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Husqvarna F2101R1, Repair Manual

The Husqvarna F2101R1 Repair Manual is a comprehensive guide that enables users to troubleshoot and fix issues with their F2101R1 model. This manual is available for free download at manualshive.com, ensuring easy access to step-by-step instructions, diagrams, and important maintenance tips for keeping your equipment in top condition.

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shift forks,  removing 
shift rails,  removing 
shift shaft,  removing 

193 
192 
191 

spacer,  removing  . . . . . . . . . . . . . . . . . . .  191 
spark plug, removing  . . . . . . . . . . . . . . . .  181 
starter drive, removing  . . . . . . . . . . . . . . .  185 
starter motor,  removing 

182 

suction pump,  removing  . . . . . . . . . . . . . .  186 
timing chain tensioner,  removing  . . . . . . . .  183 
timing chain,  removing  . . . . . . . . . . . . . . .  189 
transmission shafts,  removing  . . . . . . . . . .  193 
valve cover,  removing  . . . . . . . . . . . . . . . .  181 
water pump impeller,  removing  . . . . . . . . .  187 

Engine number 

. . . . . . . . . . . . . . . . . . . . . . .  10 

Engine oil 

adding  ..........................  263 
changing 

260 

Engine oil level 

chec�ng .........................  259 

Engine sprocket 

checking  . . . . . . . . . . . . . . . . . . . . . . . . .  126 

F 

Figures 

..............................  9 

Foot brake lever 

basic position,  adjusting  . . . . . . . . . . . . . .  156 
free travel,  checking  . . . . . . . . . . . . . . . . .  156 

Fork article number 

. . . . . . . . . . . . . . . . . . . .  1 0 

Fork bearing 

changing  . . . . . . . . . . . . . . . . . . . . . . . . .  86 
checking  . . . . . . . . . . . . . . . . . . . . . . . . . .  82 

Fork legs 

air cartridge,  assembling  ...............  31 
air cartridge,  disassembling . . . . . . . . . . . . .  25 
air pressure,  adjusting  . . . . . . . . . . . . . . . .  15 
assembling  . . . . . . . . . . . . . . . . . . . . . . . .  33 
basic setting,  checking  ................  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 

removing  . . . . . . . . . . . . . . . . . . . . . . . . .  19 

Frame 

checking  . . . . . . . . . . . . . . . . . . . . . . . . . .  52 

Front fender 

installing 
removing 

Front wheel 

installing 
removing 

Fuel filter 

changing 

Fuel pressure 

checking 

Fuel pump 

changing 

Fuel screen 

changing 

Fuel tank 

installing 
removing 

Fuel tank filler cap 

113 
113 

119 
118 

108 

104 

105 

111 

102 
101 

closing  ...........................  98 
opening  ..........................  98 

Fuel,  oils, etc. 

. . . . . . . . . . . . . . . . . . . . . . . . .  9 

Fuse 

main fuse,  changing  . . . . . . . . . . . . . . . . .  134 

H 

Hand brake lever 

basic position,  adjusting 

146 

free travel,  checking  . . . . . . . . . . . . . . . . .  145 

Handlebar position 

. . . . . . . . . . . . . . . . . . . .  46 

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . .  46 

Heim joint 

checking . . . . . . . . . . . . . . . . . . . . . . . . . .  90 

High-speed compression damping 

shock absorber,  adjusting  ..............  54 

Idle speed 

adjusting 

Ignition coil 

secondary winding,  checking 

275 

266 

Implied warranty 

. . . . . . . . . . . . . . . . . . . . . . .  9 

Initialization run 

performing  . . . . . . . . . . . . . . . . . . . . . . .  275 

325 

INDEX 

Summary of Contents for F2101R1

Page 1: ...PIONEERING SINCE 1903 REPAIR MANUAL2018 FC250 Art no 3403058en 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 40 Installing the lower triple clamp 41 6 23 Checking steering head bearing play 43 ...

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: ... impeller removing 187 17 3 18 Removing the clutch cover 187 17 3 19 Removing the clutch discs 188 17 3 20 Removing the clutch basket 188 17 3 21 Removing the primary gear wheel 189 17 3 22 timing chain removing 189 17 3 23 Removing the force pump 190 17 3 24 Removing the locking lever 190 17 3 25 shift drum locating unit removing 191 17 3 26 Removing the shift shaft 191 17 3 27 spacer removing 19...

Page 7: ...lling 236 17 5 20 Installing the rotor 236 17 5 21 Installing the piston 236 17 5 22 Installing the cylinder head 238 17 5 23 Installing the camshafts 239 17 5 24 Installing the timing chain tensioner 240 17 5 25 Checking the valve clearance 240 TABLE OF CONTENTS 17 5 26 Adjusting the valve clearance 241 17 5 27 Installing the starter motor 242 17 5 28 Installing the valve cover 242 17 5 29 spark ...

Page 8: ...rical system 282 Tires 282 Fork 282 Shock absorber 283 25 10 Chassis tightening torques 283 26 CLEANING PROTECTIVE TREATMENT 286 26 1 Cleaning the motorcycle 286 27 STORAGE 288 27 1 Storage 288 27 2 Putting into operation after storage 289 28 SERVICE SCHEDULE 290 28 1 Additional information 290 28 2 Required work 290 28 3 Recommended work 291 29 WIRING DIAGRAM 292 29 1 Page 1 of 3 292 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 313 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: ... clockwise 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 17 clicks 12 clicks 7 clicks I Turn clockwise to increase damping turn counter clockwise to reduce damping Adjusting the rebound damping of the fork Info The hydraulic ...

Page 19: ... 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 f...

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: ...ocated in the 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 Mou...

Page 22: ...g Mount and tighten 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 ...

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 318 Release cartridge O using special tool 8 I Ring wrench T14017 8 p 317 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 318 Remove the screw Remove adjuster 8 on compression damping Loosen cartridge C Ring wrench T14017 0 p 317 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: ...emove piston D Remove end stop Remove spring pack 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 318 Loosen screw cap 8 1 Special socket T14084 0 p 319 Remove the screw cap with sh...

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 317 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 300 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 318 Lubricate friction ring on the shock absorber cartridge I Fork oil SAE 4 48601166S1 0 p 299 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 299 Lubricate O ring 41 on the screw cover I Lubricant T158 8 p 300 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 319 Assembling the air cartridge 803556 10 Slot special tool O over thread on p...

Page 34: ...rtridge Grease capacity left cartridge Clamp the air cartridge 11 ml 0 37 fl oz I Clamping stand T14072 a p 318 Multi purpose grease 00062010051 a p 301 Position the special tool in the cartridge I Mounting sleeve T14092 a p 319 Push the piston rod into the air cartridge Info The air cartridge must be absolutely clean on the inside Do not damage the gasket when inserting the piston Remove the spec...

Page 35: ...si I Fork airpump 79412966000 ra l p 313 Mount protection cap Info Only mount the protection cap by hand Preparatory work Check the fork legs ra l p 28 Left fork leg Clamp the inside fork tube using the axle clamp Guideline I Use soft jaws Mount the special tool I Protecting sleeve T1401 ra l p 317 Grease and push on dust boot O I Lubricant T14034 ra l p 300 The sealing lip is mounted with the spr...

Page 36: ...tack slightly apart by hand Warm up the outside fork tube in area 6 of the lower slide bearings Guideline I so 0 c 122 F Hold the lower slide bearing with the longer side of the special tool I Mounting tool T14040S 8 p 318 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 t...

Page 37: ...mp with brake mount and outside fork tube with warning label 0 screw cartridge Slide the air cartridge into the inside fork tube Lubricate O ring I Lubricant T158 0 p 300 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 ig ml 6 76 g fl...

Page 38: ...h T14017 0 p 317 Right fork leg 50 Nm 36 9 lbf ft Clamp the inside fork tube using the axle clamp Guideline I Use soft jaws Mount the special tool I Protecting sleeve T1401 0 p 317 Grease and push on dust boot O I Lubricant T14034 0 p 300 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 ...

Page 39: ... G of the lower slide bearings Guideline I so 0 c 122 F Hold the lower slide bearing with the longer side of the special tool I Mounting tool T14040S 8 p 318 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 318 Press the seal ring and suppo...

Page 40: ...und adjuster I Lubricant T158 0 p 300 Mount and tighten the rebound adjuster Guideline Rebound adjuster on the axle clamp M20x1 Clamp the left fork leg vertically Guideline I Use soft jaws Fill with fork oil Oil capacity exter nal mechanism right 200 18 ml 6 76 Jg fl oz 45 Nm 33 2 lbf ft Fork oil SAE 4 48601166S1 0 p 299 Lubricate O ring fD on the shock absorber cartridge I Lubricant T158 0 p 300 ...

Page 41: ...rre sponding to the fork type Guideline Compression damping Comfort Standard Sport Rebound damping Comfort Standard Sport Mount protection cap 48 Condition Value determined on removal 17 clicks 12 clicks 7 clicks 17 clicks 12 clicks 7 clicks Turn compression adjusting screw Gi and rebound adjusting screw 48 clockwise all the way Turn the adjusting screws to the position they were in before removin...

Page 42: ...e the handlebar cushion Main work Remove indicator lamp holder Open cable holder O on the left and detach the wiring har ness Remove screw 8 Remove screw fD Take off the upper triple clamp with the handlebar and place to one side Info Cover the components to protect them against dam age Do not kink the cables and lines Remove 0 ring 8 Remove protective ring 0 Remove the lower triple clamp with the...

Page 43: ... protective ring 8 and O ring 8 Position the upper triple clamp with the handlebar Mount screw 8 but do not tighten yet Position the fork legs Air bleeder screw 0 of the right fork leg is positioned to the front Valve f of the left fork leg faces the front Info Grooves are milled into the side of the upper end of the fork legs The second milled groove from the top must be flush with the upper edge...

Page 44: ...sing a plastic hammer tap lightly on the upper triple clamp to avoid stresses Tighten screws Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Secure the wiring harness with cable holder on the left Mount indicator lamp holder Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake caliper Mount and tighten screws 41 Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Lo...

Page 45: ...eriod with play in the steering head bearing the bearings and the bearing seats in the frame can become damaged over time Preparatory work Raise the motorcycle with a lift stand 0 p 12 Main work Move the handlebar to the straight ahead position Move the fork legs to and fro in the direction of travel Play should not be detectable on the steering head bear ing If there is detectable play Adjust ste...

Page 46: ...e lower bearing ring O with special tool 8 Tool bracket 58429089000 8 p 305 Pressing tool 58429092000 8 p 306 Press the new bearing ring up to the stop with special tool CD Tool bracket 58429089000 8 p 305 Pressing tool 58429091000 8 p 306 Remove upper bearing ring C with special tool Tool bracket 58429089000 8 p 305 Pressing tool 58429092000 0 p 306 Remove the seal ring Press the new bearing ring...

Page 47: ...ing head bearing play a p 43 Remove the motorcycle from the lift stand a p 12 Mount the handlebar cushion Ad usting steering head bearing la Preparatory work Raise the motorcycle with a lift stand a p 12 Remove the handlebar cushion Main work Loosen screws O Remove screw Loosen and retighten screw Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Using a plastic hammer tap lightly on the ...

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: ...ip tube 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 312 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 312 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 61 5 Nm 3 7 lbf ft Check the free travel of the foot brake lever 0 p 156 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: ...sorber 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 Option Brembo Remove sc...

Page 62: ...ove the connecting link of the chain Take off the chain Info Cover the components to protect them against dam age Remove nut and pull out the 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 ...

Page 63: ...M16x1 5 100 Nm 73 8 lbf ft Mount the chain Connect the chain with connecting link Guideline The closed side of the chain joint lock must face in the direction of travel Option Brembo Position the foot brake cylinder Push rod C engages in the foot brake cylinder Info Ensure that the dust boot is correctly seated Mount and tighten screws 0 Guideline Remaining screws M6 chassis Option MAGURA Position...

Page 64: ... the screw more easily Position the frame protectors on the left and right Mount and tighten screws Guideline Screw frame pro tector M5 3 Nm 2 2 lbf ft Mount and tighten screws with the washers Guideline Screw frame pro tector M5 Mount the new cable ties Finishing work 3 Nm 2 2 lbf ft Check the free travel of the foot brake lever ri ll p 156 Remove the motorcycle from the lift stand ri ll p 12 Che...

Page 65: ... the needle bearings Check spacers D and for damage and wear If there is damage or wear Change the spacers Check the shaft seal rings for damage and wear If there is damage or wear Change the shaft seal rings Check dimension 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 63 ...

Page 66: ...Guideline Nut linkage lever to M14x1 5 angle lever Info 80 Nm 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 8 Guideline Nut angle lever to link fork M14x1 5 60 Nm 44 3 lbf ft Loctite 2701 TM 80 Nm 59 lbf ft Servicing the shock absorber Caution Risk of injury Parts of the shock absorber will mov...

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 316 ...

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 319 69 ...

Page 72: ...rt seal ring retainer 8 with sleeve 9 of the special tool I Mounting tool T150S 0 p 319 Press the special tool through the new pilot bushing I Calibrating unit T1205 8 p 315 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 316 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 316 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 315 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 300 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 320 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 300 Lubricate the thread I Lubricant T159 8 p 301 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 315 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: ...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 switched o...

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 320 Filling adapter T1296 8 p 317 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 314 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: ... p 86 Finishing work Remove the motorcycle from the lift stand l I p 12 Preparatory work Raise the motorcycle with a lift stand l J p 12 Remove the rear wheel 0 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 Remove connecting link O of the chain Take off the chain Info...

Page 86: ...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 I 100 Nm 73 8 lbf ft I Position the frame protectors on the left and right Mount and tighten screws 8 Guideline I Screw frame pro tector 13Nm 2 2 lbf ft Mount and tighten screws fD with the washers Guideline Screw frame pro tector Mount the cable ties...

Page 87: ...M14x1 5 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 Install the rear wheel 8 p 123 Remove the motorcycle from the lift stand 8 p 12 85 ...

Page 88: ...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 Remove shaft seal rings 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 ...

Page 89: ...R02761 10 SHOCK ABSORBER LINK FORK 9 Mount bushing 8 Grease the shaft seal rings I Long life grease 8 p 300 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 300 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 316 Position the new heim joint and the special tool Guideline I Use soft jaws I Pressing tool T1206 8 p 316 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 316 Mount second lock ring 8 Position both collar bushings O and press in Finishing work Install the shock absorber 0 p 61 Che...

Page 92: ... Raise 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 314 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 314 Tighten screw 8 Guideline Remaining screws chassis Lower the link fork M8 25 Nm 18 4 lbf ft ...

Page 95: ...cover 0 p 99 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 314 Remove screws 8 and take off the ...

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: ...g pin 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 ...

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 301 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 12 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: ...ck it If there is detectable play Change the rear wheel bearing 8 p 132 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 the thi...

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: ...nter 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 Option Brembo Press the brake caliper onto the brake disc by hand in order to push back the brake pistons Info Make sure that you do no...

Page 121: ...ake lever when the front wheel is removed Remove spacers IID I OJI I H00934 10 14 7 2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary H00935 10 Check the wheel bearing for damage and wear If the wheel bearing is damaged or wor...

Page 122: ...deline I Screw fork stub Changing the front brake disc 1 15 Nm 11 1 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 0 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 out...

Page 123: ... press the bearing in 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 300 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 un...

Page 124: ... Remove chain adjuster 8 Pull out wheel spindle fD 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 damage Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged ...

Page 125: ...nfo Cover the components to protect them against damage Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Hold the rear wheel and remove the wheel spindle Take the rear wheel out of the link fork Info I Do not operate the foot brake lever when the rear wheel is removed Remove spacers 8 f f e H03002 1...

Page 126: ...C but do not tighten it yet Make sure that chain adjusters 5 are fitted correctly on adjusting screws Check the chain tension 8 p 125 Tighten nut C Guideline M25x1 5 Info 80 Nm 59 lbf ft The wide adjustment range of the chain adjusters 32 mm 1 26 in enables different secondary ratios with the same chain length Chain adjusters 5 can be turned by 180 Operate the foot brake lever repeatedly until the...

Page 127: ...ar more quickly Some components may break if overloaded If the chain is too loose the chain may fall off the engine sprocket or the rear sprocket As a result the rear wheel locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the specification Preparatory work Raise the motorcycle with a lift stand 8 p 12 Main work Pull the chain at the end...

Page 128: ...k Loosen nut O Loosen nuts 8 Adjust the chain tension by turning adjusting screws 8 left and right Guideline Chain tension 1 55 58 mm 2 17 2 28 in Turn adjusting screws 8 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 G The rear wheel is then correctly aligned Tighten nuts 8 Make sure that chain adjusters C are ...

Page 129: ...cified weight 6 Guideline Weight chain wear mea surement 10 15 kg 22 33 lb Measure distance 0 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 Ci at the longest chain section 272 mm 10 71 in If distance 0 is greater than the specified measurement Change the drivetrain kit 8 p 130 I ...

Page 130: ...he chain sliding piece for wear 6 Nm 4 4 lbf ft Loctite 243 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 M8 ing piece 15 Nm 11 1 lbf ft Check the chain guide with a slid...

Page 131: ... 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 gre...

Page 132: ...k Remove the motorcycle from the lift stand 0 p 12 Preparatory work Remove the air filter box cover 0 p 95 Raise the motorcycle with a lift stand 0 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 CD with the washer Remove the rear wheel 0 p 122 Remove connecting link 8 of the chain Take off the ch...

Page 133: ... 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 p 123 Have an assistant operate the rear brake Mount and tighten screw fD with the washer Guideline Screw engine sprocket M10 60 Nm 44 3 lbf ft Loctite 2701TM 131 ...

Page 134: ...ter box cover llill p 95 10 Nm 7 4 lbf ft 20 Nm 14 8 lbf ft Remove the motorcycle from the lift stand llill p 12 14 8 10 Changing the rear wheel bearing 132 Preparatory work Raise the motorcycle with a lift stand llill p 12 Remove the rear wheel llill p 122 Main work Remove shaft seal ring O Remove lock ring 8 Remove shaft seal ring 8 Using a suitable tool press bearing C out from the inside to th...

Page 135: ... will be damaged when it is pressed in Clean grease and mount spacing tube I Long life grease a p 300 Press new bearing C all the way in from the outside to the inside Info I 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 D and press it in until it is flush Mount lock ring The lock ring engages audibly Gre...

Page 136: ...the engine stops Remove the air filter box cover 8 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 Info A faulty fuse has a burned out fuse wire f A spare fuse C is located in the starter relay Insert a new main fuse I Fuse 58011109110 8 p 282 Check that the electrical system is functioning properly Tip I Insert a spare fu...

Page 137: ... 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 MS nal 2 5 Nm 1 84 lbf ft Contact disks 9 must be mounted under the screw 8 and the cable lug with the claws toward the battery terminal Slide negative terminal cover over the negative terminal Fini...

Page 138: ...atteries 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 an...

Page 139: ...inal Connect negative cable to the 12 V battery Guideline Screw battery termi M5 nal 2 5 Nm 1 84 lbf ft Slide negative terminal cover fD over the negative terminal Finishing work Mount the seat a p 100 Install the air filter box cover a 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...

Page 140: ... battery is depleted from starting the vehicle repeatedly the battery must be charged immedi ately If the 12 V battery is left in a discharged 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 0 p 95 Remove the seat 0 p 99 Press and hold t...

Page 141: ...rcycle to check the function 0 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 stato...

Page 142: ...ount the seat a p 100 Install the air filter box cover 0 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 C...

Page 143: ...8 Pull back the cover Disconnect cable 8 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 O Q If the value displayed does not meet specifications Change the starter relay Clamp cable 8 on the starter relay Plug in connector 8 Mount the starter relay onto the holder and route ...

Page 144: ...ountered Change the front brake linings 0 p 142 Changing the front brake linings Warning Danger of accidents Incorrect servicing will cause the brake system to fail Ensure that service work and repairs are performed professionally Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allo...

Page 145: ...tainer 100397 01 Option Brembo Move the brake reservoir mounted on the handlebar to a horizontal position Remove screws O Take off cover 8 with membrane D Manually press the brake caliper toward the brake disc to push back the brake pistons Ensure that brake fluid does not flow out of the brake fluid reservoir if necessary extract excess Info Make sure that you do not press the brake caliper again...

Page 146: ...ews O Info Clean up overflowed or spilled brake fluid immedi ately with water Option MAGURA Move the brake reservoir mounted on the handlebar to a horizontal position Remove screws O Take off cover 8 with membrane Manually press the brake caliper toward the brake disc to push back the brake pistons Ensure that brake fluid does not flow out of the brake fluid reservoir if necessary extract excess I...

Page 147: ... is a pressure point Add brake fluid up to level f Guideline Level f brake fluid level 5 mm 0 2 in below reservoir rim I Brake fluid DOT 4 DOT 5 1 a p 298 Position cover 8 with membrane D Mount and tighten screws O Info Clean up overflowed or spilled brake fluid immedi ately with water Checking the free travel of the hand brake lever O tion Brembo Warning Danger of accidents The brake system fails...

Page 148: ...ebar Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and 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 Option MAGURA Adjust the basic position of the hand brake lever to your hand size by turning adjusting screw O Info Turn the adjusting screw clock...

Page 149: ... the front brake linings IOI p 142 Main work Option Brembo Move the brake reservoir mounted on the handlebar to a horizontal position Check the brake fluid level in level viewer O If the brake fluid level has dropped below the mark ing Q Add front brake fluid IOI p 147 Option MAGURA Move the brake reservoir mounted on the handlebar to a horizontal position Check the brake fluid level in level view...

Page 150: ...ce 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 painted p...

Page 151: ...me 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 41 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 Note Environmental hazar...

Page 152: ...he Owner s Manual of the bleeding device Ensure that the filling pressure is set on pressure gauge f Correct the filling pressure on pressure regulator 0 if necessary Guideline I Filling pressure I 2 2 5 bar 29 36 psi Pull off protection cap 0 of the brake caliper bleeder screw Connect the bleeder bottle hose I Bleeding device 00029013100 8 p 303 Open bleeder screw D by approx one half turn Info I...

Page 153: ... horizontal position Cover painted parts Remove screws O Take off cover 8 with the membrane Extract the old brake fluid from the brake fluid reservoir using a syringe and fill with fresh brake fluid Syringe 50329050000 IUI p 304 Brake fluid DOT 4 DOT 5 1 IUI p 298 Mount bleeder cover 8 I Bleeder cover 00029013019 IUI p 302 Connect the bleeding device I Bleeding device 00029013100 IUI p 303 Open sh...

Page 154: ...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 level 9 Guideline Level 9 brake fluid level 5 mm 0 2 in below reservoir rim I Brake fluid DOT 4 DOT 5 1 el p 298 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilled brake fluid im...

Page 155: ...airs are performed professionally Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of con...

Page 156: ... excess Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston Remove cotter pin Cs pull out pin C and remove the brake linings Clean the brake caliper and brake caliper bracket Check that spring plate 0 in the brake caliper and slid ing plate 3 in the brake caliper bracket are seated prop erly Info The arrow on the spring plate points in the d...

Page 157: ...out of the brake fluid reservoir if necessary extract excess Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston Remove cotter pin D Push spring plate 8 downwards and remove pin 0 Remove the brake linings Clean the brake caliper and brake caliper bracket Check that spring plate 8 in the brake caliper and slid ing plate D in the brake caliper...

Page 158: ...he brake system on the rear brake Set the free travel on the foot brake lever in accordance with the specification l 402026 10 Disconnect spring O Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel fj Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in If the free travel does not meet specifications Adjust ...

Page 159: ...eline Remaining nuts chassis M6 Hold screw fD and tighten nut 8 Guideline Nut foot brake lever stop Attach spring O Option MAGURA Detach spring O M8 10 Nm 7 4 lbf ft 20 Nm 14 8 lbf ft Loosen nut C and with push rod 0 turn it back until you have maximum free travel To adjust the basic position of the foot brake lever to indi vidual requirements loosen nut 8 and turn screw fD accordingly Info The ra...

Page 160: ...dance with the service schedule Adding rear brake fluid Warning Preparatory work Check the brake linings of the rear brake 0 p 152 Main work Option Brembo Stand the vehicle upright Check the brake fluid level in level viewer O If the brake fluid level has dropped below the mark ing 6 Add rear brake fluid 8 p 158 Option MAGURA Stand the vehicle upright Check the brake fluid level in level viewer O ...

Page 161: ...r 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 brake fluid ...

Page 162: ... 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 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 applicabl...

Page 163: ...g device 00029013100 0 p 303 Open bleeder screw 0 by approx one half turn Info I Drain until fresh brake fluid emerges in the bleeder bottle hose without bubbles Tighten the bleeder screw Close shut off valve Open the bleeder screw again until brake fluid stops emerging Info I Overfilling the brake fluid reservoir is prevented Tighten the bleeder screw Remove the bleeder bottle hose Attach the pro...

Page 164: ...ng device I Bleeding device 00029013100 0 p 303 Open shut off valve C Info I Follow the instructions in the Owner s Manual of the bleeding device Ensure that the filling pressure is set on pressure gauge f Correct the filling pressure on pressure regulator G if necessary Guideline I Filling pressure 1 2 2 5 bar 29 36 psi Pull off protection cap 0 of the bleeder screw Connect the bleeder bottle hos...

Page 165: ...e Attach the protection cap Disconnect the bleeding device Remove the bleeder cover Stand the vehicle upright Correct the brake fluid to marking 9 I Brake fluid DOT 4 DOT 5 1 0 p 298 Mount and tighten screw cap with the membrane and the shim Info I Clean up overflowed or spilled brake fluid immedi ately with water Check the foot brake lever for a firm pressure point Mount the cable tie 163 ...

Page 166: ...ght 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 Remove the main silencer 0 p 93 Main work Remove the cable ties Remove screw O Remove screws 8 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 ...

Page 167: ... 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 C ENGINE 17 Pivot the shock absorber toward the rear and twist it slightly 165 ...

Page 168: ...I Spring hook 5030501700004 8 p 314 Remove screw Gi with the washer Take off the manifold Remove fittings 48 Take off the engine brace Disconnect plug in connector 48 Disconnect plug in connectors G Disconnect plug in connector 4D ...

Page 169: ... clamps and expose the cable Push back protection cap 48 Unplug the connector Loosen hose clip Pull off the radiator hose Loosen hose clip 4D Pull off the radiator hose Pull capacitor 41 off of the holder and hang to one side ENGINE 17 167 ...

Page 170: ...ylinder 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 Remove the connecting link of the chain Take off the chain Info I Cover the components to protect them against dam age ...

Page 171: ...ke off the shift lever Loosen hose clip Ci ENGINE 17 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 9 and remove the nut Hang the positive cable to the side Remove spring 169 ...

Page 172: ...move screws Ii 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 D Remove the link fork pivot Carefully pull the link fork back and secure it Remove screws G ...

Page 173: ...e 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 Cover the components to protect them against dam age 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 Guideline I Nut fork pivot I M16x1 5 Position the brake line in the ...

Page 174: ...ten fitting 0 Guideline Nut linkage lever to angle lever Info M14x1 5 10 Nm 7 4 lbf ft 80 Nm 59 lbf ft 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 Mount the vent hose and position hose clamp Position the thrott...

Page 175: ... M10 60 Nm 44 3 lbf ft Loctite 2701 TM Mount the chain Connect the chain with connecting link Guideline The closed side of the chain joint lock must face in the direction of travel Actuate the foot brake lever Tighten screw 4D Guideline Screw engine sprocket M10 60 Nm 44 3 lbf ft Loctite 2701 Info The help of an assistant is useful in this step Position clutch slave cylinder with the new gasket Mo...

Page 176: ...ew clutch slave M6 cylinder Mount and tighten screw Guideline Screw engine sprocket cover M8 Plug in spark plug connector G Mount capacitor 49 Mount the radiator hose Position and tighten hose clip G Mount the radiator hose Position and tighten hose clip G 10 Nm 7 4 lbf ft 20 Nm 14 8 lbf ft ...

Page 177: ...p 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 of the crankshaft speed sensor Join plug in connectors of the alternator Route the cable without tension 175 ...

Page 178: ...bf ft Loctite 2701TM 60 Nm 44 3 lbf ft Mount screw with the washer but do not tighten yet Guideline Remaining screws chassis Mount springs M8 25 Nm 18 4 lbf ft I Spring hook 5030501700004 0 p 314 Tighten screw Guideline Remaining screws chassis M8 Position the shock absorber Mount and tighten screw D Guideline Screw top M10 shock absorber 25 Nm 18 4 lbf ft 60 Nm 44 3 lbf ft Loctite 2701 ...

Page 179: ...w fl Guideline Screw sub frame Remove screw Ci MB Mount and tighten screw Ci Guideline Screw sub frame MB 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 Ci Plug in the connector Mount protection cap G Position and tighten hose clip G 177 ...

Page 180: ... screw 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 G with the O ring and fill up with engine oil Engine oil 1 0 I 1 1 qt Engine oil SAE 10W 50 a p 298 Mount and tighten oil filler plug G with the O ring Finishing work Install the main silencer a p 93 Insta...

Page 181: ...varna Motorcycles diagnostics tool Check the engine for leak tightness Check the engine oil level ll l p 259 Check the coolant level ilt l p 256 Mount the special tool on the engine assembly stand Holder and fitting for work stand 79229002000 8 p 312 Engine assembly stand 80329001000 8 p 314 Mount the engine on the special tool Info Work with an assistant or a motorized hoist 41 41 Removing the cl...

Page 182: ...ove oil drain plug 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 out of the oil filter housing I Lock ring plier 51012011000 8 p 305 gear position sensor removing Remove screws O Remove the protective plate and the gear position sensor ...

Page 183: ...oving the valve cover Remove the spark plug with special tool O I Spark plug wrench with link 77229172000 p 310 Remove screws O Take off the valve cover with the valve cover seal Remove gasket 8 Remove spark plug wrench insert D ENGINE 17 181 ...

Page 184: ...O Take off the alternator cover Remove gasket 8 Remove torque limiter D 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 ...

Page 185: ...g chain tensioner 17 3 11 Removing the camshafts Loosen screw O Remove screw with the seal ring Pull out timing chain tensioner D Remove O ring 8 Loosen and remove screws O from the outside to the inside Take off slide rail 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 41 41 183 ...

Page 186: ... head Remove cylinder head gasket 8 Remove dowels 8 Push the cylinder upward Info 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 ...

Page 187: ... tool 8 into the crankshaft I Protection cap 75029090000 0 p 309 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 313 Info Ensure that the woodruff key remains in place Remove screw O with the washer Take off starter idler gear 8 185 ...

Page 188: ...17 ENGINE 17 3 16 Removing the suction pump 186 Take off freewheel gear D Remove screws O Take off oil pump cover Remove O ring D Take off suction pump e Remove needle roller 0 ...

Page 189: ...ng 17 3 18 Removing the clutch cover Remove screws O Take off the water pump cover Remove gasket 8 Remove nut D Take off two part water pump impeller 8 Remove screws O Take off the clutch cover Remove clutch cover gasket 8 ENGINE 17 187 ...

Page 190: ...ap Remove clutch discs 8 completely Remove clutch throw out Remove two opposite sleeves O Bend up the lock washer Hold the inner clutch hub with the special tool Loosen nut 8 I Holding wrench 51129003000 IUI p 305 Remove the nut with the lock washer Take off inner clutch hub and washer C Info I The washer usually sticks to the inner clutch hub Take off clutch basket G ...

Page 191: ...ankshaft I Protection cap 75029090000 g p 309 Pull off primary gear wheel 8 using the special tool I Puller 46129021000 8 p 304 Remove screws O Remove the timing chain guide rail 8 Remove the timing chain tensioning rail 8 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 189 ...

Page 192: ...dler gear with the washer Remove lock ring 8 Take off washer 0 Take off oil pump gear wheel 0 Remove pin Remove screws D Take off the oil pump cover Remove pin Push oil pump shaft inward and take it out of the engine from the ignition side Remove force pump 48 Unscrew O and remove together with locking lever 8 washer sleeve and spring ...

Page 193: ...26 Removing the shift shaft 17 3 27 spacer removing Take off the shift drum locating unit Take out shift shaft O with the washer Remove spacer O of the crankshaft Remove screw fj 17 3 28 Removing the left engine case Remove screws O Tilt the left section of the engine case upward and remove the fitting of the engine fixing arm 191 ...

Page 194: ...ble screws I Puller 79229048000 a p 313 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 fD Remove shift rail O Remove shift rail 8 Tilt shift forks O to the side Info Do not misplace the shift rollers Remove shift drum 8 ...

Page 195: ...rks O 17 3 32 Removing the transmission shafts 17 3 33 Removing the crankshaft Remove lock ring O Pull both transmission shafts 8 out of the bearing seats together Remove crankshaft O Take off the right section of the engine case ENGINE 17 41 41 193 ...

Page 196: ...uitable tool Blow out oil nozzle 3 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 engi...

Page 197: ...bf ft Loctite 243 Mount the oil nozzle for piston cooling Mount and tighten screw 8 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 0 p 199 Blow out the oil channel with compressed air and check that it is cl...

Page 198: ...e 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 199: ...ing M5 Position all bearing retainers Mount and tighten screws 3 Guideline Locking screw for bearing M5 ENGINE 17 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 i Remove shaft seal ring D 41 197 ...

Page 200: ...tside 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 Blo...

Page 201: ...ve Oil pressure control valve Minimu 1 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 8 and the sealing seat If there is damage or wear Change the ball and machine the sealing seat Insert ball eand pressure spring CD Mount and tighten screw plug O with sealing washer Guideline Screw plug oil pres M12x1 5 sure control va...

Page 202: ... the oil pump cover for damage and wear If there is damage or wear Change the oil pump cover 17 4 6 Removing the crankshaft bearing inner race 310373 10 Fix the crankshaft in the vise Guideline I Use soft jaws Warm up special tool O Guideline 1150 c 302 F I Puller 58429037037 al p 305 Push the warmed up special tool O onto the crankshaft bearing inner race press firmly together and pull jointly fr...

Page 203: ...l 8 and mount together Guideline 1120 C 248 F I Puller 58429037037 8 p 305 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 8 p 204 17 4 8 connecting rod conrod bearing and crank pin changing Main work Position cranks...

Page 204: ...l 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 a p 309 Insert for crankshaft pressing tool 79029008000 a p 311 Insert the crankweb with the connecting rod and bearing Position the second crankweb Position special tool with the heel pointing down ...

Page 205: ... 59029041100 0 p 307 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 203 17 4 9 Checking the crankshaft run out at the bearing pin Position the crankshaft on a roller block Turn the cranks...

Page 206: ...does not meet specifications Remove the crankshaft Remove the crankshaft bearing inner race ra l p 200 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 ra l p 201 17 4 11 Removing the d...

Page 207: ...in better performance low wear and a lightweight cylinder 17 4 14 Checking measuring the cylinder 310346 10 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 mm 3...

Page 208: ...the piston 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 pisto...

Page 209: ...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 17 4 17 Checking the piston ring end gap 310347 10 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 6 with a feeler gauge Guideline Piston ring end gap Compress...

Page 210: ...8 Check 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 f Plastigauge clearance gauge 60029012000 0 p 307 Position camshaft bearing support O Mount and tighten the screws Guideline Screw M7x1 14 Nm 10 3 lbf ft camshaft Lubricated ...

Page 211: ...parts Remove screw plugs O with the O ring Screw appropriate screw 8 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 s...

Page 212: ... 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 f on valve for damage and wear If the sealing surface is damaged or worn Machine the valve seat Check t...

Page 213: ...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 77229026000 ...

Page 214: ...haust 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 8 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 tigh...

Page 215: ...oved 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 The ...

Page 216: ...nsion ring i together with suitable pliers and take off Remove freewheel D Thoroughly oil all parts Mount freewheel O Info Note the direction of rotation Mount spreader ring i Ensure that all the holding lugs of the expansion ring pass through slots 6 of the freewheel and engage in groove G of the rotor ...

Page 217: ...gear 8 for damage and wear If there is damage or wear Change the freewheel gear or bearing Check freewheel 8 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 0 ring D of the starter motor ENGINE 17 Connect the negative cable of a 12 volt power supply to the hous...

Page 218: ...for damage 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 3 for damage and wear If there is damage or wear Change the timing chain 310344 1...

Page 219: ...n 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 I 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 vente...

Page 220: ...an specified 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 C for damage and wear If there is damage or wear Change the needle bearing and collar sleeve Check ...

Page 221: ...and wear If there is damage or wear Change the sleeves 17 4 34 Checking the shift mechanism JO 8 e I ii Check shift forks O on plate t for damage and wear visual check If there is damage or wear Change the shift fork Check shift grooves 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 8 If the shift drum is not seated correctly...

Page 222: ...seness and wear If the guide pin is loose and or worn Change the sliding plate 310356 10 17 4 35 Preassembling the shift shaft 220 Preassemble the shift shaft p 220 Check clearance 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 Secure the sh...

Page 223: ...nt 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 8 p 304 D05797 10 Remove fifth gear idler gear CD and needle bearing e Remove stop disk 0 Remove lockring 3 Remove third gear sliding gear Remove lockring 3 Remove stop disk Remove fourth gear idler gear 41 221 ...

Page 224: ...emove needle bearing CD and stop disk e Remove fourth gear sliding gear 0 Remove lock ring CD Remove stop disk Remove third gear idler gear and needle bearing Q Remove stop disk Gi Remove lock ring 48 Remove fifth gear sliding gear 48 Remove lock ring Remove stop disk 4D Remove second gear idler gear 48 and needle bearing 4D 17 4 38 Checking the transmission Condition The transmission has been dis...

Page 225: ...gears for damage and wear If there is damage or wear Change the gear wheel pair Check the tooth faces of idler gears 8 sliding gears and fixed gear s for damage and wear If there is damage or wear Change the gear wheel pair Check the tooth profiles of sliding gears 0 for damage and wear If there is damage or wear Change the gear wheel pair Check sliding gears 0 for smooth operation in the profile ...

Page 226: ...I Use soft jaws Mount fourth gear idler gear O Mount stop disk Position special tool f on the transmission shaft I Mounting tool for lock ring 79029005000 0 p 311 Position lock ring fs on special tool f and push down with sleeve Cs 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...

Page 227: ...ench 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 O on the transmission shaft I Mounting tool for lock ring 75029005000 0 p 308 Position lock ring 8 on special tool O and push down with sleeve 4 The lock ring engages in th...

Page 228: ...ve facing downward Mount stop disk 41 Mount needle bearing 41 and first gear idler gear 41 Mount stop disk Ci Finally check all the gear wheels for smooth operation 17 5 17 5 1 17 5 2 226 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 8 p 298 Slide crankshaft O into the bearing seat Insta...

Page 229: ...meter 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 D 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 227 ...

Page 230: ...the 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 fj but do not tighten yet Guideline I Screw engine case I M6x65 110 Nm 7 4 lbf ft Mount screws 8 and tighten all screws in a crisscross pat tern Guideline I Screw engine case I M6x70 I10 Nm 7 4 lbf ft Mount the screw cap of the engine fixing arm Mount the O ring on th...

Page 231: ...locating unit are not symmetric Mount and tighten screw 8 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 8 Guideline 41 Screw locking lever M5 6 Nm 4 4 lbf ft Loctite 243 Shift through the transmission 41 Oil the oil pump shaft internal rotor and external rotor before assembly I Engine oil SAE 10W ...

Page 232: ... pump gear wheel 0 Mount washer Mount lock ring 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 G Mount lock ring 8 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 ...

Page 233: ...f the timing chain was used before ensure it is run ning in the correct direction Mount and tighten screw 8 Guideline Screw timing M6 chain securing guide Position timing chain guide rail 6 Mount and tighten screw C Guideline Screw timing M6 chain guide rail 10 Nm 7 4 lbf ft Loctite 243 10 Nm 7 4 lbf ft Loctite 243 Position timing chain tensioning rail 0 Mount and tighten screw D Guideline Screw t...

Page 234: ...in the wide recess of the crankshaft Markings f and 4D are aligned Mount and tighten nut 8 Guideline Nut primary gear wheel M18LHx1 5 100 Nm 73 8 lbf ft Loctite 243 Mount collar sleeve O and needle bearing 8 Slide clutch basket CD onto the gearbox main shaft Turn the oil pump gear wheel until the gearing of the clutch basket meshes Slide on washer 8 and inner clutch hub 0 ...

Page 235: ...sher Mount sleeves Thoroughly oil the clutch facing discs I Engine oil SAE 10W 50 p 298 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 8 with the washers and spring...

Page 236: ...seated 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 I10 Nm 7 4 lbf ft Mount screws D but do not tighten yet Guideline I Screw clutch cover I M6x45 110 Nm 7 4 lbf ft Mount screw C with the washer but do not tighten yet Guideline...

Page 237: ...nfo Ensure that the dowel pins are seated properly Mount screw 8 with the seal ring b ut to not tighten yet Guideline Screw water pump cover M6x25 Mount screw 0 b ut do not tighten yet Guideline Screw water pump cover M6x25 Mount and tighten screws 0 Guideline Screw water pump cover M6x40 Tighten screws 8 and 0 Guideline Screw water pump cover M6x25 10 Nm 7 4 lbfft 10 Nm 7 4 lbfft 10 Nm 7 4 lbfft ...

Page 238: ...ure that the woodruff key is seated properly Mount the rotor Info I 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 Place the special tool onto the oiled piston Clamp the piston rings together using the special tool I Piston ...

Page 239: ...marking 6 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 the ...

Page 240: ...k into the groove I Insertion for piston ring lock 77729030100 0 p 311 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 D with the washers and tighten in a crisscross pattern ...

Page 241: ...nd 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 8 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 a...

Page 242: ... seal 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 0 p 308 The timing chain tensioner unlocks Mount and tighten screw C Guideline Screw unlocking M10x1 of timing chain ten sioner 8 Nm 5 9 lbf ft 17 5 25 Checking the valve clearan...

Page 243: ...eler gauge 59029041100 8 p 307 If the valve clearance does not meet specifications Adjust the valve clearance 8 p 241 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 Main work Remove the timing chain tensioner al p 183 Remove the camshafts al p 183 Raise cam levers O Correct the shims according to th...

Page 244: ... screws O Guideline I Screw starter motor I M6 110 Nm 7 4 lbf ft Thoroughly oil the bearing pin of the torque limiter Position torque limiter Position gasket 8 Info Ensure that the dowel pins are seated properly Position the alternator cover Mount and tighten screws 8 Guideline Screw alternator cover M6 10 Nm 7 4 lbf ft Grease the 0 rings and mount spark plug wrench insert O ...

Page 245: ...crew valve cover I M6 I 8 Nm 5 9 lbf ft Mount and tighten the spark plug with special tool O Guideline ISpark plug IM10x1 1 10 12 Nm 7 4 _ _ _ 8 9 lbf ft I Spark plug wrench with link 77229172000 p 310 17 5 30 gear position sensor installing Position gear position sensor Position protective plate Mount and tighten screws O Guideline Screw gear M5 position sensor 5 Nm 3 7 lbf ft Loctite 243 243 ...

Page 246: ...i Guideline I Screw oil filter cover I M6 110 Nm 7 4 lbf ft Mount and tighten oil drain plug O with the O ring Guideline I Oil drain plug I M14x1 5 11s Nm 11 1 lbf ft Mount and tighten oil drain plug 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...

Page 247: ... 17 5 33 Installing the clutch push rod Mount clutch push rod O 17 5 34 Removing the engine from the engine assembly stand Remove thefittingfrom the special tool I Holder andfittingfor work stand 79229002000 p 312 Remove the enginefrom the engine assemb ly stand Info Work with an assistant or a motorized hoist 245 ...

Page 248: ...the clothing Info I The fluid level rises with increasing wear of the clutch facing discs 246 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...

Page 249: ...mental 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 Fill bleeding syringe 8 with the appropriate hydraulic fluid Syringe 50329050000 ...

Page 250: ... 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 contact rinse t...

Page 251: ...ng 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 CLUTCH 18 249 ...

Page 252: ...osen nut I Holding wrench 51129003000 IUI p 305 Remove the nut with the lock washer Take off inner clutch hub Gi and washer 48 Info The washer usually sticks to the inner clutch hub Take off clutch basket 48 Take off needle bearing G and collar sleeve 41 Info The needle bearing and collar sleeve may be in the clutch basket ...

Page 253: ...act surface of clutch pressure cap 8 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 41 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 48 and G i for damage ...

Page 254: ...e inner clutch hub Check sleeves for damage and wear If there is damage or wear Change the sleeves Mount collar sleeve e and needle bearing 48 Mount clutch basket 8 Turn clutch basket until the gear teeth mesh with the oil pump gear wheel Mount washer 48 and inner clutch hub G Position the new lock washer and mount nut Tighten the nut holding the inner clutch hub with a special tool Guideline Nut ...

Page 255: ...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 I M6 Position the clutch cover Mount and tighten screws 8 Guideline I Screw clutch cover I M6x25 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 25...

Page 256: ...18 CLUTCH T01346 10 254 Attach spring O Place vehicle in upright position and rest on the plug in stand Finishing work Check the engine oil level l ll p 259 ...

Page 257: ...es 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 coo...

Page 258: ...e 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 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 immed...

Page 259: ... 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 Refilling with coolant Warning 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 8 Complet...

Page 260: ...is tightened Position the motorcycle upright Pour coolant in up to measurement 6 above the radiator fins Guideline Distance 6 above the radi 10 mm 0 39 in ator fins I Coolant p 298 Mount the radiator cap Go for a short test ride Check the coolant level p 256 ...

Page 261: ... lubrication Oil nozzle for piston cooling fD Oil nozzle for alternator cooling Oil nozzle for clutch lubrication Gi 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 259 ...

Page 262: ...If the engine oil does not reach the middle of level viewer 6 Add engine oil 8 p 263 the oil screen 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 ...

Page 263: ...n 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 wit...

Page 264: ...I M6 110 Nm 7 4 lbf ft Stand the motorcycle upright Remove filler plug fD from the clutch cover together with the 0 ring and fill up with engine oil Engine oil Info 1 0 I 1 1 qt Engine oil SAE 10W 50 a p 29s 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 0 ring Danger Danger of poisoning Exhaust gas...

Page 265: ...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 8 p 259 Danger of scalding Engine and gear oil get very hot...

Page 266: ...ng 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 let it warm up Check the oil pressure Oil pressure Engine oil temperature 80 C 176 F Engine speed Idle speed Engine oil temperature...

Page 267: ...e 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 p 259 8 Nm 5 9 lbf ft 265 ...

Page 268: ... ignition 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 disc...

Page 269: ...value Replace the stator Removing the stator and crankshaft SReed sensor Condition The alternator cover has been removed Remove screws O Remove the retaining bracket Remove screws 8 Remove rubber grommet from the alternator cover Remove the stator and crankshaft speed sensor from the alternator cover Installing the stator and crankshaft s eed sensor Blow out oil nozzle O with compressed air and ch...

Page 270: ...n rubber grommet C 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 0 p 99 Remove the fuel tank 0 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 s I Spark plug wrench with link 77229172000 0 p 310 Mount and tighten the ...

Page 271: ...N SYSTEM 21 Plug in spark plug connector 8 Mount capacitor O Finishing work Install the fuel tank 0 p 102 Mount the seat 0 p 100 Install the air filter box cover 8 p 95 Install the right side cover 8 p 99 269 ...

Page 272: ...ank 0 p 101 Main work Pull capacitor O off of the holder and hang to one side Push back protection cap and remove the connector Disconnect spark plug connector 8 Remove the spark plug with special tool 8 I Spark plug wrench with link 77229172000 a p 31O 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 ...

Page 273: ...lve 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 Feeler gauge 59029041100 p 307 If the valve clearance does not meet specifications Adjust the valve clearance p 273 Remove screw Crank the engine several times Check the valve clearance and correct it i...

Page 274: ...unt gasket Position the valve cover with the gasket Mount and tighten screws D Guideline I Screw valve cover I M6 I 8Nm 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 IM10x1 I10 12Nm 7 4 8 9 lbf ft I Spark plug wrench with link 77229172000 0 p 310 Plug in spark plug connector 8 Plug in connector and position prot...

Page 275: ...ver 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 270 Remove the timing chain tensioner 8 p 183 Remove the camshafts 8 p 183 Main work Swing up cam lever O Correct the shims based on the results of the valve clearance B03742 10 check Finishing work Install the camshafts 8 p 239 Install the timing chain tensioner 8 p ...

Page 276: ... motor 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 ...

Page 277: ... Run the engine until warm The cold start button is deactivated The cold start but ton is in its basic position Set the idle speed by turning the idle speed adjusting screw O Guideline I Idle speed I2 250 2 350 rpm I Tachometer 45129075000 0 p 304 Info I Turning counterclockwise lowers the idle speed Turning clockwise raises the idle speed Performing the initialization run Condition The diagnostic...

Page 278: ...sed space 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 so 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 compl...

Page 279: ...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 280: ...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 in C...

Page 281: ... 5 lbf ft Loctite 243 Screw bearing bolt oil pump idler M5 6 Nm 4 4 lbf ft gear Loctite 243 Screw crankshaft speed sensor M5 6 Nm 4 4 lbf ft Loctite 243 Screw gear position sensor M5 5 Nm 3 7 lbf ft Loctite 243 Screw locking lever M5 6 Nm 4 4 lbf ft Loctite 243 Screw oil pump cover M5 6 Nm 4 4 lbf ft Loctite 243 Screw stator M5 6 Nm 4 4 lbf ft Loctite 243 Nut cylinder head M6 10 Nm 7 4 lbf ft Lubr...

Page 282: ...M10x1 70 Nm 51 6 lbf ft Collar and thread oiled cone degreased Screw unlocking of timing chain M10x1 8 Nm 5 9 lbf ft tensioner Spark plug M10x1 10 12 Nm 7 4 8 9 lbf ft Coolant temperature sensor M10x1 25 12 Nm 8 9 lbf ft Nut cylinder head M10x1 25 Tightening sequence Tighten diagonally 1st tightening stage 10 Nm 7 4 lbf ft 2nd tightening stage 30 Nm 22 1 lbf ft 3rd tightening stage 50 Nm 36 9 lbf ...

Page 283: ...oaded Weight without fuel approx Maximum permissible front axle load Maximum permissible rear axle load Maximum permissible overall weight TECHNICAL DATA 25 I Engine oil SAE 10W 50 el p 298 I Coolant el p 298 I 71 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 Suspension 5018 DCC Link Disc brakes...

Page 284: ...na motorcycles com 25 8 Fork Fork article number 34 18 SR 55 Fork WP Suspension Upside down AER 48 Compression damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Rebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Air pressure 10 6 bar 154 psi Fork length 950 mm 37 4 in Oil capacity external mechanism 200 g ml 6 76 6 fl oz Fork oil SAE 4 48601166S1 right 8 p 299 Oil capaci...

Page 285: ... 18 18 7R 55 WP Suspension 5018 DCC Link 17 clicks 15 clicks 13 clicks 2 5 turns 2 turns 1 5 turns 17 clicks 15 clicks 13 clicks 6 mm 0 24 in 39 N mm 223 lb in 42 N mm 240 lb in 45 N mm 257 lb in 260 mm 10 24 in 260 mm 10 24 in 260 mm 10 24 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 8 p 299 3 5 Nm 2 58 lbf ft Screw intake air temperature ...

Page 286: ...ssis Screw bottom shock absorber Screw handlebar support Screw top shock absorber Nut fuel pump 284 M5 3 Nm 2 2 lbf ft M5 5 Nm 3 7 lbf ft M5 7 Nm 5 2 lbf ft M6 10 Nm 7 4 lbf ft M6 10 Nm 7 4 lbf ft M6 10 Nm 7 4 lbf ft M6 10 Nm 7 4 lbf ft M6 6 Nm 4 4 lbf ft M6 14 Nm 10 3 lbf ft M6 14 Nm 10 3 lbf ft M6 4 Nm 3 lbf ft M6 5 Nm 3 7 lbf ft M8 10 Nm 7 4 lbf ft M8 20 Nm 14 8 lbf ft M8 35 Nm 25 8 lbf ft M8 1...

Page 287: ...t Nut linkage lever to angle lever M14x1 5 80 Nm 59 lbf ft Nut fork pivot M16x1 5 100 Nm 73 8 lbf ft Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft 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 285 ...

Page 288: ...ppearance will be maintained over a long period Avoid direct sunshine on the motorcycle during cleaning 7 11111111111111 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 0 p 301 I Info Use warm water containing...

Page 289: ...ll moving parts and bearings Clean the chain 0 p 129 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 301 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 301 41 287 26 ...

Page 290: ...r replacements are necessary you should do this during the storage period less workshop overload In this way you can avoid long workshop waiting times at the start of the new season 1111 When refueling for the last time before taking the motorcycle out of service add fuel additive I Fuel additive p 300 Refuel Clean the motorcycle p 286 Change the engine oil and oil filter clean the oil screen p 26...

Page 291: ...ly 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 8 p 137 Remove the motorcycle from the lift stand 8 p 12 Perform checks and maintenance measures when preparing for use Take a test ride 41 41 289 ...

Page 292: ...im joint for play 0 p 90 I I I I I Check the shock absorber linkage 8 p 62 I I I Check the tire condition 8 p 115 0 I I I Check tire pressure 0 p 115 0 I I I I I Check the wheel bearing for play 0 p 116 I I I I I Check the wheel hubs I I I Check the rim run out l l p 117 0 I I I Check the spoke tension 8 p 117 0 I I I Check the chain rear sprocket engine sprocket and chain guide 0 p 126 I I I Chec...

Page 293: ... I I I I I I I I I Annually Every 100 operating hours Every 50 operating hours Once after 20 operating hours Once after 10 operating hours Change the front brake fluid a p 149 Change the rear brake fluid a p 160 Change the hydraulic clutch fluid 0 p 247 Lubricate the steering head bearing a p 39 Service the fork a p 20 Service the shock absorber 8 p 64 Change the fuel filter 0 p 108 Perform minor ...

Page 294: ... 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 C II C II ...

Page 295: ...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 29 293 ...

Page 296: ...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 297: ...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 29 295 ...

Page 298: ...16 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 4 l I I I ...

Page 299: ...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 29 297 ...

Page 300: ...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 301: ...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 302: ...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 300 ...

Page 303: ... 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 304: ...eder cover Art no 00029013005 00029013005 H00504 01 Bleeder cover Art no 00029013006 I 00029013006 H00505 01 Bleeder cover Art no 00029013019 00029013019 H02440 01 Bleeder cover Art no 00029013020 00029013020 H02441 01 302 ...

Page 305: ...x Charger cable 5 m 16 ft H01065 01 length approx US battery charger XCharge professional Art no 00029095051 Feature US plug Nominal voltage 120V Mains fuse 32A Power cable length 5 m 16 ft approx H01065 01 Charger cable 5 m 16 ft length approx e professional Art no 00029095052 Feature UK safety plug Nominal voltage 230V Mains fuse 16A Power cable length 5 m 16 ft approx H01065 01 Charger cable 5 ...

Page 306: ... CH 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 Tachometer Art no 45129075000 45129075000 H00525 01 Puller Art no 46129021000 46129021000 H01519 01 S ringe Art no 50329050000 50329050000 H00565 01 304 ...

Page 307: ...012011000 51012011000 H00572 01 Holding wrench Art no 51129003000 r 51129003000 H00575 01 Puller Art no 58429037037 Feature I Inside diameter I 37 5 mm 1 476 in 58429037037 H00596 01 Tool bracket Art no 58429089000 2x 58429089000 H00603 01 305 ...

Page 308: ...0606 01 Valve s ring mounter 59029019000 H00610 01 306 Art no 58429091000 Art no 58429092000 Art no 58429094000 Feature Torque Open ended bit Open ended bit Open ended bit Open ended bit Bit diameter Art no 59029019000 3 15 Nm 2 2 11 1 lbf ft 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 ...

Page 309: ...0 Hose clam lier 60029057000 H00627 01 H00628 01 H00650 01 Art no 59029041100 Feature SPECIAL TOOLS 32 I 5 piece I 0 10 0 25 mm 0 0039 0 0098 in Art no 60029012000 Feature I 0 025 0 175 mm 0 00098 0 00689 in Art no 60029015000 Feature Height Diameter Art no 60029057000 80 mm 3 15 in 57 125 mm 2 24 4 92 in 307 ...

Page 310: ...000 61029093000 H00659 01 Pressure testing tool Art no 61029094000 4x 61029094000 H00660 01 Release device for timing chain tensioner Art no 61229021000 61229021000 H00675 01 Mounting tool for lock rin Art no 75029005000 75029005000 H00705 01 308 ...

Page 311: ...tool Art no 75029047000 75029047000 H00714 01 Protection ca Art no 75029090000 75029090000 H00726 01 Insert for valve s ring lever Art no 77029041200 77029041200 H00746 01 Valve stem seals lier Art no 77229010000 77229010000 H00752 01 309 ...

Page 312: ... H00755 01 Se arator late Q 77229032000 H00756 01 lug wrench with link 77229172000 H00761 01 310 Art no 77229026000 Feature I Diameter Art no 77229031000 Art no 77229032000 Art no 77229172000 Feature Drive Hexagonal part Length I 5 55 mm 0 2185 in 3 8 in 14 mm 0 55 in 130 mm 5 12 in ...

Page 313: ...ion for iston ring lock 77729030100 H01126 01 Mounting tool for lock ring 79029005000 HOOB00 01 Insert for crankshaft ressing tool 79029008000 H00801 01 SPECIAL TOOLS 32 Art no 77329006000 Art no 77729030100 Art no 79029005000 Art no 79029008000 311 ...

Page 314: ...00802 01 Insert for valve s ring lever 79029060000 H00803 01 Footrest s ring lier 79029083000 H00804 01 Holder and fittin for work stand 2xffiffi 79229002000 H01127 01 312 Art no 79029009000 Art no 79029060000 Art no 79029083000 Art no 79229002000 ...

Page 315: ...00 H02607 01 79412966000 H01687 01 Art no 79229032044 Art no 79229048000 Art no 79329006000 Art no 79412966000 Feature Maximum pressure Display Valve connection Units Material SPECIAL TOOLS 32 20 bar 290 psi Digital pressure gauge Schrader valve bar psi and kg cm2 Aluminum tube 313 ...

Page 316: ...t stand 81329955100 Hook wrench 90129051000 S ring hook 5030501700004 314 H01047 01 H00985 01 H00831 01 H00973 01 Art no 80329001000 Art no 81329955100 Feature Height Load Art no 90129051000 315 425 mm 12 4 16 73 in 5 150 kg 5 331 lb Art no 5030501700004 ...

Page 317: ...1 Mounting sleeve T1204 H00878 01 Calibratin unit T1205 H00879 01 Art no T107S Art no T120 Feature I Diameter Art no T1204 Feature I Diameter Art no T1205 Feature I Diameter SPECIAL TOOLS 32 I 8 mm 0 31 in I 25 5 30 5 mm 1 004 1 201 in 118 mm 0 71 in 315 ...

Page 318: ...ressing tool l T1207S Pressing tool C T1216 Vacuum T1240S 316 Art no T1206 Feature I Diameter H00880 01 Art no T1207S H00881 01 Art no T1216 Feature I Diameter H00887 01 Art no T1240S H00890 01 1 15 30 mm 0 59 1 18 in I 38 49 mm 1 5 1 93 in ...

Page 319: ...nd 2x ill T14016S Ring wrench T14017 Art no T1296 H01573 01 Art no T1401 Feature I Diameter H00894 01 Art no T14016S Feature I Diameter H01036 01 Art no T14017 Feature I Hexagonal part H00904 01 I 48 mm 1 89 in 112 mm 0 47 in I 50 mm 1 97 in SPECIAL TOOLS 32 317 ...

Page 320: ...2 Protecting sleeve T14073 318 H00896 01 H00922 01 H00928 01 H00929 01 Art no T1403S Feature Diameter Diameter Art no T14040S Feature I Diameter Art no T14072 Feature I Diameter Art no T14073 Feature I Diameter 48 mm 1 89 in 60 mm 2 36 in I 48 mm 1 89 in I 37 mm 1 46 in 111 5 mm 0 453 in ...

Page 321: ...2261 01 Pressing tool T1504 H00899 01 Mounting tool T150S H00852 01 Art no T14084 Feature I Drive Diameter Art no T14092 Feature I Diameter Art no T1504 Feature I Diameter Art no T150S 1 1 2 in 4 mm 0 94 in I 34 mm 1 34 in 118 mm 0 71 in SPECIAL TOOLS 32 319 ...

Page 322: ...32 SPECIAL TOOLS Mounting sleeve T1515 Filling tool 2x 3x T170S1 320 H00900 01 H00855 01 Art no T1515 Feature I Diameter Art no T170S1 118 mm 0 71 in ...

Page 323: ...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 324: ...34 LIST OF ABBREVIATIONS Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly 322 ...

Page 325: ...ecking of rear brake changing rear brake checking 120 124 116 147 149 158 160 147 158 142 142 153 152 Capacitor checking Capacity coolant 140 281 engine oil 178 262 281 Chain checking cleaning Chain guide checking Chain tension adjusting checking 126 129 126 126 125 Characteristic map of the throttle response adjusting 50 Charging voltage checking 139 Clutch fluid level checking correcting 246 flu...

Page 326: ...lling 239 Checking the valve clearance 240 clutch basket installing clutch cover installing clutch discs installing 324 232 234 233 clutch push rod installing 245 crankshaft installing 226 cylinder head installing 238 engine removing from the engine assembly stand 245 force pump installing 229 gear position sensor installing 243 left engine case installing 228 locking lever installing 229 oil filt...

Page 327: ...4 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 removing 19 Frame checking 52 Front fender installing removing Front wheel installing removing Fuel filter changing Fu...

Page 328: ...im run out checking 117 Rubber grips checking 47 s Seat mounting 100 removing 99 Service schedule 290 291 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 ...

Page 329: ...chassis 281 chassis tightening torques 283 electrical system 282 engine 277 engine tolerance wear limits 278 engine tightening torques 279 fork 282 shock absorber 283 tires 282 Throttle cable play adjusting 49 checking 48 Throttle cable routing checking 48 Tire condition checking 115 Tire pressure checking 115 Type label 10 II Valve clearance checking 270 Vehicle identification number 10 Wheel bea...

Page 330: ...111111111111111111111111111IIIIIIIIIIII 3403058en 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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