 2 050 2 150 rpm Info Turn counterclockwise to increase the idle speed Turn clockwise to decrease the idle speed 17 4 Checking the basic position of the shift lever Info When driving the shift lever must not touch the driver s boot when in the basic position When the shift lever keeps touching the boot the transmission will be subject to an excessive load 400692 10...

Page 97: ...on the shift shaft in the required position and engage the gearing Info The range of adjustment is limited The shift lever must not come into contact with any other vehicle compo nents during the shift procedure Locate and tighten screw with washers Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 ...

Page 98: ...l line thoroughly with compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Disconnect the plug in connection of the fuel line Pull fuel screen out of the connecting piece Insert the new fuel screen all the way into the connecting piece Lubricate the O ring and connect plug in connection of the fuel line Danger Danger of po...

Page 99: ...m Preparatory work Park the motorcycle on a level surface Remove the engine guard p 67 B01769 10 Main work Place a suitable container under the engine Remove oil drain plug with the magnet and seal ring Info Do not remove screws on both sides B01770 10 Remove screw plug with oil screen and the O rings Completely drain the engine oil Thoroughly clean the parts and sealing surfaces B01771 10 Positio...

Page 100: ...cle upright M00445 10 Remove filler plug and O ring from the clutch cover and fill up with engine oil Engine oil 1 0 l 1 1 qt Engine oil SAE 10W 50 p 113 Info Too little engine oil or poor quality engine oil results in premature wear to the engine Install and tighten the oil filler plug with O ring Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness a...

Page 101: ...ne oil If appropriate change the engine oil Install and tighten the oil filler plug with O ring Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engin...

Page 102: ...pray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to a dry vehicle always rinse the vehicle with water first After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the closure of the exhaust system Warning Danger of acc...

Page 103: ...torcycle p 100 Clean the brake system Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings in the cooled down and installed state with cold water and dry carefully After riding on salted roads thoroughly wash the vehicle with cold water and dry it well Treat the engine swingarm and all other bright and zinc plated parts except for the brake discs with a wax ba...

Page 104: ...e last time before taking the motorcycle out of service add fuel additive Refuel p 32 Clean the motorcycle p 100 Change the engine oil and oil filter clean the oil screen p 97 Check the antifreeze and coolant level p 90 Check the tire air pressure p 80 Remove the battery p 82 Charge the battery p 83 Guideline Storage temperature of battery with out direct sunshine 0 35 C 32 95 F Store the vehicle ...

Page 105: ... system Read out the fault memory using the Husq varna Motorcycles diagnostics tool Engine does not speed up Defect in fuel injection system Read out the fault memory using the Husq varna Motorcycles diagnostics tool Ignition system defective Ignition coil check the secondary winding Check the spark plug connector Check the stator winding of the alternator Engine has too little power Air filter he...

Page 106: ... hose bent Route the vent hose without bends or replace it if necessary Engine oil level too high Check the engine oil level p 96 Engine oil too thin low viscosity Change the engine oil and oil filter clean the oil screen p 97 Piston and cylinder worn Measure the piston cylinder mounting clear ance Battery discharged Battery is not being charged by alter nator Check the charging voltage Check the ...

Page 107: ...de FI warning lamp MIL 13 FI warning lamp MIL flashes 1x long 3x short Error level condition Intake air temperature sensor input signal too low Intake air temperature sensor input signal too high Blink code FI warning lamp MIL 15 FI warning lamp MIL flashes 1x long 5x short Error level condition Rollover sensor A D type input signal too low Rollover sensor A D type input signal too high Blink code...

Page 108: ...arning lamp MIL 45 FI warning lamp MIL flashes 4x long 5x short Error level condition FE EU Lambda sensor heater cylinder 1 sensor 1 short circuit to ground or open circuit Lambda sensor heater cylinder 1 sensor 1 input signal too high ...

Page 109: ...gear 16 24 4th gear 23 28 5th gear 23 23 6th gear 26 20 Alternator 12 V 168 W Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment Spark plug NGK LMAR9AI 10 Spark plug electrode gap 1 0 mm 0 039 in Cooling Water cooling permanent circulation of coolant by water pump Starting aid Electric starter 23 2 Engine tightening torques Nozzle crank chamber ventilation ...

Page 110: ...ing bridge M7x1 14 Nm 10 3 lbf ft Lubricated with engine oil Screw plug crankshaft location M8 10 Nm 7 4 lbf ft Screw timing chain tensioning rail M8 15 Nm 11 1 lbf ft Loctite 243 Screw engine sprocket M10 60 Nm 44 3 lbf ft Loctite 2701 Plug oil channel M10x1 15 Nm 11 1 lbf ft Loctite 243 Rotor screw M10x1 70 Nm 51 6 lbf ft Thread oiled with engine oil cone degreased Screw plug cam lever axis M10x...

Page 111: ...formance Systems 5018 DCC Brake system Disc brakes brake calipers on floating bearings Brake discs diameter Front 260 mm 10 24 in Rear 220 mm 8 66 in Brake discs wear limit Front 2 5 mm 0 098 in Rear 3 5 mm 0 138 in Tire air pressure off road Front 1 0 bar 15 psi Rear 1 0 bar 15 psi Road tire pressure FE EU AU Front 1 5 bar 22 psi Rear 1 5 bar 22 psi Final drive FE EU AU 14 52 13 52 Final drive FE...

Page 112: ...in ENDURO COMPETITION IIIe FE US 90 90 21 54M TT Dunlop GEOMAX AT 81 F 110 100 18 64M TT Dunlop GEOMAX AT 81 Additional information is available in the Service section under www husqvarna motorcycles com 23 7 Fork Fork part number 24 18 7P 67 Fork WP Performance Systems Up Side Down 4860 MXMA 4CS Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Rebound damping Comfort 14 cl...

Page 113: ... 2 lbf ft Spoke nipple front wheel M4 5 6 Nm 4 4 lbf ft Spoke nipple rear wheel M4 5 6 Nm 4 4 lbf ft Remaining nuts chassis M5 5 Nm 3 7 lbf ft Remaining screws chassis M5 5 Nm 3 7 lbf ft Screw battery terminal M5 2 5 Nm 1 84 lbf ft Screw intake air temperature sensor M5 2 Nm 1 5 lbf ft Screw shock absorber adjusting ring M5 5 Nm 3 7 lbf ft Screw spoiler on fuel tank FE US M5x12 1 5 Nm 1 11 lbf ft ...

Page 114: ...op triple clamp M8 17 Nm 12 5 lbf ft Engine attachment bolt M10 60 Nm 44 3 lbf ft Remaining nuts chassis M10 45 Nm 33 2 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Screw bottom shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 Screw handlebar holder M10 40 Nm 29 5 lbf ft Loctite 243 Screw top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 Nut fuel pump fixation M12 15 Nm 11 1 lbf ft N...

Page 115: ...rds see specifications on the container and that possess the corre sponding properties Synthetic engine oil Recommended supplier Bel Ray Works Thumper Racing Synthetic Ester 4T Fork oil SAE 4 48601166S1 Standard classification SAE p 115 SAE 4 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding properties Shock abso...

Page 116: ...ended supplier SKF LGHB 2 Long life grease Recommended supplier Bel Ray Waterproof Grease Offroad chain spray Guideline Recommended supplier Bel Ray Blue Tac Chain Lube Oil for foam air filter Recommended supplier Bel Ray Foam Filter Oil Preserving materials for paints metal and rubber Recommended supplier Bel Ray Silicone Detailer Protectant Spray Universal oil spray Recommended supplier Bel Ray ...

Page 117: ...rvice intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils ...

Page 118: ...27 INDEX OF SPECIAL TERMS 116 OBD On board diagnosis Vehicle system that monitors emission and safety related val ues ...

Page 119: ...28 LIST OF ABBREVIATIONS 117 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 120: ...ls FI Warning lamp MIL lights up flashes orange The OBD has detected an emission or safety critical fault The low fuel warning lamp lights up orange The fuel level has reached the reserve mark 29 2 Green and blue symbols Green and blue symbols reflect information The high beam indicator light lights up blue The high beam is switched on Turn signal indicator light flashes green The turn signal is s...

Page 121: ... Chain tension adjusting 62 checking 62 Chassis number 12 Clutch fluid level checking rectifying 66 fluid changing 67 Clutch lever 14 basic position adjusting 66 Combination instrument overview 21 Compression damping fork adjusting 39 Compression damping low speed shock absorber adjusting 35 Coolant draining 91 refilling 92 Coolant level checking 90 91 Cooling system 90 Customer service 9 D Diffic...

Page 122: ...dle speed adjusting 94 Idle speed adjusting screw 18 Implied warranty 9 Intended use 6 K Key number 12 Kill switch 14 L Light switch 15 Lower triple clamp installing 45 removing 44 M Main fuse changing 84 Main silencer glass fiber yarn filling changing 54 installing 53 removing 52 spark arrestor cleaning 53 Manifold installing 57 removing 56 Motorcycle cleaning 100 lift stand raising with 42 remov...

Page 123: ...nlocking 20 Steering head bearing lubricating 48 Steering head bearing play adjusting 47 checking 47 Storage 102 Swingarm checking 65 T Technical data capacities 109 chassis 109 chassis tightening torques 111 electrical system 110 engine 107 engine tightening torques 107 fork 110 shock absorber 111 tires 110 Throttle cable play adjusting 93 Throttle cable routing checking 65 Throttle grip 14 Tire ...

Page 124: ... 3402063en 3402063en 07 2015 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria www husqvarna motorcycles com Photo Mitterbauer Husqvarna Motorcycles GmbH ...

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