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Husqvarna F2101O1, Repair Manual

The Husqvarna F2101O1 Repair Manual is a comprehensive and essential resource for users of this powerful outdoor equipment. With detailed instructions and troubleshooting tips, this manual is available for free download from manualshive.com. Unlock the full potential of your Husqvarna F2101O1 with this invaluable resource.

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17  ENGINE 

-

Remove needle bearing 

G,.

17.4.37  Disassembling  the countershaft 

306558-10 

-

Secure the countershaft with the toothed end facing downward in the bench vise.
Guideline

I 

Using soft jaws

-

Remove stop disk 

O 

and first-gear idler gear 

@.

-

Remove needle bearing 

fs) 

and stop disk 

C,.

-

Remove fifth-gear sliding gear 

0.

-

Remove lock ring  (D.

-

Remove stop disk  @.

-

Remove third-gear idler gear 

fD 

and needle bearing@).

-

Remove stop disk  Gi).

-

Remove lock ring 

G,.

-

Remove fourth-gear sliding gear 

48.

-

Remove lock ring 

48.

-

Remove stop disk 

4D.

-

Remove second-gear idler gear 

e 

and needle bearing 

4D).

17.4.38  Checking the transmission 

Condition 

The transmission has been disassembled. 

162 

Summary of Contents for F2101O1

Page 1: ...PIONEERING SINCE 1903 REPAIR MANUAL2015 FC250 Art no 3403012en Husqvarna MOTORCYCLES ...

Page 2: ......

Page 3: ...ithout prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice Husqvarna accepts no lia bility for delivery options deviations from illustrations and descriptions as well as misprints and other errors The models portrayed partly contain special equipment that does not belong to the regular scope of supp...

Page 4: ...the handlebar position 36 8 9 7 3 Adjusting the basic position of the clutch 2 lever 36 7 4 Checking the throttle cable routing 37 7 5 Checking the play in the throttle cable 37 7 6 Adjusting the play in the throttle cable 38 FRAME 39 8 1 Checking the frame 39 SHOCK ABSORBER SWINGARM 40 9 1 Adjusting the high speed compression damping of the shock absorber 40 9 2 Adjusting the low speed compressio...

Page 5: ... the front brake fluid level 106 16 6 Adding front brake fluid 107 16 7 Changing the front brake fluid 108 3 16 8 Checking the rear brake linings 109 16 9 Changing the rear brake linings 109 16 10 Checking the free travel of foot brake lever 111 16 11 Adjusting the basic position of the foot brake lever 111 16 12 Checking the rear brake fluid level 112 16 13 Adding rear brake fluid 112 16 14 Chang...

Page 6: ...stalling the locking lever 170 Installing the shift drum locating unit 170 Installing the shift shaft 171 Installing the clutch basket 171 Installing the clutch discs 172 Installing the clutch cover 172 Installing the water pump cover 173 Installing the starter drive 174 18 19 20 21 22 23 17 5 20 17 5 21 17 5 22 17 5 23 17 5 24 17 5 25 4 Installing the rotor and ignition pulse generator 174 Instal...

Page 7: ...fter storage 205 27 SERVICE SCHEDULE 206 27 1 Service schedule 206 27 2 Service work as additional order 207 28 WIRING DIAGRAM 208 28 1 Page 1 of 3 FC 250 EU 208 28 2 Page 2 of 3 FC 250 EU 210 28 3 Page 3 of 3 FC 250 EU 212 28 4 Page 1 of 3 FC 250 US 214 28 5 Page 2 of 3 FC 250 US 216 28 6 Page 3 of 3 FC 250 US 218 29 SUBSTANCES 220 30 AUXILIARY SUBSTANCES 221 31 SPECIAL TOOLS 223 32 STANDARDS 235...

Page 8: ...e Indicates information with more details or tips Indicates the result of a testing step V Denotes a voltage measurement A Denotes a current measurement Denotes a resistance measurement 1 2 Formats used The typographical formats used in this document are explained below Proprietary name Name Brand Underlined terms Identifies a proprietary name Identifies a protected name Identifies a trademark Ref...

Page 9: ...riate measures are not taken Warning Indicates a danger 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 Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken Warning Indicates a danger that...

Page 10: ...g of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system Use the operating and auxiliary substances such as fuel and lubricants as specified in the manual 3 3 Spare parts accessories Only use spare parts and accessories approved and or recommended by Husqvarna Husqvarna accepts no liability for other prod ucts and any resulting damage or los...

Page 11: ...ering head The type label O is fixed to the front of the steering head The engine number O is stamped on the left side of the engine under the engine sprocket The fork part number O is stamped on the inner side of the axle clamp The shock absorber article number O is stamped on the top of the shock absorber above the adjusting ring towards the engine side 9 ...

Page 12: ...plug in stand O into the left side of the wheel spindle Info Remove the plug in stand before starting on a trip 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 Engine damage High revving speed ...

Page 13: ...s 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 Info Press the starter for a maximum of 5 seconds Wait for a least 5 seconds before trying again 400733 01 Shift the transmission to idle Press the electric starter button Info Do not open the throttle 11 ...

Page 14: ...ckwise to increase damping turn counterclockwise to reduce damping Adjusting the rebound dam ing of the fork Info The hydraulic rebound damping determines the fork suspension behavior Bleeding the fork legs Turn the red adjusting screw O all the way clockwise Info I Adjusting screw O is located at the upper end of the right fork leg The rebound damping is located in the right fork leg red adjustin...

Page 15: ... oil seals behind can start to leak Warning Danger of accidents Oil or grease on the brake discs reduces the brak ing 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 I Universal oil spray I p 222 Press the dust boots back into their normal position Remove excess oil...

Page 16: ... milled groove from the top must be flush with the top edge of the upper triple clamp Tighten screws Guideline I Screw top triple clamp Tighten screws CD Guideline I Screw bottom triple clamp Position the brake caliper Mount and tighten screws C Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft 17 Nm 12 5 lbf ft 12 Nm 8 9 lbf ft Loctite 243 Position the brake line and clamp Mount and tighte...

Page 17: ... the cartridge a p 18 Disassemble the piston rod a p 20 Disassemble the hydrostop unit 1 1 p 21 Disassemble the seal ring retainer p 22 Check the fork legs p 22 Assemble the seal ring retainer p 23 Assemble the hydrostop unit a p 24 Assemble the piston rod a p 25 Assemble the cartridge a p 26 0 r t Assemble the fork legs p 27 II i oo 0 201926 01 Disassembling the fork legs Info The steps are ident...

Page 18: ...he outer tube down Drain the fork oil Clamp the fork leg with the axle clamp Release hydrostop unit 0 and remove it Info I Do not use an impact wrench Place a pan underneath since oil will run out Remove the cartridge from the fork leg I Press out tool T14051 p 234 Info I Removing the O ring seat from the cartridge usually requires the applica tion of force Remove dust boot 3 Remove fork protectio...

Page 19: ... Info I The lower sliding bushing must be pulled out of its bearing seat Remove the upper sliding bushing Info Do not use a tool pull the ends apart slightly by hand Take off the lower sliding bushing Take off support ring Take off seal ring a Take off lock ring Take off dust boot D Unclamp the fork leg The steps are identical for both fork legs Preparatory work Disassemble the fork legs l l p 15 ...

Page 20: ... e Info The steps are identical for both fork legs 202480 10 201726 12 Preparatory work Disassemble the fork legs ill p 15 Remove the spring ill p 17 Main work Degrease piston rod O and clamp it in the vise I Clamping stand T14049S ill p 234 Remove adjusting tube Unscrew spring guide CD Remove spring seat 8 Pull the piston rod out of the cartridge Clamp the tube of the cartridge into a vise I Clam...

Page 21: ...ngs CB Disassembling the cartridge Info The steps are identical for both fork legs j 202480 10 t 201726 12 Preparatory work Disassemble the fork legs a p 15 Remove the spring a p 17 Main work Degrease piston rod O and clamp it in the vise I Clamping stand T14049S a p 234 Remove adjusting tube Unscrew spring guide s Remove spring seat C Pull the piston rod out of the cartridge 19 ...

Page 22: ... are identical for both fork legs except for the hydrostop needle and valve e 201728 10 Preparatory work Disassemble the fork legs l l p 15 Remove the spring l l p 17 Disassemble the cartridge l l p 19 Main work Degrease the piston rod Clamp the piston rod with the special tool as far up as possible I Clamping stand T14049S l l p 234 Release hydrostop needle O and remove it from the piston rod The...

Page 23: ... and washer Remove spring Remove valve needle 0 from the piston rod Info The adjusting tube can be used for this Disassembling the h drostoR unit Info The steps are identical for both fork legs Preparatory work Disassemble the fork legs l l p 15 Main work Mount the hydrostop unit on a fitting hexagon socket and clamp into a vice Remove sleeve O Remove shim stack 8 21 ...

Page 24: ... the seal rin retainer Info The steps are identical for both fork legs Checking the fork legs 200728 10 Preparatory work Disassemble the fork legs 1 1 p 15 Remove the spring 1 1 p 17 Disassemble the cartridge 1 1 p 19 Main work Remove pilot bushing support O Remove O ring 8 and seal ring CD Condition The fork legs have been disassembled Check the inner tube and axle clamp for damage If there is da...

Page 25: ...1 937 in If the measured value is larger than the specified value Change the outer tube Check the outer tube for damage If there is damage Change the outer tube Check the surface of the sliding bushings 23 If the bronze colored layer G under sliding layer 0 is visible or the surface is rough e 200665 10 200666 10 Change the sliding bushings Check the spring length Guideline I Spring length with pr...

Page 26: ...ing downward Mount the new O ring on hub C Mount the hub with washers Info I It is possible that only one or no washer is present Mount and tighten adapter D Guideline I Hydrostop unit adapter I M6x0 5 I 7 Nm 5 2 lbf ft Mount shim stack with the smaller washers facing downward Mount and tighten sleeve Q Guideline I Hydrostop unit sleeve I M6x0 5 Check distance 8 and total length of the hydrostop G...

Page 27: ...t T158 IOI p 221 Mount spring 8 Mount and tighten adapter CD with spring e and washer Guideline I Adapter of piston rod I M6x0 5 Position the spring 112 Nm 8 9 lbf ft Mount the compression shim stack 0 with the smaller washers facing down ward Grind the piston on both sides on a surfacing plate using 1200 grit sandpaper Clean the piston Lubricate the piston ring I Fork oil SAE 4 48601166S1 p 220 M...

Page 28: ...Main work Mount and grease seal rings O and O ring I Lubricant T158 11 l p 221 Mount and lubricate pilot bushings 8 I Fork oil SAE 4 48601166S1 a p 220 Check the length of the reservoir spring Guideline Reservoir spring length with preload spacer If the length is out of tolerance Correct the preload spacers 46 mm 1 81 in Position the spring with the preload spacers in the reservoir Position sleeve...

Page 29: ...esponding screw cap Compression damping side screw cap with mark COMP brake caliper holder white adjuster Rebound damping side screw cap with mark REB no brake caliper holder red adjuster 201714 10 Preparatory work Assemble the hydrostop unit a p 24 Main work Clamp the inner tube with the axle clamp Guideline I Use soft jaws Mount special tool I Protecting sleeve T1401 p 233 Lubricate and mount du...

Page 30: ...ower sliding bushing Guideline 1 so 0 c 122 F Slide the outer tube onto the inner tube Hold the lower sliding bushing with the longer section of the special tool I Mounting tool T14040S p 233 Push the sliding bushing all the way into the outer tube Position the support ring Hold the seal ring with the shorter section of the special tool I Mounting tool T14040S p 233 Push the seal ring and support ...

Page 31: ...he remaining quantity of fork oil I M30x1 I 40 Nm 29 5 lbf ft I Pull out the piston rod and push it back in numerous times while pressing it to one side slightly Air bubbles emerge and the cartridge is bled Keep bleeding until no more air bubbles emerge The piston rod moves out automatically to the middle of the total stroke distance Info I When fully bled the correct air chamber length is achieve...

Page 32: ... compression damping G i mark COMP and the adjuster of rebound damping 41 mark REB all the way clockwise Guideline Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Turn counterclockwise by the number of clicks corresponding to the fork type Alternative 2 Warning Danger of accident Modifications to the susp...

Page 33: ...3 Remove the start number plate ll J p 82 Remove the front fender ll J p 82 Remove the handlebar cushion Main work Take off cable holder O in front of the left radiator Remove screw 8 Remove screw 8 Take off the upper triple clamp with the handlebar and set it aside Info I Protect the components against damage by covering them Do not bend the cables and lines Remove O ring C Remove protective ring...

Page 34: ...lamp with the steering Mount screw 8 but do not tighten yet Position the fork legs Bleeder screws 0 face forward Info I The rebound damping is located in the right fork leg red adjusting screw The compression damping is located in the left fork leg white adjusting screw Grooves are milled into the side of the upper end of the fork legs The sec ond milled groove from the top must be flush with the ...

Page 35: ...ront fender a p 82 Install the start number plate p 83 Install the front wheel p 86 Check that the wiring harness cables and brake and clutch lines can move freely and are routed correctly Check the steering head bearing play p 33 Remove the motorcycle from the lift stand a p 10 Mount the handlebar cushion Checking the steering head bearing la Warning Danger of accidents Incorrect steering head be...

Page 36: ...lick positions are noticeable Adjust the play of the steering head bearing Ii p 35 Check the steering head bearing and change if necessary Finishing work Remove the motorcycle from the lift stand I p 10 Changing the steering head bearing Preparatory work Raise the motorcycle with a lift stand Ii p 10 Remove the front wheel Ii p 86 Remove the fork legs p 13 Remove the start number plate a p 82 Remo...

Page 37: ...eering head bearing play 0 p 33 Remove the motorcycle from the lift stand 0 p 10 Mount the handlebar cushion Adjusting the play of the steering head bearing Preparatory work Raise the motorcycle with a lift stand p 10 Remove the handlebar cushion Main work Loosen screws O Remove screw 8 Loosen and retighten screw s Guideline I Screw top steering head I M20x1 5 112 Nm 8 9 lbf ft Using a plastic ham...

Page 38: ...emove the handlebar support Place the handlebar support in the required position Mount and tighten screws 8 Guideline Screw handlebar support M10 Info 40 Nm 29 5 lbf ft Position the left and right handlebar supports evenly Position the handlebar Info Loctite 243 I Make sure the cables and wiring are positioned correctly Position the handlebar clamps Mount and tighten screws O evenly Guideline I Sc...

Page 39: ...ght ahead position Turn the throttle grip back and forth slightly and determine the play in throttle cable G I Throttle cable play 13 5 mm 0 12 0 2 in If the throttle cable play does not meet specifications Adjust the play in the throttle cable p 38 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient vent...

Page 40: ...ible 38 Loosen nut 8 Turn adjusting screw 0 so that there is play in the throttle cable at the throttle grip Guideline I Throttle cable play 13 5 mm 0 12 0 2 in Tighten nut 8 Press and hold the throttle grip in the closed setting Turn adjusting screw out until there is no play in the throttle cable 0 Tighten nut Push sleeves O on Check the throttle grip for smooth operation Finishing work Check th...

Page 41: ...d deformation If the frame exhibits cracking or deformation due to a mechanical impact Change the frame Info 39 I A frame that has been damaged due to a mechanical impact must always be changed Repair of the frame is not authorized by Husq varna ...

Page 42: ...n clockwise to increase damping turn counterclockwise to reduce damping Adjusting the low 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 nitrogen Please follow the description provided Info The low speed setting can be seen during th...

Page 43: ...asurin rear wheel sa unloaded Preparatory work Raise the motorcycle with a lift stand p 10 Main work Measure the distance as vertical as possible between the rear axle and a fixed point for example a mark on the side cover Note down the value as dimension f Finishing work Remove the motorcycle from the lift stand il l p 10 Checkin the static sag of the shock absorber Measure distance f of rear whe...

Page 44: ...sorber is disassembled incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided 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 a lift stand 0 p 10 Remove the seat 0 p 73 Remove the right side cover 0 p 72 Remove the main silencer 0 ...

Page 45: ... 65 75 kg 143 165 lb Weight of rider 75 85 kg 165 187 lb Weight of rider 85 95 kg 187 209 lb Info 51 N mm 291 lb in 54 N mm 308 lb in 57 N mm 325 lb in I The spring rate is shown on the outside of the spring Finishing work Install the shock absorber 11 1 p 44 Install the main silencer l I p 68 Install the right side cover l I p 73 Mount the seat 0 p 73 Check the static sag of the shock absorber 0 ...

Page 46: ...ff the manifold Remove screws on both sides Loosen screws on both sides Remove screw Raise the rear frame slightly and remove the shock absorber toward the top Main work Raise the rear frame slightly and insert the shock absorber from above Position the shock absorber Mount and tighten screw O Guideline Screw top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 44 ...

Page 47: ...uideline 30 Nm 22 1 lbf ft 30 Nm 22 1 lbf ft I Nut linkage lever to angle lever I M14x1 5 Mount and tighten screw Guideline Screw bottom shock absorber Finishing work M10 Install the main silencer p 68 Install the right side cover p 73 Mount the seat p 73 60 Nm 44 3 lbf ft Remove the motorcycle from the lift stand p 10 9 11 Checkin the shock absorber linkage Preparatory work Raise the motorcycle w...

Page 48: ...s damage or wear Change the spacers Check the shaft seal rings for damage and wear If there is damage or wear Change the shaft seal rings Check dimension 6 303096 10 I 54 91 55 00 mm 2 1618 2 1654 in If dimension 6 is less than the specified value Add the corresponding spacing washers D Position the angle lever Mount screw connection CD but do not tighten yet Guideline I Nut linkage lever on swing...

Page 49: ...t I Nut linkage lever on swingarm I M14x1 5 Servicing 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 follow the description provided 201457 01 Condition The shock absorber has been removed Remove the spring a p 48 Disassemble the damper I p 48 Di...

Page 50: ...no longer under tension I Hook wrench T106S p 231 Remove ring 8 Remove spring retainer and intermediate washer C Remove the spring Disassembling the dam er 0 Preparatory work Remove the spring p 48 Main work Note down the current state of rebound damping O and compression damp ing 8 Completely open the adjusters of the rebound and compression damping Remove rubber cap of the reservoir Open screw C...

Page 51: ...mbly tool T1216 a p 232 Remove lock ring Info Do not scratch the inner surface Remove the piston rod Remove adjusting ring with the intermediate washer Drain the oil Remove compression adjuster Remove the spring and piston iston rod Preparatory work Remove the spring a p 48 Disassemble the damper a p 48 49 ...

Page 52: ...n as a unit Remove piston 8 Remove compression shim stack 0 Info I Place the compression shim stack onto a screwdriver and set it down as a unit Remove rebound washer D Remove seal ring retainer Remove locking cap and rubber buffer Disassembling the seal ring retainer 201405 10 Preparatory work Remove the spring p 48 Disassemble the damper p 48 Disassemble the piston rod p 49 Main work Remove spri...

Page 53: ...ing O onto the special tool I Press drift T1504 l t J p 234 Position the pilot bushing in the seal ring retainer using the special tool I Press drift T1504 p 234 Support seal ring retainer 8 with sleeve f of the special tool Press the pilot bushing all the way in I Assembly tool T150S 0 p 234 Lubricate the special tool Shock absorber fluid SAE 2 5 50180751S1 a p 220 Calibration pin T1205 I p 232 S...

Page 54: ...diameter of the piston rod Piston rod Diameter 17 95 mm 0 7067 in If the measured value is less than the specified value Change the piston rod Measure the run out of the piston rod I Piston rod Run out I s 0 02 mm s 0 0008 in If the measured value is greater than the specified value Change the piston rod Check the piston rod for damage and wear If there is damage or wear Change the piston rod Chec...

Page 55: ... tool f underneath and press out heim joint D with special tool I Pressing tool T1207S il l p 232 Position the new heim joint O and the special tool into a vise as shown Guideline I Use soft jaws I Pressing tool T1206 il l p 232 Press the heim joint all the way in Press the heim joint against the lock ring using the special tool I Pressing tool T1207S il l p 232 Mount the second lock ring 8 Mount ...

Page 56: ...ing sleeve T1204 a p 231 Lubricate the sealing lip of the dust boot I Lubricant T625 l ll p 221 Mount washer Position washer Don seal ring e Grease seal ring 8 and mount with the washer facing downward I Lubricant T511 l t I p 221 Mount centering disk Mount rebound rubber 0 Lubricate the groove of the O ring I Lubricant T158 I p 221 Mount O ring Mount spring 54 ...

Page 57: ...unting sleeve T1215 a p 232 Grease the dust boot and push seal ring retainer onto the piston rod I Lubricant T625 a p 221 Remove the special tool Mount rebound washer 8 with the cut out facing downward Mount the compression shim stack 0 with the smaller shims facing downward Sand both sides of piston D on a surface plate using 1200 grit sandpaper Clean the piston Assemble the piston Guideline View...

Page 58: ...icate the threads I Lubricant T159 a p 221 Mount the piston with the spring Mount and tighten the compression adjuster 0 Guideline I Compression adjuster Clamp the damper in a bench vise Guideline I Use soft jaws I M31x1 Mount adjusting ring with the intermediate washer Info 56 I 45 Nm 33 2 lbf ft I I 45 Nm 33 2 lbf ft I The adjusting ring cannot be mounted after the piston rod is mounted Fill the...

Page 59: ...pti ble click Turn counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Compression damping low speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Turn adjusting screw all the way clockwise with a socket wrench Turn counterclockwise by the number of turns corresponding to the shock absorber type Guideline Compression damping high speed Comfort 2 5 tur...

Page 60: ...10 Remove the screw of the filling port Install adapter O on the damper Info I Tighten only hand tight without the use of tools Connect the adapter O to connector of the vacuum pump I Vacuum pump T1240S l ll p 233 Clamp the damper with soft jaws or hold it as shown in the figure Info I Clamp the damper only lightly The filling port must be at the highest point The piston rod slides in and out duri...

Page 61: ...fied value turn the Damper C con trol lever to Vacuum Guideline 3 bar The pressure gauge drops to the specified value 0 bar When the pressure gauge reaches the specified value turn the Oil reservoir 0 control lever to Vacuum Guideline 0 bar The vacuum gauge falls to the specified value 8 mbar When the vacuum pressure gauge reaches the specified value turn the Oil reser voir control lever 0 to Equa...

Page 62: ...ly extended otherwise damage will occur during compression of the shock absorber Remove the special tool Remove adapter O from connection of the vacuum pump Info I Hold the damper so that the filling port is at the highest point Remove the adapter Mount and tighten screw Guideline I Screw filling port I M10x1 1 14 Nm 10 3 lbf ft I Filling the dam er with nitrogen 201396 10 201397 10 Screw in screw...

Page 63: ...ight of rider 75 85 kg 165 54 N mm 308 lb in 187 lb Weight of rider 85 95 kg 187 57 N mm 325 lb in 209 lb Mount intermediate washer 8 and spring retainer C Mount ring C Alternative 1 Tension the spring to the prescribed amount by turning the adjusting ring Guideline I Spring preload 18 mm 0 31 in I Hook wrench T106S p 231 Alternative 2 Warning Danger of accident Modifications to the suspension set...

Page 64: ...f damage cracking or deformation Change the swingarm Info I Always change a damaged swingarm Repair of the swingarm is not authorized by Husqvarna Motorcycles Preparatory work Raise the motorcycle with a lift stand 0 p 10 Remove the rear wheel p 89 Main work Take the brake line out of the guide Push the brake caliper forward remove it and hang it to the side Info Cover the components to protect th...

Page 65: ...ot Remove the swingarm Main work Position the swingarm Mount the swingarm pivot Mount and tighten nut O Guideline Nut swingarm pivot Lift the swingarm Mount and tighten fitting Guideline Nut linkage lever on swingarm Mount the chain M16x1 5 M14x1 5 Connect the chain with connecting link CD Guideline 100 Nm 73 8 lbf ft I 80 Nm 59 lbf ft The closed side of the chain joint lock must face in the direc...

Page 66: ...per and pull it back Position the brake line in the guide Finishing work Install the rear wheel a p 90 M6 M8 Remove the motorcycle from the lift stand a p 10 Changing the swingarm bearing Info These operations are the same on both swingarm bearings Preparatory work Raise the motorcycle with a lift stand li l p 10 Remove the rear wheel ta p 89 Remove the swingarm a p 62 64 10 Nm 7 4 lbf ft 25 Nm 18...

Page 67: ...01813 10 G01814 10 Main work Remove collar bushings 0 Remove bushing 8 Remove shaft seal rings D using a suitable tool Press out the bearing with a suitable tool Press in the new bearing until it is flush using a suitable tool 65 ...

Page 68: ...ings CD Mount bushing Grease the shaft seal rings I Long life grease 0 p 221 Position collar bushings O with the shoulder facing inward Finishing work Install the swingarm l l l p 63 Install the rear wheel l l l p 90 Remove the motorcycle from the lift stand l i p 10 66 ...

Page 69: ...24 Remove screw Take off the manifold Position the manifold Mount screw O but do not tighten yet Guideline I Screw manifold Attach springs I Spring hook 50305017000 p 224 Tighten screw O Guideline I Screw manifold 67 115 Nm 11 1 lbf ft I 115 Nm 11 1 lbf ft I ...

Page 70: ...ttach spring 8 I Spring hook 50305017000 p 224 Tighten screws O Guideline I Remaining screws chassis Finishing work Install the right side cover ll p 73 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down before performing any work on the vehicle Info Over time the fiber...

Page 71: ...yarn filling 0 from inner tube D Clean the parts that are to be reinstalled Mount the new glass fiber yarn filling 0 on the inner tube Slide O ring C and outer tube CD over the glass fiber yarn filling Insert O ring and silencer cap O into the outer tube Mount and tighten all screws Finishing work Install the main silencer p 68 Install the right side cover p 73 69 ...

Page 72: ...filter 11 4 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 regulations lnstallin the air filter Preparatory work Remove the air filter box lid p 70 Main work Push air filter holder O toward the air filter at position f and detach it at end G Swing the ai...

Page 73: ... fuel or petroleum since these substances attack the foam Sealin the air filter box 401559 01 Preparatory work Remove the air filter box lid a p 70 Remove the air filter a p 70 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly I Air filter cleaning agent p 221 Info I Only press the air filter to dry it never wring it out Oil the dry air filter with a ...

Page 74: ...f 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 Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Warning Environmental hazard Improper handling of fuel is a d...

Page 75: ...ly 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 Warning Danger of poisoning Fuel is ...

Page 76: ...h cap set f I Wash cap set 81212016100 Remove the tube from the fuel tank breather Remove screws D with the collar bushing Remove screw C with the rubber bushing Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank 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 Swi...

Page 77: ...en screws with the collar bushing Guideline I Remaining screws chassis Plug in connector D I10Nm 7 41bf ft 10Nm 7 4 lbf ft Remove the wash cap set and thoroughly clean the plug in connection of the fuel line using compressed air Info I Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Lubricate the O ring and connect plug in connection 8 of...

Page 78: ...out of the fuel hose Mount special tool 8 I Pressure tester 61029094000 a p 227 Mount special tool D with nozzle code 0 60 I Testing hose 61029093000 0 p 227 Position the hose end in a fuel can Guideline I Minimum size fuel can Connect the diagnostics tool and start it 110 I 2 6 US gal Select the Function test of fuel pump control actuator test Guideline I Maximum duration of the actuator test I 3...

Page 79: ...hing 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 Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Warning ...

Page 80: ...uideline I Fuel connection on fuel tank Mount and tighten screws 5 Guideline I Screw fuel pump Finishing work Install the fuel tank a p 74 Mount the seat a p 73 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 h...

Page 81: ...e your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system G01785 10 Preparatory work Drain the fuel from the fuel tank into a suitable container Remove the seat a p 73 Remove ...

Page 82: ... p 227 Position the fuel pump Mount fuel connection 8 with the gasket but do not tighten yet Mount and tighten nut O with the gasket Guideline 80 I Nut fuel pump fastener I M12x1 75 15 Nm 11 1 lbf ft G01785 10 Tighten fuel connection 8 Guideline I Fuel connection on fuel tank Mount and tighten screws 5 Guideline I Screw fuel pump Finishing work Install the fuel tank p 74 I M8x1 25 10 Nm 7 4 lbf ft...

Page 83: ...h the eyes Change your clothing in case of fuel spills on them Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system Clean plug in connection O of the fuel line thoroughly with compressed air Info I Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the inje...

Page 84: ...Remove screws O and Remove the front fender Main work Position the front fender Mount and tighten screws O and Guideline I Remaining screws chassis Finishing work Install the start number plate Jl p 83 Take brake line O out of the brake line guide Remove screw Take off the start number plate 110Nm 7 41bf ft 82 ...

Page 85: ...13 MASK FENDER Position the start number plate Mount and tighten screw O Guideline I Remaining screws chassis 110 Nm 7 4 lbf ft The holding lugs engage Position brake line 8 in the brake line guide 83 ...

Page 86: ...res have a negative effect on handling characteristics especially on wet surfaces Check the front and rear tires for cuts run in objects and other damage If the tires have cuts run in objects or other damage Change the tires Check the tread depth Info I Adhere to the legally required minimum tread depth I Minimum tread depth I 2 mm 0 08 in If the tread depth is less than the minimum tread depth Ch...

Page 87: ...they are too tightly tensioned If the tension in the spokes is too low then lat eral 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 Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes If the spokes are too tight they can break due to local overload Check the spoke te...

Page 88: ...tations Loosen screws 8 Press on screw O to push the wheel spindle out of the axle clamp Remove screw O 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 damaged Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork Info I Do not pull the hand brake lever when the front whee...

Page 89: ...om the lift stand ili p 10 Pull the front brake and compress the fork powerfully a few times The fork legs straighten Tighten screws 8 Guideline I Screw fork stub 1 1 5 Nm 11 1 lbf ft I Removing the brake disc of the front brake Preparatory work Raise the motorcycle with a lift stand p 10 Remove the front wheel p 86 Main work Remove screws O Take off the brake disc Installing the brake disc of the...

Page 90: ...ng a suitable tool Info I Only press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in Position spacing tube C Press in the new bearing D all the way using a suitable tool Info I Only press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in Grease new shaft seal rings 8 and O and press in until they are flush Fi...

Page 91: ...t of the swingarm Info I Do not operate the foot brake when the rear wheel is removed FC 250 US Always lay the wheel down in such a way that the brake disc is not damaged Press the brake caliper onto the brake disc by hand in order to push back the brake piston Info I Ensure that the brake caliper is not pressed against the spokes when pushing back the brake piston Remove nut O Remove chain adjust...

Page 92: ...wheel spindle 8 The brake linings are correctly positioned Put the chain on Position chain adjuster 8 Mount nut 8 but do not tighten it yet Make sure that chain adjusters 8 are fitted correctly on adjusting screws 0 Check the chain tension I p 91 Tighten nut 8 Guideline I Nut rear wheel spindle Info I M20x1 5 I 80 Nm 59 lbf ft I The wide adjustment range of the chain adjusters 32 mm 1 26 in enable...

Page 93: ...ith a lift stand 0 p 10 Remove the rear wheel a p 89 Main work Remove screws 0 Take off the brake disc Installing the brake disc of the rear brake Clean the contact surface of the brake disc Position the brake disc with the label facing outward Mount and tighten 14 6 5 Checking the chain tension Warning screws O Guideline Screw rear brake disc M6 Install the rear wheel 0 p 90 14 Nm 10 3 lbf ft Dan...

Page 94: ... 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 Raise the motorcycle with a lift stand p 10 Check the chain tension p 91 Main work FC 250 EU Loosen nut O Loosen nuts Adjust the chain tension by turnin...

Page 95: ...ar sprocket engine sprocket and chain guide Preparatory work 400227 01 Raise the motorcycle with a lift stand p 10 Main work Shift the transmission to idle Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Change the drivetrain kit p 95 Info I The engine sprocket rear sprocket and chain should always be replaced together Pull at the top part of ...

Page 96: ...s is in line with or below the chain sliding piece Change the chain sliding piece Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten the chain sliding piece Guideline Screw chain sliding piece Check the chain guide for wear Info M8 I 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 Chec...

Page 97: ...e cleaner when necessary 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 regulations Info The service life of the chain depends largely on its maintenance 400725 01 Preparatory work Raise the motorcycle with a lift stand 0 p 10 Main work Clean the chain r...

Page 98: ...ve engine sprocket Remove fittings Q Take off the rear sprocket Position the new rear sprocket Mount and tighten the fittings Guideline Nut rear sprocket screw M8 35 Nm 25 8 lbf ft Slide new engine sprocket 0 onto the countershaft Mount the new chain Connect the chain with connecting link C Guideline Loctite 2701 TM The closed side of the chain joint lock must face in the direction of travel Insta...

Page 99: ...0 Nm 44 3 lbf ft Loctite 2701 TM 10 Nm 7 4 lbf ft 97 I Remaining screws chassis I 25 Nm 18 4 lbf ft I Finishing work Remove the motorcycle from the lift stand p 10 14 6 11 Changing the rear wheel bearing Preparatory work Raise the motorcycle with a lift stand p 10 Remove the rear wheel p 89 Main work Remove shaft seal ring O Remove lock ring 8 Remove shaft seal ring Using a suitable tool press bea...

Page 100: ...t spacing tube 0 I Long life grease I p 221 Press new bearing C all the way in from the outside to the inside Info I Only press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in Grease new shaft seal ring 8 and press it in until it is flush Mount lock ring The lock ring engages audibly Grease new shaft seal ring O and press it in until it is flush Finish...

Page 101: ...in the starter relay Install a new main fuse I Fuse 58011109110 i I p 201 Check that the electrical equipment is functioning Tip I Insert the spare fuse so that it is available if needed Mount the protection caps Finishing work Install the air filter box lid p 70 Risk of injury Battery acid and battery gases cause serious chemical burns Keep batteries out of the reach of children Wear suitable pro...

Page 102: ...e negative terminal cover D over the negative terminal Finishing work Mount the seat p 73 Recharging the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Keep sparks and open flames away from the battery Only charge in...

Page 103: ...l US 00029095051 ll I p 223 Battery charger XCharge professional GB 00029095052 I p 224 Battery charger XCharge professional CH 00029095053 p 224 Info I Follow the instructions of the charger and the manual Disconnect the battery charger after charging the battery Guideline The charging current charging voltage and charging time must not be exceeded Charge the battery regularly when the 13months m...

Page 104: ...ve the capacitor Discharge the capacitor by bridging the two contacts Connect the capacitor with a 12 V test lamp on one connector and connect it to the battery as shown in the figure Info I As the charge of the capacitor increases the test lamp becomes dimmer The lamp lights up for 0 5 2 0 s The capacitor is functional The lamp lights up for 0 5 s Change the capacitor The lamp lights up for 2 0 s...

Page 105: ...to a 12 V power supply as shown in the figure Measure the resistance between the specified points I Resistance of open circuit I O n If the display does not equal the setpoint value Change the starter relay Mount the starter relay onto the holder and lay the cable Clamp cable fj on the starter relay Plug in connector 0 Connect the negative cable of the battery Finishing work Install the air filter...

Page 106: ...ing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Mak...

Page 107: ...ke linings insert pin 0 and mount cotter pins 8 Info I Always change the brake linings in pairs Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Add brake fluid up to level 6 Guideline Level O brake fluid level below reservoir rim I Brake fluid DOT 4 p 220 Position cover with membrane D Mount and tighten screws O Info ...

Page 108: ...ment is limited Only turn the adjusting screw by hand and do not use force Do not make any adjustments while riding Checkin the front 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 specified marking or the specified value the brake system is leaking or the brake linings are worn down Check...

Page 109: ...ing 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 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 regulations Info Never us...

Page 110: ...nts brake fluid etc correctly and in compliance with the applicable regulations Info Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container 108 Move the brake fluid reservoir mounted on the handlebar to a horizontal position Cover the painted parts Remove screws O Remove cover 8 with membrane Draw the old brake fluid out of ...

Page 111: ...below con 5 mm 0 2 in tainer rim I Brake fluid DOT 4 p 220 Position the cover with the membrane Mount and tighten the screws Info I Clean up overflowed or spilt brake fluid immediately with water Check the hand brake lever for a firm pressure point Checking the rear brake linings Warning Danger of accidents Worn out brake linings reduce the braking effect Ensure that worn out brake linings are rep...

Page 112: ...ers fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed 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 Stand the vehicle upright Remov...

Page 113: ... is no free travel on the foot brake lever pressure builds up in the brake system on the rear brake Set the free travel on the foot brake lever in accordance with the specification l 402026 10 Disconnect spring O 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 f Guideline I Free travel at foot brake lever 13 5 mm...

Page 114: ... Nm 14 8 lbf ft I 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 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 wit...

Page 115: ...ned 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 Preparatory work Check the rear brake linings p 109 Main work Stand the vehicle upright Remove screw cap O with membrane fj and the O ring Add brake fluid to level f I Brake fluid DOT 4 p 220 Mount and tighten the screw cap with the membrane and...

Page 116: ...eeding device Ensure that the inflation pressure is correctly set at pressure gauge f If neces sary adjust the inflation pressure at pressure regulator Guideline I Inflation pressure I 2 2 5 bar 29 36 psi Pull off protection cap C of the bleeder screw Connect the hose of the bleeder bottle I Bleeding device 00029013100 p 223 Open bleeder screw 0 by approx one half turn Info I Bleed until fresh bra...

Page 117: ...t the brake fluid up to marking 9 I Brake fluid DOT 4 a p 220 Mount and tighten the screw cap with the membrane and 0 ring Info I Clean up overflowed or spilt brake fluid immediately with water Check the foot brake lever for a firm pressure point 115 ...

Page 118: ...emove the fuel tank il JJ p 73 Remove the right side cover il ll p 72 Remove the main silencer il ll p 68 Main work Connect the negative cable of the battery Pull EFI control unit O from the holder and hang it to one side Remove the cable tie s and expose the cable Disconnect plug in connector 8 Disconnect plug in connectors 8 Loosen hose clip 8 116 ...

Page 119: ... and expose the cable Remove screw D Loosen screw Repeat these steps on the opposite side Pivot up the subframe and secure it Remove screw Pivot the shock absorber toward the rear and twist it slightly Remove springs I Spring hook 50305017000 I p 224 117 ...

Page 120: ...rew C Take off the manifold Loosen hose clip 49 Pull off the radiator hose Loosen hose clip Pull off the radiator hose Push back protection cap G Unplug connector 4D Disconnect spark plug connector 48 Remove screw 4D 118 ...

Page 121: ...de Info I Do not kink the clutch line Do not activate the clutch lever while the slave cylinder of the clutch is removed Activate the foot brake lever Loosen screw G Info The help of an assistant is useful in this step Remove the connecting link of the chain Take off the chain Remove screw G Take off the engine sprocket Remove screw D Take off the shift lever 119 ...

Page 122: ...ad toward the rear and hang it to one side Push back hose clamp and remove the vent hose Push back protection cap and remove the nut Remove fittings Take off the engine braces Remove spring Remove nut Remove the swingarm pivot Pull the swingarm slightly toward the rear Remove screws fl ...

Page 123: ...e engine is sufficiently secured against falling over Protect the frame and attachments against damage Mount screws O but do not tighten yet Guideline I Engine carrying screw Position the swingarm Insert the swingarm pivot Mount and tighten nut 8 Guideline Nut swingarm pivot Tighten screws O Guideline I Engine carrying screw Mount spring CD Position the engine braces Mount and tighten fittings 8 G...

Page 124: ...0 3 lbf ft Slide on the engine sprocket with the collar facing the engine Mount screw Q with the washer but do not tighten yet Guideline Screw engine sprocket M10 Mount the chain Connect the chain with connecting link CD Guideline 60 Nm 44 3 lbf ft 122 10 Nm 7 4 lbf ft Loctite 243 Loctite 2701TM The closed side of the chain joint lock must face in the direction of travel Have an assistant operate ...

Page 125: ...the engine sprocket cover Mount and tighten screw CB Guideline I Screw clutch slave cylinder Mount and tighten screw 48 Guideline Remaining screws chassis Plug in spark plug connector 4D Plug in connector 48 Mount the protection cap Mount the radiator hose Position and tighten hose clip G s M6 M6 M8 123 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft I 25 Nm 18 4 lbf ft I ...

Page 126: ...k absorber Mount and tighten screw Guideline Screw top shock absorber M10 60 Nm 44 3 lbf ft Remove the locking piece and position the subframe Info I Watch out for the intake flange Mount and tighten screw a Guideline Screw subframe Remove screw fl Mount and tighten screw fl Guideline Screw subframe MS MS Repeat the operation on the opposite side 30 Nm 22 1 lbf ft 30 Nm 22 1 lbf ft 124 15 Nm 11 1 ...

Page 127: ...th cable clamps Plug in connector Position and tighten hose clip Connect plug in connector of the crankshaft position sensor Connect plug in connectors of the alternator Route the cable without tension and secure with cable tie s Mount EFI control unit 125 ...

Page 128: ...nstall the right side cover a p 73 Install the fuel tank a p 74 Mount the seat p 73 Remove the motorcycle from the lift stand p 10 Refill with coolant a p 187 Execute the initialization run a p 196 Go for a short test ride Read out the fault memory using the Husqvarna Motorcycles diagnostics tool Check the engine for leak tightness Check the engine oil level a p 188 Check the coolant level a p 186...

Page 129: ...er Draining the engine oil Remove clutch push rod O Remove spacer O of the countershaft Remove O ring Remove plug O with oil screen and the O rings Remove the oil drain plug with the magnet and seal ring Remove oil drain plug 8 with the O ring Completely drain the engine oil 127 ...

Page 130: ...e screws O Remove the oil filter cover with the O ring Pull oil filter D out of the oil filter housing I Circlip pliers reverse 51012011000 p 225 Remove the spark plug using special tool O I Spark plug wrench 77229172000 p 230 Remove screws O Remove the valve cover with the valve cover seal Remove gasket 8 128 ...

Page 131: ...ng the starter motor Remove spark plug shaft insert Remove screws O and take off cover 8 Take off the gasket Remove torque limiter Remove screws C Remove the alternator cover Remove screws 0 and take off the starter motor 129 ...

Page 132: ...e position notch of the crankshaft is visible Mount and tighten screw O without the washer 17 3 10 Removing the timing chain tensioner 17 3 11 Removing the camshaft Loosen screw O Remove screw 8 with the seal ring Pull out timing chain tensioner Remove O ring 8 Loosen screws O from the outside to the inside and remove Take off guide rail 8 Take off the camshaft bearing bridge Info Ensure that the ...

Page 133: ... with the washers Remove the cylinder head Remove cylinder head gasket D Push the cylinder upward Info 131 I Only push the cylinder as far up as necessary to take the piston pin out Remove the piston pin retainer O Remove the piston pin Take off the cylinder and piston Push the piston upward out of the cylinder Info I If no further work is to be performed on the cylinder and piston the piston can ...

Page 134: ...e crankshaft I Protection cap 75029090000 p 228 132 Attach special tool D to the rotor Hold it tight using the special tool and pull off the rotor by turning the screw in I Extractor 58012009000 p 225 Info I Ensure that the woodruff key remains in place Remove lock ring O Take off the starter idler gear with the washer Take off freewheel gear D ...

Page 135: ... Removing the suction pump Remove screws O Take off oil pump cover 8 Remove O ring 4D Take off suction pump 8 Remove needle roller 17 3 17 Removing the water pump wheel Remove screws O Take off the water pump cover 133 ...

Page 136: ...et Remove nut 8 Take off the two part water pump impeller Remove screws O Take off the clutch cover Remove the clutch cover seal Loosen screws O and remove together with the washers and springs Take off the pressure cap Completely remove clutch discs 8 Remove pressure piece fD Remove two opposite sleeves O 134 ...

Page 137: ...sher e Info I The washer usually sticks to the inner clutch hub Take off clutch basket 0 Take off needle bearing D and collar sleeve Push sliding plate O away from the shift drum locating unit 8 Remove shift shaft D with the washer 135 17 3 22 Removing the shift drum locating unit Remove screw O Push away locking lever 8 from shift drum locating unit D and remove the shift drum locating unit Relie...

Page 138: ... sleeve and spring Remove lock ring O Take off washer 8 Take off oil pump idler gear 8 with the washer Remove lock ring C Take off washer 0 Remove oil pump gear D Remove pin Remove screws fD Take off the oil pump cover Remove pin Push oil pump shaft Qi inward and take it out of the engine from the ignition side Remove force pump a 136 ...

Page 139: ...p 224 Remove screw 8 137 Remove screws O Remove the timing chain tensioning rail 8 Remove the timing chain guide rail Remove screw C Take off balancer shaft 0 with the timing chain and timing chain securing guide Info I If the timing chain is going to be used again mark its direction of travel Remove spacer O of the crankshaft 17 3 28 Removing the left section of the engine case Remove screws O Ti...

Page 140: ...ed with 772 Take off the section of the engine case Info I Do not subject the section of the engine case to any stress The washer of the main shaft usually adheres to the bearing Take off the left section of the engine case Remove the special tool Remove shift rail O together with upper spring 8 Remove shift rail CD together with upper spring e and the lower spring Tilt shift forks O to the side I...

Page 141: ...Info Do not misplace shift rollers 8 17 3 32 Removing the transmission shafts 17 3 33 Removing the crankshaft Remove lock ring O Pull both transmission shafts 8 out of the bearing seats together Take out crankshaft O Take off the right section of the engine case 139 ...

Page 142: ...tite 243 Insert the new cold bearings in the bearing seats of the heated section of the engine case if necessary use a suitable press drift to push them all the way in and make them flush Info I When pressing the bearing in ensure that the engine case section is level to prevent damage Only press the bearings in via the outer bearing race otherwise the bear ings will be damaged when they are press...

Page 143: ...ed using a suitable tool Insert the new cold bearings in the bearing seats of the heated section of the engine case if necessary use a suitable press drift to push them all the way in and make them flush Info I When pressing the bearing in ensure that the engine case section is level to prevent damage Only press the bearings in via the outer bearing race otherwise the bear ings will be damaged whe...

Page 144: ...r bearing M5 2 Nm 1 5 lbf ft 6Nm 4 4 lbf ft Loctite 243 Loctite 243 Blow out the oil channel with compressed air and check that it is clear Remove shaft seal ring O Remove lock ring 8 Remove shaft seal ring CD Press out bearing 8 toward the inside Mount lock ring 8 142 Press the shaft seal ring CD all the way in from the inside to the outside with the open side facing in ...

Page 145: ...ide suitable support for the clutch cover while pressing in Mount lock ring 0 Blow out the oil channel with compressed air and check that it is clear Checking the oil pressure regulator valve 0 8 1 o 306542 10 306115 10 Remove screw plug O with sealing washer Remove pressure spring and ball C Measure the spring length of the oil pressure regulator valve Oil pressure regulator valve Minimum length ...

Page 146: ...oil pump shaft 8 for damage and wear If there is damage or wear Change the oil pump shaft Check the oil pump cover for damage and wear If there is damage or wear Change the oil pump cover 17 4 6 Removing the crankshaft bearing inner race Fix the crankshaft in the vise Info I Use soft jaws Warm up special tool O Guideline 1150 C 302 F I Tool for inner bearing race 58429037037 p 225 Push the warmed ...

Page 147: ...r race is flush Info I After replacing the crankshaft bearings the crankshaft end play must be measured Finishing work Measure the crankshaft end play l t J p 147 17 4 8 Changing the connecting rod conrod bearing and crank pin 306571 10 Main work Position crankshaft O in the press using special tool 8 I Separator plate 77029009001 a p 228 Push the crank pin out of the upper crankweb using the spec...

Page 148: ...al tool and check that the connecting rod can move freely Measure axial play 9 between the connecting rod and the crank webs using the special tool I Feeler gauge 59029041100 a p 226 Connecting rod axial play of lower conrod bearing If the specification is not reached 0 20 0 45 mm 0 0079 0 0177 in Correct it so the dimension is equal to the specified value Finishing work Check the crankshaft run o...

Page 149: ...ce I p 144 Calculate the thickness of the compensating disks Add or remove compensating disks equally on both sides Info I If the axial play is too small remove compensating disks If the axial play is too large add compensating disks Install the crankshaft bearing inner race I p 145 17 4 11 Removing the drive wheel of the balancer shaft Position the balancer shaft in the press with special tool O ...

Page 150: ...5 mm 3 07133 3 07184 in I The cylinder size O is marked on the cylinder collar Using a straightedge and the special tool check the sealing area of the cylinder head for distortion I Feeler gauge 59029041100 p 226 Cylinder cylinder head distortion of sealing area s 0 10 mm 0 0039 in If the measured value does not meet specifications Change the cylinder 17 4 15 Checking measuring the piston 400995 1...

Page 151: ...ylinder mounting clearance 306757 10 Check measure the cylinder p 148 Check measure the piston p 148 The smallest piston cylinder mounting clearance equals the smallest cylinder bore diameter minus the largest piston diameter The largest piston cylinder mount ing clearance equals the largest cylinder bore diameter minus the smallest piston diameter Guideline Piston cylinder mounting clearance Size...

Page 152: ...here is damage or wear Change the cylinder head with the camshaft bearing bridge Position the camshafts The valves are not activated Insert the Plastigauge clearance gauge in area G I Plastigauge clearance gauge 60029012000 il l p 226 Position camshaft bearing bridge O Mount and tighten the screws Guideline Screw camshaft bearing bridge Info M7x1 14 Nm 10 3 lbf ft Lubricated with engine oil I Ensu...

Page 153: ...ation position Pre tension the valve spring using the special tool Valve spring mounter 59029019000 lllll p 226 Insert for valve spring lever 77229060000 p 230 Remove the valve keys and unload the valve spring Remove the valve spring retainer and valve springs Mark the valve spring according to its normal built in position Pull the valve down out of the valve guide Remove valve stem seal C with th...

Page 154: ...o I Intake valves are marked with a green color coding Exhaust valves are marked with a brown color coding If the valve spring is broken or worn Change the valve spring Measure the length of the valve springs Valve spring Minimum length of intake valve Minimum length of exhaust valve I 41 20 mm 1 622 in I 41 10 mm 1 6181 in If the measured value does not meet specifications Change the valve spring...

Page 155: ...sealing area of the cylinder for distortion I Feeler gauge 59029041100 p 226 Cylinder cylinder head distortion of sealing area 0 10 mm 0 0039 in If the measured value does not meet specifications Change the cylinder head Check sealing seat 6 of the valves Valve sealing seat width Intake Valve sealing seat width Exhaust 1 40 mm 0 0551 in 1 40 mm 0 0551 in If the measured value does not meet specifi...

Page 156: ...amount of grease Position cam levers C in the positions they had before they were removed Mount the cam lever shafts Remove screw 0 Mount and tighten screw plugs D Guideline I Screw plug cam lever axis I M10x1 10 Nm 7 4 lbf ft Place the shims in the valve spring retainers corresponding to their installation position Insert freewheel gear O into the freewheel hub turning the freewheel gear clock wi...

Page 157: ...g the freewheel 308684 11 308685 10 Remove lock ring O Press expansion ring fj together with suitable pliers and take off Take freewheel 8 out of the primary gear Thoroughly oil all parts Slide freewheel O into the primary gear Info Note the direction of rotation Mount spreader ring 155 ...

Page 158: ...is damage or wear Change the starter idler gear Check the gear mesh and bearing of torque limiter 8 for damage and wear If there is damage or wear Change the torque limiter Check the gear mesh and bearing of freewheel gear 6 for damage and wear If there is damage or wear Change the freewheel gear or bearing Check freewheel C for damage and wear If there is damage or wear Change the free wheel Chec...

Page 159: ...g rail 8 for damage and wear If there is damage or wear Replace the timing chain tensioning rail Check the timing chain guide rail D for damage and wear If there is damage or wear Replace the timing chain guide rail Check the timing chain securing guide 8 for damage and wear If there is damage or wear Replace the timing chain securing guide Check camshaft gears 0 for damage and wear If there is da...

Page 160: ...in tensioner The detent mechanism engages and the piston remains in place Final position of the piston after engagement Info 3 mm 0 12 in This position is necessary for installation If the timing chain tensioner is now pressed again and is only extended a maximum of half way it is prevented from extending completely This locks the detent mechanism and the timing chain tensioner can no longer be sq...

Page 161: ... CD for damage and wear If there is damage or wear Change the needle bearing and collar sleeve Check intermediate clutch discs and G for damage and wear If the intermediate clutch discs are not even or are pitted Change all intermediate clutch discs Check clutch facing discs Qi for discoloration and scoring If there is discoloration or scoring Change all clutch facing discs Check the thickness of ...

Page 162: ...rollers for damage and wear If there is damage or wear Change the shift rollers Check the springs of shift rails 8 for damage and wear If the spring is damaged or worn Change the spring of the shift rail Check the shift rails 8 for run out on a flat surface If there is run out Change the shift rail 306554 10 Check the shift rails for scoring wear and smooth operation in the shift forks If scoring ...

Page 163: ...late O with the guide pin facing downward and put the guide pin on the shift quadrant Mount pressure spring Slide on spring guide push return spring C with the offset end facing upward over the spring guide and lift the offset end over abutment bolt Mount washer D 17 4 36 Disassembling the main shaft 306556 10 Secure the main shaft with the toothed end facing downward in the bench vise Guideline U...

Page 164: ...idler gear Remove needle bearing fs and stop disk C Remove fifth gear sliding gear 0 Remove lock ring D Remove stop disk Remove third gear idler gear fD and needle bearing Remove stop disk Gi Remove lock ring G Remove fourth gear sliding gear 48 Remove lock ring 48 Remove stop disk 4D Remove second gear idler gear e and needle bearing 4D 17 4 38 Checking the transmission Condition The transmission...

Page 165: ...e or wear Change the gear wheel pair Check the tooth faces of idler gears 8 sliding gears and fixed gear C for damage and wear If there is damage or wear Change the gear wheel pair Check the tooth profiles of sliding gears 0 for damage and wear If there is damage or wear Change the gear wheel pair Check sliding gears 0 for smooth operation in the profile of main shaft 8 If the sliding gear does no...

Page 166: ...t fifth gear idler gear Mount stop disk D and lock ring 8 Mount third gear sliding gear 0 Mount lock ring D and stop disk Mount needle bearing Mount fourth gear idler gear 0 Mount second gear fixed gear Gi and stop disk 48 In conclusion check all gear wheels for smooth operation 17 4 40 Assembling the countershaft Info I Use new lock rings with every repair Preparatory work Check the transmission ...

Page 167: ...ing D and stop disk Mount needle bearing G and the third gear idler gear with the shift dogs facing up Mount stop disk GD and lock ring 41 Mount the fifth gear sliding gear 48 with the shift groove facing down Mount stop disk G Mount needle bearing and first gear idler gear 48 Mount stop disk 41 In conclusion check all gear wheels for smooth operation 17 5 Engine assembl 17 5 1 Installing the cran...

Page 168: ...ng Shift fork O has a smaller inside diameter mount this in the shift groove of the main shaft Mount shift fork in the lower shift groove of the countershaft Mount shift fork fD in the upper shift groove of the countershaft Slide on shift rollers 8 Tip Fix the shift rollers in the shift forks with grease Push shift drum O into the bearing seat Put shift forks in the shift drum Info Do not misplace...

Page 169: ...ection of the engine case If necessary strike it lightly with a rub ber mallet and turn the transmission shafts Info I Do not use the screws to pull the two sections of the engine case together Mount screws O but do not tighten yet Guideline I Screw engine case I M6x55 Mount screws 8 but do not tighten yet Guideline 10 Nm 7 4 lbf ft I Screw engine case I M6x65 I 10 Nm 7 4 lbf ft Mount screws D and...

Page 170: ...ne Screw timing chain securing guide M6 Position timing chain guide rail 8 Mount and tighten screw C Guideline Screw timing chain guide M6 rail Position timing chain tensioning rail 0 Mount and tighten screw D Guideline Screw timing chain ten sioning rail Position primary gear 0 M8 Markings f and G are aligned 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 15 Nm 11 1 lbf ft Loctite 243 Loctite 243 Loctite 243 ...

Page 171: ... the engine case Mount the oil pump shaft 8 from the ignition side Mount pin Position the oil pump cover Marking 6 faces upward Mount and tighten screws C Guideline Screw oil pump cover Insert pin 0 Position oil pump gear D Mount washer Mount lock ring C MS 6Nm 4 4 lbf ft Crank the oil pump gear and ensure that it can move easily Mount oil pump idler gear 0 with the washer Mount washers i Mount lo...

Page 172: ... ft Mount locking lever O with the washer sleeve and spring Mount and tighten screw Guideline Screw locking lever M5 6Nm 4 4 lbf ft Loctite 243 Loctite 243 17 5 13 Installing the shift drum locating unit Push away locking lever O from the shift drum locating unit and position the shift drum locating unit Info I The flat areas of the shift drum locating unit are not symmetric Relieve tension from t...

Page 173: ... unit Shift through the transmission _ _ rl Mount collar sleeve O and needle bearing 8 Slide the clutch basket 8 onto the gearbox main shaft Turn the oil pump gear until the gear of the clutch basket meshes Slide on washer 8 and inner clutch hub 0 Position the new lock washer and mount nut Q Tighten the nut holding the inner clutch hub with a special tool Guideline Nut inner clutch hub M18x1 5 I C...

Page 174: ...te discs into the outer clutch hub Insert the intermediate clutch disc Guideline I Thickness Mount pressure piece O 11 mm 0 04 in 172 Mount the pressure cap Mount screws 8 with the washers and springs Tighten the screws diagonally Guideline I Screw clutch spring Prepare the tool special screw A conventional screw is required Cut screw Q to length f Guideline I Screw I Length e I M6x70 I 60 mm 2 36...

Page 175: ...Guideline I Screw clutch cover Mount the two part water pump impeller O Mount and tighten nut 8 Guideline Nut water pump wheel M6 5Nm 3 7 lbfft Mount the water pump cover with the seal ring Info I Ensure that the dowel pins are seated properly Mount screw D with the seal ring b ut to not tighten yet Guideline I Screw water pump cover I M6x25 Mount screw C b ut do not tighten yet Guideline I Screw ...

Page 176: ...r idler gear counterclockwise Mount and tighten screw O Guideline Rotor screw M10x1 Shift the gap of the piston rings by 120 70 Nm Thread oiled with 51 6 lbf ft engine oil cone degreased Place the special tool onto the oiled piston Clamp the piston rings together using the special tool I Piston ring mounting tool 60029015000 l l l p 227 The piston ring are squeezed together fully Position the pist...

Page 177: ... chain through the chain shaft Mount the piston pin Info I For purposes of illustration the following operations are shown on the removed piston Position the piston ring lock Insert the special tool and press it with force towards the piston Turn the special tool clockwise thereby pushing the piston ring lock into the groove I Insertion tool for piston ring lock 77729030100 a p 230 Ensure that the...

Page 178: ...inder head in place Mount nuts with the washers and tighten in a crisscross pattern Guideline 176 Nut cylinder head M10x1 25 Tightening Thread oiled with I Graduated disc 60029010000 p 226 Mount and tighten nut D Guideline Nut cylinder head M6 sequence Tighten diag anally 1st tightening stage 10 Nm 7 4 lbf ft 2nd tighten ing stage 30 Nm 22 1 lbf ft 3rd tightening stage 50 Nm 36 9 lbf ft 10 Nm 7 4 ...

Page 179: ...tioned and is aligned with the edge of the cylinder head Clean all oil nozzles thoroughly and blow out with compressed air Mount the camshaft bearing bridge Info I Ensure that the dowel pins are seated properly Position guide rail C Mount screws 0 and tighten from the inside to the outside Guideline Screw camshaft bearing bridge M7x1 14 Nm 10 3 lbf ft Lubricated with engine oil 17 5 24 Installing ...

Page 180: ...ead center Marking t are aligned with the edge of the cylinder head Check the valve clearance at all valves between the camshaft and cam levers Guideline Valve clearance Intake at 20 C 68 F I 0 10 0 15 mm 0 0039 0 0059 in Exhaust at 20 C 68 F I 0 13 0 18 mm 0 0051 0 0071 in I Feeler gauge 59029041100 Ill p 226 If the valve clearance does not meet specifications Adjust the valve clearance l I p 178...

Page 181: ...ighten yet Guideline I Screw starter motor Position the gasket Info I Ensure that the dowel pins are seated properly Position the alternator cover Mount and tighten screws Guideline I Screw alternator cover Position torque limiter Position the gasket Info I Ensure that the dowel pins are seated properly Position the cover Mount and tighten screws C Guideline I Screw cover of torque limiter Mount a...

Page 182: ...w starter motor Grease O rings and mount spark plug shaft insert O Position gasket Apply a thin layer of sealing compound in area f I Loctite 5910 Position the valve cover with the gasket Mount and tighten screws Guideline I Screw valve cover 180 110Nm 7 41bf ft I 8 Nm 5 9 lbf ft ...

Page 183: ...d fill the oil filter housing to about full with engine oil Insert oil filter O into the oil filter housing Oil the O ring of the oil filter cover Mount oil filter cover 8 Mount and tighten screws 5 Guideline I Screw oil filter cover Mount and tighten screw plug O with the O ring Guideline I Oil drain plug I M14x1 5 110 Nm 7 4 lbf ft 115 Nm 11 1 lbf ft I Mount and tighten the oil drain plug 8 with...

Page 184: ...e Mount and tighten screw plug D with the O ring Guideline I Screw plug oil screen I M20x1 5 Grease the shaft seal ring before mounting I1s Nm 11 1 lbf ft I Position the O ring Mount spacer O with the bevel facing inward Mount clutch push rod O 17 5 34 Removing the engine from the engine assembly stand Remove the screw connection from the special tool I Engine fixing arm 77229002000 a p 228 Remove...

Page 185: ...h lines are not designed 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 Remove screws O Remove cover with membrane fD Check the fluid level I Fluid level below container rim 14 mm 0 16 in If the fluid level does no...

Page 186: ...luid with water Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Inject the liquid into the system until it escapes from drill hole D of the master cylinder without bubbles Drain fluid occasionally from the master cylinder reservoir to prevent overflow Tighten the bleeder screw and remove the bleeding syringe with the ...

Page 187: ...compo nents 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 plenty...

Page 188: ...rcycle upright on a horizontal surface Remove the radiator cap Check the coolant level in the radiator Coolant level f above the radiator fins 10 mm 0 39 in If the coolant level does not meet specifications 400243 10 Draining the coolant Warning Correct the coolant level I Coolant p 220 Mount the radiator cap Danger of scalding During motorcycle operation the coolant gets very hot and is under pre...

Page 189: ... 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 thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing Make sure that screw O is tightened Position the motorcycle uprigh...

Page 190: ...evel Info The engine oil level can be checked when the engine is cold or warm Preparatory work Stand the motorcycle upright on a horizontal surface Condition The engine is cold Check the engine oil level IThe engine oil reaches the middle of level viewer e Condition If the engine oil does not reach the middle of the level viewer Add engine oil 0 p 191 The engine is at operating temperature Check t...

Page 191: ...nly when the engine is warm Preparatory work Park the motorcycle on a level surface Main work Place a suitable container under the engine Remove oil drain plug O with the magnet and seal ring Info Do not remove screws 8 on both sides Remove screw plug CD with oil screen e Completely drain the engine oil Thoroughly clean the parts and sealing surfaces Position oil screen 8 with the O rings on a pin...

Page 192: ... I Screw oil filter cover 10 Nm 7 4 lbf ft Stand the motorcycle upright Remove filler plug and the 0 ring from the clutch cover and fill up with engine oil I Engine oil 11 10 I 1 16 qt I Engine oil SAE 10W 50 l l p 220 Info I Too little engine oil or poor quality engine oil results in premature wear of the engine Install and tighten the oil filler plug with 0 ring mDanger Danger of poisoning Exhau...

Page 193: ...on system when starting or running the engine in an enclosed space Start the engine and check that it is oil tight Checking the engine oil ressure 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 H...

Page 194: ...6 F Engine speed 1 600 rpm Engine oil temperature 80 c 176 F Engine speed 6 000 rpm If the specification is not reached 0 35 bar 5 1 psi 2 2 bar 32 psi Change the oil filter Check the oil pumps for wear Check that all oil holes are clear Switch off the engine Warning Danger of burns Some vehicle components get very hot when the machine is driven Wear appropriate protective clothing and safety glov...

Page 195: ...esistance between the specified points Measuring point 1 Measuring point 2 Spark plug connector Resistance at 20 c 68 F If the specification is not reached Change the spark plug connector 3 75 6 25 kn Alternator checking the stator winding Condition The alternator has been disconnected Stator winding check the resistance Measure the resistance between the specified points 0 Alternator connector CR...

Page 196: ...ow out oil nozzle O with compressed air and check that it is clear Guideline Oil nozzle for alternator cooling M4 2Nm Loctite 243 1 5 lbf ft Position the stator and ignition pulse generator in the alternator cover Mount and tighten screws 8 Guideline 194 I Screw stator I 4 Nm 3 lbf ft I Loctite 2701 TM Position retaining bracket Mount and tighten screws C Guideline Screw crankshaft posi tion senso...

Page 197: ...r has been removed Connect the negative cable of a 12 volt power supply to the housing of the starter motor Connect the positive cable of the power supply briefly with the connec tor O of the starter motor If the starter motor does not turn when the circuit is closed Change the starter motor ...

Page 198: ...lowers the idle speed Turning clockwise raises the idle speed Condition The diagnostics tool is connected and running Execute Engine electronics Functions Delete adaptation values The adaptation values are deleted Select Engine electronics Measured values Coolant temperature sensor TW1 The coolant temperature is displayed during the initialization run mDanger Danger of poisoning Exhaust gases are ...

Page 199: ...ALVE BODY As soon as the specified temperature is reached switch off the ignition Info I If the initialization is not completed or the initialization process is inter rupted the entire process must be restarted 197 ...

Page 200: ...ultidisc clutch in oil bath hydraulically activated Gearbox 5 gear claw shifted Transmission ratio 1st gear 13 32 2nd gear 16 32 3rd gear 17 28 4th gear 19 26 5th gear 21 25 Alternator 12V 66W Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment Spark plug NGK LMAR9Al 8 Spark plug electrode gap 0 8 mm 0 031 in Cooling Water cooling permanent circulation of co...

Page 201: ...Screw clutch cover M6 Screw clutch slave cylinder M6 Screw clutch spring M6 Screw cover of torque limiter M6 Screw engine case M6 Screw exhaust flange M6 Screw oil filter cover M6 Screw shift drum locating M6 77 955 77 965 mm 3 06909 3 06948 in 77 965 77 975 mm 3 06948 3 06988 in 78 000 78 012 mm 3 07086 3 07133 in 78 012 78 025 mm 3 07133 3 07184 in 0 035 0 057 mm 0 00138 0 00224 in 0 037 0 060 m...

Page 202: ... 1 Engine oil I Engine oil 11 10 I 1 16 qt 24 4 2 Coolant I Coolant 24 4 3 Fuel Totalfuel tank capacity approx I 0 95 I 1 qt 7 5 I 1 98 US gal 14 Nm 10 3 lbfft 10 Nm 7 4 lbfft 10 Nm 7 4 lbfft 10 Nm 7 4 lbfft 8 Nm 5 9 lbfft 10 Nm 7 4 lbfft 10 Nm 7 4 lbfft 15 Nm 11 1 lbfft 14 Nm 10 3 lbfft 10 Nm 7 4 lbfft 15 Nm 11 1 lbfft 60 Nm 44 3 lbfft 15 Nm 11 1 lbfft 70 Nm 51 6 lbfft 10 Nm 7 4 lbfft 10 Nm 7 4 l...

Page 203: ...able rear sprockets 48 50 52 Steering head angle 63 5 Wheelbase 1 495 10 mm 58 86 0 39 in Ground clearance unloaded 375 mm 14 76 in Seat height unloaded 992 mm 39 06 in Weight without fuel approx 103 7 kg 228 6 lb Maximum permissible front axle load 145 kg 320 lb Maximum permissible rear axle load 190 kg 419 lb Maximum permissible overall weight 335 kg 739 lb 24 6 Electrical system Battery YTX5L B...

Page 204: ... Spring rate Weight of rider 65 75 kg 143 165 lb Weight of rider 75 85 kg 165 187 lb Weight of rider 85 95 kg 187 209 lb Spring length Gas pressure Static sag Riding sag Fitted length I Shock absorber oil 202 24 18 70 55 WP Suspension Up Side Down 4860 MXMA 4CS 17 clicks 15 clicks 13 clicks 17 clicks 15 clicks 13 clicks 480 mm 18 9 in 4 4 N mm 25 1 lb in 4 6 N mm 26 3 lb in 4 8 N mm 27 4 lb in 940...

Page 205: ... M12 Nut frame to linkage lever M14x1 5 Nut linkage lever on swingarm M14x1 5 Nut linkage lever to angle lever M14x1 5 Nut swingarm pivot M16x1 5 Nut rear wheel spindle FC 250 EU M20x1 5 Screw front wheel spindle M20x1 5 Screw top steering head M20x1 5 Screw in nozzles cooling system M20x1 5 Nut rear wheel spindle FC 250 US M25x1 5 3 Nm 2 2 lbf ft 3 Nm 2 2 lbf ft 6 Nm 4 4 lbf ft 6 Nm 4 4 lbf ft 2 ...

Page 206: ...se dirt particles with a gentle spray of water Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush Info I Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to a dry vehicle always rinse the vehicle with water first After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the c...

Page 207: ...cycle out of service add 1111 fuel additive Refuel Clean the motorcycle I p 204 Change the engine oil and oil filter clean the oil screen I p 189 Check the antifreeze and coolant level I p 185 Check the tire air pressure 0 p 84 Remove the battery 0 p 99 26 2 401058 01 Recharge the battery Guideline Storage temperature of battery with out direct sunshine 0 35 C 32 95 F Store the vehicle in a dry lo...

Page 208: ...er chain and check for smooth operation Check correct the fluid level of the hydraulic clutch p 183 Check the front brake fluid level p 106 Check the free travel of the hand brake lever p 105 Check the steering head bearing play l ll p 33 Check the valve clearance Check the clutch Change the shaft seal rings of the water pump Change the engine oil and oil filter clean the oil screen l ll p 189 Che...

Page 209: ...plug connector Change the piston Check measure the cylinder Check the cylinder head Change the valves valve springs and valve spring seats Check the camshaft and cam lever Change the connecting rod conrod bearing and crank pin Check the transmission and shift mechanism Check the oil pressure regulator valve Change the suction pump Check the force pump and lubrication system Change the timing chain...

Page 210: ... 2 1 FC 2 X7 1 l X16 1 1 1 1AP 6 X295 c ol S21 l5 l x19 iBR 4 I N K 4 s E 1 MBI I K 4 BR 4 1 X19 j 4 II I I II 0 0 0 0 M10 G L n J G10 X17 il 1 5 X302 l b ls 1 l N EB 4 1 TI0nt1 WB U w u 1 _ 1 r If EB 4 i EZ 3 X1 X18 j j 0 I l5 l a 2 F1 __ l b 2 F1 Hu rna FC 250 EU 2014 2015 1 3 0 0 IC ...

Page 211: ...Components A11 EFI control unit C10 Capacitor G10 Battery G20 Alternator K10 Starter relay with main fuse K30 Power relay M10 Starter motor T20 Voltage regulator S21 Electric starter button X295 Diagnostics connector 209 ...

Page 212: ... B I I I I I cc J C w t l 11 9 1 9 0 ii C j xs X2 C BF 1 I NCX 2 NAT 2 j NDQ 2 M GA 3 BA 1 30 NCW 2 ru S20 P25 X295 t X301 E 1 N AP 6 r 7 0 n CW 2 i D W r G M D CX 2 X3 XS D X2 0 0 0 0 DDD X300 l 1 1 E E C I z 0 1 FB a 1 1 cc G 1 FB b g 0 F F C0 1 1 C I FC 250 EU 2014 2015 I Hu5 Mlrna I 2 3 1 2 I 3 I 4 5 I 6 I 7 I 8 ...

Page 213: ...28 WIRING DIAGRAM Components A11 EFI control unit M13 Fuel pump M51 Injection valve cylinder 1 P25 Fl warning lamp MIL R30 CAN bus terminating resistor S20 Kill switch X295 Diagnostics connector 211 ...

Page 214: ...W i D X6 t V 2 X15 X12 X13 _5 c 5 _5 c 5 cc J C w E C I z 0 I cc G g 0 F C0 I C I FC 250 EU 2014 2015 Hu5 Mlrna 1 2 I 3 I 4 5 ii or X16 l t fx11 CR 1 I R51 I 5 I i1 D T0 X16 B37 1 I l X10 NAL 2 rn e I 6 I 1 1DTI X16 1 4 AP 6 n n X14 5 il 6 I 7 I 8 C C 0 I 0 A me tj iome I D T X16 X16 X16 5 il B C 49 NCM 2 I i X9 D 5 5 il E F I I I 3 3 7 I 8 ...

Page 215: ...ature sensor cylinder 1 826 Rollover sensor 837 Crankshaft position sensor 841 Manifold absolute pressure sensor cylinder 1 R51 Ignition coil cylinder 1 S51 Map switch for ride mode optional S55 Map Select switch optional Cable colors bl Black br Brown bu Blue gn Green gr Gray lbu Light blue or Orange pk Pink pu Violet rd Red wh White ye Yellow 213 ...

Page 216: ...1 AS 2 1 FC 2 X7 1 l X16 1 1 1 1AP 6 X295 col S21 l5 l x19 iBR 4 I N K 4 s E 1 MBI I K 4 BR 4 1 X19 j 4 II I I II 0 0 0 0 M10 G L n J G10 X17 il 1 5 X302 l b ls 1 l N EB 4 1 TI0nt1 WB U w u 1 _ 1 r If EB 4 i EZ 3 X1 X18 j j 0 I l5 l a 2 F1 __ l b 2 F1 Hu rna FC 250 US 2015 1 3 0 0 IC ...

Page 217: ...Components A11 EFI control unit C10 Capacitor G10 Battery G20 Alternator K10 Starter relay with main fuse K30 Power relay M10 Starter motor T20 Voltage regulator S21 Electric starter button X295 Diagnostics connector 215 ...

Page 218: ...B B I I I I I cc u C t l 11 9 1 9 0 ii C j xs X2 C BF 1 I NCX 2 NAT 2 j NDQ 2 M GA 3 BA 1 30 NCW 2 ru S20 P25 X295 t X301 E 1 N AP 6 r 7 0 n CW 2 i D W r G M D CX 2 X3 XS D X2 0 0 0 0 DDD X300 l ll 1 1 E E C I z 0 1 FB a 1 1 cc G 1 FB b g 0 F F C0 ll C I FC 250 US 2015 I Hu5 Mlrna I 2 3 1 2 I 3 I 4 5 I 6 I 7 I 8 ...

Page 219: ...28 WIRING DIAGRAM Components A11 EFI control unit M13 Fuel pump M51 Injection valve cylinder 1 P25 Fl warning lamp MIL R30 CAN bus terminating resistor S20 Kill switch X295 Diagnostics connector 217 ...

Page 220: ...2 n W i D X6 t V 2 X15 X12 X13 _5 c 5 _5 c 5 cc u C E C I z 0 I cc G g 0 F C0 C I FC 250 us 2015 Hu5 Mlrna 1 2 I 3 I 4 5 ii or X16 l t fx11 CR 1 I R51 I 5 I i1 D T0 X16 B37 1 I l X10 NAL 2 rn e I 6 I 1 1DTI X16 1 4 AP 6 n n X14 5 il 6 I 7 I 8 0 I 0 A me tj iome I D T X16 X16 X16 5 il B C 49 NCM 2 I i X9 D 5 5 il E F I I I 3 3 7 I 8 ...

Page 221: ...e sensor cylinder 1 826 Rollover sensor 837 Crankshaft position sensor 841 Manifold absolute pressure sensor cylinder 1 R51 Ignition coil cylinder 1 S51 Map Select Switch for ride mode optional S55 Map Select switch optional Cable colors bl Black br Brown bu Blue gn Green gr Gray lbu Light blue or Orange pk Pink pu Violet rd Red wh White ye Yellow 219 ...

Page 222: ...s see specifications on the container and that possess the corre sponding properties I Synthetic engine oil Recommended supplier Bel Ray Works Thumper Racing Synthetic Ester 4T Fork oil SAE 4 48601166S1 Standard classification SAE a p 235 SAE 4 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding properties Shock ab...

Page 223: ... Recommended supplier Lubcon Turmogrease PP 300 Lubricant T511 Recommended supplier Lubcon Turmsilon GTI 300 P Lubricant T625 Recommended supplier Molykote 33 Medium Lubricant I152 Recommended supplier Bel Ray Molylube Anti Seize Lubricant I159 Recommended supplier Bel Ray MC 11 Offroad chain s ra Guideline Recommended supplier Bel Ray Blue Tac Chain Lube Oil for foam air filter Recommended suppli...

Page 224: ...30 AUXILIARY SUBSTANCES Preserving materials for aints metal and rubber Recommended supplier Bel Ray Silicone Detailer Protectant Spray Universal oil s ray Recommended supplier Bel Ray 6 in 1 222 ...

Page 225: ...5 H00504 01 Bleeder cover Art no 00029013006 00029013006 H00505 01 Bleedin device Art no 00029013100 00029013100 H00518 01 Battery charger XCharge professional EU Art no 00029095050 H01065 01 Batte charger XCharge rofessional US Art no 00029095051 H01065 01 223 ...

Page 226: ... 00029095052 H01065 01 Batte rofessional CH Art no 00029095053 H01065 01 Tachometer Art no 45129075000 45129075000 H00525 01 Extractor Art no 46129021000 46129021000 H01519 01 S ring hook Art no 50305017000 50305017000 H00973 01 ...

Page 227: ... reverse 51012011000 Clutch holder 51129003000 Extractor 58012009000 H00565 01 H00572 01 H00575 01 H00592 01 Tool for inner bearing race 58429037037 H00596 01 Art no 50329050000 Art no 51012011000 Art no 51129003000 Art no 58012009000 Art no 58429037037 225 ...

Page 228: ...no 58429094000 flt 58429094000 H00606 01 Valve s Art no 59029019000 2x 59029019000 H00610 01 Feeler Art no 59029041100 c 7 59029041100 H00616 01 Graduated disc Art no 60029010000 2x 60029010000 H00625 01 Plastigauge clearance gauge Art no 60029012000 60029012000 H00627 01 ...

Page 229: ...lam liers 60029057000 Testin hose 61029093000 Pressure tester 4x D 61029094000 Engine assembly stand 61229001000 H00628 01 H00650 01 H00659 01 H00660 01 H00662 01 Art no 60029015000 Art no 60029057000 Art no 61029093000 Art no 61029094000 Art no 61229001000 227 ...

Page 230: ...1000 61229021000 H00675 01 Pressin tool for crankshaft com lete Art no 75029047000 75029047000 H00714 01 Protection cap Art no 75029090000 75029090000 H00726 01 Separator plate Art no 77029009001 77029009001 H00738 01 Engine fixing arm Art no 77229002000 2x 77229002000 H00748 01 ...

Page 231: ... no 77229010000 77229010000 H00752 01 Limit Art no 77229026000 77229026000 H00753 01 Protection cap Art no 77229031000 0 77229031000 H00755 01 Separator plate Art no 77229032000 Co 77229032000 H00756 01 Puller Art no 77229048000 2x 77229048000 H00758 01 ...

Page 232: ...060000 H00760 01 Art no 77229172000 77229172000 H00761 01 Oil pressure adapter Art no 77329006000 77329006000 H00764 01 Insert for crankshaft pressing tool Art no 77729008000 77729008000 H00779 01 Insertion tool for iston ring lock Art no 77729030100 77729030100 H01126 01 ...

Page 233: ...231 Lift stand Art no 81329955100 81329955100 H00985 01 Hook wrench Art no T106S T106S H00841 01 Depth micrometer Art no T107S T107S H00842 01 Pin Art no T120 T120 H00844 01 Mounting sleeve Art no T1204 T1204 H00878 01 ...

Page 234: ... Calibration in Art no T1205 T1205 H00879 01 Pressin tool Art no T1206 T1206 H00880 01 Pressin tool Art no T1207S T1207S H00881 01 Mounting sleeve Art no T1215 T1215 H00886 01 Disassembly tool Art no T1216 T1216 H00887 01 ...

Page 235: ...cuum Art no T1240S T1240S H00890 01 Protectin sleeve Art no T1401 cs T1401 H00894 01 Clampin stand Art no T1403S 2x T1403S H00896 01 Mounting tool Art no T14040S T14040S H00922 01 S ecial socket Art no T14047 T14047 H00923 01 ...

Page 236: ...tand Art no T14049S 2x T14049S H00924 01 Press out tool Art no T14051 T14051 H00926 01 Press drift Art no T1504 T1504 H00899 01 Assembly tool Art no T150S 0 Q T150S H00852 01 Nitrogen filling tool Art no T170S1 2x 3x T170S1 H00855 01 ...

Page 237: ...vice 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 a...

Page 238: ...ltage checking 101 Chassis number 9 Clutch fluid level checking correcting 183 fluid changing 183 Clutch lever basic position adjusting 36 Compression damping fork adjusting 12 Compression damping high speed shock absorber adjusting 40 Compression damping low speed shock absorber adjusting 40 Coolant draining 186 refilling 187 Coolant level checking 185 186 Cooling system 185 Cylinder Nikasil coat...

Page 239: ...spacer installing 168 182 spark plug installing 181 starter drive installing 174 starter motor installing 179 suction pump installing 169 timing chain tensioner installing timing chain installing 177 168 transmission shafts installing 166 valve clearance adjusting 178 valve clearance checking 178 valve cover installing 180 water pump cover installing 173 237 Engine disassembly camshaft removing 13...

Page 240: ...use changing 99 H Hand brake lever basic position adjusting 106 free travel checking 105 Handlebar position 36 adjusting 36 Hydrostop unit fork legs assembling 24 fork legs disassembling 21 Idle speed adjusting 196 Ignition coil secondary winding checking 193 Implied warranty 8 Main fuse changing 99 Main silencer glass fiber yarn filling changing 68 installing 68 removing 68 Manifold installing 67...

Page 241: ... linkage checking 45 Spare parts 8 Spark plug connector checking 193 Spoke tension checking 85 Spring fork legs removing 17 Start number plate installing 83 removing 82 Starter motor checking 195 Starter relay checking 102 Starting 10 for checking 11 Steering head bearing changing 34 greasing 31 Steering head bearing play adjusting 35 checking 33 Storage 205 239 Swingarm checking installing 62 63 ...

Page 242: ...11111111111111111111IIIIIIIIIIII 3403012en 06 2016 Husqvarna MOTORCYCLES Husqvarna Motorcycles GmbH fiiiHiAvl StallhofnerstraBe 3 5230 Mattighofen Austria llmi LZZa O www husqvarna motorcycles com __ __ Photo Mitterbauer Husqvarna Motorcycles GmbH ...

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