Husqvarna 701 Supermoto 2016 Page 95 Owner'S Manual Download

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12 SERVICE WORK ON THE CHASSIS

–

Check the headlight setting. (

p. 151)

12.16

Removing the air filter

Preparatory work

–

Remove the seat. (

p. 90)

H00402-10

Main work

–

Remove screws



–

Remove the upper part of the air filter box



H00403-10

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 increased wear.

–

Remove air filter



Summary of Contents for 701 Supermoto 2016

Page 1: ...OWNER S MANUAL 2016 701 Supermoto Art no 3402073en ...

Page 2: ......

Page 3: ...Minor differences due to devel opments 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 of...

Page 4: ...ght 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 Supermoto US F2675P3 ...

Page 5: ...ccessories 21 3 4 Service 22 3 5 Figures 22 3 6 Customer service 22 4 VIEW OF VEHICLE 24 4 1 View of vehicle front left side 24 4 2 View of vehicle rear right side 26 5 SERIAL NUMBERS 28 5 1 Chassis number 28 5 2 Type label 29 5 3 Key number 30 5 4 Engine number 30 5 5 Fork part number 31 5 6 Shock absorber article number 31 6 CONTROLS 32 6 1 Clutch lever 32 6 2 Hand brake lever 32 6 3 Throttle gr...

Page 6: ... shock absorber 72 11 2 Adjusting the compression damping of the fork 72 11 3 Adjusting the rebound damping of the fork 73 11 4 Compression damping of the shock absorber 74 11 5 Adjusting the low speed compression damping of the shock absorber 74 11 6 Adjusting the high speed compression damping of the shock absorber 75 11 7 Adjusting the rebound damping of the shock absorber 76 11 8 Measuring the...

Page 7: ...sition of the hand brake lever 108 13 3 Checking the brake discs 109 13 4 Checking the front brake fluid level 110 13 5 Adding front brake fluid 111 13 6 Checking the front brake linings 112 13 7 Checking the free travel of foot brake lever 113 13 8 Adjusting the basic position of the foot brake lever 114 13 9 Checking rear brake fluid level 115 13 10 Adding rear brake fluid 115 13 11 Checking the...

Page 8: ...ne oil level 164 18 2 Changing the engine oil and oil filter cleaning the oil screens 164 18 3 Adding engine oil 169 19 CLEANING CARE 171 19 1 Cleaning the motorcycle 171 19 2 Checks and maintenance steps for winter operation 173 20 STORAGE 174 20 1 Storage 174 20 2 Preparing for use after storage 175 21 TROUBLESHOOTING 176 22 BLINK CODE 179 23 TECHNICAL DATA 186 23 1 Engine 186 23 2 Engine tighte...

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: ...the homologated version 2 2 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 are referred 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 missin...

Page 12: ... that is likely to lead to fatal or serious injury if the appropriate measures are not taken Caution Indicates a danger that may lead to minor injuries if the appropriate measures are not taken Note Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken Warning Indicates a danger that will lead to environmental damage if the appropri...

Page 13: ...11 ...

Page 14: ...2 SAFETY ADVICE 12 2 4 Overview of labels H00430 10 ...

Page 15: ...on 2 Information suspension setting 3 Information noise emission 4 Type label USA 5 Type label Canada 6 Information emission control 7 Information putting into operation M01410 01 Information chain tension M01409 01 Information suspension setting ...

Page 16: ...2 SAFETY ADVICE 14 M01408 01 Information noise emission M01406 01 Type label USA ...

Page 17: ...2 SAFETY ADVICE 15 M01405 01 Type label Canada M01407 01 Information emission control ...

Page 18: ...cycles North America Inc You can contact NHTSA via the toll free Auto Safety Hotline on 1 888 327 4236 visit the www nhtsa dot gov website or write to NHTSA Headquarters 1200 New Jersey Avenue SE West Building Washington DC 20590 You can also obtain other information about motor vehicle safety from the hotline 2 6 Noise emission warranty Husqvarna Motorcycles North America Inc guarantees that this...

Page 19: ...53 www husqvarna motorcycles com Husqvarna Motorcycles North America 1375 3 Marie Victorin Saint Bruno QC J3V 6B7 Canada Phone 450 441 9222 www husqvarna motorcycles com Different rights may apply according to national or regional legislation 2 9 Tampering warning Tampering with the noise control system is prohibited Federal law prohibits the following acts or the causing thereof 1 The removal or ...

Page 20: ...ult 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 exhaust extraction system Warning Danger of burns Some vehicle components become very hot when the vehicle is operated Do not touch hot components such as exhaust system radiator engine shock absorber and the brake...

Page 21: ...rts 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 13 Environment If you use your motorcycle responsibly you can ensure that...

Page 22: ...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 23: ...danger to the environment Do not allow fuel to get into the ground water the ground 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 authorize...

Page 24: ...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 25: ...23 ...

Page 26: ...4 VIEW OF VEHICLE 24 4 1 View of vehicle front left side S01031 01 ...

Page 27: ...E 25 1 Hand brake lever p 32 2 Clutch lever p 32 3 Handrails p 39 4 Filler cap 5 Passenger footrest p 40 6 Shock absorber rebound damping 7 Side stand p 42 8 Seat unlocking p 39 9 Shift lever p 40 10 Engine number p 30 ...

Page 28: ...4 VIEW OF VEHICLE 26 4 2 View of vehicle rear right side S01032 01 ...

Page 29: ...4 Turn signal switch p 34 5 Light switch p 34 6 Speedometer 7 Electric starter button p 35 8 Emergency OFF switch p 35 9 Throttle grip p 33 10 Fork rebound adjustment 11 Chassis number p 28 12 Type label p 29 13 Level viewer engine oil 14 Foot brake lever p 41 15 Shock absorber compression adjustment ...

Page 30: ...5 SERIAL NUMBERS 28 5 1 Chassis number 401945 10 The chassis number is stamped on the steering head on the right ...

Page 31: ...5 SERIAL NUMBERS 29 5 2 Type label 0 0 2 2 H01055 10 The type label USA is located on the right side of the frame The type label Canada is located on the left side of the frame ...

Page 32: ...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 33: ...1 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 34: ...r is fitted on the handlebar on the left The clutch is activated hydraulically and adjusts itself automatically 6 2 Hand brake lever S00986 10 The hand break lever is fitted on the right side of the handlebar The hand brake lever operates the front brake ...

Page 35: ...hrottle grip is fitted on the right side of the handlebar 6 4 Horn button S00989 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 36: ... tail light are switched on 6 6 Turn signal switch S00991 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 37: ...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 S00993 10 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 38: ...ing 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 when 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 FI warning lamp MIL lig...

Page 39: ...erfilled Follow the instructions 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 physic...

Page 40: ...tion 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 41: ...3 Seat unlocking S00996 10 The loop unlocks the seat 6 14 Handrails S00997 10 The handrails are used for moving the motorcycle around When you have a passenger the passenger can hold on the handrails during the journey ...

Page 42: ...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 43: ...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 44: ...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 45: ... 10 1 Indicator lamps overview p 36 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 46: ...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 47: ...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 48: ...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 49: ... 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 50: ...reases 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 righ...

Page 51: ...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 52: ...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 53: ...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 54: ...er of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Non approved or non recommended tires and wheels impact the handling characteristic Only use tires wheels approved by Husqvarna Motorcycles with the ...

Page 55: ...ervice and Warranty Booklet at vehicle handover Before your first trip read the entire Owner s Manual carefully Get to know the controls Adjust the basic position of the clutch lever p 105 Adjust the basic position of the hand brake lever p 108 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 als...

Page 56: ...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 57: ... 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 58: ...d level p 115 Check the front brake linings p 112 Check the rear brake linings p 117 Check the brake system function Check the coolant level p 156 Check the chain for dirt p 95 Check the chain tension p 96 Check the tire condition p 127 Check the tire air pressure p 130 Check the settings of all controls and ensure that they can be operated smoothly Check that the electrical equipment is functioni...

Page 59: ...ever operate the vehicle with a discharged battery or without a battery Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine Always warm up the engine at low engine speeds B00782 10 Turn the emergency OFF switch to the position Switch on the ignition by turning the ignition key to position ON After you switch on the ignition you can hear t...

Page 60: ...ng system You can only start the engine if the transmission is in neutral or if the clutch lever is pulled when a gear is engaged If the side stand is 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 ABS M01403 10 Switching off ABS Husqvarna Motorcycles recommends riding with ABS a...

Page 61: ...n lock up Warning 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 pass...

Page 62: ... 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 baggage ...

Page 63: ...ch 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 so it is open This will barely reduce the speed but fuel consumption will be consid erabl...

Page 64: ...e blink code tells you which component is affected by a malfunction 9 5 Applying the brakes Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake system Clean or dry a dirty or wet brake system by riding and braking gently Warning Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake Check the brake system and do not cont...

Page 65: ...ater stopping distance due to ABS Braking should be appropriate to the driving situation and the road conditions Warning Danger of accidents Very forceful braking can cause the wheels to block ABS must be switched on to be effective Warning Danger of accidents Locking of the wheels due to braking action of the engine Pull the clutch during emergency braking full brake application and when braking ...

Page 66: ... persons Never leave the vehicle unattended while the engine is running Secure the vehicle against use by unauthorized persons If you leave the vehicle lock the steering and remove the ignition key Warning Danger of burns Some vehicle components become very hot when the vehicle is operated Do not touch hot components such as exhaust system radiator engine shock absorber and the brake system Allow ...

Page 67: ... lock power continues to flow to most power consumers This discharges the battery You should therefore always switch off the engine with the ignition key the emergency OFF switch is intended for emergencies only Park the motorcycle 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 le...

Page 68: ...the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately The fuel in the fuel tank expands when warm and may emerge if overfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact ...

Page 69: ... glad to help Only refuel with clean fuel that meets the specified standards 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 S01027 10 Switch off the engine Open the filler cap p 37 Fill the fuel tank with fuel up to level Guideline Level 20 mm 0 79 in Total fuel tank capacity appro...

Page 70: ...cal system is functioning properly Change the engine oil and oil filter and clean the oil screens p 164 Check the front brake linings p 112 Check the rear brake linings p 117 Check the brake discs p 109 Check the brake lines for damage and leakage Change the front brake fluid Change the rear brake fluid Change the clutch fluid Check the rear brake fluid level p 115 Check the front brake fluid leve...

Page 71: ...130 Check the spoke tension p 131 Check the rim run out Check the chain rear sprocket engine sprocket and chain guide p 99 Check the chain tension p 96 Change the fuel screen Change the spark plugs Check the valve clearance Check the antifreeze and coolant level p 154 Check the cables for damage and routing without sharp bends Change the air filter Clean the air filter box Check the fuel pressure ...

Page 72: ... 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 73: ...k the wheel bearing for play 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 rout ing Check correct the fluid level of the hydraulic clutch p 105 Check the screws and nuts for tightness Change the coolant One time interval Periodic interval ...

Page 74: ...t change 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 H00397 10 Turn white adjusting screw all the way clockwise Info Adjusting screw is located at the upper end of the left fork l...

Page 75: ...ng of the fork Info The hydraulic rebound damping determines the fork suspension behavior H00398 10 Turn red adjusting screw all the way clockwise 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 n...

Page 76: ...ing over an asphalt edge the rear 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...

Page 77: ...k absorber type Guideline Compression damping low speed Comfort 25 clicks Standard 15 clicks Sport 10 clicks Full payload 10 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 Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with h...

Page 78: ...sorber type Guideline Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 11 7 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 high density nitrogen Adher...

Page 79: ... Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 11 8 Measuring the rear wheel dimension unloaded Preparatory work Raise the motorcycle with the work stand 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 N...

Page 80: ...unloaded p 77 Hold the motorcycle 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 25 mm 0 98 in If the static sag is less or more than the specified value Adjust the spring preload of the shock absorber p 79 ...

Page 81: ...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 70 75 mm 2 76 2 95 in If the riding sag differs from the specified measurement Adjust the riding sag p 81 11 11 Adjusting the spring preload of the shock absorber Caution Danger of accidents Disassembly of pr...

Page 82: ...ock absorber clean it thoroughly 201271 11 Main work Loosen retaining ring Turn adjusting 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 the specified measurement Guideline Spring preload 21 mm 0 83 in Info Depending on the static sag and or the riding sag it ...

Page 83: ... the seat p 90 Take off the side cover p 91 Remove the air filter box Remove the shock absorber After removing the shock absorber clean it thoroughly 201352 10 Main work Choose and mount a suitable spring Guideline Spring rate Medium standard 75 N mm 428 lb in Hard 80 N mm 457 lb in Info The spring rate is shown on the outside of the spring Finishing work Install the shock absorber Install the air...

Page 84: ...andlebar 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 Handlebar breakage If the handlebar is bent or straightened it will cause material fatigue and the h...

Page 85: ... 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 86: ...face 402346 01 Insert the adapter into the rear wheel stand and screw into the swingarm on both sides Adapter 61029055110 Rear wheel stand 61029055400 Position the motorcycle upright align the stand and raise the motorcycle 12 2 Removing the rear of the motorcycle from the wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even su...

Page 87: ...amage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Preparatory work Raise the motorcycle with the rear wheel stand p 84 402344 01 Main work Move the handlebar to the straight ahead position Align the front wheel stand with the fork legs using the adapters Front wheel stand 61029055300 Info Always raise the rear of the motorcycle first Raise the ...

Page 88: ...ector p 87 H00400 10 Main work Push dust boots of both fork legs downward Info The dust boots remove dust and coarse dirt particles from the inside fork tubes Over time dirt can accumulate behind the dust boots If this dirt is not removed the oil seals behind can start to leak Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs...

Page 89: ...eg Take off the fork protector Remove screws on the right fork leg Take off the fork protector 12 7 Installing the fork protector H00401 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 the fork protector on the right fork leg Mount a...

Page 90: ... time Preparatory work Raise the motorcycle with the work stand Place a load on rear of vehicle The front wheel is not in contact with the ground 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 ...

Page 91: ...vehicle The front wheel is not in contact with the ground D00865 10 Main work Loosen screws Remove 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 N...

Page 92: ... the side cover Pull seat back and lift it off 12 11 Mounting the seat S01001 10 Stretch the seat at the front ends slightly and position holding tabs on holders The holding tabs engage in the holder Press holding tab into the 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 corre...

Page 93: ... the side cover Repeat these steps on the opposite side 12 13 Mounting the side cover S00984 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 90 ...

Page 94: ... p 145 S00983 10 Main work Remove screws Remove screws and take off the fender 12 15 Installing the front fender S00987 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 Install the headlight mask with the headlight p 147 ...

Page 95: ...seat p 90 H00402 10 Main work Remove screws Remove the upper part of the air filter box H00403 10 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 increased wear Remove air filter ...

Page 96: ...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 H00402 11 Mount and tighten screws Guideline Screw air filter box top M6 2 Nm 1 5 lbf ft Finishing work Mount the seat p 90 ...

Page 97: ...their grip Remove oil and grease with a suitable cleaning material 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 Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be di...

Page 98: ... Warning Danger of accidents Danger caused by incorrect chain tension If the chain is too taut the components of the secondary power transmission chain engine sprocket rear sprocket bear ings in the transmission and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or the countershaft of the transmission to break in extreme cases If the chain is...

Page 99: ...e from the chain sliding guard and determine the chain tension Info The 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 specifications Adjust the chain tension p 98 ...

Page 100: ... bear ings in the transmission and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or the countershaft of the transmission to break in extreme cases If the chain is too loose however it may fall off the engine sprocket or rear sprocket and block the rear wheel or damage the engine Ensure that the chain tension is correct and adjust it if neces...

Page 101: ...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 90 Nm 66 4 lbf ft 12 22 Checking the chain rear spr...

Page 102: ...aced together 1 2 3 16 17 18 0 0 0 B B 0 0 A A 400987 10 Pull at the top part of the chain with the specified weight Guideline Weight of chain wear measurement 15 kg 33 lb Measure distance of 18 chain rollers in the 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...

Page 103: ...or engine sprocket H00407 01 Check the chain sliding guard for wear If the lower edge 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 104: ... 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 105: ...0409 01 Check that the chain guide is firmly seated If the chain guide is loose Tighten the screws on the chain guide Guideline Screw chain guide M6 8 Nm 5 9 lbf ft Finishing work Remove the rear of the motorcycle from the wheel stand p 84 ...

Page 106: ...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 107: ...ts while riding H00410 10 Adjust the basic position 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 12 25 Checking correcting the fluid level of the hydraulic clutch Warning Skin irritation Brake fluid can cause skin irritation on contact Avo...

Page 108: ...ed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container Move the clutch fluid reservoir mounted on the handlebar to a horizontal position S01002 10 Remove screws Remove cover with membrane Check the fluid level Fluid level below container rim 4 mm 0 16 in If the fluid level does not meet specification...

Page 109: ...orcycles 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 The ABS is a safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces Warning Danger of accidents Vehicle rollover It is not always ...

Page 110: ...available The ABS warning lamp may also light up if the rotating speeds of the front and rear wheels differ greatly under extreme riding conditions for example when making wheelies or if the rear wheel spins This causes the ABS to switch off To reactivate the ABS the vehicle must be stopped and the ignition switched off The ABS is reactivated when the vehicle is switched on again The ABS warning l...

Page 111: ...ts on each brake disc to ensure it is at least thickness Info Wear will reduce the thickness of the brake disc at the contact surface of the brake linings Brake discs wear limit Front 4 0 mm 0 157 in Rear 4 5 mm 0 177 in If the brake disc thickness is less than the specified value Change the front brake disc Change the rear brake disc Check the front and rear brake discs for damage cracking and de...

Page 112: ...o not continue riding Your autho rized 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 Motorcy cles workshop will be glad to help H00417 10 Move the brake fluid reservoir mounted on the handlebar to a horizo...

Page 113: ...ake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately 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 Motorcy cles workshop will be glad to help Warning Environmental hazard Hazardous substances ca...

Page 114: ...overflowed or spilled brake fluid immediately with water 13 6 Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized Husqvarna Motorcycles workshop will be glad to help Note Danger of accidents Reduced braking efficiency caused by damaged brake discs If the brake linings are not chan...

Page 115: ...rake 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 specifications 402027 10 Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in Info You will know that c...

Page 116: ...ecifications H00413 10 Loosen fittings on foot brake cylinder To adjust the basic position of the foot brake lever individually loosen nut and turn screw accordingly Info The range of adjustment is limited The screw must be screwed into the footrest bracket by at least four turns Position foot brake cylinder so that the foot brake lever has the necessary free travel Mount and tighten fittings Guid...

Page 117: ...e the brake fluid of the front and rear brake according to the service schedule Your authorized Husqvarna Motorcy cles workshop will be glad to help H00414 10 Stand the vehicle upright Check the brake fluid level in the brake fluid reservoir If the fluid level reaches the MIN marking Add rear brake fluid p 115 13 10 Adding rear brake fluid Warning Danger of accidents Failure of the brake system If...

Page 118: ... the front and rear brake according to the service schedule Your authorized Husqvarna Motorcy cles 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 brake fluid It is silicone based and purple in color Oil seals...

Page 119: ... linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized Husqvarna Motorcycles workshop will be glad to help Note Danger of accidents Reduced braking efficiency caused by damaged brake discs If the brake linings are not changed in time the steel brake lining carriers grind on the brake disc The braking effect...

Page 120: ...e linings for minimum thickness Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings Check the brake linings for damage and cracking If there is wear or tearing Change the rear brake linings ...

Page 121: ...the brake disc Pull the brake caliper carefully back from the brake disc and hang it to one side Info Do not pull the hand brake lever while the brake caliper is removed S01003 10 Loosen screw by several rotations Loosen screws Press your hand on screw to push the wheel spindle out of the axle clamp Remove screw Warning Danger of accidents Reduced braking efficiency due to damaged brake disc Alway...

Page 122: ...e brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary H00935 10 Main work Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change the front wheel bearing Clean and grease shaft seal rings and mating surfaces of the spacers Long life grease p 203 Insert the spacers ...

Page 123: ...Nm 4 4 lbf ft Position the brake caliper on the brake disc The brake linings are correctly positioned Position spacers Mount screws but do not tighten yet Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Fix the hand brake lever in the activated position The brake caliper straightens Tighten screws Guideline Screw fron...

Page 124: ...few times firmly The fork legs straighten Tighten screws Guideline Screw fork stub M8 15 Nm 11 1 lbf ft Finishing work Remove the rear of the motorcycle from the wheel stand p 84 14 3 Removing the rear wheel Preparatory work Raise the motorcycle with the rear wheel stand p 84 S01029 10 Main work Take the brake line out of the guide ...

Page 125: ...ct with the adjusting screw E00026 01 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 Holding the rear wheel withdraw the wheel spindle Warning Danger of accidents Reduced braking efficiency due to damaged brake disc Always lay the wheel down in such a way that the brake disc is not dam aged Take the r...

Page 126: ...rate the foot brake until the pressure point is reached Main work Check the rear hub rubber dampers p 126 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 seal ring and contact surface of the spacer Long life grease p 203 Insert the spacer Clean and grease the thread of the wheel spindle...

Page 127: ...e left and right chain adjusters are in the same posi tion relative to reference marks The rear wheel is then correctly aligned Tighten nut Guideline Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Position wheel speed sensor in the drill hole Mount and tighten screw Guideline Screw wheel speed sensor M6 6 Nm 4 4 lbf ft S01029 10 Position the brake line in the guide Operate the foot brake lever r...

Page 128: ... 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 the rear wheel stand p 84 Remove the rear wheel p 122 E00029 10 Main work Check bearing If the bearing is damaged or worn Change the bearing of the rear sprocket carrier Check rubber dampers of the rear hub for damage and wear If the r...

Page 129: ... Finishing work Install the rear wheel p 124 Remove the rear of the motorcycle from the wheel stand p 84 Check the chain tension p 96 14 6 Checking the tire condition Warning Danger of accidents Uncontrollable vehicle handling in the event of a flat tire In the interest of safety replace damaged or worn tires immediately Your authorized Husqvarna Motorcycles workshop will be glad to help Warning D...

Page 130: ...ding 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 damage If ...

Page 131: ... last four digits of the DOT number The first two digits indicate the week of manufacture and the last two digits the year of manufacture Husqvarna Motorcycles recommends that the tires be changed after 5 years at the latest regardless of the actual state of wear If the tires are more than 5 years old Change the tires ...

Page 132: ...hese wheels are smaller than in conventional spoke wheels with a tube This results in better handling and riding comfort The rigid rim design results in a spoke wheel that is almost entirely maintenance free Husqvarna Motorcycles recommends that the tubeless sealing profile be changed after 5 years at the latest regardless of the actual state of wear 14 8 Checking the tire air pressure Info Low ti...

Page 133: ...fications Correct tire pressure Mount the protection cap 14 9 Checking spoke tension Warning Danger of accidents Instable handling due to incorrect spoke tension Ensure that the spoke tension is correct 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 short period If the spokes are too tight they can...

Page 134: ...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 135: ...attery 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 all power consumers and switch off the engine Remove the seat p 90 S01007 10 Main work Remove battery cover Pul...

Page 136: ... cable and positive cable from the battery S01010 10 Remove screws Pull retaining bracket of the battery forward and remove it 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 137: ...tment with the terminals facing rearward Battery YTZ10S p 192 Position retaining bracket and mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft S01011 10 Position washer positive cable and ABS connection cable Mount and tighten screw Guideline Screw battery terminal M6 4 5 Nm 3 32 lbf ft ...

Page 138: ...ive terminal cover Position washer and negative cable and mount and tighten the screw Guideline Screw battery terminal M6 4 5 Nm 3 32 lbf ft S01012 10 Position EFI control unit Mount battery cover Finishing work Mount the seat p 90 Set the clock p 47 ...

Page 139: ...n 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 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 War...

Page 140: ...r charging 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 c...

Page 141: ...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 142: ...ed Use only fuses with the prescribed amperage Never bypass or repair fuses Info The main fuse protects all power consumers in the vehicle It is in the housing of the starter relay next to the battery Preparatory work Switch off all power consumers and switch off the engine Remove the seat p 90 S01014 10 Main work Remove protection covers ...

Page 143: ...needed Check the functioning of the electrical equipment Mount the protection covers Finishing work Mount the seat p 90 Set the clock p 47 15 5 Changing the ABS fuses Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never bypass or repair fuses Info Two fuses for the ABS are located under the seat These fuses protec...

Page 144: ...p 90 Remove the battery cover Pull the EFI control unit from the holder and set it to one side S01017 10 Main work Unlock catch and lift off the holder S01019 11 To change the fuse of the ABS hydraulic unit Take off the protection cap and remove fuse Insert a new fuse Fuse 58011109115 p 193 Mount the protection cap ...

Page 145: ...93 Mount the protection cap Finishing work Position the EFI control unit Mount the battery cover Mount the seat p 90 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 all power consumers and switch off the engine Remove the seat p 90 ...

Page 146: ... 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 A de...

Page 147: ...fuses with the correct rating only Fuse 75011088010 p 192 Fuse 75011088015 p 193 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 90 15 7 Removing the headlight mask with the headlight Preparatory work Switch off all power consumers and switch off the engine ...

Page 148: ...over the fender with a cloth to protect it from damage Detach the brake line and wiring harness from holder Remove screws on both sides Tip the headlight mask forward E00032 10 Disconnect plug in connector of the headlight Remove the headlight mask ...

Page 149: ... with the headlight E00033 10 Main work Connect plug in connector of the headlight Check that the lighting is functioning properly E00034 10 Remove the cloth from the fender and position the headlight mask Both holding lugs engage in drilled holes of the fender ...

Page 150: ...Check the headlight setting p 151 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 all power consumers and switch off the engine Remove the headlight mask with the headlight p 145 ...

Page 151: ...ve it E00037 10 Pull out headlight bulb Insert the new headlight bulb Headlight H4 socket P43t p 193 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 147 Check the headlight setting p 151 ...

Page 152: ...atory work Switch off all power consumers and switch off the engine Remove the headlight mask with the headlight p 145 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 mask wi...

Page 153: ...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 154: ... 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 15 13 Changing the turn signal 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 ...

Page 155: ...nfo Do not touch the reflector with your fingers and keep it free from grease Lightly push the new lamp into the socket and turn all the way clockwise Turn signal RY10W socket BAU15s p 193 Check that the turn signal is functioning properly Position the diffuser Info Insert catch into recess Insert the screw and first turn counterclockwise until it engages in the thread with a small jerk Tighten th...

Page 156: ...nt temperature will not result in a risk of malfunctions S01021 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 cooling effect Dirty cooling fins also reduce the cooling effect 16 2 Checking the antifreeze and coolant level Warning Danger of scalding During motorcycle operation the coolant gets ...

Page 157: ...aminated with coolant Keep coolant out of reach of children Condition The engine is cold S01022 10 Stand the motorcycle on its side stand on a horizontal surface Remove the cover of compensating tank 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 compensatin...

Page 158: ...ycle 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 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 ...

Page 159: ...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 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 othe...

Page 160: ...ht Place a suitable container under the engine Remove screw Remove the radiator cap Completely drain the coolant Mount and tighten screw with a new seal ring Guideline Plug drain hole of water pump M10x1 15 Nm 11 1 lbf ft 16 5 Filling bleeding the cooling system Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If...

Page 161: ...zontal surface Remove radiator cap S01025 10 Refill with coolant Coolant p 200 Completely fill the radiator with coolant Mount radiator cap S01022 11 Remove the cover of compensating tank Add coolant up to the level between the two markings Mount the cover of the compensating tank ...

Page 162: ...onsciousness 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 effec tive exhaust extraction system Start the engine and let it warm up Stop the engine and allow it to cool down Check the coolant level p 156 ...

Page 163: ... Soft Set the adjusting wheel to position 1 Soft reduced homologated peak performance for better driveability Set the Map Select switch to Advanced Set the adjusting wheel to position 2 Advanced homologated performance with extremely direct responsiveness Set the Map Select switch to Standard Set the adjusting wheel to position 3 4 5 6 7 8 or 9 Standard homologated performance with balanced respon...

Page 164: ...r must not touch the rider s boot when in the basic position When the shift lever keeps touching the boot the transmission will be subject to an excessive load 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 ...

Page 165: ...h of the shift lever and shift shaft Mount shift lever on 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 Locate and tighten screw with washers Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 ...

Page 166: ...ng of the oil level viewer If the engine oil level is not at the specified level Add engine oil p 169 18 2 Changing the engine oil and oil filter cleaning the oil screens Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water Warning Environmental haz...

Page 167: ...hile the engine is at operating temperature H01066 10 Main work Place a suitable container under the engine Remove oil filler plug with the O ring from the clutch cover E00041 10 Remove oil drain plug with the magnet and seal ring Completely drain the engine oil ...

Page 168: ...net M12x1 5 20 Nm 14 8 lbf ft E00043 10 Remove screws Remove oil filter cover with the O ring Pull oil filter out of the oil filter housing Circlip pliers reverse 51012011000 E00044 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 169: ...rings E00046 10 Remove screw plug with oil screen and the O rings Completely drain the engine oil Thoroughly clean the parts and sealing surfaces E00047 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 ...

Page 170: ... the O ring of the oil filter cover Position oil filter cover Mount and tighten screws Guideline Screw oil filter cover M5x16 6 Nm 4 4 lbf ft E00050 10 Insert oil filter Lubricate the O ring of the oil filter cover Position oil filter cover Mount and tighten screws Guideline Screw oil filter cover M5x16 6 Nm 4 4 lbf ft Fill up with engine oil at the clutch cover Engine oil 1 70 l 1 8 qt Engine oil...

Page 171: ... 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 effec tive exhaust extraction system Start the engine and check that it is oil tight Finishing work Check the engine oil level p 164 18 3 Adding engine oil Info Too little engine oil or poor quality eng...

Page 172: ...ug with the 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 ventilation and do not start or run the engine in an enclosed space without an effec tive exhaust extraction system Start the engine and check that it is oil tight Finishing work Check the engine oil level p ...

Page 173: ...rs fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info To maintain the value and appearance of the motorcycle over a long period clean it regularly Avoid direct sunshine when cleaning the motorcycle 401061 01 Close off the exhaust system to keep water from entering Remove loose dirt first with a soft jet of water Spray very dirty parts with a normal com...

Page 174: ... the brake system to evaporate Push back the protection caps of the handlebar controls to allow any water that has penetrated to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Clean the chain p 95 Treat bare metal except for brake discs and the exhaust system with a corrosion inhibitor Preserving materials for paints metal and rubber p 203 Treat all painted p...

Page 175: ...le p 171 Clean the brake system Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings with cold water and dry carefully This should be done after 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...

Page 176: ... for a longer period perform the following steps or have them performed Before storing the motorcycle check all parts for function and wear If service repairs or replacements are necessary you should do this during the storage period less workshop overload In this way you can avoid long workshop waiting times at the start of the new season 401058 01 When refueling for the last time before taking t...

Page 177: ...se non porous materials since they prevent humidity 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 Take the motorcycle off of the front wheel stand p 86 Remove the rear of t...

Page 178: ... in gear and the side stand is folded out Shift gear to neutral The engine turns but does not start Operating error Carry out the start procedure p 57 Fuse 3 blown Change the fuses of individual power consumers p 143 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...

Page 179: ...ose Thermostat is faulty Check the thermostat Fuse 4 blown Change the fuses of individual power consumers p 143 Defect in radiator fan system Check the radiator fan system Air in cooling system Fill bleed the cooling system p 158 FI warning lamp MIL lights flashes Defect in fuel injection system Read out the fault memory using the Husqvarna Motorcycles diagnostics tool N The idling speed indicator...

Page 180: ...and oil filter and clean the oil screens p 164 Headlight and parking light are not functioning Fuse 6 blown Change the fuses of individual power consumers p 143 Turn signal brake light and horn not functioning Fuse 5 blown Change the fuses of individual power consumers p 143 Time is not correctly displayed Fuse 1 blown Change the fuses of individual power consumers p 143 Set the clock p 47 Battery...

Page 181: ...warning lamp MIL 12 FI warning lamp MIL flashes 1x long 2x short Error level condition Engine coolant temperature sensor input signal too low Engine coolant temperature sensor input signal too high Blink code FI of 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 ...

Page 182: ...t Error level condition Lambda sensor cylinder 1 sensor 1 circuit fault Blink code FI of warning lamp MIL 22 FI warning lamp MIL flashes 2x long 2x short Error level condition Gear position sensor circuit fault Blink code FI of warning lamp MIL 24 FI warning lamp MIL flashes 2x long 4x short Error level condition System voltage circuit fault Blink code FI of warning lamp MIL 25 FI warning lamp MIL...

Page 183: ...nder 1 circuit fault Blink code FI of warning lamp MIL 37 FI warning lamp MIL flashes 3x long 7x short Error level condition Ignition coil 1 cylinder 1 circuit fault Blink code FI of warning lamp MIL 39 FI warning lamp MIL flashes 3x long 9x short Error level condition Ignition coil 2 cylinder 1 circuit fault Blink code FI of warning lamp MIL 41 FI warning lamp MIL flashes 4x long 1x short Error l...

Page 184: ...und or open circuit Fuel evaporation valve input signal too high Blink code FI of warning lamp MIL 65 FI warning lamp MIL flashes 6x long 5x short Error level condition E PROM Error Blink code FI of warning lamp MIL 82 FI warning lamp MIL flashes 8x long 2x short Error level condition Throttle position sensor circuit A input signal too low Throttle position sensor circuit A input signal too high B...

Page 185: ... low Accelerator position sensor circuit A input signal too high Blink code FI of warning lamp MIL 86 FI warning lamp MIL flashes 8x long 6x short Error level condition Accelerator position sensor circuit B input signal too high Blink code FI of warning lamp MIL 87 FI warning lamp MIL flashes 8x long 7x short Error level condition Accelerator position sensor circuit A and B plausibility fault Blin...

Page 186: ...E DBW internal power relay stuck in ACTIVE Blink code FI of warning lamp MIL 92 FI warning lamp MIL flashes 9x long 2x short Error level condition DBW throttle actuator control IC stuck open Blink code FI of warning lamp MIL 93 FI warning lamp MIL flashes 9x long 3x short Error level condition CPU mutual surveillance error Blink code FI of warning lamp MIL 94 FI warning lamp MIL flashes 9x long 4x...

Page 187: ...hes 9x long 5x short Error level condition DBW stop function system error stop function B system error Blink code FI of warning lamp MIL 96 FI warning lamp MIL flashes 9x long 6x short Error level condition System voltage input voltage too low System voltage input signal too high ...

Page 188: ... diameter exhaust 34 mm 1 34 in Valve play cold 0 07 0 13 mm 0 0028 0 0051 in Crankshaft bearing 2 roller bearings Conrod bearing Needle bearing Piston pin bearing Piston pin with DLC coating Pistons Forged light alloy Piston rings 1 L ring 1 tapered compression piston ring 1 oil scraper ring Engine lubrication Semi dry sump lubrication system with two rotor pumps Primary transmission 36 79 Clutch...

Page 189: ...ing permanent circulation of coolant by water pump Starting aid Electric starter automatic decompressor 23 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 conrod bearing lubrica tion M4 2 Nm 1 5 lbf ft Loctite 243 Locking screw for bearing M5 6 Nm 4 4 lbf ft Loctite 243 Remaining screws engine M5 6 Nm ...

Page 190: ...ft M6 10 Nm 7 4 lbf ft Loctite 243 Screw clutch cover M6 10 Nm 7 4 lbf ft Screw clutch slave cylinder M6x20 10 Nm 7 4 lbf ft Loctite 243 Screw clutch slave cylinder M6x35 10 Nm 7 4 lbf ft Loctite 243 Screw crankshaft position sensor M6x16 10 Nm 7 4 lbf ft Loctite 243 Screw cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw engine case M6 10 Nm 7 4 lbf ft Screw ignition coil M6 10 Nm 7 4 lbf ft Screw l...

Page 191: ...ankshaft clamp screw plug M8 15 Nm 11 1 lbf ft Stud exhaust flange M8 10 Nm 7 4 lbf ft Loctite 243 Cylinder head screw M10 Tightening sequence Tighten diagonally begin ning with the rear screw on the timing chain shaft Step 1 15 Nm 11 1 lbf ft Step 2 30 Nm 22 1 lbf ft Step 3 45 Nm 33 2 lbf ft Step 4 60 Nm 44 3 lbf ft Lubricated with engine oil Oil line for oil pressure sensor M10x1 10 Nm 7 4 lbf f...

Page 192: ...M14x1 5 15 Nm 11 1 lbf ft Loctite 243 Engine case stud M16x1 5 25 Nm 18 4 lbf ft Loctite 243 Rotor nut M18x1 5 100 Nm 73 8 lbf ft Nut engine sprocket M20x1 5 80 Nm 59 lbf ft Loctite 243 Nut inner clutch hub M20x1 5 100 Nm 73 8 lbf ft Loctite 243 Nut primary gear M20LHx1 5 90 Nm 66 4 lbf ft Loctite 243 Plug oil screen M20x1 5 15 Nm 11 1 lbf ft Plug timing chain tensioner M20x1 5 25 Nm 18 4 lbf ft P...

Page 193: ...me molybdenum steel tubing powder coated Fork WP Performance Systems 4860 ROTA SPLIT Shock absorber WP Performance Systems 4618 with Pro Lever linkage Suspension travel Front 215 mm 8 46 in Rear 250 mm 9 84 in Brake system Front Disc brake with radially screwed four piston brake caliper float ing brake disc Rear Disc brake with single piston brake caliper floating Brake discs diameter Front 320 mm...

Page 194: ... 4 X ring Steering head angle 63 Wheelbase 1 485 15 mm 58 46 0 59 in Seat height unloaded 915 mm 36 02 in Ground clearance unloaded 275 mm 10 83 in Weight without fuel approx 147 kg 324 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 23 5 Electrical system Battery YTZ10S Battery voltage 12 V Nomi...

Page 195: ...amps LED Turn signal RY10W socket BAU15s 12 V 10 W Brake tail light LED License plate lamp LED 23 6 Tires Front tires Rear tires 120 70 R 17 M C 58H TL Continental ContiAttack SM 160 60 R 17 M C 69H TL Continental ContiAttack SM Additional information is available in the Service section under www husqvarna motorcycles com 23 7 Fork Fork part number 14 15 8P 12 Fork WP Performance Systems 4860 ROTA...

Page 196: ... 43 in Spring rate Medium standard 5 6 N mm 32 lb in Air chamber length 110 20 30 mm 4 33 0 79 1 18 in Fork length 895 mm 35 24 in Fork oil per fork leg 640 ml 21 64 fl oz Fork oil SAE 4 48601166S1 p 201 23 8 Shock absorber Shock absorber article number 15 15 7P 12 Shock absorber WP Performance Systems 4618 with Pro Lever linkage Compression damping low speed Comfort 25 clicks Standard 15 clicks S...

Page 197: ...ard 15 clicks Sport 10 clicks Full payload 10 clicks Spring preload 21 mm 0 83 in Spring rate Medium standard 75 N mm 428 lb in Hard 80 N mm 457 lb in Spring length 220 mm 8 66 in Gas pressure 10 bar 145 psi Static sag 25 mm 0 98 in Riding sag 70 75 mm 2 76 2 95 in Fitted length 395 mm 15 55 in Shock absorber fluid Shock absorber fluid SAE 2 5 50180751S1 p 201 ...

Page 198: ...f 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 9 lbf ft Loctite 243 Screw fuel hose clamp on fuel tank M5 5 Nm 3 7 lbf ft Screw fuel level sensor M5 3 Nm 2 2 lbf ft Scr...

Page 199: ...nal M6 4 5 Nm 3 32 lbf ft Screw brake assembly M6 5 Nm 3 7 lbf ft Screw brake fluid reservoir of rear brake M6 5 Nm 3 7 lbf ft Screw chain guard M6 2 Nm 1 5 lbf ft Loctite 243 Screw chain guide M6 8 Nm 5 9 lbf ft Screw chain sliding guard M6 8 Nm 5 9 lbf ft Loctite 243 Screw clutch assembly M6 5 Nm 3 7 lbf ft Screw front brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Screw ignition lock M6 10 Nm 7 4 ...

Page 200: ...nection lever on frame M8 30 Nm 22 1 lbf ft Loctite 243 Screw foot brake lever M8 25 Nm 18 4 lbf ft Loctite 243 Screw fork stub M8 15 Nm 11 1 lbf ft Screw front footrest bracket M8 25 Nm 18 4 lbf ft Screw fuel tank bracket M8 15 Nm 11 1 lbf ft Screw fuel tank bottom M8 25 Nm 18 4 lbf ft Loctite 243 Screw fuel tank top M8 25 Nm 18 4 lbf ft Loctite 243 Screw grab handle M8 10 Nm 7 4 lbf ft Screw han...

Page 201: ...crew handlebar support M10 45 Nm 33 2 lbf ft Loctite 243 Screw side stand M10 35 Nm 25 8 lbf ft Loctite 243 Screw top shock absorber M10 45 Nm 33 2 lbf ft Loctite 243 Banjo bolt brake line M10x1 25 Nm 18 4 lbf ft Screw front brake caliper M10x1 25 45 Nm 33 2 lbf ft Loctite 243 Screw swingarm pivot M12 80 Nm 59 lbf ft Lambda sensor M12x1 25 25 Nm 18 4 lbf ft Copper paste Nut linkage lever on swinga...

Page 202: ...uper DOT 4 Brake Fluid Coolant Guideline Only use high quality coolant with corrosion inhibitor for aluminum motors even in countries with high temperatures Using inferior antifreeze can result in corrosion and foaming Mixture ratio Antifreeze protection 25 45 C 13 49 F anti corrosion antifreeze distilled water Recommended supplier Bel Ray Moto Chill Racing Coolant Engine oil SAE 10W 50 Standard c...

Page 203: ...t 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 standards see specifications on the container and that exhibit the corresponding prop erties Super unleaded ROZ 95 RON 95 PON 91 Standard clas...

Page 204: ...24 SUBSTANCES 202 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: ...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 207: ...ing of the wheels when driving straight ahead without the influence of lateral forces MIL Malfunction indicator lamp Indicator lamp that supports vehicle diagnostics through flash codes OBD On board diagnosis Vehicle system that monitors emission and safety related values ...

Page 208: ...28 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: ...ntervention 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 when an error is detected The low fuel warning lamp lights up orange The fuel level has reached the reserve mark FI warning lamp MIL lights up flashes orange The OBD has detected an emission or safety critical fault 29 3 Green and ...

Page 210: ...29 LIST OF SYMBOLS 208 Turn signal indicator lamp flashes green The turn signal is switched on ...

Page 211: ...ing 115 Brake fluid level front brake checking 110 rear brake checking 115 Brake linings front brake checking 112 rear brake checking 117 Brakes 62 C Capacity coolant 191 engine oil 168 190 fuel 67 191 Chain checking 99 cleaning 95 dirt checking for 95 Chain guide checking 99 setting 104 Chain tension adjusting 98 checking 96 Changing the headlight bulb 148 Chassis number 28 Checking the headlight...

Page 212: ...9 changing 164 Engine oil level checking 164 Engine sprocket checking 99 Environment 19 F Figures 22 Filler cap closing 38 opening 37 Foot brake lever 41 basic position adjusting 114 free travel checking 113 Fork 72 compression damping adjusting 72 dust boots cleaning 86 rebound adjusting 73 Fork part number 31 Fork protector installing 87 removing 87 Front fender installing 92 removing 92 Front w...

Page 213: ...ght switch 34 Loading the vehicle 54 Luggage 54 M Main fuse changing 140 Motorcycle cleaning 171 raising with the front wheel stand 85 raising with the rear wheel stand 84 removing the rear from the wheel stand 84 taking off of the front wheel stand 86 O Oil filter changing 164 Oil screens cleaning 164 Operating substances 21 Owner s Manual 20 P Parking 64 Parking light bulb changing 150 Passenger...

Page 214: ...3 basic position checking 162 Shifting 59 Shock absorber 72 compression damping general 74 high speed compression damping adjusting 75 low speed compression damping adjusting 74 rebound damping adjusting 76 riding sag checking 79 spring preload adjusting 79 static sag checking 78 Shock absorber article number 31 Side cover mounting 91 removing 91 Side stand 42 Spare parts 21 Speedometer activation...

Page 215: ...186 engine tightening torques 187 fork 193 shock absorber 194 tires 193 Throttle grip 33 Tire air pressure checking 130 Tire condition checking 127 Transport 65 Troubleshooting 176 178 Tubeless tire system 130 Turn signal bulb changing 152 Turn signal switch 34 Type label 29 U Use definition 9 V View of vehicle front left 24 rear right 26 W Warranty 21 Winter operation checks and maintenance steps...

Page 216: ... 3402073en 3402073en 10 2015 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria www husqvarna motorcycles com Photo Mitterbauer Husqvarna Motorcycles GmbH ...

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