Husqvarna 701 Enduro 2017 Owner'S Manual Download Page 101 | Manualshive

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12 SERVICE WORK ON THE CHASSIS

99

12.23

Adjusting basic position of clutch lever

Info

Turn the adjusting 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!

S01043-10

–

Adjust the basic setting of the clutch lever to your hand size by turning adjusting
screw



.

–

When adjusting the clutch lever, make sure to leave a minimum clearance to other

parts of the vehicle.
Guideline

Minimum clearance

5 mm (0.2 in)

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Summary of Contents for 701 Enduro 2017

Page 1: ...OWNER S MANUAL 2017 701 Enduro Art no 3402114en ...

Page 2: ......

Page 3: ...ver minor differences due to developments in design cannot be ruled out completely All specifications are non binding Husqvarna Motorcycles GmbH specifically reserves the right to modify or delete technical specifica tions prices colors 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...

Page 4: ...ight owner ISO 9001 12 100 6061 Husqvarna Motorcycles applies quality assurance processes that lead to the highest possible product quality as defined in the ISO 9001 international quality management standard Issued by TÜV Management Service Husqvarna Motorcycles GmbH 5230 Mattighofen Austria This document is valid for the following models 701 Enduro EU F2603Q1 ...

Page 5: ...4 2 View of vehicle rear right example 18 5 SERIAL NUMBERS 20 5 1 Chassis number 20 5 2 Type label 20 5 3 Key number 21 5 4 Engine number 21 5 5 Fork part number 22 5 6 Shock absorber article number 22 6 CONTROLS 23 6 1 Clutch lever 23 6 2 Hand brake lever 23 6 3 Throttle grip 24 6 4 Horn button 24 6 5 Light switch 25 6 6 Turn signal switch 25 6 7 Emergency OFF switch 26 6 8 Electric starter butto...

Page 6: ... 66 11 5 Adjusting the low speed compression damping of the shock absorber 66 11 6 Adjusting the high speed compression damping of the shock absorber 67 11 7 Adjusting the rebound damping of the shock absorber 68 11 8 Measuring the unloaded rear wheel sag 69 11 9 Checking the static sag of the shock absorber 70 11 10 Checking the riding sag of the shock absorber 71 11 11 Adjusting the spring prelo...

Page 7: ... foot brake lever 113 13 9 Adjusting the basic position of the foot brake lever 114 13 10 Checking the rear brake fluid level 115 13 11 Adding rear brake fluid 116 13 12 Checking the rear brake linings 118 13 13 Changing the rear brake linings 119 14 WHEELS TIRES 123 14 1 Removing the front wheel 123 14 2 Installing the front wheel 124 14 3 Removing the rear wheel 126 14 4 Installing the rear whee...

Page 8: ...CLEANING CARE 176 19 1 Cleaning the motorcycle 176 19 2 Checks and maintenance steps for winter operation 178 20 STORAGE 180 20 1 Storage 180 20 2 Preparing for use after storage 181 21 TROUBLESHOOTING 182 22 TECHNICAL DATA 185 22 1 Engine 185 22 2 Engine tightening torques 186 22 3 Capacities 190 22 3 1 Engine oil 190 22 3 2 Coolant 190 22 3 3 Fuel 190 22 4 Chassis 191 22 5 Electrical system 192 ...

Page 9: ...symbol requires specialist knowledge and technical understanding In the interests of your own safety have these jobs performed by an authorized Husqvarna Motorcycles workshop 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 ...

Page 10: ...s document are explained below Proprietary name Indicates a proprietary name Name Indicates a protected name Brand Indicates a brand available on the open market Underlined terms Refer to technical details of the vehicle or indicate technical terms which are explained in the glossary ...

Page 11: ...y use of the vehicle beyond the intended and defined use constitutes misuse Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the respective use 2 3 Safety advice A number of safety instructions need to be followed to operate the vehicle safely Therefore read this manual carefully The safety instructions are highlighted in the text and ...

Page 12: ...en Warning Indicates a danger that will lead to environmental damage if the appropriate measures are not taken 2 5 Tampering warning Tampering with the noise control system is prohibited Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design ...

Page 13: ...e toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Warning Danger of burns Some vehicle components become very hot when the vehicle is operated Do not touch any parts such as the exhaust system radiator engine sh...

Page 14: ...ck washers must be replaced by new parts In some instances a thread locker e g Loctite is required The manufacturer instructions for use must be followed After disassembly clean the parts that are to be reused and check them for damage and wear Change damaged or worn parts After you complete the repair or service work check the operating safety of the vehicle 2 9 Environment If you use your motorc...

Page 15: ...l 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 Husqvarna Motorcycles dealer The Owner s Manual is an important component of th...

Page 16: ... a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system Use operating and auxiliary substances such as fuel and lubricants as specified in the Owner s Manual 3 3 Spare parts accessories For your own safety only use spare parts and accessory products that are approved and or recommended by Husqvarna Motorcycles and have them installed by an authorized H...

Page 17: ...rvice It is imperative that you adhere to the stipulated run in times and service intervals If you observe these exactly you will ensure a much longer service life for your motorcycle 3 5 Figures The figures contained in the manual may depict special equipment In the interest of clarity some components may be shown disassembled or may not be shown at all It is not always necessary to disas semble ...

Page 18: ...4 VIEW OF VEHICLE 16 4 1 View of vehicle front left example V00523 10 ...

Page 19: ...EW OF VEHICLE 17 1 Clutch lever p 23 2 Seat 3 Filler cap 4 Grab handles p 30 5 Passenger footrest p 31 6 Side stand p 33 7 Seat unlocking p 30 8 Shift lever p 31 9 Engine number p 21 10 Front brake caliper ...

Page 20: ...4 VIEW OF VEHICLE 18 4 2 View of vehicle rear right example V00522 10 ...

Page 21: ...27 2 Light switch p 25 2 Turn signal switch p 25 2 Horn button p 24 3 Emergency OFF switch p 26 3 Electric starter button p 26 4 Throttle grip p 24 5 Hand brake lever p 23 6 Chassis number p 20 7 Foot brake lever p 32 8 Footrest 9 Rear brake caliper ...

Page 22: ...5 SERIAL NUMBERS 20 5 1 Chassis number 401945 10 The chassis number is stamped on the steering head on the right 5 2 Type label H01049 10 The type label is located on the right side of the frame ...

Page 23: ...The key number can be found on the KEYCODECARD Info You need the key number to order a spare key Keep the KEYCODECARD in a safe place 5 4 Engine number 401949 10 The engine number is stamped on the left side of the engine under the engine sprocket ...

Page 24: ...2 5 5 Fork part number 401947 10 The fork part number is stamped on the inner side of the fork stub 5 6 Shock absorber article number 402025 10 The shock absorber article number is on the left side of the shock absorber ...

Page 25: ...r is fitted on the handlebar on the left The clutch is activated hydraulically and adjusts itself automatically 6 2 Hand brake lever E00058 10 The hand break lever is fitted on the right side of the handlebar The hand brake lever operates the front brake ...

Page 26: ...hrottle grip is fitted on the right side of the handlebar 6 4 Horn button E00060 10 The horn button is fitted on the left side of the handlebar Possible states Horn button in neutral position Horn button pressed The horn is operated in this position ...

Page 27: ... tail light are switched on 6 6 Turn signal switch E00062 10 The turn signal switch is fitted on the left side of the handlebar Possible states Turn signal off Left turn signal on Turn signal switch pressed to the left The turn signal switch returns to the center position after activation Right turn signal on Turn signal switch pressed to the right The turn signal switch returns to the center posi...

Page 28: ...pted a running engine stops and the engine cannot be started Emergency OFF switch on This position is necessary for operation as the ignition circuit is closed 6 8 Electric starter button E00072 11 The electric starter button is fitted on the right side of the handlebar Possible states Electric starter button in basic position Electric starter button pressed In this position the electric starter i...

Page 29: ... steering locked The ignition key can be removed 6 10 Indicator lamps overview ABS H01070 01 Possible states ABS warning lamp lights up flashes yellow ABS is not active The ABS lamp also lights up if an error is detected The high beam indicator lamp lights up blue The high beam is switched on The low fuel warning lamp lights up orange The fuel level has reached the reserve mark Malfunction indicat...

Page 30: ... no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty ...

Page 31: ...soil or the sewage system V00525 10 Lift cover of filler cap and insert the ignition key Turn the ignition key 90 counterclockwise and remove the filler cap Info The filler cap has a fuel tank breather 6 12 Closing filler cap H00393 01 Put the filler cap back on and turn the ignition key 90 clockwise Remove the ignition key and fold down the cover ...

Page 32: ...eat unlocking V00492 10 The loop unlocks the seat 6 14 Grab handles S00997 10 The grab handles are used for moving the motorcycle around If you carry a passenger the passenger can hold onto the grab handles during the trip ...

Page 33: ...ssenger footrests are foldable Possible states Passenger footrest folded in For operation without a passenger Passenger footrest folded out For operation with a passenger 6 16 Shift lever 401950 10 The shift lever is mounted on the left side of the engine ...

Page 34: ...ns can be seen in the photograph The neutral or idle position is between the first and second gears 6 17 Foot brake lever 401956 10 Foot brake lever is located in front of the right footrest The rear brake is engaged with the foot brake lever ...

Page 35: ...and must be folded up during motorcycle use The side stand is coupled with the safety starting system see the riding instruc tions Possible states Side stand folded out The vehicle can be supported on the side stand The safety starting system is active Side stand folded in This position is mandatory when riding the motorcycle The safety starting system is inactive ...

Page 36: ... 10 1 Indicator lamps overview p 27 2 Left button 3 Display 4 Right button 7 2 Activation H01069 10 Activating the speedometer The speedometer is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor ...

Page 37: ...battery voltage of the speedometer is too low Change the battery 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 38: ...conds The speedometer changes to the next menu item The symbol flashes Resetting the time Press the left button The value decreases Advancing the time Press the right button The value increases 401913 01 Wait for 5 seconds The speedometer changes to the next menu item The symbol flashes Set the service Guideline Service display deactivated Shortening the service interval Press the left button The ...

Page 39: ...value increases 401914 01 Switching off the service interval display Press and hold the left button off appears on the display 7 5 Setting kilometers or miles Info If the unit is changed the value ODO is retained and converted accordingly Condition The motorcycle is stationary ...

Page 40: ... to select UNIT for the speed in kilometers KM H or miles M H 7 6 Setting the clock Condition The motorcycle is stationary 401911 01 Press both buttons for 3 5 seconds The Setup menu is displayed The UNIT display flashes Wait for the menu of the clock to flash Press one of the buttons to select the 24h display or 12h display for the clock ...

Page 41: ...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 Service display switched off Shortening the service interval Press the left button The value decreases Extending the service interval Press the r...

Page 42: ...the speed shows the time DST shows the distance since the last reset such as between two refueling stops Info If the value of 39999 9 is exceeded DST is automatically reset to 0 0 Press the left button briefly Next display mode Press the left button for 3 5 seconds DST can be preset to a value between 0 0 and 39999 9 by pressing the buttons Press the right but ton briefly Next display mode Press t...

Page 43: ...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 button briefly Next display mode Press the left button for 3 5 seconds DST2 can be preset to a value between 0 0 and 39999 9 by pressing the buttons Press the right but ton briefly Next display mode Press the right but ton for 3 5 sec onds DST2 is reset to 0...

Page 44: ...verage speed since the last reset ART shows the operating hours ODO shows the total distance covered Press the left button briefly Next display mode Press the left button for 3 5 seconds The OPEN END WRENCH SYMBOL shows the remaining oper ating hours until the next service is due Press the right but ton briefly Next display mode Press the right but ton for 3 5 sec onds AVG is reset to 0 0 ...

Page 45: ...crashing Different tire tread patterns on the front and rear wheel impair the handling characteristic Different tire tread patterns can make the vehicle significantly more difficult to control Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel Warning Danger of accidents Non approved or non recommended tires and wheels impact the handling characteris...

Page 46: ...le handover Before your first trip read the entire Owner s Manual carefully Get to know the controls adjust the basic position of clutch lever p 99 Adjust the basic position of the hand brake lever p 105 Adjust the basic position of the foot brake lever p 114 Get used to handling the motorcycle on a suitable piece of land before making a longer trip Try also to ride as slowly as possible and in a ...

Page 47: ...elmet baggage Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and or tank rucksack Mount and secure suitcase and tank rucksack according to the manufacturer s instructions Warning Danger of accidents Unstable handling characteristics at high speed Adapt your speed according to your payload Ride more slowly if your motorcycle is loaded with cases ...

Page 48: ... handling characteristics due to slipped baggage Check the way your baggage is fixed regularly Warning Danger of burns A hot exhaust system can burn baggage Fasten your baggage in such a way that it cannot be burned or singed by the hot exhaust system If you carry luggage make sure you secure it firmly as close as possible to the center of the vehicle and ensure even weight distri bution between t...

Page 49: ...ke fluid level p 115 Check the front brake linings p 109 Check the rear brake linings p 118 Check the brake system function Check the coolant level p 159 Check the chain for dirt p 88 Check the chain tension p 89 Check the tire condition p 130 Check the tire air pressure p 132 Check the settings of all controls and ensure that they can be operated smoothly Check that the electrical equipment is fu...

Page 50: ...maged Never operate the vehicle with a discharged battery or without a battery Note Engine damage High revving speed with a cold engine negatively impacts the lifespan of the engine Always run the engine warm at a low speed B00782 10 Turn the emergency OFF switch to the position Switch on the ignition by turning the ignition key to the ON position After you switch on the ignition you can hear the ...

Page 51: ... folded out and you shift into gear and release the clutch the engine stops Take the weight off the side stand and swing it back up with your foot as far as it will go Switching off ABS Husqvarna Motorcycles recommends riding with ABS at all times However situations may arise in which ABS is not advantageous ABS M01403 10 Condition The motorcycle is stationary Vehicle speed before stopping 5 km h ...

Page 52: ...g Danger of accidents Malfunctions caused by incorrect ignition key position Do not change the ignition key position during a journey Warning Danger of accidents Distraction from traffic activity by adjustments to the vehicle Make all adjustments when the vehicle is at a standstill Warning Risk of injury Falling off of the passenger The passenger must be seated properly on the passenger seat and h...

Page 53: ...il the tires have been run in Warning Danger of accidents Unstable handling characteristics Do not exceed the maximum permitted weight and axle loads The overall weight consists of motorcycle operational and with a full tank driver and passenger with protective clothing and helmet baggage Warning Danger of accidents Unstable handling characteristics due to slipped baggage Check the way your baggag...

Page 54: ...le while simultaneously pulling the clutch lever shift into the next gear release the clutch lever and open the throttle Info You can see the positions of the 6 forward gears in the figure The neutral or idle position is between the first and second gears First gear is used for starting off or for steep inclines After reaching maximum speed by fully opening the throttle grip turn the throttle back...

Page 55: ...ger 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 Warning 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 b...

Page 56: ...tched on to be effective Warning Danger of accidents The rear wheel can lock due to the engine braking effect Pull in the clutch if you perform emergency or full braking or if you brake on a slippery ground When braking release the throttle and apply the front and rear brakes at the same time Info When the ABS is enabled you can achieve maximum braking power even on low grip surfaces such as sandy...

Page 57: ...cle is operated Do not touch any parts such as the exhaust system radiator engine shock absorber or brake system before the vehicle parts have cooled down Let the vehicle parts cool down before you perform any work on the vehicle Note Material damage The vehicle may be damaged by incorrect procedure when parking Significant damage may be caused if the vehicle rolls away or falls over The component...

Page 58: ...on a firm surface Swing the side stand forward with your foot as far as it will go and lean the vehicle on it Lock the steering by turning the handlebar fully to the left pressing down the ignition key to the position and turning it to the posi tion To make the steering lock engage more easily move the handlebar a little to the left and right Remove the ignition key 9 7 Transport Note Danger of da...

Page 59: ...ling 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 Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling ...

Page 60: ...hange your clothing in case of fuel spills on them Note Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged 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 ...

Page 61: ...0 Switch off the engine Open the filler cap p 28 Fill the fuel tank with fuel up to level Guideline Level 20 mm 0 79 in Total fuel tank capacity approx 13 l 3 4 US gal Super unleaded ROZ 95 RON 95 PON 91 p 202 Close the filler cap p 29 ...

Page 62: ...stics tool Check that the electrical system is functioning properly Change the engine oil and oil filter and clean the oil screens p 169 Check the front brake linings p 109 Check the rear brake linings p 118 Check the brake discs p 105 Check the brake lines for damage and leakage Change the front brake fluid Change the rear brake fluid Change the hydraulic clutch fluid Check the rear brake fluid l...

Page 63: ...aring p 81 Check the tire condition p 130 Check the tire air pressure p 132 Check the spoke tension p 133 Check the rim run out Check the chain rear sprocket engine sprocket and chain guide p 93 Check the chain tension p 89 Change the fuel screen p 167 Change the spark plugs Check the valve clearance Check the antifreeze and coolant level p 157 Check the cables for damage and routing without sharp...

Page 64: ... Check that the radiator fan is functioning properly Final check Check the vehicle for roadworthiness and take a test ride Read out the fault memory after the test ride using the Husqvarna Motorcycles diagnostics tool Make the service entry in the Husqvarna Motorcycles Dealer net and in the Service and Warranty Book let One time interval Periodic interval ...

Page 65: ...hecking the swingarm bearing for play Check the wheel bearing for play Empty the drainage hoses Grease all moving parts e g side stand hand lever chain and check for smooth operation Check all hoses e g fuel coolant bleeder drainage etc and sleeves for cracking leaks and incorrect routing Check the screws and nuts for tightness Change the coolant One time interval Periodic interval ...

Page 66: ...ange the adjustments at random or by more than 40 since otherwise the riding characteristics could deteriorate particu larly at high speeds 11 2 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior V00506 10 Turn white adjusting screw clockwise as far as it will go Info Adjusting screw is located at the upper end of the left f...

Page 67: ...nfo The hydraulic rebound damping determines the fork suspension behavior V00506 11 Turn red adjusting screw clockwise as far as it will go Info Adjusting screw is located at the upper end of the right fork leg The rebound damping is located in right fork leg REB red adjusting screw The compression damping is located in left fork leg COMP white adjusting screw Turn counterclockwise by the number o...

Page 68: ... wheel suspension compresses quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses slowly These two ranges can be adjusted separately although the transition between high speed and low speed is gradual Thus changes in the high speed range affect the compression damping in the low speed range and vice versa 11 5 Adjusting th...

Page 69: ...he shock absorber type Guideline Compression damping low speed Standard 15 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 11 6 Adjusting the high speed compression damping of the shock absorber Caution Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly The shock absorber is filled with highly compressed...

Page 70: ... absorber type Guideline Compression damping high speed Standard 1 5 turns Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 11 7 Adjusting the rebound damping of the shock absorber Caution Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly The shock absorber is filled with highly compressed nitrogen Please follo...

Page 71: ... Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 11 8 Measuring the unloaded rear wheel sag Preparatory work Raise the motorcycle with a lift stand p 77 0 0 A A 400988 10 Main work Measure the distance as vertical as possible between the rear axle and a fixed point for example a mark on the rear fairing Note down the value as dimension Finishing work Remove the mot...

Page 72: ...ycle upright with the aid of an assistant Measure the distance between the rear axle and the fixed point again Note down the value as dimension Info The static 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 72 ...

Page 73: ...the seat in a normal sitting position feet on footrests and bounces up and down a few times The rear wheel suspension levels out Another person now measures the distance between the rear axle and the fixed point Note down the value as dimension Info The riding sag is the difference between measurements and Check the riding sag Riding sag 75 85 mm 2 95 3 35 in If the riding sag differs from the spe...

Page 74: ...ided 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 length of the spring Preparatory work Raise the motorcycle with the work stand Remove the seat p 83 Take off the side cover p 84 Remove the air filter box Remove the rear fairing Remove the rear left side cover Remove the rear righ...

Page 75: ...g by turning adjusting ring to the specified measurement Guideline Spring preload 22 mm 0 87 in Info Depending on the static sag and or the riding sag it may be necessary to increase or decrease the spring preload Tighten retaining ring Finishing work Install the shock absorber Install the rear right side cover Install the rear left side cover Fit the rear fairing Install the air filter box Mount ...

Page 76: ...the rear fairing Remove the rear left side cover Remove the rear right side cover Remove the shock absorber After removing the shock absorber clean it thoroughly B00292 10 Main work Choose and mount a suitable spring Guideline Spring rate Medium standard 69 N mm 394 lb in Info The spring rate is shown on the outside of the spring Finishing work Install the shock absorber Install the rear right sid...

Page 77: ...n the handlebar support are placed at a distance of from the center Hole distance 3 5 mm 0 138 in The handlebar can be mounted in 2 different positions In this way the handlebar can be mounted in the most comfortable position for the rider 11 14 Adjusting the handlebar position Warning Danger of accidents A repaired handlebar poses a safety risk If the handlebar is bent or straightened the materia...

Page 78: ... and push through nuts from below Place the handlebar support in the required position Mount and tighten screws Guideline Screw handlebar support M10 45 Nm 33 2 lbf ft Loctite 243 Position the handlebar Info Make sure the cables and wiring are positioned correctly Position the handlebar clamps Mount screws but do not tighten yet Screw the handlebar clamps so that both parts touch at the front and ...

Page 79: ...ehicle on a firm and level surface 401942 01 Use the underride guard underneath the engine to raise the vehicle Neither wheel is in contact with the ground Secure the motorcycle against falling over 12 2 Removing the motorcycle from the lift stand Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface ...

Page 80: ... stand Remove the lift stand 12 3 Bleeding the fork legs Preparatory work Raise the motorcycle with a lift stand p 77 402556 10 Main work Release bleeder screws Any excess pressure escapes from the interior of the fork Tighten the bleeder screws Finishing work Remove the motorcycle from the lift stand p 77 ...

Page 81: ...te behind the dust boots If this dirt is not removed the oil seals behind can start to leak 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 Clean and oil the dust boots and inner fork tubes of both fork legs Universal oil spray p 203 Press the dust boot...

Page 82: ... leg Take off the fork protector 12 6 Installing the fork protector E00071 10 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 the fork protector on the right fork leg Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm ...

Page 83: ... over time Preparatory work Raise the motorcycle with a lift stand p 77 400738 11 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 bearing If there is detectable play Adjust the steering head bearing play p 82 Move the handlebar to and fro over the entire steering range It must be...

Page 84: ...ve screw Loosen and retighten screw Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid stresses Tighten screws Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Mount and tighten screw Guideline Screw steering stem M8 20 Nm 14 8 lbf ft Finishing work Check the play of the steering head bearing p 81 ...

Page 85: ...eat back and lift it off 12 10 Mounting the seat V00497 10 Stretch the seat at the front ends slightly and position holding tabs on holders The holding tabs engage in the holder Press holding tabs into bushings Insert locking pin into the lock housing and push down the rear of the seat until the locking pin engages with an audible click Check finally that the seat is correctly mounted ...

Page 86: ... the side cover Repeat these steps on the opposite side 12 12 Mounting the side cover V00508 10 Main work Position the side cover and mount and tighten screws Guideline Screw trim M5x12 3 5 Nm 2 58 lbf ft Mount and tighten screws Guideline Screw trim M5x17 3 5 Nm 2 58 lbf ft Repeat these steps on the opposite side Finishing work Mount the seat p 83 ...

Page 87: ...eadlight p 148 S01037 10 Main work Remove screws Remove screws and take off the fender 12 14 Installing the front fender S01037 11 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 Install the headlight mask with the headlight p 150 ...

Page 88: ...e seat p 83 V00498 10 Main work Remove screws Remove the upper part of the air filter box V00499 10 Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine Dust and dirt will enter the engine without an air filter Never start to use the vehicle without an air filter Remove air filter ...

Page 89: ...sh against the air filter box along the entire sealing sur face If the air filter is not mounted correctly dust and dirt may enter the engine and result in damage Hook air filter box top into the front of the air filter box and swing down V00498 11 Mount and tighten screws Guideline Screw air filter box top M6 2 Nm 1 5 lbf ft Finishing work Mount the seat p 83 ...

Page 90: ...move the lubricant from the tires using a suitable cleaning agent 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 Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake flui...

Page 91: ...he motorcycle from the lift stand p 77 12 19 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents If the chain is tensioned too much the chain engine sprocket rear sprocket transmission and rear wheel bearings wear more quickly Some components may break if overloaded If the chain is too loose the chain may fall off the engine sp...

Page 92: ...tance from the chain sliding guard and determine chain tension Info Upper chain section must be taut Chain wear is not always even Repeat this measurement at different chain positions Chain tension 5 mm 0 2 in Distance to chain sliding guard 30 mm 1 18 in If the chain tension does not meet the specification Adjust the chain tension p 91 ...

Page 93: ...cket transmission and rear wheel bearings wear more quickly Some components may break if overloaded If the chain is too loose the chain may fall off the engine sprocket or the rear sprocket As a result the rear wheel locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the specification Preparatory work Check the chain tension p 89 Raise th...

Page 94: ...he left and right chain adjusters are in the same position relative to the reference marks The rear wheel is then correctly aligned Info The upper part of the chain must be taut Chain wear is not always even Repeat this measurement at different chain positions Tighten nuts Make sure that chain adjusters are fitted correctly on adjusting screws Tighten nut Guideline Nut rear wheel spindle M25x1 5 9...

Page 95: ...ory work Raise the motorcycle with a lift stand p 77 100132 10 Main work Shift the transmission to idle 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 ...

Page 96: ... lower chain section Info Chain wear is not always even so you should repeat this measurement at dif ferent chain positions Maximum distance at the longest chain section 272 mm 10 71 in If the distance is greater than the specified measurement Change the drivetrain kit Info When the chain is replaced the rear sprocket and engine sprocket should also be changed New chains wear out faster on an old ...

Page 97: ...e of the chain pins is in line with or below the chain sliding guard Replace the chain sliding guard Check that the chain sliding guard is firmly seated If the chain sliding guard is loose Tighten the screws on the chain sliding guard Guideline Screw chain sliding guard M6 8 Nm 5 9 lbf ft Loctite 243 ...

Page 98: ...the chain sliding piece Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten the screw on 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 can be seen on the front of the chain guide If the light part of the chain guide is worn Change the chain guide ...

Page 99: ...V00514 01 Check that the chain guide is firmly seated If the chain guide is loose Tighten the screws on the chain guide Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Remove the motorcycle from the lift stand p 77 ...

Page 100: ...guide Condition Number of teeth 44 teeth Insert nut in hole Position the chain guide Mount and tighten screws and Guideline Screw chain guide M6 8 Nm 5 9 lbf ft Condition Number of teeth 45 teeth Insert nut in hole Position the chain guide Mount and tighten screws and Guideline Screw chain guide M6 8 Nm 5 9 lbf ft ...

Page 101: ...ase 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 S01043 10 Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw When adjusting the clutch lever make sure to leave a minimum clearance to other parts of the vehicl...

Page 102: ...a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regula tions Info The fluid level rises with increasing wear of the clutch facing discs ...

Page 103: ...es not meet specifications Correct the fluid level of the hydraulic clutch Brake fluid DOT 4 p 200 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilled brake fluid immediately with water 12 25 Removing the engine guard S01036 10 Remove screws on the left and right Pull the engine guard forward out of the holders and remove it ...

Page 104: ... ON THE CHASSIS 102 12 26 Installing the engine guard S01036 11 Slide the engine guard into holders at the rear Position the engine guard Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft ...

Page 105: ...h have been approved and rec ommended by Husqvarna Motorcycles Only use tires wheels approved by Husqvarna Motorcycles with the corre sponding speed index Maintain the specified tire air pressure Service work and repairs must be performed properly Your authorized Husq varna Motorcycles workshop will be glad to help Warning Voiding of the government approval for road use and the insurance cover age...

Page 106: ...ng of the hand and foot brake levers ABS warning lamp must light up after the ignition is switched on and go out after starting off If it does not go out after starting off or if it lights up while riding this indicates a fault in the ABS system In this case the ABS is no longer enabled and the wheels may lock during braking The brake system itself stays functional only ABS control is not availabl...

Page 107: ...king the brake discs 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 Motorcycles workshop will be glad to help 400406 10 Check the thickness of the front and rear brake discs at multiple points on each brake disc to ensure it is at least thickness Info Wear will reduce the thickness of...

Page 108: ...ents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the brake system is leaking or the brake linings are worn down Check the brake system and do not continue riding until the problem is eliminated Your authorized Husqvarna Motorcycles workshop will be glad to help Warning Danger of accidents Ol...

Page 109: ...07 13 5 Adding front brake fluid Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the brake system is leaking or the brake linings are worn down Check the brake system and do not continue riding until the problem is eliminated Your authorized Husqvarna Motorcycles work...

Page 110: ...hing 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 Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc corr...

Page 111: ...ed brake fluid immediately with water 13 6 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 Motorcycles workshop will be glad to help Warning Danger of accidents Damaged brake discs reduce the braking effect If the brake linings are not changed in time ...

Page 112: ...airs are performed professionally Your authorized Husqvarna Motorcycles workshop will be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallo...

Page 113: ...he brake lin ings and thus their brake power may vary greatly from that of original brake linings If brake linings are used that differ from the original equipment compliance with the original homologation is not guaranteed In this case the vehicle no longer corresponds to its condition at delivery and the warranty shall be void Only use brake linings approved and recommended by Husqvarna motorcyc...

Page 114: ...n order to push back the brake pistons Ensure that brake fluid does not flow out of the brake fluid reservoir extract ing it by suction if it does Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons 400418 11 Remove cotter pin remove pin toward the right by striking it and remove the brake linings Clean the brake caliper and brake caliper s...

Page 115: ...pressure point V00502 12 Correct the brake fluid quantity to level Guideline Level 5 mm 0 2 in Brake fluid DOT 4 p 200 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilled brake fluid immediately with water 13 8 Checking the free travel of foot brake lever Warning Danger of accidents The brake system fails in the event of overheating If there is no ...

Page 116: ...on when there is increased resistance when you activate the foot brake lever If the free travel does not meet specifications Adjust the basic position of the foot brake lever p 114 13 9 Adjusting the basic position of the foot brake lever Warning Danger of accidents The brake system fails in the event of overheating If there is no free travel on the foot brake lever pressure builds up in the brake...

Page 117: ...cessary free travel Tighten fitting Guideline Screw connection foot brake cylinder M6 10 Nm 7 4 lbf ft Check the free travel of the foot brake lever p 113 Tighten nut 13 10 Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the MIN marking the brake system is leaking or the brake...

Page 118: ...e brake fluid level of the brake fluid reservoir If the fluid level reaches the MIN marking Add rear brake fluid p 116 13 11 Adding rear brake fluid Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the MIN marking the brake system is leaking or the brake linings are worn down Check the brake system and do not con...

Page 119: ...thing 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 Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc cor...

Page 120: ...arning Danger of accidents Worn out brake linings reduce the braking effect Ensure that worn out brake linings are replaced immediately Your authorized Husqvarna Motorcycles workshop will be glad to help Warning Danger of accidents Damaged brake discs reduce the braking effect If the brake linings are not changed in time the brake lining carriers grind against the brake disc As a consequence the b...

Page 121: ...irs are performed professionally Your authorized Husqvarna Motorcycles workshop will be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallow...

Page 122: ...he brake lin ings and thus their brake power may vary greatly from that of original brake linings If brake linings are used that differ from the original equipment compliance with the original homologation is not guaranteed In this case the vehicle no longer corresponds to its condition at delivery and the warranty shall be void Only use brake linings approved and recommended by Husqvarna motorcyc...

Page 123: ...ss the brake caliper against the spokes D00955 10 Remove cotter pin remove pin toward the left by striking it and remove the brake linings Clean the brake caliper and brake caliper support 400419 11 Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly Insert the new brake linings insert the pin and mount the cotter pins Info Always change ...

Page 124: ...13 BRAKE SYSTEM 122 Add brake fluid to the MAX marking Brake fluid DOT 4 p 200 Mount screw cap with membrane Info Clean up overflowed or spilled brake fluid immediately with water ...

Page 125: ... brake caliper onto the brake disc by hand in order 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 pistons S01058 10 Loosen screw by several rotations Loosen screws Press the screw with your hand to push the wheel spindle out of the axle clamp Remove screw ...

Page 126: ...ont wheel withdraw 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 H00934 10 Remove spacers 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 127: ...to the fork position it and insert the wheel spindle The brake linings are correctly positioned Mount and tighten screw Guideline Screw front wheel spindle M24x1 5 45 Nm 33 2 lbf ft Operate the hand brake lever several times until the brake linings are seated correctly against the brake disc Remove the motorcycle from the lift stand p 77 Operate the front brake and compress the fork a few times fi...

Page 128: ... of the hole Remove nut Remove chain adjuster Remove wheel spindle Push the rear wheel forward as far as possible and take the chain off the rear sprocket Info Cover the components to protect them against damage Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not dam aged Take the rear wheel out of the swingar...

Page 129: ...is no braking effect to start with at the rear brake after installing the rear wheel Actuate the foot brake several times before going on a ride until you can feel a firm pressure point Main work Check the rear hub rubber dampers p 129 H00937 11 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change the rear wheel bearing Remove spacer Clean and grease shaft sea...

Page 130: ...at chain adjusters are fitted correctly on adjusting screws Guideline In order for the rear wheel to be correctly aligned the markings on the left and right chain adjusters must be in the same position relative to the reference marks Info Mount left and right chain adjusters in the same position Tighten nut Guideline Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Position wheel speed sensor in t...

Page 131: ...sprocket to the rear wheel via 6 rubber dampers They eventually wear out during operation If the rubber dampers are not changed in time the rear sprocket carrier and the rear hub become damaged Preparatory work Raise the motorcycle with a lift stand p 77 Remove the rear wheel p 126 V00512 10 Main work Check bearing If the bearing is damaged or worn Change the bearing of the rear sprocket carrier C...

Page 132: ...ear wheel p 127 Remove the motorcycle from the lift stand p 77 Check the chain tension p 89 14 6 Checking the tire condition Warning Danger of accidents If a tire bursts while riding the vehicle becomes uncontrollable Ensure that damaged or worn tires are replaced immediately Your authorized Husqvarna Motorcycles workshop will be glad to help Warning Danger of crashing Different tire tread pattern...

Page 133: ...derate riding at alternating angles The full grip levels are not achieved until the tires have been run in Info The type condition and air pressure of the tires all have a major impact on the handling characteristics of the motorcycle Worn tires have a negative effect on handling characteristics especially on wet surfaces 400602 10 Check the front and rear tires for cuts run in objects and other d...

Page 134: ...ardless of the actual state of wear If the tires are more than 5 years old Change the tires 14 7 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 o...

Page 135: ...ing overloaded if they are too tightly tensioned If the tension in the spokes is too low then lateral and radial run out will form in the wheel 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 Info A loose spoke can unbalance the wheel and other spokes may loosen within a...

Page 136: ...frequency of the sound depends on the spoke length and spoke diameter If you hear different tone frequencies from different spokes of equal length and diameter this is an indication of different spoke tensions You should hear a high note If the spoke tension differs Correct the spoke tension ...

Page 137: ...ery gases Keep sparks and open flames away from the battery Only charge in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Preparatory work Switch off the ignition by turning the ignition key to the OFF position Remove the seat p 83 F00564 10 Main work Pull engine ...

Page 138: ...the battery Take off positive terminal cover F00567 10 Disconnect ABS connection cable and positive cable from the battery Lift the battery up and out Info Never operate the motorcycle with a discharged battery or without a battery In both cases electrical components and safety devices can be damaged The vehicle will therefore no longer be roadworthy ...

Page 139: ...minals facing rearward Battery YTZ10S p 192 Position washer positive cable and ABS connection cable Mount and tighten screw Guideline Screw battery terminal M6 4 5 Nm 3 32 lbf ft F00569 10 Position positive terminal cover Position washer and negative cable Mount and tighten screw Guideline Screw battery terminal M6 4 5 Nm 3 32 lbf ft ...

Page 140: ...00565 11 Position retaining bracket and mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft F00564 11 Position the engine electronics control unit Finishing work Mount the seat p 83 Set the clock p 38 ...

Page 141: ... rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Warning Environmental hazard Batteries contain environmentally hazardous materials Do not dispose of batteries as household waste Return batteries to your authorized Husqvarna Motorcycles dealer or dispose of them at a collection point for used batteries Warning Envi...

Page 142: ...ing time is exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted by repeated starting 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 sulfated destroying the bat tery The battery is maintenance free The acid level does not have to be checked ...

Page 143: ...tor With this device you cannot overcharge the battery Info Never remove lid Charge the battery to a maximum of 10 of the capacity specified on battery housing Switch off the battery charger after charging and disconnect from the battery Guideline The charging current charging voltage and charging time must not be exceeded Charge the battery regularly when the motorcycle is not in use 3 months Fin...

Page 144: ...th the required ampere value Do not bypass or repair fuses Info The main fuse protects all power consumers of the vehicle It is in the housing of the starter relay next to the battery Preparatory work Switch off the ignition by turning the ignition key to the OFF position Remove the seat p 83 F00571 10 Main work Take off protection caps ...

Page 145: ... Fuse 58011109130 p 192 Info Insert a new spare fuse into the starter relay to have it available when needed Check that the electrical equipment is functioning properly Mount the protection caps Finishing work Mount the seat p 83 Set the clock p 38 15 5 Changing the ABS fuses Warning Fire hazard Incorrect fuses overload the electrical system Only use fuses with the required ampere value Do not byp...

Page 146: ... protects the ABS control unit is located in the fuse box Preparatory work Switch off all power consumers and switch off the engine Remove the seat p 83 Pull the engine electronics control unit off of the holder and set it to one side F00565 12 Main work Remove screws Pull retaining bracket of the battery forward and remove it F00572 10 Unlock catch and lift off holder ...

Page 147: ...tion cap and remove fuse Insert a new fuse Fuse 58011109115 p 192 Mount the protection cap F00574 10 To change the fuse of the ABS return pump Take off the protection cap and remove fuse Insert a new fuse Fuse 58011109125 p 192 Mount the protection cap F00572 10 Position holder Catch engages audibly ...

Page 148: ...f ft Finishing work Position the engine electronics control unit Mount the seat p 83 15 6 Changing the fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat Preparatory work Switch off the ignition by turning the ignition key to the OFF position Remove the seat p 83 ...

Page 149: ...0 A radiator fan Fuse 5 10 A horn brake light turn signal oil pressure sensor Fuse 6 15 A high beam low beam parking light tail light license plate lamp Fuse 7 10 A for auxiliary equipment permanent positive Fuse 8 10 A for auxiliary equipment accessories connected with ignition switch Fuse 9 10 A ABS control unit diagnostics connector Fuse 10 not assigned Fuse SPARE 10 A 15 A spare fuses Info You...

Page 150: ...orrect rating only Fuse 75011088010 p 192 Fuse 75011088015 p 192 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 83 15 7 Removing the headlight mask with the headlight Preparatory work Switch off the ignition by turning the ignition key to the OFF position ...

Page 151: ...ver the fender with a cloth to protect it from damage Detach the brake line and wiring harness from holder Remove screws on both sides Fold the headlight mask forward V00503 10 Disconnect plug in connector of the headlight Remove the headlight mask ...

Page 152: ... with the headlight V00503 11 Main work Connect plug in connector of the headlight Check that the lighting is functioning properly K00399 10 Remove the cloth from the fender and position the headlight mask Both holding lugs engage in drilled holes of the fender ...

Page 153: ...e headlight setting p 154 15 9 Changing the headlight bulb Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Preparatory work Switch off the ignition by turning the ignition key to the OFF position Remove the headlight mask with the headlight p 148 ...

Page 154: ...ve it E00037 10 Pull out headlight bulb Insert the new headlight bulb Headlight H4 socket P43t p 192 Insert the protection cap with the bulb socket into the reflector and turn it clockwise all the way Info Ensure that O ring is seated properly Finishing work Install the headlight mask with the headlight p 150 Check the headlight setting p 154 ...

Page 155: ...ork Switch off the ignition by turning the ignition key to the OFF position Remove the headlight mask with the headlight p 148 E00038 10 Main work Pull bulb socket out of the reflector Pull parking light bulb out of the bulb socket Insert a new parking light bulb in the bulb socket Parking light W5W socket W2 1x9 5d p 193 Insert the bulb socket in the reflector Finishing work Install the headlight...

Page 156: ...tance away from the wall Guideline Distance 5 m 16 ft The rider with luggage and passenger if applicable now mounts the motorcycle Switch on the low beam Check the headlight setting The light dark boundary must lie exactly on the lower mark when the motorcycle is ready to operate with the rider mounted along with any luggage and a passenger if applicable If the boundary between light and dark does...

Page 157: ...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 Info If you have a payload you may have to correct the headlight range Tighten screw ...

Page 158: ...o flow into compensating tank When the temperature falls this surplus coolant is sucked back into the cool ing system This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions V00519 10 125 C 257 F Cooling takes place by means of the air stream and a radiator fan which is controlled by a thermoswitch The lower the speed the less the cool...

Page 159: ...r components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water 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 Rinse the affected area immediately with plent...

Page 160: ...el must be between the two markings If the coolant level does not match the specified value Correct the coolant level Coolant p 200 Mount cover of the compensating tank V00520 11 Remove radiator cap Check the antifreeze in the coolant 25 45 C 13 49 F If the antifreeze in the coolant does not match the specified value Correct the antifreeze in the coolant Check the coolant level in the radiator The...

Page 161: ...her components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water 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 Rinse the affected area immediately with ple...

Page 162: ...en the two markings If the coolant level does not match the specified value Correct the coolant level Coolant p 200 V00520 11 Remove radiator cap and check the coolant level in the radiator The radiator must be filled completely If the coolant level does not match the specified value Check the coolant level and the reason for the loss Coolant p 200 Mount the radiator cap ...

Page 163: ...cooling system In the event of scalding rinse the area affected immediately with lukewarm water 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 Rinse the affected area immediately with plenty of water in the ev...

Page 164: ...rd p 102 16 5 Filling bleeding the 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 Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes thorou...

Page 165: ...rface Remove radiator cap V00521 10 Refill with coolant Coolant 1 20 l 1 27 qt Coolant p 200 Completely fill the radiator with coolant Mount radiator cap V00518 11 Remove cover of the compensating tank Add coolant up to a level between the two marks Mount the cover of the compensating tank ...

Page 166: ...unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Start the engine and let it warm up Stop the engine and allow it to cool down Check the coolant level p 159 ...

Page 167: ...to an excessive load 0 0 0 A A 400692 10 Sit on the vehicle in the riding position and determine distance between the upper edge of your boot and the shift lever Distance between shift lever and upper edge of boot 10 20 mm 0 39 0 79 in If the distance does not meet specifications Adjust the basic position of the shift lever p 165 17 2 Adjusting the basic position of the shift lever 401950 12 Remov...

Page 168: ...the shift shaft in the required position and engage the gear ing Info The range of adjustment is limited The shift lever must not come into contact with any other vehicle components during the shift procedure Mount and tighten screw with the washers Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 ...

Page 169: ...diately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes...

Page 170: ... the connecting piece Lubricate the O ring and connect plug in connection of the fuel line Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Start the engine and check ...

Page 171: ... 18 3 Changing the engine oil and oil filter cleaning the oil screens Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden Wear suitable protective clothing and safety gloves In the event of scalding rinse the area affected immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters...

Page 172: ...k Remove the engine guard p 101 H01066 10 Main work Place a suitable container under the engine Remove oil filler plug with the O ring from the clutch cover F00579 10 Remove oil drain plug with the magnet and seal ring Completely drain the engine oil ...

Page 173: ...net M12x1 5 20 Nm 14 8 lbf ft F00582 10 Remove screws Remove oil filter cover with the O ring Pull oil filter out of the oil filter housing Circlip pliers reverse 51012011000 F00588 10 Remove screws Remove oil filter cover with the O ring Pull oil filter out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing surfaces ...

Page 174: ...l screen and the O rings Completely drain the engine oil Thoroughly clean the parts and sealing surfaces F00586 10 Position oil screen with the O rings on a pin wrench Position the pin wrench through the drilled hole of the screw plug in the opposite sec tion of the engine case Push the oil screen all the way into the engine case ...

Page 175: ... 1 lbf ft F00584 10 Position oil screen with the O rings Mount and tighten screw plug with the O ring Guideline Plug oil screen M20x1 5 15 Nm 11 1 lbf ft F00585 10 Insert new oil filter Lubricate the O ring of the oil filter cover Position oil filter cover Mount and tighten screws Guideline Screw oil filter cover M5 6 Nm 4 4 lbf ft ...

Page 176: ...l or poor quality engine oil results in premature wear of the engine H01066 10 Mount and tighten oil filler plug with the O ring Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an encl...

Page 177: ...performance of the engine oil do not mix different types of engine oil We recommended changing the engine oil when necessary Mount and tighten oil filler plug with the O ring Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system ...

Page 178: ...jet directly on to electrical components connectors throttle cables or bearings Maintain a minimum distance between the nozzle of the pressure cleaner and the component Minimum clearance 60 cm 23 6 in Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regula...

Page 179: ...e effects of salt 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 accidents Moisture and dirt impair the brake system Brake carefully several times to dry out and remove dirt from the brake lin ings and the brake discs After cleaning ride the vehicle a short distance until the engine warms up Info The h...

Page 180: ...air the material quality Treat all plastic parts and powder coated parts with a mild cleaning and care product Lubricate the ignition steering lock Universal oil spray p 203 19 2 Checks and maintenance steps for winter operation Info If you use the motorcycle in winter you must expect salt on the roads You should therefore take precautions against aggressive road salt If the vehicle was operated i...

Page 181: ...fter the parts are cooled down and while they are installed After use on salted roads clean the motorcycle thoroughly with cold water and dry it properly Treat the engine the swingarm and all other bare or galvanized parts except brake discs with a wax based anti corrosion substance Info To prevent serious reduction of the braking efficiency make sure no anti corrosion substance gets on to the bra...

Page 182: ...1058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Info The fuel additive stabilities the fuel for longer storage and makes starting eas ier next time Refuel p 57 Clean the motorcycle p 176 Change the engine oil and oil filter and clean the oil screens p 169 Check the antifreeze and coolant level p 157 Check the tire air pressure p 132 Remove the...

Page 183: ...umidity from escaping thus causing corrosion 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 401059 01 Remove the motorcycle from the lift stand p 77 Install the battery p 137 Set the clock p 38 Perform checks and vehicle...

Page 184: ...Engine turns but does not start Operating error Carry out the start procedure p 48 Fuse 3 blown Change the fuses of individual power consumers p 146 The plug in connection of the fuel hose connection is not connected Connect the plug in connection of the fuel line Defect in fuel injection system Read out the fault memory using the Husqvarna Motorcycles diagnostics tool Throttle opened while starti...

Page 185: ...p 162 Malfunction indicator lamp lights up or flashes Defect in fuel injection system Read out the fault memory using the Husqvarna Motorcycles diagnostics tool N The idling speed indicator lamp does not light up when the transmis sion is in neutral Gear position sensor not programmed Read out the fault memory using the Husqvarna Motorcycles diagnostics tool Engine dies during the journey Lack of ...

Page 186: ...s of individual power consumers p 146 Turn signal brake light and horn not functioning Fuse 5 blown Change the fuses of individual power consumers p 146 Time is not correctly displayed Fuse 1 blown Change the fuses of individual power consumers p 146 Set the clock p 38 Battery discharged Ignition not switched off when vehicle was parked Recharge the battery p 139 Battery is not charged by alternat...

Page 187: ...5 in Valve diameter exhaust 34 mm 1 34 in Valve play cold Intake at 20 C 68 F 0 10 0 15 mm 0 0039 0 0059 in Exhaust at 20 C 68 F 0 20 0 25 mm 0 0079 0 0098 in Crankshaft bearing 2 roller bearings Conrod bearing Slide bearing Piston pin bearing Piston pin with DLC coating Pistons Forged light alloy Piston rings 1 compression ring 1 lower compression ring 1 oil ring with spring expander Engine lubri...

Page 188: ...2 V 300 W Spark plug Inside spark plug NGK LKAR9BI 10 Outside spark plug NGK LMAR7DI 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 automatic decompressor 22 2 Engine tightening torques Screw membrane fixation M3 2 Nm 1 5 lbf ft Loctite 243 Hose clamp intake flange M4 2 5 Nm 1 84 lbf ft Oil nozzle for c...

Page 189: ...ft Screw in alternator cover M6 10 Nm 7 4 lbf ft Screw alternator cover M6x30 10 Nm 7 4 lbf ft Screw alternator cover chain shaft through hole M6 10 Nm 7 4 lbf ft Loctite 243 Screw auto decompression M6 3 5 Nm 2 58 lbf ft Loctite 243 Screw camshaft bearing support M6x80 10 Nm 7 4 lbf ft Screw camshaft bearing support M6x90 10 Nm 7 4 lbf ft Screw chain shaft M6 10 Nm 7 4 lbf ft Loctite 243 Screw cl...

Page 190: ...6 10 Nm 7 4 lbf ft Loctite 243 Screw timing chain guide rail M6x30 10 Nm 7 4 lbf ft Loctite 2701 Screw timing chain tensioning rail M6x30 10 Nm 7 4 lbf ft Loctite 2701 Screw valve cover M6 10 Nm 7 4 lbf ft Screw water pump cover M6 10 Nm 7 4 lbf ft Screw water pump wheel M6 10 Nm 7 4 lbf ft Loctite 243 Screws SAS cover M6x12 10 Nm 7 4 lbf ft Loctite 243 Intake channel vacuum connection M6x0 75 2 5...

Page 191: ... M10x1 15 Nm 11 1 lbf ft Screw plug oil channel M10x1 15 Nm 11 1 lbf ft Loctite 243 Screw plug oil channel for oil radiator M10x1 15 Nm 11 1 lbf ft Screw unlocking of timing chain ten sioner M10x1 10 Nm 7 4 lbf ft Spark plug outside M10x1 11 Nm 8 1 lbf ft Spark plug inside M12x1 25 18 Nm 13 3 lbf ft Coolant temperature sensor on cylinder head M12x1 5 12 Nm 8 9 lbf ft Oil drain plug with magnet M12...

Page 192: ...M20x1 5 15 Nm 11 1 lbf ft Plug timing chain tensioner M20x1 5 25 Nm 18 4 lbf ft Plug oil thermostat M24x1 5 15 Nm 11 1 lbf ft Screw in alternator cover M24x1 5 8 Nm 5 9 lbf ft 22 3 Capacities 22 3 1 Engine oil Engine oil 1 70 l 1 8 qt Engine oil SAE 10W 50 p 201 22 3 2 Coolant Coolant 1 20 l 1 27 qt Coolant p 200 22 3 3 Fuel Total fuel tank capacity approx 13 l 3 4 US gal Super unleaded ROZ 95 RON...

Page 193: ...ear 275 mm 10 83 in Brake system Front Disc brake with dual piston brake caliper floating Rear Disc brake with single piston brake caliper floating Brake discs diameter Front 300 mm 11 81 in Rear 240 mm 9 45 in Brake discs wear limit Front 4 5 mm 0 177 in Rear 4 5 mm 0 177 in Tire air pressure road solo Front 1 8 bar 26 psi Rear 1 8 bar 26 psi Tire air pressure with passenger fully loaded Front 2 ...

Page 194: ...97 in Weight without fuel approx 150 4 kg 331 6 lb Maximum permissible front axle load 150 kg 331 lb Maximum permissible rear axle load 200 kg 441 lb Maximum permissible overall weight 350 kg 772 lb 22 5 Electrical system Battery YTZ10S Battery voltage 12 V Nominal capacity 8 6 Ah maintenance free Fuse 75011088010 10 A Fuse 75011088015 15 A Fuse 58011109115 15 A Fuse 58011109125 25 A Fuse 58011109...

Page 195: ...TKC 80 140 80 18 M C 70R TT Continental TKC 80 The tires specified represent one of the possible series production tires Additional information is available in the Service section under www husqvarna motorcycles com 22 7 Fork Fork part number 24 15 7P 10 Fork WP Performance Systems Up Side Down 4860 MXMA 4CS Compression damping Comfort 15 clicks Standard 12 clicks Sport 10 clicks Rebound damping C...

Page 196: ...1166S1 p 201 22 8 Shock absorber Shock absorber article number 15 15 7P 10 Shock absorber WP Performance Systems 4618 with Pro Lever linkage Compression damping low speed Standard 15 clicks Compression damping high speed Standard 1 5 turns Rebound damping Standard 15 clicks Spring preload 22 mm 0 87 in Spring rate Medium standard 69 N mm 394 lb in Spring length 225 mm 8 86 in Gas pressure 10 bar 1...

Page 197: ...r stub M5 6 Nm 4 4 lbf ft Loctite 243 Rear fairing screw tail light M5 2 Nm 1 5 lbf ft Remaining nuts chassis M5 4 Nm 3 lbf ft Remaining screws chassis M5 4 Nm 3 lbf ft Screw brake line holder on swingarm M5 4 Nm 3 lbf ft Screw cable on starter motor M5 3 Nm 2 2 lbf ft Screw combination switch left M5 3 5 Nm 2 58 lbf ft Screw electrical holder M5 3 Nm 2 2 lbf ft Screw exhaust heat shield M5 8 Nm 5...

Page 198: ...SAS valve screw on frame M6 12 Nm 8 9 lbf ft Screw connection foot brake cylinder M6 10 Nm 7 4 lbf ft Screw ABS control unit M6 5 Nm 3 7 lbf ft Screw air filter box top M6 2 Nm 1 5 lbf ft Screw air filter box on frame M6 6 Nm 4 4 lbf ft Screw ball joint of push rod on foot brake cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw battery terminal M6 4 5 Nm 3 32 lbf ft Screw brake assembly M6 5 Nm 3 7 l...

Page 199: ...f ft Loctite 243 Screw seat lock M6 5 Nm 3 7 lbf ft Screw upper radiator bracket M6 10 Nm 7 4 lbf ft Screw voltage regulator M6 8 Nm 5 9 lbf ft Screw wheel speed sensor M6 6 Nm 4 4 lbf ft Nut manifold on cylinder head M8 20 Nm 14 8 lbf ft Copper paste Nut rear sprocket screw M8 35 Nm 25 8 lbf ft Loctite 2701 Remaining nuts chassis M8 25 Nm 18 4 lbf ft Remaining screws chassis M8 25 Nm 18 4 lbf ft ...

Page 200: ...5 Nm 18 4 lbf ft Screw rear footrest bracket M8x16 25 Nm 18 4 lbf ft Screw side stand bracket M8 25 Nm 18 4 lbf ft Loctite 243 Screw spring holder on side stand bracket M8 25 Nm 18 4 lbf ft Loctite 243 Screw steering stem M8 20 Nm 14 8 lbf ft Screw top triple clamp M8 17 Nm 12 5 lbf ft Engine carrying screw M10 45 Nm 33 2 lbf ft Loctite 243 Remaining nuts chassis M10 45 Nm 33 2 lbf ft Remaining sc...

Page 201: ... lever on swingarm M14x1 5 100 Nm 73 8 lbf ft Nut linkage lever to rocker arm M14x1 5 100 Nm 73 8 lbf ft Screw radiator temperature sensor M18 20 Nm 14 8 lbf ft Screw bottom steering head M20x1 5 60 Nm 44 3 lbf ft Loctite 243 Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Screw front wheel spindle M24x1 5 45 Nm 33 2 lbf ft Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft ...

Page 202: ...t use pure water as only coolant is able to meet the requirements needed in terms of corrosion protection and lubrication properties Only use coolant that complies with the requirements stated see specifications on the container and that has the relevant proper ties Antifreeze protection to at least 25 C 13 F The mixture ratio must be adjusted to the necessary antifreeze protection Use distilled w...

Page 203: ...nded supplier Bel Ray EXS Synthetic Ester 4T Fork oil SAE 4 48601166S1 Standard classification SAE p 204 SAE 4 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding prop erties Shock absorber fluid SAE 2 5 50180751S1 Standard classification SAE p 204 SAE 2 5 Guideline Use only oils that comply with the specified stan...

Page 204: ...28 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100 ...

Page 205: ... Ray Waterproof Grease Offroad chain spray Guideline Recommended supplier Bel Ray Blue Tac Chain Lube Preserving materials for paints metal and rubber Recommended supplier Bel Ray Silicone Detailer Protectant Spray Universal oil spray Recommended supplier Bel Ray 6 in 1 ...

Page 206: ...long service intervals are demanded for automobile engines the focus for motorcycle engines is on high performance at high engine speeds In most motorcycle engines the transmission and the clutch are lubricated with the same oil 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 a...

Page 207: ...TERMS 205 ABS ABS Safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces OBD On board diagnosis Vehicle system that monitors emission and safety related values ...

Page 208: ...27 LIST OF ABBREVIATIONS 206 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 209: ... intervention Active driving aids are also represented by yellow or orange symbols ABS warning lamp lights up flashes yellow ABS is not active The ABS lamp also lights up if an error is detected The low fuel warning lamp lights up orange The fuel level has reached the reserve mark Malfunction indicator lamp lights up flashes orange The OBD has detected an emission or safety critical fault 28 3 Gre...

Page 210: ...28 LIST OF SYMBOLS 208 Turn signal indicator lamp flashes green The turn signal is switched on ...

Page 211: ...luid level of front brake 106 rear brake checking 115 Brake linings front brake changing 110 front brake checking 109 rear brake changing 119 rear brake checking 118 Brakes 53 C Capacity coolant 163 190 engine oil 174 190 fuel 59 190 Chain checking 93 cleaning 88 dirt checking for 88 Chain guide checking 93 setting 98 Chain tension adjusting 91 checking 89 Changing the headlight bulb 151 Chassis n...

Page 212: ...oil adding 175 changing 169 Engine oil level checking 168 Engine sprocket checking 93 Environment 12 F Figures 15 Filler cap closing 29 opening 28 Foot brake lever 32 basic position adjusting 114 free travel checking 113 Fork 64 compression damping adjusting 64 dust boots cleaning 79 fork legs bleeding 78 rebound adjusting 65 Fork part number 22 Fork protector installing 80 removing 80 Front fende...

Page 213: ...ng 150 removing 148 Horn button 24 I Ignition lock 27 Implied warranty 14 Indicator lamps overview 27 Intended use 9 K Key number 21 L Light switch 25 Loading the vehicle 45 Luggage 45 M Main fuse changing 142 Misuse 9 Motorcycle cleaning 176 lift stand raising with 77 removing from lift stand 77 O Oil filter changing 169 Oil screens cleaning 169 Operating substances 14 Owner s Manual 13 P Parking...

Page 214: ... 83 unlocking 30 Service 15 Service schedule 60 63 Shift lever 31 basic position adjusting 165 basic position checking 165 Shifting 50 Shock absorber 64 compression damping general 66 high speed compression damping adjusting 67 low speed compression damping adjusting 66 rebound damping adjusting 68 riding sag checking 71 spring preload adjusting 72 static sag checking 70 Shock absorber article num...

Page 215: ...sis 191 chassis tightening torques 195 electrical system 192 engine 185 engine tightening torques 186 fork 193 shock absorber 194 tires 193 Throttle grip 24 Tire air pressure checking 132 Tire condition checking 130 Transport 56 Troubleshooting 182 184 Turn signal switch 25 Type label 20 U Use definition 9 V View of vehicle front left 16 rear right 18 W Warranty 14 Winter operation checks and main...

Page 216: ... 3402114en 3402114en 09 2016 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria www husqvarna motorcycles com Photo Mitterbauer Husqvarna Motorcycles GmbH ...

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