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Husqvarna F2101Q1, Repair Manual

The Husqvarna F2101Q1 Repair Manual is essential for any DIY enthusiast or professional seeking detailed instructions for servicing and fixing their equipment. This comprehensive manual can be easily downloaded for free from our website, providing users with access to essential troubleshooting information and maintenance guidelines.

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LUBRICATION SYSTEM  20 

Condition 

The engine is cold. 

-

Check the engine oil level.

The engine oil reaches the middle of level viewer  f).

If the engine oil does not reach the middle of the level 

viewer: 

Chan 

Warning 

- Add engine oil. (

!el 

p. 254)

Condition 

The engine is at operating temperature. 

-

Check the engine oil level.

Info 

After switching off the engine,  wait one minute 
before checking the level. 

The engine oil level is between the middle of the level 
viewer  f) and the upper edge of the level viewer@). 

If the engine oil does not reach the middle of level 

viewer 

G: 

- Add engine oil. (

0 

p. 254)

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.

Note 
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 

Check the O-rings for damage. 

Replace damaged O-rings. 
Drain the engine oil while the engine is at operating temperature. 

Preparatory work 

-

Park the motorcycle on a level surface.

... 

251 

Summary of Contents for F2101Q1

Page 1: ...PIONEERING SINCE 1903 REPAIR MANUAL2017 FC250 Art no 3403040en Husqvarna MOTORCYCLES ...

Page 2: ......

Page 3: ...t to modify or delete technical specifications prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice Husqvarna accepts no liability for delivery options deviations from figures and descriptions as well as misprints and other errors T...

Page 4: ...mbling the air cartridge 25 6 15 6 16 6 17 6 18 6 19 6 20 6 21 6 22 Disassembling the shock absorber cartridge 26 Checking the fork legs 28 Assembling the shock absorber cartridge 29 Assembling the air cartridge 31 Assembling the fork legs 33 Lubricating the steering head bearing 39 Removing the lower triple clamp 39 Installing the lower triple clamp 40 6 23 Checking steering head bearing play 42 ...

Page 5: ...e right side cover 99 12 5 Removing the seat 99 12 6 Mounting the seat 100 12 7 Removing the fuel tank 101 TABLE OF CONTENTS 12 8 Installing the fuel tank 102 12 9 Checking the fuel pressure 104 12 10 Changing the fuel pump 105 12 11 Changing the fuel filter 108 12 12 Changing the fuel screen 111 13 MASK FENDER 113 13 1 Removing front fender 113 13 2 Installing front fender 113 13 3 Removing the s...

Page 6: ...mp 177 water pump impeller removing 178 Removing the clutch cover 178 Removing the clutch discs 179 Removing the clutch basket 179 17 3 21 Removing the primary gear wheel 180 17 3 22 timing chain removing 180 17 3 23 Removing the force pump 181 17 3 24 Removing the locking lever 181 17 3 25 shift drum locating unit removing 182 17 3 26 Removing the shift shaft 182 17 3 27 spacer removing 182 17 3 ...

Page 7: ...lling 227 17 5 20 Installing the rotor 227 17 5 21 Installing the piston 227 17 5 22 Installing the cylinder head 229 17 5 23 Installing the camshafts 230 17 5 24 Installing the timing chain tensioner 231 17 5 25 Checking the valve clearance 231 TABLE OF CONTENTS 17 5 26 Adjusting the valve clearance 232 17 5 27 Installing the starter motor 233 17 5 28 Installing the valve cover 233 17 5 29 spark ...

Page 8: ...rical system 273 Tires 273 Fork 273 Shock absorber 274 25 10 Chassis tightening torques 274 26 CLEANING PROTECTIVE TREATMENT 277 26 1 Cleaning the motorcycle 277 27 STORAGE 279 27 1 Storage 279 27 2 Putting into operation after storage 280 28 SERVICE SCHEDULE 281 28 1 Additional information 281 28 2 Required work 281 28 3 Recommended work 282 29 WIRING DIAGRAM 284 29 1 Page 1 of 3 284 29 2 Page 2 ...

Page 9: ...tips Indicates the result of a testing step V Indicates a voltage measurement A Indicates a current measurement 0 Indicates a resistance measurement Indicates the end of an activity including potential rework 1 2 Formats used The typographical formats used in this document are explained below Proprietary name Name Brand Underlined terms Indicates a proprietary name Indicates a protected name Indic...

Page 10: ...s permanent injury if the appropriate measures are not taken Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken Caution Identifies a danger that may lead to minor injuries if the appropriate measures are not taken Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not ta...

Page 11: ... 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 specified in the manual 3 3 S are arts accessories Only use spare parts and accessories approved and or recommended by Husqvarna Motorcycles Husqvarna Motorcycles accepts no liability for other products and any resulting damage or loss ...

Page 12: ...icle number 401947 10 10 The vehicle identification number O is stamped on the right side of the steering head The type label O is fixed to the front of the steering head Engine number O is stamped onto the engine case at the top near the engine sprocket The fork article number O is stamped on the inside of the axle clamp ...

Page 13: ...4 5 Shock absorber article number SERIAL NUMBERS 4 The shock absorber article number O is stamped on the top of the shock absorber above the adjusting ring towards the engine side 11 ...

Page 14: ...vehicle on a firm and level surface 402001 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle insert plug in stand O into the left side of the wheel spindle Info Remove the plug in stand before riding 5 3 Startin the vehicle Note Danger Danger of poisoning death Exhaust gases are toxic and inhaling them may result in unconsciousness and Always make sure there...

Page 15: ...tartin the motorcycle to check the function Danger Danger of poisoning death Exhaust gases are toxic and inhaling them may result in unconsciousness and Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space 400733 01 Shift the transmission to the neutral position Press the electric starter ...

Page 16: ...led The time con suming mounting of harder or softer fork springs is not required If the air chamber loses air due to a damaged seal the fork will still not sag In this case the air is retained in the fork The sus pension travel is maintained as far as possible The damping becomes harder and the riding comfort reduces As with a conventional fork the damping can be adjusted in rebound and compressi...

Page 17: ...Preparatory work Raise the motorcycle with a lift stand 0 p 12 Main work Remove protection cap O Push together fork airpump 8 fully I Fork airpump 79412966000 0 p 305 Info I The fork airpump is included as part of the motorcy cle s accessory pack Connect the fork airpump to the left fork leg The fork airpump indicator switches on automatically A little air escapes from the fork leg when connecting...

Page 18: ...lockwise all the way Info Adjusting screw O is located at the upper end of the right fork leg Turn counterclockwise by the number of clicks correspond ing to the fork type Guideline Compression damping Comfort Standard Sport Info 20 clicks 17 clicks 12 clicks I Turn clockwise to increase damping turn counter clockwise to reduce damping Adjusting the rebound damping of the fork Info The hydraulic r...

Page 19: ...y excess pressure escapes from the interior of the fork Tighten the bleeder screws Finishing work Remove the motorcycle from the lift stand a p 12 Cleaning the dust boots of the fork legs Preparatory work Raise the motorcycle with a lift stand a p 12 Remove the fork protector a p 19 Main work Push dust boots O of both fork legs downward Info I The dust boots remove dust and coarse dirt parti cles ...

Page 20: ...ots back into their installation position Remove excess oil Finishing work Install the fork protector al p 20 Remove the motorcycle from the lift stand 8 p 12 Preparatory work Raise the motorcycle with a lift stand 0 p 12 Remove the front wheel 0 p 118 Main work Remove screws O and take off the clamp Remove screws 8 and take off the brake caliper Allow the brake caliper and brake line to hang loos...

Page 21: ... left fork leg The pressure and rebound damping is located in the right fork leg Tighten screws 8 Guideline Screw top triple clamp Tighten screws Guideline M8 Screw bottom triple M8 clamp 17 Nm 12 5 lbf ft 12 Nm 8 9 lbf ft Position the brake caliper Mount and tighten screws C Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Position the brake line and the clamp Mount and tighte...

Page 22: ...en screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Danger of accidents Disassembling pressurized parts can cause injuries The fork is filled with compressed air Please follow the description provided 0 Q 311645 01 Condition The fork legs have been removed Disassemble the fork legs 0 p 21 Disassemble the air cartridge 0 p 25 Disassemble the shock absorber cartridge 0 p 26 Check the fo...

Page 23: ...4 10 Condition The fork legs have been removed Left fork leg Clamp the fork leg in the area of the lower triple clamp I Clamping stand T1403S al p 309 Release cartridge O using special tool 8 I Ring wrench T14017 8 p 309 Info The cartridge cannot be taken off yet Unclamp the fork leg Drain the fork oil Clamp the fork leg with the axle clamp Guideline I Use soft jaws Remove protection cap f Remove ...

Page 24: ...plied Warm up the outside fork tube in area i of the lower slide bearing Guideline 1 so 0 c 122 F Pull the outside fork tube off the inside fork tube with a jerk Info Lower slide bearing D must be drawn out of its bearing seat Remove upper slide bearing Info Without using a tool pull the stack slightly apart by hand Take off lower slide bearing D Take off support ring fD Take off seal ring Take of...

Page 25: ...sion damping Open the adjusters of the rebound and compression damping completely Clamp the fork leg in the area of the lower triple clamp I Clamping stand T1403S ll I p 309 Remove the screw Remove adjuster 8 on compression damping Loosen cartridge C Ring wrench T14017 0 p 309 Info The cartridge cannot be taken off yet Unclamp the fork leg Drain the fork oil 23 ...

Page 26: ...g G Info The fork protector ring does not necessarily need to be removed for repair work Remove lock ring Info The lock ring has a beveled end where a screw driver can be applied Warm up the outside fork tube in area 9 of the lower slide bearing Guideline I so 0 c 122 F Pull the outside fork tube off the inside fork tube with a jerk Info The lower slide bearing must be drawn out of its bearing sea...

Page 27: ...illed with compressed air Please follow the description provided 0 e B03552 10 Preparatory work Disassemble the fork legs a p 21 Main work Remove protection cap O Slowly release the pressure from the air cartridge Info I Hold the piston rod in extended position to allow the air pressure to balance between the positive air cham ber and the negative air chamber Remove valve core 8 Clamp the air cart...

Page 28: ...Remove end stop Remove spring 0 with spring support and spring sup port Ci Remove seal ring retainer 0 6 15 Disassembling the shock absorber cartridge 26 Preparatory work Disassemble the fork legs 8 p 21 Main work Allow oil to drain from breathing hole O Degrease and clamp the top of the shock absorber cartridge I Clamping stand T14072 8 p 310 Loosen screw cap 8 1 Special socket T14084 0 p 310 Rem...

Page 29: ...er cartridge f Guideline I so 0 c 122 F Loosen seal ring retainer 0 Remove piston rod with seal ring retainer and shock absorber unit Degrease piston rod and clamp underneath spring I Clamping stand T14016S 0 p 309 Heat up the thread area of piston retainer 6 Guideline I so 0 c 122 F Remove piston retainer 6 with the shock absorber unit Remove adjustment valve Qi with the spring from the piston ro...

Page 30: ... If damage is found Change the inside fork tube Measure the outside diameter of the inside fork tube at sev eral places Outside diameter of the inside fork tube 47 975 48 005 mm 1 88878 1 88996 in If the measured value is less than the specified value Change the inside fork tube Measure the run out of the inside fork tube Run out of the inside fork tube 0 20 mm 0 0079 in If the measured value is g...

Page 31: ...he surface is rough Change the slide bearing Check the piston rod for damage If damage is found Replace the piston rod Measure the outside diameter of the piston rod at several locations Outside diameter of the pis 11 965 mm 0 47106 in ton rod If the measured value is less than the specified value Replace the piston rod Measure the run out of the piston rod I Run out of the piston rod I s 0 40 mm ...

Page 32: ...f adjustment valve I Lubricant T158 0 p 292 Mount and tighten piston retainer 0 with shock absorber unit Guideline Piston retainer on piston rod M9x1 20 Nm 14 8 lbf ft Loctite 2701 TM Clamp the shock absorber cartridge at the bottom I Clamping stand T14072 0 p 310 Lubricate friction ring on the shock absorber cartridge I Fork oil SAE 4 48601166S1 0 p 291 Push the piston rod into the shock absorber...

Page 33: ...bricate seals G and friction rings 4D I Fork oil SAE 4 48601166S1 8 p 291 Lubricate O ring 41 on the screw cover I Lubricant T158 8 p 292 Mount the screw cover with pressure stage unit tighten with special tool Guideline Pressure stage unit M44x1 40 Nm 29 5 lbf ft on shock absorber cartridge I Special socket T14084 8 p 310 Assembling the air cartridge 803556 10 Slot special tool O over thread on p...

Page 34: ... Piston on piston M12x1 rod 20 Nm 14 8 lbf ft Loctite 2701 TM Lubricate piston in area of f and inside of the cartridge Grease capacity left cartridge Clamp the air cartridge 11 ml 0 37 fl oz I Clamping stand T14072 a p 310 Push the piston rod into the air cartridge Multi purpose grease 00062010051 a p 293 Lubricate O ring 0 of seal ring retainer 8 I Lubricant T158 a p 292 Mount and tighten the se...

Page 35: ...axle clamp Guideline I Use soft jaws Mount the special tool I Protecting sleeve T1401 IUI p 308 Grease and push on dust boot O I Lubricant T14034 IUI p 292 The sealing lip is mounted with the spring expander facing down Info I Always change the dust boot seal ring lock ring and support ring Push on lock ring 8 Grease and push on seal ring fD I Lubricant T14034 IUI p 292 The sealing lip points down...

Page 36: ... side of the special tool I Mounting tool T14040S 0 p 309 Slide on the outside fork tube Press the slide bearing all the way into the outside fork tube Position the support ring Hold the seal ring with the shorter side of the special tool I Mounting tool T14040S 8 p 309 Press the seal ring and support ring all the way into the outside fork tube Mount lock ring 8 The lock ring engages audibly Mount...

Page 37: ...tube Lubricate O ring I Lubricant T158 8 p 292 Mount and tighten the screw Guideline Screw cartridge on M20x1 45 Nm 33 2 lbf ft axle clamp Clamp the left fork leg vertically Guideline I Use soft jaws Fill with fork oil Oil capacity exter nal mechanism left 200 8 ml 6 76 l g fl oz Fork oil SAE 4 48601166S1 8 p 291 Lubricate O ring fD on the air cartridge I Lubricant T158 8 p 292 Push the outside fo...

Page 38: ...The sealing lip is mounted with the spring expander facing down Info Always change the dust boot seal ring lock ring and support ring Push on lock ring 8 Grease and push on seal ring 8 I Lubricant T14034 ral p 292 The sealing lip points downward the open side upward Remove the special tool Push on support ring C Sand the edges of the slide bearings with 600 grit sand paper then clean and grease th...

Page 39: ...tube Position the support ring Hold the seal ring with the shorter side of the special tool I Mounting tool T14040S al p 309 Press the seal ring and support ring all the way into the outside fork tube Mount lock ring 8 The lock ring engages audibly Mount dust boot O Mount fork protector ring G Assemble the individual components that belong together Info I Shock absorber cartridge right fork leg ca...

Page 40: ...l 6 76 il fl oz 45 Nm 33 2 lbf ft Fork oil SAE 4 48601166S1 a p 291 Lubricate O ring on the shock absorber cartridge I Lubricant T158 a p 292 Push the outside fork tube upwards and screw in the shock absorber cartridge Clamp the outside fork tube in the area of the lower triple clamp I Clamping stand T1403S a p 309 Tighten the shock absorber cartridge Guideline Cartridge on the outside fork tube M...

Page 41: ...crew and rebound adjusting screw 48 clockwise all the way Turn the adjusting screws to the position they were in before removing Mount protection cap 8 6 20 Lubricating the steering head bearing 9 H02387 01 6 21 Removin the lower tri Remove the lower triple clamp ra l p 39 Install the lower triple clamp ra l p 40 Info The steering head bearing is cleaned and lubricated in the course of removal and...

Page 42: ...bles and lines Remove 0 ring 8 Remove protective ring 0 Remove the lower triple clamp with the steering stem Remove the upper steering head bearing 6 22 Installing the lower tri le clam 102146 10 40 Main work Clean the bearing and sealing elements check for damage and grease I High viscosity grease 8 p 292 Insert the lower triple clamp with the steering stem Mount the upper steering head bearing C...

Page 43: ...e of the upper end of the fork legs The second milled groove from the top must be flush with the upper edge of the upper triple clamp The air suspension is located in the left fork leg The pressure and rebound damping is located in the right fork leg Tighten screws Q Guideline Screw bottom triple M8 clamp Tighten screw C Guideline Screw top steering head M20x1 5 Mount and tighten screw Guideline S...

Page 44: ...113 Install the start number plate 8 p 114 Install the front wheel 8 p 119 Check that the wiring harness throttle cables and brake and clutch lines can move freely and are routed correctly Check steering head bearing play 0 p 42 Remove the motorcycle from the lift stand 0 p 12 Mount the handlebar cushion Checking steering head bearing play Warning Danger of accidents Incorrect steering head bearin...

Page 45: ...ust steering head bearing play a p 44 Check the steering head bearing and adjust if neces sary Finishing work Remove the motorcycle from the lift stand a p 12 Changing the steering head bearing 8 Preparatory work Raise the motorcycle with a lift stand a p 12 Remove the front wheel a p 118 Remove the fork legs a p 18 Remove the start number plate a p 114 Remove front fender a p 113 Remove the handl...

Page 46: ...new seal ring Press on the new bearing with a suitable tube as far as it will go Info Only press the bearing in via the inner bearing race Finishing work Install the lower triple clamp i ll p 40 Install front fender i ll p 113 Install the start number plate 0 p 114 Install the front wheel 0 p 119 Check that the wiring harness throttle cables and brake and clutch lines can move freely and are route...

Page 47: ...ic hammer tap lightly on the upper triple clamp to avoid stresses Tighten screws O Guideline Screw top triple clamp M8 Mount and tighten screw 8 Guideline 17 Nm 12 5 lbf ft Screw top steering stem M8 20 Nm 14 8 lbf ft Loctite 243 Finishing work Check steering head bearing play 8 p 42 Remove the motorcycle from the lift stand 8 p 12 Mount the handlebar cushion 45 ...

Page 48: ...0 o e 0 ca e e 0 01189 11 Preparatory work Remove the handlebar cushion Main work Remove screws O Take off the handlebar clamp Remove the handlebar and lay it to one side Info Cover the components to protect them against dam age Do not kink the cables and lines Remove screws 8 Take off handlebar supports Position rubber bushings 8 and push through nuts 0 from below Place the handlebar supports in ...

Page 49: ...ndlebar When the adjusting screw is turned clockwise the clutch lever moves closer to the handlebar The range of adjustment is limited Only turn the adjusting screw by hand and do not use force Do not make any adjustments while riding Check the rubber grips on the handlebar for damage wear and looseness Info The rubber grips are vulcanized onto a sleeve on the left and onto the handle tube of the ...

Page 50: ...outing Finishing work Install the fuel tank 0 p 102 Mount the seat 0 p 100 Install the air filter box cover a p 95 Install the right side cover a p 99 7 6 Checkin throttle cable play Check the throttle grip for smooth operation Move the handlebar to the straight ahead position Turn the throttle grip back and forth slightly and determine the play in throttle cable f I Throttle cable play I 3 5 mm 0...

Page 51: ...n secured the fuel tank does not need to be removed Preparatory work Remove the right side cover a p 99 Remove the air filter box cover a p 95 Remove the seat 0 p 99 Remove the fuel tank 0 p 101 Check throttle cable routing 0 p 48 Main work Move the handlebar to the straight ahead position Push back sleeve O Loosen nut Turn adjusting screw D in as far as possible Loosen nut 8 Push cold start butto...

Page 52: ...teristic map is supplied 0 e Main work Push back sleeve O Remove screws 8 and half shells D Detach the throttle cables and take off the grip tube Remove guide plate C from handle tube 0 Position the required guide plate on the grip tube Guideline The label OUTSIDE must be visible Marking f must be positioned at marking G Alternative 1 I Grey guide plate 79002014000 Alternative 2 I Black guide plat...

Page 53: ...be on the handlebar Attach the throttle cables to the guide plate and route cor rectly Position half shells mount and tighten screws 8 Guideline I Screw throttle grip I M6 I 5 Nm 3 7 lbf ft Slide on sleeve O and check the throttle grip for ease of movement Finishing work Check throttle cable play 0 p 48 51 ...

Page 54: ...r of the frame is not authorized by Husqvarna Motorcycles The procedures are the same on both footrests R00445 10 Condition The frame protectors have been removed on the left and right Remove pin O and take off the washer Press the spring with special tool 8 1 Footrest spring plier 79029083000 0 p 304 The special tool is applied to area f on the footrest Remove pin Position the new footrest and pi...

Page 55: ...spring as shown Spring G engages in area Press the spring with special tool 8 I Footrest spring plier 79029083000 ll I p 304 The special tool is applied to area f on the footrest Mount pin 8 Mount the washer and splint O FRAME 8 53 ...

Page 56: ...nfo I Do not loosen fitting 81 Turn counterclockwise by the number of turns corresponding to the shock absorber type Guideline Highspeed compression damping Comfort Standard Sport Info 2 5 turns 2 turns 1 5 turns I Turn clockwise to increase damping turn counter clockwise to reduce damping 9 2 Adjusting the low speed compression damping of the shock absorber A 54 Caution Risk of injury rectly Part...

Page 57: ...duce damping Adjusting the rebound dam ing of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incor rectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Turn adjusting screw O clockwise up to the last perceptible click Turn counterclockwise by the number of clicks correspo...

Page 58: ...torcycle from the lift stand 8 p 12 Checking the static sag of the shock absorber Measure dimension 6 of rear wheel unloaded 8 p 56 Hold the motorcycle upright with the aid of an assistant Measure the distance again between the rear axle and mark ing SAG on the rear fender using the sag gage Note down the value as dimension Cs Info The static sag is the difference between measure ments 6 and Cs Ch...

Page 59: ... value as dimension 9 Info The riding sag is the difference between measure ments G and 9 Check the riding sag I Riding sag I 105mm 4 13in If the riding sag differs from the specified measurement Adjust the riding sag 8 p 58 reload of the shock absorber Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incor rectly The shock absorber is filled with highl...

Page 60: ...ock M5 absorber adjusting ring Finishing work Install the shock absorber 0 p 60 5 Nm 3 7 lbf ft Check the free travel of the foot brake lever 0 p 150 Remove the motorcycle from the lift stand 0 p 12 Preparatory work Raise the motorcycle with a lift stand 0 p 12 Remove the shock absorber 0 p 59 After removing the shock absorber clean it thoroughly Main work Choose and mount a suitable spring Guidel...

Page 61: ...hock absorber Preparatory work Raise the motorcycle with a lift stand 8 p 12 Main work Remove the cable ties Remove screws O Remove screws 8 with the washers Remove the frame protectors on the left and right Remove screw fD Remove fitting C Info I Raise the wheel slightly to be able to remove the screws more easily Press angle lever 0 toward the rear Press linkage lever D downward Remove screws Pu...

Page 62: ...e fork pivot Pull the link fork to the rear and secure it against falling over Hold the shock absorber and remove screw Remove the shock absorber carefully at the bottom Installing the shock absorber Main work Carefully position the shock absorber into the vehicle from the bottom Mount and tighten screw O Guideline Screw top M10 shock absorber 60 Nm 44 3 lbf ft Loctite 2701 TM ...

Page 63: ...brake cylinder Push rod 8 engages in the foot brake cylinder Info I Ensure that the dust boot is correctly seated Mount and tighten screws 0 Guideline Remaining screws chassis M6 Position the angle lever and linkage lever Mount and tighten fitting D Guideline Nut linkage lever to M14x1 5 angle lever Info I Pay attention to flat area 0 Mount and tighten screw Guideline 10 Nm 7 4 lbf ft 80 Nm 59 lbf...

Page 64: ...ro tector M5 Mount the new cable ties Finishing work 3 Nm 2 2 lbf ft Check the free travel of the foot brake lever i ll p 150 Remove the motorcycle from the lift stand i ll p 12 Checking the shock absorber linkage Preparatory work Raise the motorcycle with a lift stand 0 p 12 Main work Remove screw O Remove fitting 8 Info Raise the wheel slightly to be able to remove the screws more easily Remove ...

Page 65: ...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 f 303096 10 I 54 91 55 00 mm 2 1618 2 1654 in If dimension f is below the specified value Add the necessary spacing washers Position the angle lever Mount fitting 8 but do not tighten yet Guideline Nut angle lever to link fork M14x1 5 80 Nm 59 lbf ft 63 ...

Page 66: ...m 59 lbf ft Raise the wheel slightly to be able to mount the screw more easily Tighten screw O Guideline Screw bottom M10 shock absorber Tighten fitting Ci Guideline Nut angle lever to link fork M14x1 5 60 Nm 44 3 lbf ft Loctite 2701 TM 80 Nm 59 lbf ft Servicin the shock absorber Caution Risk of injury rectly Parts of the shock absorber will move around if the shock absorber is detached incor The ...

Page 67: ...im joint 0 p 72 Assemble the seal ring retainer 0 p 72 Assemble the piston rod 0 p 73 Assemble the damper IUI p 75 Install the spring IUI p 81 Condition The shock absorber has been removed Clamp the shock absorber into the vise Guideline I Use soft jaws Measure and note the spring length while the spring is under tension Loosen screw O Turn the adjusting ring until the spring is completely without...

Page 68: ...5 Main work Make a note of the present state of rebound O and com pression damping Open the adjusters of the rebound and compression damp ing completely Slowly open screw The nitrogen pressure dissipates Remove screw with the 0 ring Remove locking cap 8 Press in seal ring retainer 0 using the special tool Pressing tool T1216 alp 308 ...

Page 69: ...Check inner surface do not scratch If necessary remove any burrs with sandpaper Remove the piston rod Remove adjusting ring with the clamping ring Drain the oil Remove compression adjuster Remove the spring and piston 41 Preparatory work Remove the spring 0 p 65 Disassemble the damper 0 p 66 67 ...

Page 70: ...k onto a screwdriver and put them aside together Remove piston C Remove compression shim stack 0 Info Guide the compression shim stack onto a screwdriver and put them aside together Remove rebound washer D Remove seal ring retainer Remove locking cap and rubber buffer Disassembling the seal ring retainer Preparatory work Remove the spring 8 p 65 Disassemble the damper 8 p 66 Disassemble the piston...

Page 71: ...move washer 3 from seal ring 0 Remove washer Remove dust boot 9 17 Changing the pilot bushing 200796 10 Preparatory work Remove the spring a p 65 Disassemble the damper a p 66 Disassemble the piston rod a p 67 Disassemble the seal ring retainer a p 68 Main work Press pilot bushing O out of seal ring retainer 8 with the special tool I Pressing tool T1504 a p 310 69 ...

Page 72: ...rt seal ring retainer 8 with sleeve 9 of the special tool I Mounting tool T150S 0 p 311 Press the special tool through the new pilot bushing I Calibrating unit T1205 8 p 307 The pilot bushing is calibrated Finishing work Assemble the seal ring retainer 8 p 72 Condition The damper has been disassembled Measure the inside diameter on both ends and in the middle of the damper cartridge Damper cartrid...

Page 73: ...fied value Change the piston rod Check the piston rod for damage and wear If there is damage or wear Change the piston rod Check the piston rings for damage and wear If damage or a bronze colored surface is visible Change the piston Condition The shock absorber has been removed Clamp the shock absorber into the vise Guideline I Use soft jaws Remove both collar bushings O of the heim joint with a s...

Page 74: ...e bench vise Guideline I Use soft jaws I Pressing tool T1206 IOI p 307 Press the heim joint all the way in Press the heim joint against the lock ring using the special tool I Pressing tool T1207S IOI p 307 Mount second lock ring 8 Position both collar bushings D and press in Mount dust boot O with the special tool I Mounting sleeve T1204 0 p 307 Grease the sealing lip of the dust boot I Lubricant ...

Page 75: ... D Mount rebound rubber Grease the 0 ring groove I Lubricant T158 8 p 292 Mount 0 ring Preparatory work Assemble the seal ring retainer 8 p 72 Main work Clamp the piston rod with the fork in a bench vise Guideline I Use soft jaws Mount rubber buffer O and protection cap Position special tool on the piston rod I Mounting sleeve T1515 8 p 311 Grease the dust boot and slide the seal ring retainer ont...

Page 76: ... with the smaller washers facing downward Sand down piston D on both sides on a surface plate using 1200 grit sandpaper Clean the piston Mount the piston Guideline ViewO ViewG of piston from above of piston from below Mount rebound shim stack with the smaller washers fac ing upward Mount washer fD with the groove facing downward ...

Page 77: ...158 0 p 292 Lubricate the thread I Lubricant T159 8 p 293 Mount the piston with the spring Mount and tighten compression adjuster O Guideline Compression damp M31x1 ing adjuster Clamp the damper in a bench vise Guideline I Use soft jaws 35 Nm 25 8 lbf ft Mount adjusting ring 8 with the clamping ring Info The adjusting ring cannot be mounted after the piston rod has been mounted Fill the damper car...

Page 78: ... counterclockwise by the number of clicks corre sponding to the shock absorber type Guideline Lowspeed compression damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Turn adjusting screw fD all the way clockwise with a socket wrench Turn counterclockwise by the number of turns corre sponding to the shock absorber type Guideline Highspeed compression damping Comfort 2 5 turns Standard 2 t...

Page 79: ...ws and in the location determined during disassembly Bleeding and filling the dam er Info Before working with the vacuum pump carefully read the operating manual included with the vacuum pump Open the adjusters of the rebound and compression damping completely Clamp the damper as shown Guideline I Use soft jaws Info I The filling port must be located at the highest position The piston rod moves in...

Page 80: ...tool I Depth micrometer T107S al p 306 The floating piston is located in the lowermost position When the vacuum gauge reaches the required value turn control lever Oil reservoir 0 to Equalize pressure Guideline 14 mbar The pressure gauge increases to the required value 0 bar When the pressure gauge reaches the specified value turn control lever Damper C to Pressure Guideline 0 bar Oil is pumped in...

Page 81: ...per 8 to Pressure Guideline 0 bar Oil is pumped into the damper The pressure gauge increases to the required value 3 bar When the pressure gauge reaches the specified value turn control lever Damper 8 to Vacuum Guideline 3 bar The pressure gauge drops to the required value 0 bar When the pressure gauge reaches the required value acti vate the On Off switch Guideline 0 bar The vacuum pump is switch...

Page 82: ...illing damper with nitrogen B04383 10 Mount screw O with the O ring and screw in approx 2 full turns but do not tighten it fully Info The piston rod is fully extended Fix the special tool in the vise Filling tool T170S1 IUI p 311 Filling adapter T1296 8 p 308 Connect the special tool to the pressure regulator of the filling cylinder I Filling gas nitrogen Adjust the pressure regulator Guideline I ...

Page 83: ...O is mounted with the clamping ring Mount washer 8 Measure the overall spring length while the spring is not under tension Position the spring Guideline 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 Mount washer 8 Mount spring retainer C Mount lock ring 0 Alternative 1 39 N mm 223 lb in 42 N mm 240 lb in 45 N mm 257 lb in Te...

Page 84: ...handling characteristic Tension the spring to the length measured during disas sembly by turning the adjusting ring I Hook wrench 90129051000 8 p 306 Tighten screw D Guideline Screw shock MS 5 Nm 3 7 lbf ft absorber adjusting ring Check the link fork for damage cracking and deformation If the link fork exhibits damage cracking or deformation Change the link fork Info I Always replace a damaged lin...

Page 85: ...the other If there is detectable play Change the fork bearing 8 p 86 Finishing work Remove the motorcycle from the lift stand 8 p 12 Preparatory work Raise the motorcycle with a lift stand l I p 12 Remove the rear wheel al p 122 Main work Take the brake line out of the guide Push the brake caliper forward slip it out and hang it to the side Info Cover the components to protect them against dam age...

Page 86: ...e fitting 8 Lower the link fork Remove the cable ties Remove screws 8 Remove screws C with the washers Remove the frame protectors on the left and right Remove nut 0 Remove the link fork pivot Take off the link fork Main work Position the link fork Mount the fork pivot Mount and tighten nut O Guideline I Nut fork pivot I M16x1 5 1100 Nm 73 8 lbf ft I ...

Page 87: ...tector Mount the cable ties Lift the link fork M5 Mount and tighten fitting C Guideline Nut angle lever to link fork Mount the chain M14x1 5 3 Nm 2 2 lbf ft 80 Nm 59 lbf ft Connect the chain with connecting link 0 Guideline The closed side of the chain joint lock must face in the direction of travel Position the brake caliper and pull it back Position the brake line in the guide Finishing work Ins...

Page 88: ...torcycle with a lift stand 8 p 12 Remove the rear wheel 0 p 122 Remove the link fork 0 p 83 Left fork bearing Remove collar bushings O Remove bushing 8 Remove shaft seal rings D using a suitable tool Remove stop disks C Press out bearing 0 using a suitable tool Using a suitable tool press in new bearing 0 Position the stop disks C Press in shaft seal rings D ...

Page 89: ...R02761 10 SHOCK ABSORBER LINK FORK 9 Mount bushing 8 Grease the shaft seal rings I Long life grease 8 p 292 Position the collar bushings O with the shoulder facing inward Right fork bearing Remove collar bushings 0 Remove bushing 87 ...

Page 90: ...gs I Long life grease a p 292 Position the collar bushings 0 with the shoulder facing inward Finishing work Install the link fork a p 84 Install the rear wheel 8 p 123 Remove the motorcycle from the lift stand 0 p 12 Preparatory work Raise the motorcycle with a lift stand 8 p 12 Remove the shock absorber 8 p 59 Main work Clamp the shock absorber into the vise Guideline I Use soft jaws Remove both ...

Page 91: ... tool Ci I Pressing tool T1207S 8 p 307 Position the new heim joint and the special tool Guideline I Use soft jaws I Pressing tool T1206 8 p 307 Press the heim joint all the way in Press the heim joint against the lock ring using the special tool I Pressing tool T1207S 8 p 307 Mount second lock ring 8 Position both collar bushings O and press in Finishing work Install the shock absorber 0 p 60 Che...

Page 92: ...e the motorcycle with a lift stand 8 p 12 Place a load on the front of the vehicle The rear wheel is not in contact with the ground Main work Move the link fork up and down If there is detectable play Change the heim joint 0 p 88 Finishing work Remove the load from the front of the vehicle Remove the motorcycle from the lift stand 0 p 12 ...

Page 93: ...t side cover 0 p 99 Remove the main silencer 0 p 93 Main work Remove screw O Remove fitting 8 Info Raise the link fork slightly to be able to remove the screws more easily Press angle lever 8 toward the rear Press linkage lever C downward Detach springs 0 I Spring hook 5030501700004 0 p 306 Remove screw D Lift the link fork 91 ...

Page 94: ... the shock absorber and mount and tighten screw O Guideline Screw top M10 shock absorber 60 Nm 44 3 lbf ft Loctite 2701 TM Mount screw 8 but do not tighten yet Guideline Remaining screws chassis Attach springs CD M8 25 Nm 18 4 lbf ft I Spring hook 5030501700004 p 306 Tighten screw 8 Guideline Remaining screws chassis Lower the link fork M8 25 Nm 18 4 lbf ft ...

Page 95: ... Remove the motorcycle from the lift stand 0 p 12 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down before performing any work on the vehicle Preparatory work Remove the right side cover 0 p 99 Main work Detach spring O I Spring hook 5030501700004 0 p 306 Remove screws 8 and take off the main silence...

Page 96: ...he performance characteristic changes 402618 10 Preparatory work Remove the right side cover 8 p 99 Remove the main silencer 8 p 93 Main work Remove all the screws on the main silencer Take off silencer cap O Take off outer tube Pull glass fiber yarn filling D off of inner tube C Clean the parts that need to be reinstalled and check for damage Mount new glass fiber yarn filling D on the inner tube...

Page 97: ...air filter box cover in areas 6 Ce and 9 Engine damage Unfiltered intake air has a negative effect on the service life of the engine Dust and dirt will enter the engine without an air filter Never start to use the vehicle without an air filter Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and ...

Page 98: ... i is secured by retaining tab s Info If the air filter is not mounted correctly dust and dirt may enter the engine and result in damage Finishing work Install the air filter box cover l l l p 95 Cleaning the air filter and air filter box Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in co...

Page 99: ...ng it out Oil the dry air filter with a high grade air filter oil I Oil for foam air filter Sl p 293 Clean the air filter box Clean the intake flange and check it for damage and tight ness Finishing work Install the air filter Sl p 96 Install the air filter box cover Sl p 95 Preparatory work Remove the air filter box cover Sl p 95 Main work Seal the air filter box in the marked area 6 Finishing wo...

Page 100: ...ing 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 Note Envi...

Page 101: ...d G and remove toward the front Installing the right side cover Removing the seat Position side cover on collar bushings 0 and and push toward the rear Engage side cover in areas f and G Mount and tighten screw D Guideline Remaining screws chassis Preparatory work M5 Remove the air filter box cover 0 p 95 5 Nm 3 7 lbf ft 99 ...

Page 102: ...n work Mount the front of the seat on the collar bushing of the fuel tank and the rear in the bracket Push the seat forward Make sure that the seat is correctly locked in Mount and tighten screw O Guideline Remaining screws chassis Finishing work M6 Install the air filter box cover l l l p 95 10 Nm 7 4 lbf ft ...

Page 103: ... 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 Preparatory work Remove the right side cover 8 p 99 Remove the air filter box cover 8 p 95 Remove the seat 8 p 99...

Page 104: ...f 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 poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin con...

Page 105: ...ne Remaining screws chassis M6 Plug in connector fD for the fuel pump 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft Remove the wash cap set and thoroughly clean the plug in connection of the fuel line using compressed air Info 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 for the fuel line Info ...

Page 106: ...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 Condition The fuel tank is completely full Ensure that the battery voltage does not drop below 12 5 V The diagnostics tool is disc...

Page 107: ...f the fuel line 41 12 10 Changing the fuel pump A Danger Fire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediat...

Page 108: ...il or the sewage system Preparatory work Drain the fuel from the fuel tank into a suitable container Remove the right side cover 0 p 99 Remove the air filter box cover 0 p 95 Remove the seat 0 p 99 Remove the fuel tank 0 p 101 Main work Remove nut O with the gasket Remove fuel connection 8 with the gasket Remove screws Pull out the fuel pump R00450 10 106 ...

Page 109: ...se and position The hoses in the tank are located in the left half of the tank The connector points downwards Mount and tighten screws ti Guideline I Screw fuel pump I EJOT 1 2 3 Nm 1 7 lbf ft Mount fuel connection 8 with the gasket but do not tighten yet Tighten nut O Guideline Nut fuel pump fas tener M12x1 75 Tighten fuel connection 8 Guideline Fuel connection on fuel tank Finishing work M8x1 25...

Page 110: ... 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 Note Environ...

Page 111: ... 305317 10 FUEL TANK SEAT TRIM 12 Remove screws 8 Pull out the fuel pump Remove hose clamps C Remove fuel filter 0 Press locking mechanism C _ Pull back fuel pump housing Change fuel screen _ Mount the fuel pump housing 109 ...

Page 112: ...O with gasket but do not tighten yet Pull out the fuel pump The fuel filter remains in the fuel tank Info I Make sure that the fuel filter is not pulled out too far Keep the fuel pump with hose tensioned turn clockwise and position The hoses in the tank are located in the left half of the tank The connector points downwards Mount and tighten screws D Guideline I Screw fuel pump I EJOT 1 2 3 Nm 1 7...

Page 113: ...en 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 poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not i...

Page 114: ...he fuel hose Pull fuel screen 8 out of the connecting piece Insert the new fuel screen all the way into the connecting piece Lubricate the O ring and connect plug in connection of the fuel line Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust ex...

Page 115: ...e the start number plate 8 p 114 Main work Remove screws O and Take off the front fender Main work Position front fender Mount and tighten screws O and 8 Guideline Remaining screws chassis Finishing work M6 Install the start number plate 0 p 114 10 Nm 7 4 lbf ft 113 ...

Page 116: ...ber plate to one side Remove screw 8 and take off the brake line guide and start number plate Position the brake line and brake line guide on the start num ber plate Mount and tighten screw O Position the start number plate The holding lugs engage in the fender Mount and tighten screw 8 ...

Page 117: ...e of the tires all have a major impact on the handling characteristic of the motorcycle The tires mounted on the front and rear wheels must have a similar profile Worn tires 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...

Page 118: ...o check it If there is detectable play Change the rear wheel bearing 8 p 131 Finishing work Remove the motorcycle from the lift stand 8 p 12 Danger of accidents Worn out brake discs reduce the braking effect Make sure that worn out brake discs are replaced immediately _ _A _____ __ H00938 10 Check the front and rear brake disc thickness at multiple points for the dimension 6 Info I Wear reduces th...

Page 119: ...on the spoke length and spoke diameter If you hear different tone frequencies from different spokes of equal length and diameter this is an indica tion of different spoke tensions I You should hear a high note If the spoke tension differs Correct the spoke tension Check the spoke torque Guideline Spoke nipple front wheel Spoke nipple rear wheel M4 5 M4 5 6 Nm 4 4 lbf ft 6 Nm 4 4 lbf ft I Torque wr...

Page 120: ...than the specified value Center the rim Info Center the rim by pulling the spoke nipple on the other side of the rim run out If there is sig nificant deformation change the rim Correct the spoke tension 14 7 1 Removing the front wheel 118 Preparatory work Raise the motorcycle with a lift stand 8 p 12 Main work Press the brake caliper onto the brake disc by hand in order to push back the brake pist...

Page 121: ...rning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary H00935 10 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change front wheel bearing 0 p 120 Clean and grease shaft seal rings O and contact surfaces f of the spacers I Lo...

Page 122: ...lbf ft Info If the brake discs are changed the brake linings must also be changed 14 7 4 120 Preparatory work Raise the motorcycle with a lift stand a p 12 Remove the front wheel 0 p 118 Main work Remove screws O Remove the brake disc Clean the contact surface of the brake disc Position the new brake disc with the label facing outward Mount and tighten screws O Guideline Screw front brake disc Fin...

Page 123: ... via the outer bearing race otherwise the bearing will be damaged when it is pressed in Clean grease and mount spacing tube C I Long life grease a p 292 Press in new bearing D all the way using a suitable tool Info Only press the bearing in via the outer bearing race 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 124: ...ve chain adjuster 8 Pull out wheel spindle 8 far enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Remove the chain from the rear sprocket Info Cover the components to protect them against dam age 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 Hold ...

Page 125: ...rease IOJ p 292 Position the rear wheel and insert wheel spindle 8 The brake linings are correctly positioned Mount the chain Position chain adjuster 4D Mount nut C but do not tighten it yet Make sure that chain adjusters 8 are fitted correctly on adjusting screws 0 Check the chain tension IOJ p 124 Tighten nut C Guideline Nut rear wheel spin M25x1 5 die Info 80 Nm 59 lbf ft I The wide adjustment ...

Page 126: ...hain is tensioned too much the chain engine sprocket rear sprocket transmission and rear wheel bearings wear more quickly Some components may break if overloaded If the chain is too loose the chain may fall off the engine 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 specif...

Page 127: ...nut O Loosen nuts 8 Adjust the chain tension by turning adjusting screws left and right Guideline Chain tension 1 55 58 mm 2 17 2 28 in Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks t The rear wheel is then correctly aligned Tighten nuts 8 Make sure that chain adjusters 8 are fitted correc...

Page 128: ...pecified weight O Guideline Weight chain wear mea surement 10 15 kg 22 33 lb Measure distance G of 18 chain rollers in the lower chain section Info Chain wear is not always even so you should repeat this measurement at different chain positions Maximum distance G at the longest chain section 272 mm 10 71 in If distance G is greater than the specified measurement Change the drivetrain kit lall p 12...

Page 129: ... ft Loctite 243 Check the chain sliding piece for wear If the lower edge of the chain pins 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 screw on the chain sliding piece Guideline Screw chain slid MS ing piece 15 Nm 11 1 lbf ft Check the chain guide with a slide gau...

Page 130: ...ents Lubricants on the tires reduces the road grip Remove lubricants from the tires using a suitable cleaning agent Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils...

Page 131: ...otorcycle from the lift stand el p 12 Preparatory work Remove the air filter box cover el p 95 Raise the motorcycle with a lift stand el p 12 Main work Remove screw O with the washer Remove screw 8 Take off the engine sprocket cover Have an assistant operate the rear brake Remove screw with the washer Remove the rear wheel el p 122 Remove connecting link C of the chain Take off the chain Info WHEE...

Page 132: ... ft Loctite 2701TM Slide new engine sprocket 0 onto the countershaft Mount the new chain Connect the chain with connecting link C Guideline The closed side of the chain joint lock must face in the direction of travel Install the rear wheel I p 123 Have an assistant operate the rear brake Mount and tighten screw CD with the washer Guideline Screw engine sprocket M10 60 Nm 44 3 lbf ft Loctite 2701TM...

Page 133: ... ft Finishing work Install the air filter box cover ie JJ p 95 Remove the motorcycle from the lift stand IOI p 12 14 8 10 Changing the rear wheel bearing Preparatory work Raise the motorcycle with a lift stand IOI p 12 Remove the rear wheel IOI p 122 Main work Remove shaft seal ring O Remove lock ring Remove shaft seal ring D Using a suitable tool press bearing 8 out from the inside to the outside...

Page 134: ...ing will be damaged when it is pressed in Clean grease and mount spacing tube 0 I Long life grease 8 p 292 Press new bearing C all the way in from the outside to the inside Info Only press the bearing in via the outer bearing race otherwise the bearing will be damaged when it is pressed in Grease new shaft seal ring CD and press it in until it is flush Mount lock ring 8 The lock ring engages audib...

Page 135: ...ngine stops Remove the air filter box cover 0 p 95 Remove the seat 0 p 99 Main work Pull starter relay O from the holder Take off protection caps Remove faulty main fuse 8 Info A faulty fuse has a burned out fuse wire 6 A spare fuse C is located in the starter relay Insert a new main fuse I Fuse 58011109110 0 p 273 Check that the electrical system is functioning properly Tip I Insert a spare fuse ...

Page 136: ...ack the negative terminal cover Disconnect negative cable O of the 12 V battery ative cable of the 12 V batte T02638 10 Main work Connect negative cable O of the 12 V battery Guideline Screw battery termi M5 nal 2 5 Nm 1 84 lbf ft Contact disks O must be mounted under the screw and the cable lug 8 with the claws toward the battery terminal Slide negative terminal cover over the negative terminal F...

Page 137: ...s if the charge is already below the minimum voltage Minimum voltage before the start of the charge 9 V Dispose of 12 V batteries with less than the minimum voltage correctly H01190 10 Preparatory work Press and hold the kill switch while the engine is idling until the engine stops Remove the air filter box cover 0 p 95 Remove the seat 0 p 99 Main work Pull back negative terminal cover O and disco...

Page 138: ... 2 5 Nm 1 84 lbf ft Slide negative terminal cover over the negative terminal Finishing work Mount the seat 8 p 100 Install the air filter box cover 8 p 95 Risk of injury 12 V batteries contain harmful substances Keep 12 V batteries out of the reach of children Keep sparks and open flames away from 12 V batteries Only charge 12 V batteries in well ventilated rooms Maintain a minimum clearance from ...

Page 139: ...d state for an extended period it will become deeply discharged and suffer a loss of capacity destroying the battery The 12 V battery is maintenance free 311910 10 Preparatory work Remove the air filter box cover IUI p 95 Remove the seat 0 p 99 Press and hold the kill switch while the engine is idling until the engine stops Disconnect the negative cable of the 12 V battery 0 p 134 Main work Connec...

Page 140: ...ck the function al p 13 V Measure the voltage between the specified points Measuring point plus Measuring point Ground I Charging voltage 5 000 rpm 1 13 5 15 0 V If the displayed value is less than the specified value Check the plug in connections from the alternator to the voltage regulator Check the plug in connections from the voltage regu lator to the wiring harness Check the stator winding of...

Page 141: ...e seat 8 p 100 Install the air filter box cover lell p 95 Remove the capacitor Discharge the capacitor by bridging the two contacts Connect the capacitor to a 12 V test lamp to a connection and connect to the 12 V battery as shown in the figure Info As the capacitor charge increases the test lamp becomes dimmer The bulb lights up for 0 5 2 0 s The capacitor is OK The bulb lights up for 0 5 s Chang...

Page 142: ...tor Pull back the cover Disconnect cable D from the starter relay Connect the starter relay to a 12 V power supply as per the figure Measure the resistance between the specified points I Resistance of open circuit I 0 Q If the value displayed does not meet specifications Change the starter relay Clamp cable D on the starter relay Plug in connector Mount the starter relay onto the holder and route ...

Page 143: ...brake fluid to come into contact with the skin the eyes or clothing 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 Da...

Page 144: ...ot press the brake caliper against the spokes when pushing back the brake pis tons Remove the cotter pins 8 pull out pin 0 and remove the brake linings Clean the brake caliper and brake caliper bracket Check that spring plate Q in the brake caliper and sliding plate in the brake caliper bracket are seated properly Insert the new brake linings insert pin 0 and mount cotter pins 8 Info I Always chan...

Page 145: ...ere is no free travel on the hand brake lever pressure builds up on the front brake circuit Set the free travel on the hand brake lever in accordance with the specification Push the hand brake lever forward and check free travel f Free travel of hand brake lever 3 mm 0 12 in If the free travel does not match the specification Adjust the basic position of the hand brake lever 0 p 143 Adjusting the ...

Page 146: ...e 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 with the service schedule Preparatory work Check the front brake linings 8 p 141 Main work Move the brake reservoir mounted on the handlebar to a hori zontal position Addin f...

Page 147: ...rvice schedule Note 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 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 painte...

Page 148: ...ause environmental damage Dispose of oils grease filters 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 fr...

Page 149: ...fresh brake fluid emerges in the bleeder bottle hose without bubbles Tighten the bleeder screw Close shut off valve C Open the bleeder screw again until brake fluid stops emerg ing Info I Overfilling the brake fluid reservoir is prevented Tighten the bleeder screw Remove the bleeder bottle hose Attach the protection cap Disconnect the bleeding device Remove the bleeder cover Add brake fluid up to ...

Page 150: ...llow brake fluid to come into contact with the skin the eyes or clothing 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 Warni...

Page 151: ...pring plate 0 in the brake caliper and sliding plate D in the brake caliper bracket are seated properly Info I The arrow on the spring plate points in the direction of rotation of the brake disc Insert the new brake linings insert pin 8 and mount cotter pin Info I Always change the brake linings in pairs Make sure that decoupling plate is mounted on the piston side brake lining Operate the foot br...

Page 152: ...onnect spring O Adjustin the basic position of the foot brake lever Warning Danger of accidents The brake system fails in the event of overheating If there is no free travel on the foot brake lever pressure builds up in the brake system on the rear brake Set the free travel on the foot brake lever in accordance with the specification Detach spring Q Loosen nut C and with push rod turn it back unti...

Page 153: ...e fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Adding rear brake fluid Warning Preparatory work Check the brake linings of the rear brake 8 p 148 Main work Stand the vehicle upright Check the brake fluid level in level viewer O If the brake fluid has dropped below marking f Add rear brake fluid 8 p 151 D...

Page 154: ...ront and rear brake is changed in accordance with the service schedule Note 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 use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 ...

Page 155: ...tal 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 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 pa...

Page 156: ...in until fresh brake fluid emerges in the bleeder bottle hose without bubbles Tighten the bleeder screw Close shut off valve CD Open the bleeder screw again until brake fluid stops emerg ing Info I Overfilling the brake fluid reservoir is prevented Tighten the bleeder screw Remove the bleeder bottle hose Attach the protection cap Disconnect the bleeding device Remove the bleeder cover Stand the ve...

Page 157: ...r 0 p 99 Remove the air filter box cover 0 p 95 Remove the seat 0 p 99 Remove the fuel tank ra l p 101 Remove the main silencer ra l p 93 Main work Remove the cable ties Remove screw O Remove screws with the washers Remove the frame protectors on the left and right Disconnect the negative cable of the 12 V battery Loosen hose clip D ENGINE 17 155 ...

Page 158: ... connector Pull rollover sensor 0 off of the holder and hang to one side Remove screw D Loosen screw Repeat these steps on the opposite side Pivot the subframe up and secure it Remove screw Pivot the shock absorber toward the rear and twist it slightly ...

Page 159: ...gs I Spring hook 5030501700004 a p 306 Remove screw Gi with the washer Take off the manifold Remove fittings G Take off the engine brace Disconnect plug in connector 4B Disconnect plug in connectors G ENGINE 17 157 ...

Page 160: ...plug in connector 4D Remove the cable tie Remove the cable clamps and expose the cable Push back protection cap Unplug the connector Loosen hose clip Gs Pull off the radiator hose Loosen hose clip 48 Pull off the radiator hose ...

Page 161: ... off the engine sprocket cover Remove screws ENGINE 17 Take off the clutch slave cylinder with the gasket and hang it to the side Info Do not kink the clutch line Do not activate the clutch lever while the slave cylin der of the clutch is removed Actuate the foot brake lever Loosen screw Info The help of an assistant is useful in this step 159 ...

Page 162: ... with the washer Take off the engine sprocket Remove screw fJ with the washers Take off the shift lever Loosen hose clip Pull the throttle valve body off of the cylinder head toward the rear and hang it to one side Push back hose clamp and pull off the vent hose Push back protection cap D and remove the nut Hang the positive cable to the side ...

Page 163: ... fitting fJ Remove screws Remove the foot brake cylinder and allow it to hang tension free to the side Take the brake line out of the guide Remove nut 6D Remove the link fork pivot Carefully pull the link fork back and secure it 161 ...

Page 164: ...gainst dam age Main work Position the engine in the frame Info The help of an assistant is useful in this step Make sure that the engine is sufficiently secured against falling over Protect the frame and components against damage Mount screws O but do not tighten yet Guideline Engine carrying screw Position the link fork Mount the fork pivot M10 Mount and tighten nut 8 Guideline 60 Nm 44 3 lbf ft ...

Page 165: ...ng screws chassis M6 Position the linkage lever Mount and tighten fitting 0 Guideline Nut linkage lever to M14x1 5 angle lever Info 10 Nm 7 4 lbf ft 80 Nm 59 lbf ft I Raise the wheel slightly to be able to mount the screw more easily Mount spring D Position the positive cable on the starter motor Mount and tighten the nut Guideline Remaining nuts chassis M6 Position protection cap 10 Nm 7 4 lbf ft...

Page 166: ... the collar facing the engine Mount screw 41 with the washer but do not tighten yet Guideline Screw engine sprocket Mount the chain M10 60 Nm 44 3 lbf ft Loctite 2701TM Connect the chain with connecting link 48 Guideline The closed side of the chain joint lock must face in the direction of travel Actuate the foot brake lever Tighten screw 41 Guideline Screw engine sprocket Info M10 60 Nm 44 3 lbf ...

Page 167: ... Position the engine sprocket cover Mount and tighten screw 4D Guideline Screw clutch slave M6 cylinder Mount and tighten screw Guideline Screw engine sprocket cover M8 Plug in spark plug connector CD Mount capacitor 41 Mount the radiator hose Position and tighten hose clip Qi 10 Nm 7 4 lbfft 10 Nm 7 4 lbfft 20 Nm 14 8 lbfft 165 ...

Page 168: ...tor Position the protection cap fl Route the cable without tension and secure with cable clips and cable ties Join plug in connector of the gear position sensor Join plug in connector 9 of the crankshaft speed sensor Join plug in connectors of the alternator Route the cable without tension ...

Page 169: ... Loctite 2701 TM 60 Nm 44 3 lbf ft Mount screw with the washer but do not tighten yet Guideline Remaining screws chassis Mount springs MB 25 Nm 18 4 lbf ft I Spring hook 5030501700004 0 p 306 Tighten screw Guideline Remaining screws chassis MB Position the shock absorber Mount and tighten screw Guideline Screw top M10 shock absorber 25 Nm 18 4 lbf ft 60 Nm 44 3 lbf ft Loctite 2701 TM 167 ...

Page 170: ...hten screw i Guideline Screw sub frame Remove screw M8 Mount and tighten screw Guideline Screw sub frame M8 30 Nm 22 1 lbf ft Loctite 2701 TM 30 Nm 22 1 lbf ft Loctite 2701 TM Repeat the operation on the opposite side Mount rollover sensor Plug in the connector Mount protection cap G Position and tighten hose clip G ...

Page 171: ...rew G Guideline Screw frame pro tector M5 3 Nm 2 2 lbf ft Mount and tighten screws G with the washers Guideline Screw frame pro tector Mount the cable ties M5 3 Nm 2 2 lbf ft Remove filler plug 6D with the O ring and fill up with engine oil Engine oil 1 0 I 1 1 qt Engine oil SAE 10W 50 8 p 290 Mount and tighten oil filler plug 6D with the O ring Finishing work Install the main silencer 8 p 93 Inst...

Page 172: ...y using the Husqvarna Motorcycles diagnostics tool Check the engine for leak tightness Check the engine oil level l p 250 Check the coolant level p 247 Mount the special tool on the engine assembly stand Holder and fitting for work stand 79229002000 ll I p 304 Engine assembly stand 80329001000 ll I p 305 Mount the engine on the special tool Info Work with an assistant or a motorized hoist Removing...

Page 173: ... plug D with the O ring Completely drain the engine oil Remove screws O Remove the oil filter cover 8 with the O ring Pull oil filter D out of the oil filter housing I Lock ring plier 51012011000 0 p 296 17 3 5 gear position sensor removing Remove screws O Remove the protective plate and the gear position sensor 171 ...

Page 174: ...17 3 7 Removing the valve cover 172 Remove the spark plug with special tool O I Spark plug wrench with link 77229172000 p 302 Remove screws O Take off the valve cover with the valve cover seal Remove gasket 8 Remove spark plug wrench insert fD ...

Page 175: ... alternator cover Remove gasket 8 Remove torque limiter 8 Remove screws C and the starter motor Positioning the engine at ignition top dead center B03740 10 Turn the crankshaft counterclockwise until marking f is flush with the edge of the cylinder head ENGINE 17 173 ...

Page 176: ...ng chain tensioner 17 3 11 Removing the camshafts 174 Loosen screw O Remove screw 8 with the seal ring Pull out timing chain tensioner 4D Remove O ring C Loosen and remove screws O from the outside to the inside Take off slide rail 8 Take off the camshaft bearing support Info Ensure that the dowels remain in place Take the timing chain from the camshaft gear Remove the camshafts ...

Page 177: ...ylinder head gasket D Remove dowels 8 Push the cylinder upward Info ENGINE 17 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 If no further work is to be performed on the cylinder and piston the piston can remain in the cylinder 175 ...

Page 178: ...ial tool 8 into the crankshaft I Protection cap 75029090000 i I p 300 Mount special tool D on the rotor Hold it tight using the special tool and pull off the rotor by turning the screw in I Extractor 79229032044 0 p 304 Info Ensure that the woodruff key remains in place Remove screw O with the washer Take off starter idler gear ...

Page 179: ...17 3 16 Removing the suction pump Take off freewheel gear 6 Remove screws O Take off oil pump cover 8 Remove O ring 6 Take off suction pump C Remove needle roller 0 ENGINE 17 177 ...

Page 180: ...eller removing 17 3 18 Removing the clutch cover 178 Remove screws O Take off the water pump cover Remove gasket Remove nut 8 Take off two part water pump impeller 8 Remove screws O Take off the clutch cover Remove clutch cover gasket ...

Page 181: ...tch discs 8 completely Remove clutch throw out D Remove two opposite sleeves O Bend up the lock washer Hold the inner clutch hub with the special tool Loosen nut I Holding wrench 51129003000 p 296 Remove the nut with the lock washer Take off inner clutch hub D and washer C Info I The washer usually sticks to the inner clutch hub Take off clutch basket 0 ENGINE 17 179 ...

Page 182: ...the crankshaft I Protection cap 75029090000 a p 300 Pull off primary gear wheel using the special tool I Puller 46129021000 a p 296 Remove screws O Remove the timing chain guide rail Remove the timing chain tensioning rail D Remove screw 8 Take off balancer shaft 0 with the timing chain and timing chain securing guide Info If the timing chain is to be reused mark the direction of travel ...

Page 183: ...h the washer Remove lock ring C Take off washer 0 Take off oil pump gear wheel C Remove pin Remove screws G Take off the oil pump cover Remove pin ENGINE 17 Push oil pump shaft Ci inward and take it out of the engine from the ignition side Remove force pump 48 Unscrew O and remove together with locking lever washer sleeve and spring 181 ...

Page 184: ...liding plate 8 away from shift drum locating unit CD Take off the shift drum locating unit Take out shift shaft O with the washer Remove spacer O of the crankshaft Remove screw 8 17 3 28 Removing the left engine case 182 Remove screws O Tilt the left section of the engine case upward and remove the fitting of the engine fixing arm ...

Page 185: ...I Puller 79229048000 0 p 304 Info I Use the drill hole with marking 792 Pull off the section of the engine case Info Do not tension the section of the engine case Take off the left section of the engine case Remove the special tool Remove spacer Remove shift rail O Remove shift rail Tilt shift forks O to the side Info Do not misplace the shift rollers Remove shift drum 8 ENGINE 17 183 ...

Page 186: ...move shift forks O 17 3 32 Removing the transmission shafts 17 3 33 Removing the crankshaft 184 Remove lock ring O Pull both transmission shafts 8 out of the bearing seats together Remove crankshaft O Take off the right section of the engine case ...

Page 187: ...tool Blow out oil nozzle C with compressed air and check that it is clear Guideline Oil nozzle for M4 2 Nm 1 5 lbf ft balancer shaft Loctite 243 lubrication Insert the new cold bearings in the bearing seat 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 When pressing in ensure that the section of the engine case ...

Page 188: ... 5 lbf ft Loctite 243 Mount the oil nozzle for piston cooling Mount and tighten screw C Guideline Screw oil noz M4 zle for piston cooling Position all bearing retainers Mount and tighten screws 0 Guideline Locking screw for bearing M5 2 Nm 1 5 lbf ft Loctite 243 6 Nm 4 4 lbf ft Loctite 243 Check the oil pressure control valve 8 p 190 Blow out the oil channel with compressed air and check that it i...

Page 189: ...he bearing seat 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 When pressing in ensure that the section of the engine case lies flat in order prevent damage Only press the bearings in using the outer bearing race otherwise the bearings will be damaged when they are pressed in After the section of the engine case...

Page 190: ...zle pis ton cooling M5 Position all bearing retainers Mount and tighten screws D Guideline Locking screw for bearing M5 2 Nm 1 5 lbf ft Loctite 243 2 Nm 1 5 lbf ft Loctite 243 6 Nm 4 4 lbf ft 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 8 ...

Page 191: ...using a suitable tool Press in shaft seal ring O all the way with the open side facing outward Remove lock ring 0 Remove shaft seal ring D of the crankshaft Press the new shaft seal ring in with the open side facing inward Info Press the shaft seal ring inward to the point where the lock ring can be mounted Provide suitable support for the clutch cover while pressing in Mount lock ring 0 Blow out ...

Page 192: ...alve Oil pressure control valve Minimu 7 length of pres 1 23 5 mm 0 925 in sure spring If the measured value does not meet specifications Change the spring Check ball C and the sealing seat If there is damage or wear Change the ball and machine the sealing seat Insert ball C and pressure spring Mount and tighten screw plug O with sealing washer 8 Guideline Screw plug oil pres M12x1 5 sure control ...

Page 193: ...ump 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 310373 10 Fix the crankshaft in the vise Guideline I Use soft jaws Warm up special tool O Guideline 11so 0 c 302 F I Puller 58429037037 8 p 297 ENGINE 17 Push the warmed up special tool O onto the crankshaft bearing inner race press firmly together and pull jointly f...

Page 194: ... tool and mount together Guideline 1120 C 248 F I Puller 58429037037 a p 297 Repeat these steps on the opposite side Ensure that the new crankshaft bearing inner race is flush Info After replacing the crankshaft bearings the crankshaft end play must be measured Finishing work Measure the crankshaft end play a p 195 connecting rod conrod bearing and crank pin changing Main work Position crankshaft ...

Page 195: ...il Blow compressed air through the oil channel to check that it is clear Mount new connecting rod 8 Info Thoroughly oil bearing Position special tool D on the press Crankshaft pressing tool 75029047000 0 p 300 Insert for crankshaft pressing tool 79029008000 p 303 Insert the crankweb with the connecting rod and bearing Position the second crankweb Position special tool with the heel pointing down I...

Page 196: ...eeler gauge 59029041100 0 p 298 Connecting rod axial play of lower conrod bearing 0 20 0 45 mm 0 0079 0 0177 in If the measured value is less than the specification Correct it so the dimension is equal to the specified value Finishing work Check the crankshaft run out at the bearing pin 0 p 194 Checking the crankshaft run out at the bearing pin Position the crankshaft on a roller block Turn the cr...

Page 197: ...value does not meet specifications Remove the crankshaft Remove the crankshaft bearing inner race 0 p 191 Calculate the thickness of the compensating disks Add or remove compensating disks equally on both sides Info If the axial play is too small remove compen sating disks If the axial play is too large add compensating disks Install the crankshaft bearing inner race 0 p 192 17 4 11 Removing the d...

Page 198: ...n better performance low wear and a lightweight cylinder 17 4 14 Checking measuring the cylinder 310346 10 196 Check the cylinder bearing surface for damage If the cylinder bearing surface is damaged Change the cylinder and piston Measure the bore diameter at several locations on the 0 and 0 axes using a micrometer to identify oval wear Guideline Cylinder drill hole diameter Size I 78 000 78 012 m...

Page 199: ...on ring is stiff Clean the piston ring groove Tip An old piston ring can be used to clean the piston ring groove Check the piston rings for damage If the piston ring is damaged Change the piston ring Info I Mount the piston ring with the marking facing upward Check the piston pins for discoloration or signs of wear If the piston pin shows severe discoloration signs of wear Change the piston pin Pl...

Page 200: ...030 0 052 mm 0 00118 0 00205 in Size II 0 032 0 055 mm 0 00126 0 00217 in Wear limit 0 070 mm 0 00276 in 17 4 17 Checking the piston ring end gap 310347 10 198 Remove the piston ring from the piston Place the piston ring in the cylinder and align with the piston Guideline Below the upper edge of the 20 mm 0 79 in cylinder Measure end gap f with a feeler gauge Guideline Piston ring end gap Compress...

Page 201: ...eck the pivot points of the camshafts If there is damage or wear Change the cylinder head with the camshaft bearing support Position the camshafts The valves are not actuated Insert the Plastigauge clearance gauge in area 6 I Plastigauge clearance gauge 60029012000 0 p 298 Position camshaft bearing support O Mount and tighten the screws Guideline Screw M7x1 14 Nm 10 3 lbf ft camshaft Lubricated wi...

Page 202: ... parts Remove screw plugs O with the O ring Screw appropriate screw into the cam lever shaft Hold cam levers 8 and remove the cam lever shaft Info If the cam levers will continue to be used note down their installation position Take the shims from the valve spring retainers and put them aside corresponding to their installation position Pre tension the valve springs using the special tool Valve sp...

Page 203: ...to their installation position Info Place the valves in a carton corresponding to their installation position and label them Check the valve plate for run out Valve run out At the valve plate 0 05 mm 0 002 in If the measured value does not meet specifications Change the valve Check sealing seat 6 on valve for damage and wear If the sealing surface is damaged or worn Machine the valve seat Check th...

Page 204: ...pring seat Measure the thickness of the valve spring seat Valve spring seat thick ness 1 40 1 60 mm 0 0551 0 063 in If the measured value does not meet specifications Change the valve spring seat Check the cam levers and cam lever shafts for damage and wear If there is damage or wear Change the cam levers and or cam lever shafts Check valve guides O using the special tool I Limit plug gauge 772290...

Page 205: ...t 1 40 mm 0 0551 in If the measured value does not meet specifications Rework the valve seat Blow compressed air through all oil holes and check that they are clear Position valve spring seat O Mount valve stem seal Mount the valve corresponding to its installation position Mount the valve springs Info Mount the outlet spring with the taper facing upward Mount the inlet springs with the tighter co...

Page 206: ... removed Mount the cam lever shafts Remove screw 0 Mount and tighten screw plugs D with the O rings Guideline Screw plug cam lever axis 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 clockwise do not wedge Check the locking action of the starter idler gear O ...

Page 207: ...nsion ring together with suitable pliers and take off Remove freewheel 8 Thoroughly oil all parts Mount freewheel O Info Note the direction of rotation Mount spreader ring Ensure that all the holding lugs of the expansion ring pass through slots f of the freewheel and engage in groove Ci of the rotor 205 ...

Page 208: ...freewheel gear D 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 Check the gear mesh of starter motor 0 for damage and wear If there is damage or wear Change the starter motor Change O ring C of the starter motor Connect the negative cable of a 12 volt power supply to the hous...

Page 209: ...e and wear If there is damage or wear Replace the timing chain guide rail Check the timing chain securing guide C 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 damage or wear Change the camshaft Check timing chain D for damage and wear If there is damage or wear Change the timing chain 310344 10 Let the...

Page 210: ... go in all the way Guideline Thickness of the compen sating disks 2 2 5 mm 0 08 0 098 in Release the timing chain tensioner The detent mechanism engages and the piston remains in place Final position of the pis ton 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 pre ve...

Page 211: ...d Change all clutch springs Check the contact surface of clutch pressure cap 0 for damage and wear If there is damage or wear Change the clutch pressure cap Check clutch basket D for damage and wear If there is damage or wear Change the clutch basket Check needle bearing and collar sleeve for damage and wear If there is damage or wear Change the needle bearing and collar sleeve Check intermediate ...

Page 212: ...s 41 for damage and wear If there is damage or wear Change the sleeves 17 4 34 Checking the shift mechanism I Check shift forks O on plate f for damage and wear visual check If there is damage or wear Change the shift fork Check shift grooves Cs of shift drum 8 for wear If the shift groove is worn Change the shift drum Check the seat of the shift drum in bearings D If the shift drum is not seated ...

Page 213: ...If the guide pin is loose and or worn Change the sliding plate 310356 10 17 4 35 Preassembling the shift shaft I 8 C _ a 9 d 310355 10 Preassemble the shift shaft 0 p 211 Check clearance O between the sliding plate and the shift quadrant Shift shaft sliding plate shift quadrant clearance 0 40 0 80 mm 0 0157 0 0315 in If the measured value does not meet specifications Change the sliding plate Secur...

Page 214: ...a suitable screw f in the main shaft The screw is supported on the transmission shaft and not on the sleeve Pull off sleeve O using special tool G I Puller 46129021000 la p 296 D05797 10 Remove fifth gear idler gear D and needle bearing 8 Remove stop disk 0 Remove lock ring CD Remove third gear sliding gear Remove lock ring Remove stop disk 0 Remove fourth gear idler gear Ci 212 ...

Page 215: ... needle bearing D and stop disk C Remove fourth gear sliding gear 0 Remove lockring D Remove stop disk Remove third gear idler gear and needle bearing Remove stop disk 41 Remove lockring 0 Remove fifth gear sliding gear 8 Remove lockring G Remove stop disk e Remove second gear idler gear and needle bearing Ci 17 4 38 Checking the transmission Condition The transmission has been disassembled ENGINE...

Page 216: ... sliding gears 0 for damage and wear If there is damage or wear Change the gear wheel pair Check the tooth faces of idler gears C sliding gears 0 and fixed gear D 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...

Page 217: ...oft jaws Mount fourth gear idler gear O Mount stop disk 8 Position special tool f on the transmission shaft I Mounting tool for lock ring 79029005000 8 p 303 Position lock ring 8 on special tool f and push down with sleeve Ci The lock ring engages in the groove of the transmission shaft Mount third gear sliding gear 8 Position special tool f on the transmission shaft I Mounting tool for lock ring ...

Page 218: ...bench vise with the toothed end facing downward Guideline I Use soft jaws Mount needle bearing O and second gear idler gear 8 onto the countershaft with the protruding collar facing downward Mount stop disk Position special tool f on the transmission shaft I Mounting tool for lock ring 75029005000 0 p 300 Position lock ring 8 on special tool f and push down with sleeve 4D The lock ring engages in ...

Page 219: ...g downward Mount stop disk Mount needle bearing 4D and first gear idler gear 49 Mount stop disk Finally check all the gear wheels for smooth operation 17 5 17 5 1 17 5 2 En ine assembly Installing the crankshaft Position the right section of the engine case in the engine assembly stand Oil the bearing I Engine oil SAE 1 0W 50 IOI p 290 Slide crankshaft O into the bearing seat Installing the transm...

Page 220: ...diameter mount this in the shift groove of the main shaft Mount shift fork 8 in the lower shift groove of the counter shaft Mount shift fork 8 in the upper shift groove of the counter shaft Push shift drum O into the bearing seat Put shift forks 8 in the shift drum Info Do not misplace the shift rollers Mount shift rail O Mount shift rail 8 ...

Page 221: ...he engine case together Mount screws O but do not tighten yet Guideline I Screw engine case I M6x55 I10 Nm 7 4 lbf ft Mount screws but do not tighten yet Guideline I Screw engine case I M6x65 110 Nm 7 4 lbf ft Mount screws D and tighten all screws in a crisscross pat tern Guideline I Screw engine case I M6x70 10 Nm 7 4 lbf ft Mount the screw cap of the engine fixing arm Mount the O ring on the cou...

Page 222: ...ft drum locating unit are not symmetric Mount and tighten screw Guideline Screw shift drum locating M6 10 Nm 7 4 lbf ft Loctite 243 Mount locking lever O with the washer sleeve and spring Mount and tighten screw Guideline Screw locking lever M5 Shift through the transmission 6 Nm 4 4 lbf ft Loctite 243 Oil the oil pump shaft internal rotor and external rotor before assembly I Engine oil SAE 10W 50...

Page 223: ...eel C Mount washer Mount lock ring ENGINE 17 6 Nm 4 4 lbf ft Loctite 243 Crank the oil pump gear wheel and ensure that it can move easily Mount oil pump idler gear with the washer Mount washers Mount lock ring G Insert needle roller O Position suction pump 8 The rounded sides of the external rotor face the engine case Crank the oil pump gear wheel and ensure that it can move easily 221 ...

Page 224: ...fo If the timing chain was used before ensure it is run ning in the correct direction Mount and tighten screw 8 Guideline Screw timing M6 10 Nm 7 4 lbf ft chain securing Loctite 243 guide Position timing chain guide rail Mount and tighten screw C Guideline Screw timing M6 chain guide rail 10 Nm 7 4 lbf ft Loctite 243 Position timing chain tensioning rail 0 Mount and tighten screw D Guideline Screw...

Page 225: ...in the wide recess of the crankshaft Markings 6 and G are aligned Mount and tighten nut Guideline Nut primary gear wheel M18LHx1 5 100 Nm 73 8 lbf ft Loctite 243 Mount collar sleeve O and needle bearing Slide clutch basket onto the gearbox main shaft Turn the oil pump gear wheel until the gearing of the clutch basket meshes Slide on washer C and inner clutch hub 0 223 ...

Page 226: ...lock washer Mount sleeves Thoroughly oil the clutch facing discs I Engine oil SAE 10W 50 p 290 Insert the intermediate clutch disc Guideline I Thickness 11 mm 0 04 in Place the clutch facing and intermediate discs into the clutch basket Insert the intermediate clutch disc Guideline I Thickness I 1 mm 0 04 in Mount clutch throw out O Mount the clutch pressure cap Mount screws with the washers and s...

Page 227: ...ated properly Position the clutch cover Info Ensure that the shaft seal rings of the water pump and the crankshaft are not damaged Remove screw f Mount screws 8 but do not tighten yet Guideline I Screw clutch cover I M6x25 I10Nm 7 4 lbf ft Mount screws D but do not tighten yet Guideline I Screw clutch cover I M6x45 110Nm 7 4 lbf ft Mount screw C with the washer but do not tighten yet Guideline I S...

Page 228: ...r Info Ensure that the dowel pins are seated properly Mount screw C with the seal ring but to not tighten yet Guideline Screw water pump cover M6x25 Mount screw 0 but do not tighten yet Guideline Screw water pump cover M6x25 Mount and tighten screws Q Guideline Screw water pump cover M6x40 Tighten screws C and 0 Guideline Screw water pump cover M6x25 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf...

Page 229: ...hat the woodruff key is seated properly Mount the rotor Info 41 To simplify installation turn the starter idler gear coun terclockwise Mount and tighten screw O Guideline Screw rotor M10x1 70 Nm 51 6 lbf ft Collar and thread oiled cone degreased Shift the gap of the piston rings by 180 41 Place the special tool onto the oiled piston Clamp the piston rings together using the special tool I Piston r...

Page 230: ...ton marking f faces the exhaust side Thinly apply sealing compound to area G I Loctite 5910 Position the cylinder base gasket Info Ensure that the dowel pins are seated properly Cover the engine case opening with a cloth Thread the tim ing chain through the timing chain shaft Mount the piston pin Info I For purposes of illustration the following operations are shown on the removed piston Position ...

Page 231: ...to the groove I Insertion for piston ring lock 77729030100 0 p 302 Ensure that the piston ring lock is in the correct position on both sides Remove the cloth Keep the timing chain taut Press the cylinder down carefully and bring dowel pins into contact Mount dowels O Put on cylinder head gasket 8 Put the cylinder head in place Mount nuts 8 with the washers and tighten in a crisscross pattern 229 ...

Page 232: ...n and insert intake camshaft O Place the timing chain over the camshaft gear of the intake camshaft Marking f is aligned and flush with the edge of the cylinder head Ensure that bleeder is positioned properly Slip in exhaust camshaft D Place the timing chain over the camshaft gear and position the camshaft in the bearing seat Marking f is aligned and flush with the edge of the cylinder head Clean ...

Page 233: ... ring Guideline Plug timing chain tensioner Remove screw C M24x1 5 40 Nm 29 5 lbf ft Press the timing chain tensioner toward the timing chain using special tool 0 Release device for timing chain tensioner 61229021000 l ll p 300 17 5 25 Checking the valve clearance The timing chain tensioner unlocks Mount and tighten screw C Guideline Screw unlocking M10x1 of timing chain ten sioner Remove screw O ...

Page 234: ...eeler gauge 59029041100 0 p 298 If the valve clearance does not meet specifications Adjust the valve clearance 0 p 232 Mount and tighten screw O with washer Guideline Screw plug crankshaft location M8 10 Nm 7 4 lbf ft 17 5 26 Adjusting the valve clearance B03742 10 232 Main work Remove the timing chain tensioner 0 p 174 Remove the camshafts 0 p 174 Raise cam levers O Correct the shims according to...

Page 235: ...crews O Guideline I Screw starter motor M6 10 Nm 7 4 lbf ft Thoroughly oil the bearing pin of the torque limiter Position torque limiter 8 Position gasket D Info Ensure that the dowel pins are seated properly Position the alternator cover Mount and tighten screws C Guideline Screw alternator cover M6 10 Nm 7 4 lbf ft Grease the O rings and mount spark plug wrench insert O 233 ...

Page 236: ...line I Screw valve cover I M6 I 8Nm 5 9 lbf ft Mount and tighten the spark plug with special tool O Guideline I Spark plug IM10x1 I10 12Nm 7 4 8 9 lbf ft I Spark plug wrench with link 77229172000 IUI p 302 17 5 30 gear position sensor installing 234 Position gear position sensor Position protective plate Mount and tighten screws O Guideline Screw gear M5 position sensor 5Nm 3 7 lbf ft Loctite 243 ...

Page 237: ...eline I Screw oil filter cover I M6 10 Nm 7 4 lbf ft Mount and tighten oil drain plug O with the O ring Guideline I Oil drain plug I M14x1 5 15 Nm 11 1 lbf ft Mount and tighten oil drain plug 8 with the magnet and a new seal ring Guideline Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Position the oil screen with O rings on a pin wrench Position the pin wrench through the drilled hole of th...

Page 238: ... oil screen M20x1 5 Mount clutch push rod O 15 Nm 11 1 lbf ft 17 5 34 Removing the engine from the engine assembly stand 236 Remove the fitting from the special tool I Holder and fitting for work stand 79229002000 8 p 304 Remove the engine from the engine assembly stand Info Work with an assistant or a motorized hoist ...

Page 239: ... the clothing Info I The fluid level rises with increasing wear of the clutch facing discs Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and clutch 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 th...

Page 240: ...nmental 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 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws O Take off cover 8 with membrane 8 Fill bleeding syringe 8 with the appropriate hydraulic fluid Syringe 503290500...

Page 241: ... 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 poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the a...

Page 242: ...40 Detach spring O Remove screws 8 Take off the clutch cover Loosen screws 8 and remove with the washers and springs Take off clutch pressure cap C Take off clutch throw out 0 with clutch push rod Q Remove sleeves ...

Page 243: ... nut I Holding wrench 51129003000 a p 296 Remove the nut with the lock washer Take off inner clutch hub Ci and washer 48 Info The washer usually sticks to the inner clutch hub Take off clutch basket CB Take off needle bearing 41 and collar sleeve 4D Info The needle bearing and collar sleeve may be in the clutch basket 241 ...

Page 244: ...eck the contact surface of clutch pressure cap C for damage and wear If there is damage or wear Change the clutch pressure cap Check clutch basket 48 for damage and wear If there is damage or wear Change the clutch basket Check needle bearing G and collar sleeve 4D for damage and wear If there is damage or wear Change the needle bearing and collar sleeve Check intermediate clutch discs 4D and 41 f...

Page 245: ...nner clutch hub Check sleeves for damage and wear If there is damage or wear Change the sleeves Mount collar sleeve C and needle bearing G Mount clutch basket 48 Turn clutch basket until the gear teeth mesh with the oil pump gear wheel Mount washer 48 and inner clutch hub Ci Position the new lock washer and mount nut Tighten the nut holding the inner clutch hub with a special tool Guideline Nut in...

Page 246: ...utch basket Insert the intermediate clutch disc Qi Guideline I Thickness 11 mm 0 04 in Mount clutch throw out 0 with clutch push rod D Position clutch pressure cap C Mount screws D with the washers and springs Tighten the screws diagonally Guideline I Screw clutch spring M6 Position the clutch cover Mount and tighten screws 8 Guideline I Screw clutch cover M6x25 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft ...

Page 247: ...R00441 11 Attach spring O Place vehicle in upright position and rest on the plug in stand Finishing work Check the engine oil level p 250 CLUTCH 18 245 ...

Page 248: ...hoses or other cooling system components if the engine or the cooling system are at operating temperature Allow the cooling system and the engine to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep ...

Page 249: ...gine to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediate...

Page 250: ...ly 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 Condition The engine is cold Position the motorcycle upright Place an appropriate container under the water pump cover Remove screw O Take off radiator cap Completely drain the coolant Moun...

Page 251: ...ened Position the motorcycle upright Pour coolant in up to measurement f above the radiator fins Guideline Distance f above the radi 10 mm 0 39 in ator fins I Coolant il I p 290 Mount the radiator cap Go for a short test ride Check the coolant level 0 p 247 249 ...

Page 252: ...ubrication Oil nozzle for piston cooling fD Oil nozzle for alternator cooling 0 Oil nozzle for clutch lubrication 4l Suction pump 41 Oil channel transmission lubrication 48 Timing chain tensioner Checking the engine oil level Info The engine oil level can be checked when the engine is cold or warm Preparatory work H02388 10 Stand the motorcycle upright on a horizontal surface 250 ...

Page 253: ...er If the engine oil does not reach the middle of level viewer G Add engine oil 0 p 254 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 Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease ...

Page 254: ...creen C with the O rings on a pin wrench Position the pin wrench through the drill hole of the screw plug in the opposite section of the engine case Push the oil screen all the way into the engine case Mount and tighten screw plug with the O ring Guideline Screw plug oil screen M20x1 5 15 Nm 11 1 lbf ft Mount and tighten oil drain plug O with the magnet and a new seal ring Guideline Oil drain plug...

Page 255: ... Stand the motorcycle upright 110 Nm 7 4 lbf ft Remove filler plug D from the clutch cover together with the O ring and fill up with engine oil Engine oil Info 1 0 I 1 1 qt Engine oil SAE 1OW 50 0 p 290 I Too little engine oil or poor quality engine oil will result in premature wear of the engine Mount and tighten the filler plug together with the O ring Danger Danger of poisoning Exhaust gases ar...

Page 256: ...ger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Start the engine and check for tightness Finishing work Check the engine oil level p 250 Danger of scalding Engine and gear oil get very h...

Page 257: ...xhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Start the engine and let it warm up Check the oil pressure Oil pressure Engine oil temperature 80 C 176 F Engine speed Idle speed Engine oil temperature 80 ...

Page 258: ...hine is driven Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water Remove the special tools Mount and tighten screw O Guideline Screw unlocking M10x1 of timing chain ten sioner Finishing work Check the engine oil level a p 250 8 Nm 5 9 lbf ft ...

Page 259: ...ition coil connector Condition Spark plug connector cylinder 1 has been removed 0 Measure the resistance between the specified points Measuring point 1 Measuring point 2 Spark plug connector Resistance at 20 C 68 F 1 3 75 6 25 kn If the specification is not reached Change the spark plug connector Alternator checking the stator winding CR 1 6 3mm P00023 10 Condition The alternator has been disconne...

Page 260: ...t value Replace the stator Removing the stator and crankshaft s eed sensor Condition The alternator cover has been removed Remove screws O Remove the retaining bracket Remove screws 8 Remove rubber grommet fD from the alternator cover Remove the stator and crankshaft speed sensor from the alternator cover Installing the stator and crankshaft s eed sensor D00201 10 Blow out oil nozzle O with compre...

Page 261: ...bber grommet 8 in the alternator cover Preparatory work Remove the right side cover 0 p 99 Remove the air filter box cover 0 p 95 Remove the seat 8 p 99 Remove the fuel tank 8 p 101 Main work Pull capacitor O off of the holder and hang to one side Disconnect spark plug connector 8 Remove the spark plug with special tool ti I Spark plug wrench with link 77229172000 8 p 302 Mount and tighten the new...

Page 262: ...N SYSTEM 260 Plug in spark plug connector Mount capacitor O Finishing work Install the fuel tank l ll p 102 Mount the seat l ll p 100 Install the air filter box cover l ll p 95 Install the right side cover 0 p 99 ...

Page 263: ... p 101 Main work Pull capacitor O off of the holder and hang to one side Push back protection cap 8 and remove the connector Disconnect spark plug connector 8 Remove the spark plug with special tool 8 I Spark plug wrench with link 77229172000 8 p 302 Push back hose clamp 0 Pull off the air release hose Remove screws D Remove the valve cover with the gasket to the right Remove gasket 261 ...

Page 264: ...valve clearance between the camshaft and cam lever with the special tool Guideline Valve clearance Intake at 20 c 68 F 0 10 0 15 mm 0 0039 0 0059 in Exhaust at 20 C 68 F 0 13 0 18 mm 0 0051 0 0071 in I Feeler gauge 59029041100 p 298 If the valve clearance does not meet specifications Adjust the valve clearance p 264 Remove screw Crank the engine several times Check the valve clearance and correct ...

Page 265: ...asket Position the valve cover with the gasket Mount and tighten screws Cs Guideline I Screw valve cover I M6 I 8 Nm 5 9 lbf ft Mount the vent hose and position hose clamp 0 Mount and tighten the spark plug with special tool 8 Guideline I Spark plug I M10x1 1 10 12 Nm 7 4 8 9 lbf ft I Spark plug wrench with link 77229172000 0 p 302 Plug in spark plug connector Plug in connector and position protec...

Page 266: ...t side cover 8 p 99 Remove the air filter box cover 8 p 95 Remove the seat 8 p 99 Remove the fuel tank 8 p 101 Check the valve clearance 8 p 261 Remove the timing chain tensioner 8 p 174 Remove the camshafts li l p 174 Main work Swing up cam lever O Correct the shims based on the results of the valve clearance check Finishing work Install the camshafts 8 p 230 Install the timing chain tensioner 8 ...

Page 267: ...or 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 connector O of the starter motor If the starter motor does not turn when the circuit is closed Change the starter motor 265 ...

Page 268: ...un the engine until warm The cold start button is deactivated The cold start but ton is in its basic position F00046 10 Set the idle speed by turning the idle speed adjusting screw O Guideline I Idle speed I 2 250 2 350 rpm I Tachometer 45129075000 0 p 295 Info I Turning counterclockwise lowers the idle speed Turning clockwise raises the idle speed Performing the initialization run Condition The d...

Page 269: ...ce Start the engine without operating the throttle grip Guideline I Coolant temperature I 25 C 77 F Allow the engine warm up to the specified temperature at idle speed Guideline I Coolant temperature I ao 90 c 176 194 F Info Do not operate the throttle grip during the initialization process Switch off the ignition when the specified temperature is reached Info If initialization is not completed or...

Page 270: ...ings Conrod bearing Slide bearing Piston pin bearing Bearing bush Pistons Forged light alloy Piston rings 1 compression ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with two Eaton pumps Primary transmission 24 73 Clutch Multidisc clutch in oil bath hydraulically activated Gearbox 5 gear transmission claw shifted Transmission ratio 1st gear 13 32 2nd gear 16 32 3rd ge...

Page 271: ... II 77 970 77 980 mm 3 06968 3 07007 in Cylinder drill hole diameter Size I 78 000 78 012 mm 3 07086 3 07133 in Size II 78 012 78 025 mm 3 07133 3 07184 in Piston cylinder mounting clearance Size I 0 030 0 052 mm 0 00118 0 00205 in Size II 0 032 0 055 mm 0 00126 0 00217 in Wear limit 0 070 mm 0 00276 in Piston ring end gap Compression ring s 0 40 mm s 0 0157 in Oil scraper ring s 0 70 mm s 0 0276 ...

Page 272: ...m 1 5 lbf ft Loctite 243 Screw bearing bolt oil pump idler MS 6 Nm 4 4 lbf ft gear Loctite 243 Screw crankshaft speed sensor MS 6 Nm 4 4 lbf ft Loctite 243 Screw gear position sensor MS 5 Nm 3 7 lbf ft Loctite 243 Screw locking lever MS 6 Nm 4 4 lbf ft Loctite 243 Screw oil pump cover MS 6 Nm 4 4 lbf ft Loctite 243 Screw stator MS 6 Nm 4 4 lbf ft Loctite 243 Nut cylinder head M6 10 Nm 7 4 lbf ft L...

Page 273: ...10x1 M10x1 M10x1 25 M10x1 25 M10x1 25 M12x1 5 M12x1 5 M14x1 5 M18x1 5 M18LHx1 5 M20x1 5 M24x1 5 TECHNICAL DATA 25 10 Nm 7 4 lbfft 10 Nm 7 4 lbfft Loctite 243 10 Nm 7 4 lbfft Loctite 243 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 Loctite 243 14 Nm 10 3 lbfft Lub ricated with engine oil 10 Nm 7 4 lbfft 15 Nm 11 1 lbfft 60 Nm 44 3 lbfft 15 Nm 11 1 lbfft 10 Nm 7 4 ...

Page 274: ... unloaded Seat height unloaded Weight without fuel approx Maximum permissible front axle load Maximum permissible rear axle load Maximum permissible overall weight 272 118 Nm 13 3 lbf ft I Engine oil SAE 10W 50 0 p 290 I Coolant 0 p 290 I 7 I 1 8 US gal Central tube frame made of chrome molybdenum steel tubing WP Suspension Upside down AER 48 310 mm 12 2 in 300 mm 11 81 in 22 mm 0 87 in WP Suspens...

Page 275: ...na motorcycles com 25 8 Fork Fork part number 34 18 80 55 Fork WP Suspension Upside down AER 48 Compression damping Comfort 20 clicks Standard 17 clicks Sport 12 clicks Rebound damping Comfort 20 clicks Standard 17 clicks Sport 12 clicks Air pressure 10 6 bar 154 psi Fork length 950 mm 37 4 in Oil capacity external mechanism 200 g ml 6 76 fl oz Fork oil SAE 4 48601166S1 right 0 p 291 Oil capacity ...

Page 276: ... 0 24 in 39 N mm 223 lb in 42 N mm 240 lb in 45 N mm 257 lb in 247 mm 9 72 in 10 bar 145 psi 35 mm 1 38 in 105 mm 4 13 in 477 mm 18 78 in Shock absorber fluid SAE 2 5 50180751S1 l ll p 291 Screw intake air temperature sen EJOT DELTA PT 45x12 Z 0 7 Nm 0 52 lbf ft sor Screw pressure regulator EJOT PT K60x25 Z 3 Nm 2 2 lbf ft Screw fixed grip M4 5 Nm 3 7 lbf ft Loctite 243 Spoke nipple front wheel M4...

Page 277: ...ever to angle lever Nut fork pivot Screw front wheel spindle M6 M6 M6 M6 M6 M6 M6 MS MS MS MS MS MS MS MS MS MS MS MS MS MS MS MS M10 M10 M10 M10 M10 M10 M12 M14x1 5 M14x1 5 M14x1 5 M16x1 5 M20x1 5 TECHNICAL DATA 25 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 6 Nm 4 4 lbf ft 14 Nm 10 3 lbf ft 14 Nm 10 3 lbf ft 4 Nm 3 lbf ft 5 Nm 3 7 lbf ft 10 Nm 7 4 lbf ft 20 Nm 14 8 lbf ft 35 Nm 25 8 lbf ft 12 Nm 8 9 lbf f...

Page 278: ...25 TECHNICAL DATA Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Screw in nozzles cooling system M20x1 5 12 Nm 8 9 lbf ft Loctite 243 Nut rear wheel spindle M25x1 5 80 Nm 59 lbf ft 276 ...

Page 279: ...ce will be maintained over a long period Avoid direct sunshine on the motorcycle during cleaning 1 111111111111111 401061 01 Close off the exhaust system to keep water from entering First remove coarse dirt particles with a gentle spray of water Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush Motorcycle cleaner 8 p 293 I Info Use warm water containing norma...

Page 280: ...bricate all moving parts and bearings Clean the chain 8 p 128 Treat bare metal parts except for brake discs and the exhaust system with a corrosion inhibitor Preserving materials for paints metal and rubber 0 p 293 Treat all plastic parts and powder coated parts with a mild cleaning and care agent Special cleaner for glossy and matte paint finishes metal and plastic surfaces 0 p 293 ...

Page 281: ...ents are necessary you should do this during the storage period less workshop overload In this way you can avoid long workshop waiting times at the start of the new season 1111 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive I Fuel additive IUI p 292 Refuel Clean the motorcycle IUI p 277 Change the engine oil and oil filter clean the oil scr...

Page 282: ...time only Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and the exhaust system to rust Puttin into operation after stora e 401059 01 Install the 12 V battery 0 p 136 Remove the motorcycle from the lift stand 0 p 12 Perform checks and maintenance measures when preparing for use Take a test ride ...

Page 283: ...k the wheel bearing for play 0 p 116 I I I I Check the wheel hubs I I Check the rim run out 0 p 117 0 I I Check the spoke tension 0 p 117 0 I I I I Check the chain rear sprocket engine sprocket and chain guide 0 p 125 I I Check the chain tension 0 p 124 0 I I Grease all moving parts e g hand lever chain and check for smooth operation I I I I Check correct the fluid level of the hydraulic clutch 0 ...

Page 284: ... front brake fluid a p 146 Change the rear brake fluid a p 153 Change the hydraulic clutch fluid 0 p 238 Lubricate the steering head bearing 0 p 39 Service the fork a p 20 Service the shock absorber a p 64 Change the fuel filter a p 108 Perform minor engine service including removing and installing the engine Change the spark plug and spark plug connector Change the piston check and measure the cy...

Page 285: ...SERVICE SCHEDULE 28 283 ...

Page 286: ...16 j x1 NfC 2 C10 S 2 1 FC 2 X7 Husqva 1 1 X295 1r oi i I 11 2 II 1 X 1 9 NBR 4 l 521 M10 r K 4 t R 4 X19 i l 250 FC 2017 2018 3 4 I I E E 1 1 rn NAF 4 X17 11 5 j I II G10 X302 J 5 E E 1 1 1 N EB 4 u 3 1 N lB o 1 EZ 3 X1 X18 r nw 1 I I I 6 7 b 2 E1 a 2 F1 I I II ...

Page 287: ...ontrol unit C10 Capacitor G10 12 V battery G20 Alternator K10 Starter relay with main fuse K30 Power relay M10 Electric starter system T20 Voltage regulator S21 E tip switch X295 Diagnostics connector WIRING DIAGRAM 29 285 ...

Page 288: ...Y 33 t t HY 33 HY 33 520 1 X16 1 X16 I 1 X16 1 X16 1 X16 I 1 X16 1 X16 t i i is I I t X S BF 1 dA 1 E I X295 l11AP 6 1 t4 i fr12 a P25 l x2 iCX 2 W 2 W 2 CX 2 1 X2 1 xJ f1 2 Hl 2 1 x 3 0 0 1515 I 1 xs l GA 3 GA 3 1 x 5 l 1 ES b b 3 E1 1 FB a a 3 F1 HUS M ma 250 FC 2017 2018 I l I I I I I ...

Page 289: ...Components A11 EFI control unit M13 Fuel pump M51 Injection valve P25 Malfunction indicator lamp R30 CAN bus terminating resistor 1 S20 Kill switch X295 Diagnostics connector WIRING DIAGRAM 29 287 ...

Page 290: ...1 X16 1 X16 1 X16 I 1 X16 1 X16 16 1 X16 I 1 X16 t l f I f 1 t f 2 B 1 x5 tT 3 M S S f T 3 I _il s n HU 555 1NIMl IC8 MAP TC n 1 X15 NDX 3 X 3 I 5 _il s 250 FC 2017 2018 f f HV 2 lCR 1 X12 X11 B21 EE 1 r R51 I HV 2 1 x12 1i 1 f X14 tg Hf f AP 6 cM 2 I 1 X14 _il B34 r l x20 iJM 3 3 JM 3 I 1 X20 _il s I I oi HUS M rll f I 1 I 2 3 l I I I re ...

Page 291: ...or B34 Gear position sensor B37 Crankshaft speed sensor B41 Induction manifold pressure sensor B43 Throttle valve position sensor R51 Ignition coil S55 Map select switch 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 WIRING DIAGRAM 29 289 ...

Page 292: ...use coolant that complies with the requirements stated see specifications on the container and that has the relevant properties I Antifreeze protection to at least I 25 C 13 F The mixture ratio must be adjusted to the necessary antifreeze protection Use distilled water if the coolant needs to be diluted The use of premixed coolant is recommended Observe the coolant manufacturer specifications for ...

Page 293: ...5 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding properties Su er unleaded ROZ 95 RON 95 PON 91 Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to u...

Page 294: ...uel Stabilizer High viscosi grease Recommended supplier SKF LGHB 2 Long life grease Recommended supplier MOTOREX Bike Grease 2000 Lubricant 14034 Recommended supplier WP Performance Systems WP Racing Grease IPR 2 Lubricant T158 Recommended supplier Lubcon Turmogrease PP 300 Lubricant T625 Recommended supplier Molykote 33 Medium Lubricant T152 Recommended supplier Bel Ray Molylube Anti Seize 292 ...

Page 295: ... road chain SRra Recommended supplier MOTOREX Chainlube Offroad Oil for foam air filter Recommended supplier MOTOREX Racing Bio Liquid Power Preservin materials for aints metal and rubber Recommended supplier MOTOREX Moto Protect Special cleaner for lossy and matte paint finishes metal and plastic surfaces Recommended supplier MOTOREX Quick Cleaner Universal oil spray Recommended supplier MOTOREX ...

Page 296: ...0029013006 I 00029013006 H00505 01 Bleeding device Art no 00029013100 00029013100 H00518 01 EU batte charger XCharge rofessional Art no 00029095050 Feature EU safety plug Nominal voltage 230 V Mains fuse 16A Power cable length 5 m 16 ft approx Charger cable 5 m 16 ft H01065 01 length approx 294 ...

Page 297: ...essional Art no 00029095052 Feature UK safety plug Nominal voltage 230V Mains fuse 16 A Power cable length 5 m 16 ft approx Charger cable 5 m 16 ft H01065 01 length approx CH batte charger XChar e rofessional Art no 00029095053 Feature CH plug Nominal voltage 230V Mains fuse 16 A Power cable length 5 m 16 ft approx Charger cable 5 m 16 ft H01065 01 length approx Tachometer Art no 45129075000 45129...

Page 298: ...LS Puller Art no 46129021000 46129021000 H01519 01 S ringe Art no 50329050000 50329050000 H00565 01 Lock ring lier Art no 51012011000 51012011000 H00572 01 Holding wrench Art no 51129003000 51129003000 H00575 01 296 ...

Page 299: ...89000 Pressing tool 58429091000 Pressing tool 58429092000 H00596 01 H00603 01 H00604 01 H00605 01 Art no 58429037037 Feature I Inside diameter Art no 58429089000 Art no 58429091000 Art no 58429092000 SPECIAL TOOLS 32 I 37 5 mm 1 476 in 297 ...

Page 300: ... H00627 01 298 Art no 58429094000 Feature Torque Open ended bit Open ended bit Open ended bit Open ended bit Bit diameter Art no 59029019000 Art no 59029041100 Feature I 5 piece Art no 60029012000 Feature 3 15 Nm 2 2 11 1 lbfft 3 9 mm 0 154 in 4 9 mm 0 193 in 5 5 mm 0 217 in 6 8 mm 0 268 in 5 9 mm 0 232 in I 0 10 0 25 mm 0 0039 0 0098 in I 0 025 0 175 mm 0 00098 0 00689 in ...

Page 301: ...0 Testing hose 61029093000 Pressure testin tool 4x D 61029094000 H00628 01 H00650 01 H00659 01 H00660 01 SPECIAL TOOLS 32 Art no 60029015000 Feature Height 80 mm 3 15 in Diameter 57 125 mm 2 24 4 92 in Art no 60029057000 Art no 61029093000 Art no 61029094000 299 ...

Page 302: ...ain tensioner Art no 61229021000 61229021000 H00675 01 Mounting tool for lock ring Art no 75029005000 75029005000 H00705 01 Crankshaft ressing tool Art no 75029047000 75029047000 H00714 01 Protection ca Art no 75029090000 75029090000 H00726 01 300 ...

Page 303: ...Valve stem seals lier 77229010000 H00752 01 Limit lug gauge 77229026000 H00753 01 Protection ca 77229031000 H00755 01 Art no 77029041200 Art no 77229010000 Art no 77229026000 Feature I Diameter Art no 77229031000 SPECIAL TOOLS 32 I 5 55 mm 0 2185 in 301 ...

Page 304: ...th link 77229172000 H00761 01 Oil ressure ada ter 77329006000 H00764 01 Insertion for iston ring lock 77729030100 H01126 01 302 Art no 77229032000 Art no 77229172000 Feature Drive Hexagonal part Length Art no 77329006000 Art no 77729030100 3 8 in 14 mm 0 55 in 130 mm 5 12 in ...

Page 305: ...Art no 79029005000 79029005000 H00S00 01 Insert for crankshaft ressing tool Art no 79029008000 79029008000 H00801 01 Se arator late Art no 79029009000 79029009000 H00802 01 Insert for valve s ring lever Art no 79029060000 79029060000 H00803 01 303 ...

Page 306: ...ing lier Art no 79029083000 79029083000 H00804 01 Holder and fitting for work stand 2x Art no 79229002000 79229002000 H01127 01 Extractor Art no 79229032044 79229032044 H00808 01 Puller Art no 79229048000 79229048000 H00809 01 304 ...

Page 307: ...29955100 H00985 01 Art no 79329006000 Art no 79412966000 Feature Maximum pressure Display Valve connection Units Material Art no 80329001000 Art no 81329955100 Feature Height Load SPECIAL TOOLS 32 20 bar 290 psi Digital pressure gauge Schrader valve bar psi and kg cm2 Aluminum tube 315 425 mm 12 4 16 73 in 150 kg 331 lb 305 ...

Page 308: ... wrench 90129051000 S ring hook 5030501700004 De th micrometer T107S Drift T120 306 H00831 01 H00973 01 H00842 01 H00844 01 Art no 90129051000 Art no 5030501700004 Art no T107S Art no T120 Feature I Diameter I 8 mm 0 31 in ...

Page 309: ... 01 Pressing tool T1206 H00880 01 Pressing tool T1207S H00881 01 Art no T1204 Feature I Diameter Art no T1205 Feature I Diameter Art no T1206 Feature I Diameter Art no T1207S SPECIAL TOOLS 32 I 25 5 30 5 mm 1 004 1 201 in 118 mm 0 71 in 115 30 mm 0 59 1 18 in 307 ...

Page 310: ... Vacuum RUm T1240S Filling adaRter T1296 Protecting sleeve T1401 308 H00887 01 H00890 01 H01573 01 H00894 01 Art no T1216 Feature I Diameter Art no T1240S Art no T1296 Art no T1401 Feature I Diameter I 38 49 mm 1 5 1 93 in I 48 mm 1 89 in ...

Page 311: ...40S H01036 01 H00904 01 H00896 01 H00922 01 Art no T14016S Feature I Diameter Art no T14017 Feature I Hexagonal part Art no T1403S Feature Diameter Diameter Art no T14040S Feature I Diameter 112 mm 0 47 in I 50 mm 1 97 in 48 mm 1 89 in 60 mm 2 36 in I 48 mm 1 89 in SPECIAL TOOLS 32 309 ...

Page 312: ...t T14084 Pressing tool T1504 310 H00928 01 H00929 01 H01518 01 H00899 01 Art no T14072 Feature I Diameter Art no T14073 Feature I Diameter Art no T14084 Feature I Drive Diameter Art no T1504 Feature I Diameter I 37 mm 1 46 in 111 5 mm 0 453 in 1 1 2 in 24 mm 0 94 in 118 mm 0 71 in ...

Page 313: ...Mounting tool T150S H00852 01 Mounting sleeve T1515 H00900 01 Filling tool 2x 3x T170S1 H00855 01 Art no T150S Art no T1515 Feature I Diameter Art no T170S1 118 mm 0 71 in SPECIAL TOOLS 32 311 ...

Page 314: ...intervals are demanded for automobile engines the focus for motorcycle engines is on high performance at high engine speeds In most motorcycle engines the transmission and clutch are lubricated with the same oil The JASO T903 MA2 standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to...

Page 315: ...LIST OF ABBREVIATIONS 34 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly 313 ...

Page 316: ...ke checking of rear brake changing rear brake checking 314 120 124 116 144 146 153 151 144 151 141 141 148 148 Capacitor checking 139 Capacity coolant 272 engine oil 169 253 272 Chain checking cleaning Chain guide checking Chain tension adjusting checking 125 128 125 125 124 Characteristic map of the throttle response adjusting 50 Charging voltage checking 138 Clutch fluid level checking correctin...

Page 317: ...230 Checking the valve clearance 231 clutch basket installing clutch cover installing clutch discs installing 223 225 224 clutch push rod installing 236 crankshaft installing 217 cylinder head installing 229 engine removing from the engine assembly stand 236 force pump installing 220 gear position sensor installing 234 left engine case installing 219 locking lever installing 220 oil filter install...

Page 318: ...cking 14 bleeding 17 checking 28 compression damping adjusting 16 disassembling 21 dust boots cleaning 17 fork servicing 20 installing 19 rebound damping adjusting 16 removing 18 shock absorber cartridge assembling 29 shock absorber cartridge disassembling 26 Fork protector installing 20 316 removing 19 Frame checking 52 Front fender installing removing Front wheel installing removing Fuel filter ...

Page 319: ... checking 117 Rubber grips checking 47 s Seat mounting 100 removing 99 Service schedule 281 283 Servicing the fork 20 Servicing the shock absorber 64 Shock absorber changing the heim joint 88 damper assembling 75 damper bleeding and filling 77 damper checking 70 damper disassembling 66 damper filling with nitrogen 80 heim joint installing 72 heim joint removing 71 high speed compression damping ad...

Page 320: ... 272 chassis 272 chassis tightening torques 274 electrical system 273 engine 268 engine tolerance wear limits 269 engine tightening torques 270 fork 273 shock absorber 274 tires 273 Throttle cable play adjusting 49 checking 48 Throttle cable routing checking 48 Tire condition checking 115 Tire pressure checking 115 Type label 10 M Valve clearance checking 261 318 Vehicle identification number 10 w...

Page 321: ...111111111111111111111111111IIIIIIIIIIII 3403040en 06 2018 Husqvarna MOTORCYCLES Husqvarna Motorcycles GmbH _ _ StallhofnerstraBe 3 5230 Mattighofen Austria LZZa JUV Photo Mitterbauer www husqvarna motorcycles com Husqvarna Motorcycles GmbH ...

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