Husqvarna F2103P4 Repair Manual Download

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26 TECHNICAL DATA

26.2

Tolerance, engine wear limits

Valve - run-out

At the valve plate

s; 0.05 mm (s; 0.002 in)

Valve spring

Minimum length of intake valve

42 mm (1.65 in)

Minimum length of exhaust valve

42 mm (1.65 in)

Valve - sealing seat width

Intake

1 .40 mm (0.0551 in)

Exhaust

1.40 mm (0.0551 in)

Valve spring seat - thickness

0.90 ... 1.10 mm (0.0354 ... 0.0433 in)

Camshaft bearing - sleeve bearing

Radial clearance

0.020 ... 0.054 mm (0.00079 ... 0.00213 in)

Wear limit

0.065 mm (0.00256 in)

Cylinder/cylinder head - distortion of sealing area

s; 0.10 mm (s; 0.0039 in)

Piston - diameter

Size I

77.955 ... 77.965 mm (3.06909 ... 3.06948 in)

Size II

77.965 ... 77.975 mm (3.06948 ... 3.06988 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

0.035 ... 0.057 mm (0.00138 ... 0.00224 in)

Size II

0.037 ... 0.060 mm (0.00146 ... 0.00236 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)

Connecting rod - axial play of lower conrod bearing

0.20 ... 0.45 mm (0.0079 ... 0.01 77 in)

Crankshaft - run-out at bearing pin

s; 0.03 mm (s; 0.0012 in)

Clutch facing discs - thickness of total package

� 26.4 mm (� 1.039 in)

Oil pressure regulator valve

Minimum length of pressure spring

23.5 mm (0.925 in)

Shift shaft - sliding plate/shift quadrant clearance

0.40 ... 0.80 mm (0.0157 ... 0.0315 in)

Engine oil consumption

s; 30 ml/h (s; 1.01 fl. oz./hr)

26.3

Engine tightening torques

Nozzle, crank chamber ventilation

2 Nm (1 .5 lbf ft)

Loctite

243

™

Oil nozzle for alternator cooling

2 Nm (1 .5 lbf ft)

Loctite

243

™

Oil nozzle for balancer shaft lubri-

2 Nm (1 .5 lbf ft)

cation

Loctite

243

™

Oil nozzle for conrod bearing

2 Nm (1 .5 lbf ft)

lubrication

Loctite

243

™

256

Summary of Contents for F2103P4

Page 1: ...PIONEERING SINCE 1903 REPAIR MANUAL2016 FE 250 Art no 3403024en Husqvarna MOTORCYCLES ...

Page 2: ......

Page 3: ...te 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 The models portrayed...

Page 4: ...24 6 15 Disassembling the seal ring retainer 24 7 8 9 6 16 Checking the fork legs 25 6 17 Assembling the seal ring retainer 26 6 18 Assembling the hydrostop unit 26 6 19 Assembling the piston rod 27 6 20 Assembling the cartridge 29 6 21 Assembling the fork legs 30 6 22 Lubricating the steering head bearing 35 6 23 Removing the lower triple clamp 35 6 24 Installing the lower triple clamp 36 6 25 Ch...

Page 5: ... 12 5 Removing the seat 92 12 6 Mounting the seat 92 12 7 Removing the fuel tank 93 TABLE OF CONTENTS 12 8 Installing the fuel tank 94 12 9 Changing the fuel screen 96 12 10 Changing the fuel filter 97 12 11 Changing the fuel pump 100 12 12 Checking the fuel pressure 101 13 MASK FENDER 103 13 1 Removing front fender 103 13 2 Installing front fender 103 13 3 Removing the headlight mask with the hea...

Page 6: ... engine at ignition top dead center 165 Removing the timing chain tensioner 165 Removing the camshafts 166 Removing the cylinder head 166 18 3 14 Removing the piston 167 18 3 15 Removing the starter drive 167 18 3 16 Removing the suction pump 169 18 3 17 Removing the water pump wheel 170 18 3 18 Removing the clutch cover 170 18 3 19 Removing the clutch discs 170 18 3 20 Removing the clutch basket ...

Page 7: ...e locking lever 215 18 5 13 Installing the shift drum locating unit 215 18 5 14 Installing the shift shaft 215 18 5 15 Installing the clutch basket 215 18 5 16 Installing the clutch discs 216 18 5 17 Installing the clutch cover 218 19 20 TABLE OF CONTENTS 18 5 18 Installing the water pump cover 219 18 5 19 Installing the starter drive 220 18 5 20 Installing the piston 221 18 5 21 Installing the cy...

Page 8: ...teps for winter operation 265 28 STORAGE 266 28 1 Storage 266 28 2 Preparing for use after storage 267 29 SERVICE SCHEDULE 268 29 1 Service schedule 268 29 2 Service work as additional order 269 30 WIRING DIAGRAM 270 6 30 1 Page 1 of 8 FE EU 270 30 2 Page 2 of 8 FE EU 272 30 3 Page 3 of 8 FE EU 274 30 4 Page 4 of 8 FE EU 276 30 5 Page 5 of 8 FE EU 278 30 6 Page 6 of 8 FE EU 280 30 7 Page 7 of 8 FE...

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

Page 11: ... Do not allow fuel to enter the groundwater the soil or the sewage system Use the operating and auxiliary substances such as fuel and lubricants as specified in the manual 3 3 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 The current Husq...

Page 12: ...number o 402247 10 401949 10 The chassis number O is stamped on the steering head on the right The type label O is fixed to the front of the steering head The key number O for the steering lock is stamped onto the key connector The engine number O is stamped on the left side of the engine under the engine sprocket ...

Page 13: ... NUMBERS The fork part number O is stamped on the inner side of the fork stub 4 6 Shock absorber article number 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: ...rface 401943 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle press side stand Oto the ground with your foot and lean the motorcycle on it Info When you are riding the side stand must be folded up and secured with the rubber band 5 3 Startin Note Danger Danger of poisoning death Exhaust gases are toxic and inhaling them may result in unconsciousness and Alw...

Page 15: ...Fl lights up briefly as a functional con trol when starting 5 4 400733 01 Starting the motorc cle for a check 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 an effective exhaust extraction system when starting or running the engine in an enclosed space Info Pre...

Page 16: ...line Compression damping Comfort Standard Sport Info 14 clicks 12 clicks 10 clicks I Turn clockwise to increase damping turn counter clockwise to reduce damping Ad usting the rebound dam ing of the fork Info The hydraulic rebound damping determines the fork suspension behavior Turn red adjusting screw O all the way clockwise Info Adjusting screw O is located at the upper end of the right fork leg ...

Page 17: ...ift stand a p 12 Remove the fork protector a p 17 Main work Push dust boots O of both fork legs downward Info The dust boots remove dust and coarse dirt parti cles from the inside fork tubes Over time dirt can accumulate behind the dust boots If this dirt is not removed the oil seals behind can start to leak Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Al...

Page 18: ... Remove screws with the washers and take off the brake caliper Allow the brake caliper and brake line to hang loosely to the side Loosen screws 4D Take out the left fork leg Loosen screws e Take out the right fork leg Main work Position the fork legs Bleeder screws O are positioned toward the front Info The compression damping is located in left fork leg COMP white adjusting screw The rebound damp...

Page 19: ...l JI p 112 Install the headlight mask with the headlight JI p 105 Check the headlight setting JI p 151 Remove screws O and take off the clamp Remove screws 8 on the left fork leg Take off the fork pro tector Remove screws 8 on the right fork leg Take off the fork protector Installing the fork protector Position the fork protector on the left fork leg Mount and tighten screws O Guideline Remaining ...

Page 20: ...nit p 26 Assemble the piston rod ll l p 27 Assemble the cartridge ll l p 29 Assemble the fork legs ll l p 30 Disassemblin the fork le s Info The operations are the same on both fork legs 201700 10 Condition The fork legs have been removed Note down the current state of rebound damping O REB red adjuster on the right fork leg Note down the current state of compression damping 8 COMP white adjuster ...

Page 21: ...p Release hydrostop unit 0 and remove it Info Do not use an impact wrench Place a pan underneath since oil will run out Remove the cartridge from the fork leg Pressing tool T14051 a p 332 Info I Removing the O ring seat from the cartridge usually requires the application of considerable force Remove dust boot D Remove fork protector ring t Info I The fork protector ring does not necessarily need t...

Page 22: ... Info Lower sliding bushing must be pulled from its bearing seat Remove upper sliding bushing Info Without using a tool pull the stack slightly apart by hand Take off lower sliding bushing Take off support ring Ci Take off seal ring 48 Take off lock ring Take off dust boot D Unclamp the fork leg The operations are the same on both fork legs 201722 11 20 Preparatory work Disassemble the fork legs p...

Page 23: ...spring with the preload spacer s Disassembling the cartridge Info The procedures are the same on both fork legs 202480 10 111Wll R00023 10 Preparatory work Disassemble the fork legs p 18 Remove the spring p 20 Main work Degrease piston rod O and clamp using the special tool I Clamping stand T14049S a p 332 Remove adjusting tube 8 Unscrew spring guide D Remove spring seat 8 Pull the piston rod out ...

Page 24: ...ock ring D Pull reservoir out of the cartridge Pull sleeve out of the reservoir Remove spring with preload spacers Remove seal rings G and O ring G Remove pilot bushings 48 Disassembling the iston rod Info The steps are identical for both fork legs except for the hydrostop needle and valve Preparatory work Disassemble the fork legs l l p 18 Remove the spring l l p 20 Disassemble the cartridge l l ...

Page 25: ...hydrostop needle Info f silver hydrostop needle on compression damp ing side G red hydrostop needle on rebound damping side Turn piston rod degrease and clamp using the special tool I Clamping stand T14049S p 332 Remove rebound shim stack 8 Remove piston C Remove compression shim stack 0 Remove the spring Remove adapter D with spring Remove spring Remove valve needle from the piston rod Info The a...

Page 26: ...tand T1202S I p 329 Turn hydrostop unit mount on a fitting hexagon socket and clamp into a vice Remove sleeve O Remove shim stack i and washer D Remove adapter C Remove hub Cs Remove O ring from the hub Remove shim stack C Remove washer Remove O ring Disassemblin the seal ring retainer Info The steps are identical for both fork legs Preparatory work Disassemble the fork legs I p 18 Remove the spri...

Page 27: ...ameter of inner tube 47 975 48 005 mm 1 88878 1 88996 in If the measured value is smaller than the specified value Change the inner tube Measure the run out of the inner tube I Inner tube run out I 0 20 mm 0 0079 in If the measured value is larger than the specified value Change the inner tube Measure the inside diameter at multiple locations of the outer tube Inside diameter of outer tube 49 20 m...

Page 28: ...cers If the measured value is smaller than the specified value Increase the thickness of the preload spacers Assembling the seal rin retainer Info The steps are identical for both fork legs R00014 10 Mount and grease seal ring O I Lubricant T158 I p 316 Mount and grease O ring I Lubricant T158 I p 316 Position pilot bushing support Assembling the h drosto unit Info The procedures are the same on b...

Page 29: ...ool I Clamping stand T1202S i I p 329 Tighten sleeve 0 Guideline Hydrostop unit sleeve M6x0 5 6 Nm 4 4 lbf ft The steps are identical for both fork legs except for the hydrostop needle and valve 201790 10 R00033 10 Degrease the piston rod Clamp the piston rod with the special tool I Clamping stand T14049S p 332 Grease O ring Mount valve needle O in the piston rod I Lubricant T158 p 316 Mount sprin...

Page 30: ...1166S1 Ip 314 Mount the piston with chamfer f facing down Mount rebound shim stack 3 with the smaller shims facing upward Info I Note the setting list Press the piston downward against the spring Info Make sure the pistons do not squeeze the shims Position valve in hydrostop needle Mount and tighten the hydrostop needle Guideline Hydrostop needle on M6x0 5 8 Nm 5 9 lbf ft Info f silver hydrostop n...

Page 31: ...ervoir spring Guideline Reservoir spring length with 46 mm 1 81 in preload spacer If the length is out of tolerance Correct the preload spacers Position the spring with the preload spacers in the reservoir Position sleeve C in the reservoir Clamp cartridge with special tool I Clamping stand T14049S JI p 332 Slide reservoir 0 onto the cartridge Info Hold the sleeve in the reservoir to prevent it fr...

Page 32: ...ponding inner tube and the right adjuster is mounted on the corresponding screw cap Compression damping side screw cap with mark COMP brake caliper holder white adjuster Rebound damping side screw cap with mark REB no brake caliper holder red adjuster e 8 8 R00037 10 Preparatory work Assemble the hydrostop unit i Jl p 26 Main work Clamp the inner tube with the axle clamp Guideline I Use soft jaws ...

Page 33: ... using a tool pull the stack slightly apart by hand Warm up the outer tube in area fj of the lower sliding bush ing Guideline I so 0 c 122 F Slide the outer tube onto the inner tube Hold the lower sliding bushing with the longer side of the special tool I Mounting tool T14040S la p 332 Press the sliding bushing all the way into the outer tube Position the support ring Hold the seal ring with the s...

Page 34: ...dge all the way into the fork leg Turn the fork Have the entire filling quantity of fork oil available Oil capacity per fork 630 ml Fork oil SAE 4 leg 21 3 fl oz 48601166S1 a p 314 Add some of the fork oil while pulling out and pushing in the piston rod numerous times Guideline I Fork oil quantity 1510 ml 17 24 fl oz Mount and tighten hydrostop unit Guideline I Hydrostop unit I M30x1 I 40 Nm 29 5 ...

Page 35: ...nward Mount screw cap Info When assembling ensure that the screw caps are cor rectly mounted according to the hydrostop needles Rebound damping side red hydrostop needle screw cap with mark REB Compression damping side silver hydrostop needle screw cap with mark COMP Mount the open end wrench on the hexagonal part Hold the open end wrench Tighten screw cap fD Guideline Screw cap on piston M8x0 75 ...

Page 36: ...tandard 12 clicks Sport 10 clicks Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Alternative 2 Warning Danger of accident Modifications to the sus pension setting may seriously alter the handling characteristic Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components Only make adjustments with...

Page 37: ...p 12 Remove the front wheel p 111 Remove the fork legs p 16 Remove front fender l JI p 103 Main work Open cable holder O in front of the right radiator and detach the wiring harness Remove screw Remove screw fD take off the upper triple clamp with the handlebar and set it aside Info I Cover the components to protect them against dam age Do not kink the cables and lines Remove 0 ring 8 Remove prote...

Page 38: ...ring 8 and 0 ring 8 Position the upper triple clamp with the handlebar Mount screw C but do not tighten yet Position the clutch line in the guide above the voltage regula tor Position the fork legs Bleeder screws 0 are positioned toward the front Info The compression damping is located in left fork leg COMP white adjusting screw The rebound damping is located in right fork leg REB red adjusting sc...

Page 39: ... lbf ft 17 Nm 12 5 lbf ft Loctite 243 17 Nm 12 5 lbf ft Secure the wiring harness with cable holder Position the brake caliper Mount and tighten screws 6i with the washers Guideline Screw front brake caliper M8 Mount the cable tie s 25 Nm 18 4 lbf ft Loctite 243 Position the brake line wiring harness and clamp Mount and tighten screws 48 Finishing work Install front fender I p 103 Install the fron...

Page 40: ... the frame can become damaged over time Preparatory work Raise the motorcycle with a lift stand ll 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 the steering head bearing play p 38 Move the handlebar to and fro over the entire st...

Page 41: ...8 17 Nm 12 5 lbf ft Loctite 243 Finishing work Check the play of the steering head bearing ll l p 38 Remove the motorcycle from the lift stand ll l p 12 Changing the steering head bearin Preparatory work Remove the headlight mask with the headlight l I p 104 Raise the motorcycle with a lift stand ll l p 12 Remove the front wheel ll l p 111 Remove the fork legs l I p 16 Remove front fender a p 103 ...

Page 42: ...000 ll l p 321 Remove lower steering head bearing Remove the seal ring Grease and mount the new seal ring Press on the new bearing with a suitable tube as far as it will go Finishing work Install the lower triple clamp ll l p 36 Install front fender ll l p 103 Install the front wheel 0 p 112 Install the headlight mask with the headlight 0 p 105 Check that the wiring harness throttle cables and bra...

Page 43: ... The handlebar may break as a result Change the handlebar if the handlebar is damaged or bent 101860 10 Remove screws O Take off the handlebar clamps Take off the handlebar and lay it to one side Info Cover the components to protect them against dam age Do not bend the cables and lines Remove screws 8 Take off the handlebar supports Place the handlebar supports in the required position Mount and t...

Page 44: ... the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding Checking the routing of the throttle cable Preparatory work Remove the seat il l p 92 Remove the fuel tank il l p 93 Main work Check the routing of the throttle cable Both throttle cables must be routed to the throttle valve body side by side b...

Page 45: ...ning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Start the engine and let it run idle Move the handlebar to and fro over the entire steering range I The idle speed must not change If the id...

Page 46: ...e throttle cable at the throttle grip Guideline I Play in throttle cable I 3 5 mm 0 12 0 2 in Tighten nut C Press and hold the throttle grip in the closed setting Turn adjusting screw out until there is no play in throttle cable 3 Tighten nut Push sleeves O on Check the throttle grip for smooth oper ation Finishing work Install the fuel tank l ll p 94 Mount the seat l ll p 92 Check the play in the...

Page 47: ...rame at the rear and swing up at the front Turn quick release O clockwise all the way Check the frame for cracks and deformation If the frame exhibits cracks or deformation due to a mechanical impact Change the frame Info Always replace a frame that has been damaged due to a mechanical impact Repair of the frame is not authorized by Husqvarna Motorcycles 8 FRAME 45 ...

Page 48: ...o I Do not loosen fitting Turn counterclockwise by the number of turns corresponding to the shock absorber type Guideline Compression damping high speed 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 46 Caution Risk of injury rectly Parts of...

Page 49: ...e damping Ad usting the rebound dam ing of the shock absorber Caution Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled 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 correspond ...

Page 50: ... the motorcycle from the lift stand p 12 Checkin the static sa of the shock absorber Measure distance t of rear wheel unloaded p 48 Hold the motorcycle upright with the aid of an assistant Measure the distance between the rear axle and the fixed point again Note down the value as dimension G Info The static sag is the difference between measure ments t and G Check the static sag I Static sag 130 m...

Page 51: ... I Riding sag 1100 mm 3 94 in If the riding sag differs from the specified measurement Adjust the riding sag a p 50 41 Adjusting the s ring reload of the shock absorber Caution Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incor rectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Info Before chan...

Page 52: ...it may be necessary to increase or decrease the spring preload Tighten screw O Guideline Screw shock MS absorber adjusting ring Finishing work Install the shock absorber p 52 Install the manifold p 81 Mount the seat p 92 Install the main silencer a p 83 Install the right side cover a p 91 5 Nm 3 7 lbf ft Remove the motorcycle from the lift stand 0 p 12 Preparatory work Raise the motorcycle with a ...

Page 53: ...ber p 52 Install the manifold p 81 Mount the seat i p 92 Install the main silencer i p 83 Install the right side cover i p 91 Remove the motorcycle from the lift stand i p 12 Check the static sag of the shock absorber l l p 48 Check the riding sag of the shock absorber l l p 49 Adjust the rebound damping of the shock absorber l l p 47 41 9 9 Removin the shock absorber Preparatory work Raise the mo...

Page 54: ... the seat p 92 Install the main silencer p 83 Install the right side cover lll p 91 Remove the motorcycle from the lift stand lll p 12 Checking the shock absorber linkage Preparatory work Raise the motorcycle with a lift stand p 12 Main work Remove screw O Remove fitting 8 Info Raise the wheel slightly to be able to remove the screws more easily Remove fitting Take off the angle lever ...

Page 55: ...r wear Change the spacers Check the shaft seal rings for damage and wear If there is damage or wear Change the shaft seal rings Check dimension f 303096 10 I 54 91 55 00 mm 2 1618 2 1654 in If dimension f is below the specified value Add the necessary spacing washers Position angle lever Mount fitting D but do not tighten yet Guideline Nut angle lever on swingarm M14x1 5 80 Nm 59 lbf ft 53 ...

Page 56: ...9 lbf ft Raise the wheel slightly to be able to mount the screw more easily Tighten screws O Guideline Screw bottom M10 shock absorber Tighten screw cap CD Guideline Nut angle lever on swingarm M14x1 5 60 Nm 44 3 lbf ft Loctite 2701 TM 80 Nm 59 lbf ft Servicing the shock absorber Caution Risk of injury rectly Parts of the shock absorber will fly off if the shock absorber is disassembled incor The ...

Page 57: ...the seal ring retainer p 62 Assemble the piston rod p 63 Assemble the damper p 65 Install the spring p 71 Condition The shock absorber has been removed Clamp the shock absorber in the vise using soft jaws for pro tection Measure and note spring length in its preloaded state Loosen screw O Turn adjusting ring until the spring is no longer under tension I Hook wrench T106S p 328 Remove ring Remove s...

Page 58: ...mping O and compression damping 8 Completely open the adjusters of the rebound and compres sion damping Remove rubber cap 8 of the reservoir Open screw 8 slowly The pressurized nitrogen escapes Remove locking cap 0 Press in seal ring retainer 3 using the special tool I Pressing tool T1216 lll l p 331 Remove lock ring Info Do not scratch the inner surface ...

Page 59: ...ate washer Drain the oil Remove compression adjuster Remove the spring and piston Disassembling the piston rod Preparatory work Remove the spring a p 55 Disassemble the damper a p 56 Main work Clamp the piston rod with the fork in a vise Guideline I Use soft jaws Remove nut O Remove washer 8 57 ...

Page 60: ...fo I Place the compression shim stack onto a screwdriver and set it down as a unit Remove rebound washer CD Remove seal ring retainer Remove locking cap fD and rubber buffer Disassembling the seal ring retainer 201405 10 Preparatory work Remove the spring 0 p 55 Disassemble the damper 0 p 56 Disassemble the piston rod 0 p 57 Main work Remove spring O Remove O ring 8 Remove rebound rubber ...

Page 61: ... 57 Disassemble the seal ring retainer l JI p 58 Main work Press pilot bushing O out of seal ring retainer 8 with the special tool I Pressing tool T1504 l JI p 333 Slide the new pilot bushing O onto the special tool I Pressing tool T1504 p 333 Position the pilot bushing in the seal ring retainer using the special tool I Pressing tool T1504 p 333 Support seal ring retainer 8 with sleeve f of the sp...

Page 62: ...the damper cartridge Damper cartridge Diameter s 50 08 mm 5 1 9716 in If the measured value is greater than the specified value Change the damper cartridge Check the damper cartridge for damage and wear If there is damage or wear Change the damper cartridge Check the heim joint for damage and wear If there is damage or wear Change the heim joint Measure the diameter of the piston rod Piston rod Di...

Page 63: ...ise using soft jaws for pro tection Remove the collar bushing of the heim joint I Drift f120 i l p 329 Turn the shock absorber and remove the second collar bush ing of the heim joint Remove seal rings O on both sides Press the heim joint against a lock ring using the special tool I Pressing tool T1207S a p 330 Remove the second lock ring Place special tool f underneath and press out heim joint D w...

Page 64: ...6 a p 330 Press the heim joint all the way in Press the heim joint against the lock ring using the special tool I Pressing tool T1207S a p 330 Mount the second lock ring Mount seal rings D on both sides Position both collar bushings C and press them in Mount dust boot O with the special tool I Mounting sleeve T1204 a p 329 Grease the sealing lip of the dust boot I Lubricant T625 a p 316 ...

Page 65: ...bound rubber D Grease the 0 ring groove I Lubricant T158 0 p 316 Mount 0 ring Mount spring Preparatory work Assemble the seal ring retainer 0 p 62 Main work Clamp the piston rod with the fork in a vise Guideline I Use soft jaws Mount rubber buffer O and locking cap Position special tool on the piston rod I Mounting sleeve T1215 0 p 330 Grease the dust boot and push seal ring retainer Donto the pis...

Page 66: ... stack 0 with the smaller shims facing downward Sand both sides of piston 3 on a surface plate using 1200 grit sandpaper Clean the piston Assemble the piston Guideline View6 Piston from above View Piston from below Mount the rebound shim stack with the smaller shims facing upward Mount washer fD with the collar facing downward ...

Page 67: ... 316 Lubricate the threads I Lubricant T159 l t J p 316 Mount the piston with the spring Mount and tighten the compression adjuster 0 Guideline Compression adjuster M31x1 Clamp the damper in a bench vise Guideline I Use soft jaws 45 Nm 33 2 lbf ft Mount adjusting ring 8 with the intermediate washer Info The adjusting ring cannot be mounted after the piston rod is mounted Fill the damper cartridge ...

Page 68: ...rnative 1 Turn adjusting screw fD clockwise with a screwdriver up to the last perceptible click Turn counterclockwise by the number of clicks corre sponding to the shock absorber type Guideline Compression damping low speed Comfort 20 clicks Standard 18 clicks Sport 16 clicks Turn adjusting screw all the way clockwise with a socket wrench Turn counterclockwise by the number of turns corre sponding...

Page 69: ...s to get the feel of the new handling characteristic Turn adjusting screws and G to the position determined during disassembly Bleeding and filling the dam er Info Before working with the vacuum pump be sure to read the operating instructions carefully Completely open the adjusters of the rebound and compression damping Remove the screw of the filling port Install adapter O on the damper Info Tigh...

Page 70: ...crometer T107S a p 329 The floating piston is positioned all the way at the bot tom When the vacuum pressure gauge reaches the specified value turn the Oil reservoir control lever 0 to Equalize pressure Guideline 14 mbar The pressure gauge increases to the specified value 0 bar When the pressure gauge reaches the specified value turn the Damper control lever C to Pressure Guideline 0 bar Oil is pu...

Page 71: ...ol lever 8 to Pressure Guideline 0bar Oil is pumped into the damper The pressure gauge increases to the specified value 3 bar When the pressure gauge reaches the specified value turn the Damper 8 control lever to Vacuum Guideline 3 bar The pressure gauge drops to the specified value 0bar When the pressure gauge reaches the specified value oper ate the On Off switch Guideline 0bar The vacuum pump i...

Page 72: ...M10x1 Filling the damper with nitrogen 114 Nm 10 3 lbf ft 411 Screw in screw O by approx 2 rotations but do not tighten Info The piston rod is fully extended Clamp the special tool in the vise I Filling tool T170S1 ilill p 333 Connect the special tool to the pressure regulator of the filling cylinder I Filling gas nitrogen Adjust the pressure regulator Guideline I Gas pressure 110 bar 145 psi Posi...

Page 73: ... adjusting ring O is screwed on with the interme diate washer Measure the overall spring length while the spring is not under tension Position spring Guideline Spring rate Weight of rider 65 51 N mm 291 lb in 75 kg 143 165 lb Weight of rider 75 54 N mm 308 lb in 85 kg 165 187 lb Weight of rider 85 57 N mm 325 lb in 95 kg 187 209 lb Mount intermediate washer 8 and spring retainer 8 Mount ring C Alt...

Page 74: ...the new handling characteristic Tension the spring to the amount measured during dis mantling by turning the adjusting ring I Hook wrench T106S p 328 Tighten screw 0 Guideline Screw shock M5 5 Nm 3 7 lbf ft absorber adjusting ring Check the swingarm for damage cracking and deformation If the swingarm shows signs of damage cracking or deformation Change the swingarm Info I Always change a damaged s...

Page 75: ...he other If there is detectable play Change the swingarm bearing a p 76 Finishing work Remove the motorcycle from the lift stand p 12 Preparatory work Raise the motorcycle with a lift stand a p 12 Remove the rear wheel a p 114 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 7...

Page 76: ...chain Info I Cover the components to protect them against dam age Take off the chain Remove fitting C Lower the swingarm Remove nut C Remove the swingarm pivot Take off the swingarm Main work Position the swingarm Mount the swingarm pivot Mount and tighten nut O Guideline Nut swingarm pivot M16x1 5 100 Nm 73 8 lbf ft ...

Page 77: ...ust face in the direction of travel Position the motor sprocket cover and mount in the holder Mount and tighten screws C Guideline Screw clutch slave cylinder M6 Mount and tighten screws Guideline Remaining screws chassis M8 10 Nm 7 4 lbf ft 25 Nm 18 4 lbf ft Position the brake caliper and pull it back Position the brake line in the guide Finishing work Install the rear wheel Ii p 115 Remove the m...

Page 78: ...lift stand p 12 Remove the rear wheel p 114 Remove the swingarm p 73 Left swingarm 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 stop disks C Press in shaft seal rings ...

Page 79: ...R02761 10 9 SHOCK ABSORBER SWINGARM Mount bushing 8 Grease the shaft seal rings I Long life grease I p 316 Position collar bushings O with the shoulder facing inward Right swingarm bearing Remove collar bushings D Remove bushing 77 ...

Page 80: ...suitable tool Using a suitable tool press in new bearing Press in shaft seal rings Mount bushing Grease the shaft seal rings I Long life grease p 316 Position collar bushings Q with the shoulder facing inward Finishing work Install the swingarm p 74 Install the rear wheel p 115 Remove the motorcycle from the lift stand p 12 ...

Page 81: ...ve the right side cover JI p 91 Remove the main silencer i I p 82 Main work Remove screw cap O Remove screw Info Raise the wheel slightly to be able to remove the screws more easily Press angle lever 8 toward the rear Press linkage lever C downward Lift the swingarm Remove screws 0 on both sides Loosen screws D on both sides 79 ...

Page 82: ... frame slightly and lower the shock absorber FE EU Remove the fuel tank p 93 Disconnect plug in connector of the lambda sensor and remove the cable binder Remove springs I Spring hook 50305017000 p 320 Remove screw GD and take off the manifold ...

Page 83: ...e with a new cable tie Install the fuel tank 0 p 94 Lift the rear frame slightly and position the shock absorber Mount and tighten screw 8 Guideline Screw top M10 shock absorber 60 Nm 44 3 lbf ft Loctite 2701 TM Position the rear frame Mount and tighten screws 0 on both sides Guideline Screw sub frame M8 Remove screws CD on both sides 35 Nm 25 8 lbf ft Loctite 2701 TM Mount and tighten screws CD o...

Page 84: ...the main silencer 0 p 83 Install the right side cover 0 p 91 Mount the seat a p 92 Remove the motorcycle from the lift stand a p 12 Removin 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 91 Main work Detach spring 0 ...

Page 85: ...ght side cover a p 91 Changing the glass fiber arn filling in the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven 10 Nm 7 4 lbf ft Allow the exhaust system to cool down before performing any work on the vehicle Info Over time the fibers of the glass fiber yarn escape and the damper burns out Not only is the noise level higher the performance charac...

Page 86: ...m 5 2 lbf ft Remove screws O of connecting cap Remove connecting cap with the perforated pipe 0 ring and glass fiber yarn filling C Remove screws 0 and silencer cap Q with 0 ring Remove screws and insert together with insulat ing pad Remove the insulating pad from the insert Clean the parts that need to be reinstalled and check for damage Mount the new insulating pad on the insert and fasten with ...

Page 87: ...p 83 Install the right side cover il l p 91 Cleaning the s ark arrestor FE US Warning Danger of burns The exhaust system gets very hot when the vehicle is driven 7 Nm 5 2 lbf ft Allow the exhaust system to cool down before performing any work on the vehicle Info Soot particles accumulate on the screen of the spark arrestor over time This changes the performance characteristics Preparatory work Rem...

Page 88: ...breathing and eye protection when cleaning the main silencer and carbon screen Clean main silencer housing 8 and screen 0 of the spark arrestor with compressed air Mount a new 0 ring CD on silencer cap Position silencer cap Mount and tighten screws O Guideline I Screws on the main silencer Finishing work Install the main silencer p 83 Install the right side cover p 91 86 I 7 Nm 5 2 lbf ft ...

Page 89: ...without an air filter Never start to use the vehicle without an air filter Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Preparatory work Remove the air filter box cover a p 87 Main work Push air filter holding bracket O toward the air filte...

Page 90: ...tal hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Do not clean the air filter with fuel or petroleum since these substances attack the foam Preparatory work Remove the air filter box cover a p 87 Remove the air filter p 87 Main work Wash the air filter thoro...

Page 91: ...rk Install the air filter p 88 Install the air filter box cover 1ll p 87 Preparatory work Remove the air filter box cover 1ll p 87 Main work Seal the air filter box in the marked area f Finishing work Install the air filter box cover p 87 11 AIR FILTER 89 ...

Page 92: ...nd clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children W...

Page 93: ...ace the filler cap and turn clockwise until release but ton O locks in place Info Run the fuel tank breather hose without kinks 12 3 Removing the right side cover Remove screw O Pull off the side cover in area 6 sideways and remove it toward the rear Position the side cover and engage in area 6 Mount and tighten screw O Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 91 ...

Page 94: ...ft and right Raise the rear of the seat push the seat back and lift it off Mount the front of the seat on the collar bushing of the fuel tank lower the seat at the rear while pushing it forward The seat is correctly engaged Mount and tighten seat fixing screws 0 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 411 411 ...

Page 95: ...uel 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 Preparatory work Remove the seat p 92 Main work Unplug connector O of the fu...

Page 96: ...with the rubber bushing Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank The fuel in the fuel tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes 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 wip...

Page 97: ... cables are trapped or damaged Attach the hose to the fuel tank breather on the tank lid Mount and tighten screw O with the rubber bushing Guideline Remaining screws chassis FE EU AU M6 10 Nm 7 4 lbf ft Position the collar bushings and horn and mount and tighten screws 8 Guideline Remaining screws M6 chassis Connect the connector of the horn FE US 10 Nm 7 4 lbf ft Position the collar bushings and ...

Page 98: ...f the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and c...

Page 99: ...closed space Start the engine and check the response 12 10 Changing the fuel filter 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 ...

Page 100: ...tem 305313 10 305314 10 305315 10 305317 10 Preparatory work Drain the fuel from the fuel tank into a suitable container Remove the seat p 92 Remove the fuel tank p 93 Main work Remove nut O with the gasket Remove fuel connection 8 with the gasket Remove screws 8 Pull out the fuel pump Remove hose clamps C Remove fuel filter 0 Press locking mechanism D Pull back fuel pump housing ...

Page 101: ...untfuel connection 8 with the gasket b ut do not tighten yet Guideline Fuel connection on fuel pump MS 10 Nm 7 4 lbfft Mount and tighten nut O with the gasket Guideline Nut fuel pumpfixa M12 tion Tightenfuel connection 8 Guideline Fuel connection on fuel pump MS Mount and tighten screws 6 Guideline I Screw fuel pump I EJOT PT Finishing work Install thefuel tank p 94 Mount the seat p 92 15 Nm 11 1 ...

Page 102: ...sult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Warning Environmental hazard Improper handling...

Page 103: ...of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do ...

Page 104: ...US gal ter Connect the diagnostics tool and start it Select the Function test of fuel pump control actuator test Guideline Maximum duration of the actuator test 3 min Check the fuel pressure with the filler cap closed Fuel pressure When the fuel pump is active 1 3 35 3 65 bar 48 6 52 9 psi If the specification is not reached Open the filler cap a p 90 Check the tank air vent system Check the fuel ...

Page 105: ...emove screws Take off the front fender Main work Position front fender Mount and tighten screws O Guideline Remaining screws chassis M6 Mount and tighten screws 8 Guideline Remaining screws chassis Finishing work M6 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft Install the headlight mask with the headlight p 105 Check the headlight setting p 151 103 ...

Page 106: ... until the engine stops FE EU AU Detach brake line O and wiring harness f Release rubber bands D Slide the headlight mask up and swing it forward Detach plug in connectors 8 and take off the headlight mask with the headlight FE US Detach brake line O and wiring harness f Release rubber bands D Slide the headlight mask up and swing it forward Disconnect plug in connector 8 and take off the head lig...

Page 107: ...ectors 0 Position the headlight mask and secure it with rubber bands The holding lugs engage in the fender Position brake line fi and wiring harness 8 in the brake line guide FE US Connect plug in connector 0 Position the headlight mask and secure it with rubber bands The holding lugs engage in the fender 105 ...

Page 108: ...13 MASK FENDER 106 Position brake line D and wiring harness C in the brake line guide Finishing work Check the headlight setting a p 151 ...

Page 109: ...ection cap Only mount tires approved and or recommended by Husqvarna Motorcycles Other tires could have a negative effect on handling characteristics The type condition and air pressure of the tires all have a major impact on the handling of the motorcy cle The tires mounted on the front and rear wheels must have a similar profile Worn tires have a negative effect on handling characteristics espec...

Page 110: ...ge the tires Checking the wheel bearing for la Preparatory work Raise the motorcycle with a lift stand p 12 Place a load on the rear of the vehicle The front wheel is not in contact with the ground Main work Move the front wheel from side to side Info Hold the fork leg to check it If there is detectable play Change front wheel bearing ill p 113 Place a load on the front of the vehicle The rear whe...

Page 111: ...rake disc exhibits damage cracking or deforma tion Change the front brake disc ill p 112 Change the rear brake disc p 116 Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary damage The spokes break due to being overloaded if they are too tightly tensioned If the tension in the spokes is too low then lateral and radial run out will form in the...

Page 112: ...l become looser as a result Check spoke tension regularly and in particular on a new vehicle Info A loose spoke can unbalance the wheel and other spokes may loosen within a short period If the spokes are too tight they can break due to local overload Check the spoke tension regularly especially on a new motorcycle Check for lateral and radial run out of the rims Lateral runout Outside the rim join...

Page 113: ...st the spokes when pushing back the brake pis tons Loosen screw O by several rotations Loosen screws 8 Press on screw O to push the wheel spindle out of the axle clamp Remove screw O Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Holding the front wheel withdraw the wheel spindle Take the front wh...

Page 114: ... grease 0 p 316 Position the front wheel and insert the wheel spindle The brake linings are correctly positioned Mount and tighten screw 8 Guideline Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Operate the hand brake lever several times until the brake linings are seated correctly against the brake disc Remove the motorcycle from the lift stand ll p 12 Operate the front brake and compress t...

Page 115: ... p 112 14 7 4 Changing front wheel bearing Preparatory work Raise the motorcycle with a lift stand p 12 Remove the front wheel p 111 Main work Remove shaft seal rings O and 8 Press out bearing using a suitable tool Info I Spacing tube e can be pushed aside Remove the spacing tube Press out bearing 0 using a suitable tool Press in new bearing 0 all the way using a suitable tool Info Only press the ...

Page 116: ...p 12 Main work Press the brake caliper onto the brake disc by hand in order to push back the brake piston Info I Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove nut 0 Remove chain adjuster 8 Pull out wheel spindle D far enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Remove the chain f...

Page 117: ...ys keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Main work Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change the rear wheel bearing a p 123 Clean and grease shaft seal rings O and contact surface 6 of the spacers I Long life grease a p 316 Insert the spacers Clean and grease the wheel spindle I Long life...

Page 118: ...repeatedly until the brake lin ings are in contact with the brake disc and there is a pressure point Finishing work Remove the motorcycle from the lift stand ll p 12 If the brake discs are changed the brake linings must also be changed 116 Preparatory work Raise the motorcycle with a lift stand p 12 Remove the rear wheel a p 114 Main work Remove screws O Remove the brake disc Clean the contact sur...

Page 119: ...n O must be taut Chain wear is not always even so you should repeat this measurement at different chain positions 14 8 5 Adjusting the chain tension Warning I Chain tension 1 55 58 mm 2 17 2 28 in If the chain tension does not meet specifications Adjust the chain tension a p 117 Finishing work Remove the motorcycle from the lift stand a p 12 Danger of accidents Incorrect chain tension damages comp...

Page 120: ...ws D Tighten nut 0 Guideline Info M20x1 5 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 8 can be turned by 180 Finishing work Remove the motorcycle from the lift stand p 12 Checking the chain rear sprocket engine sprocket and chain guide Preparatory work 400227 01 Raise the motorcycle wit...

Page 121: ...2 mm 10 71 in If the distance ti is greater than the specified measure ment Change the drivetrain kit p 121 Info I When the chain is replaced the rear sprocket and engine sprocket should also be changed New chains wear out faster on old worn sprockets Check the chain sliding guard for wear If the bottom edge of the chain bolt is in line with or below the chain sliding guard Change the chain slidin...

Page 122: ...iding piece Guideline Screw chain slid M8 ing piece Check the chain guide for wear Info 15 Nm 11 1 lbf ft Wear is visible on the front of the chain guide If the light part of the chain guide is worn Change the chain guide Check that the chain guide is firmly seated If the chain guide is loose Tighten the chain guide Guideline Remaining M6 screws chassis Remaining nuts M6 chassis Finishing work 10 ...

Page 123: ...ake discs with brake cleaner when necessary Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info The service life of the chain depends largely on its maintenance 400725 01 Preparatory work Raise the motorcycle with a lift stand l ll p 12 Main ...

Page 124: ...her Remove the rear wheel I p 114 Remove connecting link 8 of the chain Info Cover the components to protect them against dam age Take off the chain Remove engine sprocket 0 Remove fittings D Take off the rear sprocket Position the new rear sprocket Mount and tighten the fit tings Guideline Nut rear M8 sprocket screw 35 Nm 25 8 lbf ft Loctite 2701TM ...

Page 125: ...ghten screw D with the washer Guideline Screw engine sprocket M10 60 Nm 44 3 lbf ft Loctite 2701TM Position the engine sprocket cover Mount and tighten screw O Guideline Screw clutch slave cylinder M6 Mount and tighten screw Guideline 10 Nm 7 4 lbf ft Remaining screws chassis MS 25 Nm 18 4 lbf ft Finishing work Remove the motorcycle from the lift stand ill p 12 14 8 10 Changing the rear wheel bear...

Page 126: ...be 0 Using a suitable tool press bearing D out from the inside to the outside Check spacer washer for damage and wear If the spacer washer is damaged or worn Replace the spacer washer Position spacer washer Press new bearing D all the way in from the outside to the inside Info Only press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in ...

Page 127: ...bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in Grease new shaft seal ring fD and press it in until it is flush Mount lock ring 8 The lock ring engages audibly Grease new shaft seal ring O and press it in until it is flush Finishing work Install the rear wheel p 115 Remove the motorcycle from the lift stand a p 12 125 ...

Page 128: ... Guideline Fuse 1 10 A EFI control unit Fuse 2 10 A fuel pump Fuse 3 10 A high beam low beam parking light tail light license plate lamp Fuse 4 10 A horn brake light turn signal radiator fan Fuses res 10 A spare fuses Info I You can recognize a faulty fuse by a burned out fuse wiref Warning Fire hazard Incorrect fuses overload the electrical system Only use fuses with the required ampere value Do ...

Page 129: ...ll switch while the engine is idling until the engine stops FE US Press and hold the kill switch while the engine is idling until the engine stops Remove the air filter box cover 8 p 87 Main work Take off protection caps 0 Remove faulty main fuse 8 Info You can recognize a faulty fuse by a burned out fuse wiret A spare fuse D is located in the starter relay Install a new main fuse I Fuse 580111091...

Page 130: ...ot meet specifications Change the starter relay Risk of injury Battery acid and battery gases cause serious chemical burns Keep batteries out of the reach of children Wear suitable protective clothing and safety glasses Avoid contact with battery acid and battery gases Keep sparks or open flames away from the battery Only charge batteries in well ventilated rooms Rinse the affected area immediatel...

Page 131: ...ew Guideline Screw battery termi MS nal 2 5 Nm 1 84 lbf ft Slide positive terminal cover over the positive terminal Position the negative cable and mount and tighten the screw Guideline Screw battery termi MS nal 2 5 Nm 1 84 lbf ft Slide negative terminal cover over the negative terminal Finishing work Mount the seat p 92 Risk of injury Battery acid and battery gases cause serious chemical burns K...

Page 132: ...ded the battery will be destroyed If the battery is depleted by repeated starting the battery must be charged immediately If the battery is left in a discharged state for an extended period it will become over discharged and sul fated destroying the battery The battery is maintenance free 311910 10 Preparatory work Remove the seat l I p 92 Main work Connect the battery charger to the battery Adjus...

Page 133: ...e wiring harness Check the stator winding of the alternator lit I p 244 If the displayed value is greater than the specified value Change the voltage regulator Checking the o en circuit current Preparatory work FE EU AU Press and hold the kill switch 5 while the engine is idling until the engine stops Remove the seat lit J p 92 Main work Disconnect the negative cable of the battery Measure the cur...

Page 134: ... 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 contact with the skin Rinse eyes thoroughly with water immediately...

Page 135: ...ctly and in compliance with the applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Move the brake fluid reservoir mounted on the handlebar to a horizontal posit...

Page 136: ...rane 8 Mount and tighten screws 0 Info Clean up overflowed or spilt brake fluid immediately with water Checking the free travel of the hand brake lever Warning Danger of accidents The brake system fails in the event of overheating If there is no free travel on the hand brake lever pressure builds up on the front brake circuit Set the free travel on the hand brake lever in accordance with the speci...

Page 137: ...crew counterclockwise to decrease the distance between the hand brake lever and the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding Adjusting free travel of hand brake lever FE EU AU H00198 10 Check the free travel of the hand brake lever a p 134 Adjust the free travel of the hand brake lever wit...

Page 138: ...insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the brake system is leaking or the brake linings are worn down Check the brake system and do not continue riding until the problem is eliminated Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children W...

Page 139: ...fluid DOT 4 l lll p 314 5 mm 0 2 in Position the cover with the membrane Mount and tighten the screws Info I Clean up overflowed or spilled brake fluid immediately with water Chan in the front brake fluid 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...

Page 140: ...05 a p 318 Connect the bleeding device I Bleeding device 00029013100 l I p 318 Open shut off valve 8 Info Follow the operating instructions of the bleeding device Ensure that the filling pressure is correctly set at pressure gauge 6 If necessary adjust the filling pressure at pressure regulator G Guideline I Filling pressure I 2 2 5 bar 29 36 psi Pull off protection cap 0 of the brake caliper blee...

Page 141: ...lever for a firm pressure point Checking the rear brake linings Warning Danger of accidents Worn out brake linings reduce the braking effect Ensure that worn out brake linings are replaced immediately Chan in Warning Check the brake linings for minimum thickness f I Minimum thickness f I 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings a p 139 Check the br...

Page 142: ...s with brake cleaner when necessary Warning Danger of accidents Brake linings which have not been approved alter the braking efficiency Not all brake linings are tested and approved for Husqvarna motorcycles The structure and friction coefficient of the brake linings and thus their brake power may vary greatly from that of original brake linings If brake linings are used that differ from the origi...

Page 143: ... pins pull out pin C and remove the brake linings Clean the brake caliper and brake caliper support Check that leaf spring 0 in the brake caliper and sliding plate D in the brake caliper support are seated correctly The arrow on the leaf spring points in the rotation direc tion of the brake disc Insert the new brake linings insert pin C and mount cotter pins Info I Always change the brake linings ...

Page 144: ...o free travel on the foot brake lever pressure builds up in the brake system on the rear brake Set the free travel on the foot brake lever in accordance with the specification l 402026 10 Disconnect spring O Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel f Guideline Free travel at foot brake lever 3 5 mm 0 12 0 ...

Page 145: ...ssary adjust the basic position of the foot brake lever Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in Hold screw D and tighten nut Guideline Nut foot brake lever MB stop 20 Nm 14 8 lbf ft Hold push rod 0 and tighten nut 8 Guideline Remaining nuts chassis Reconnect spring O M6 Checking the rear brake fluid level Warning 10 Nm 7 4 lbf ft Danger of accidents An insufficient brake fluid...

Page 146: ... brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the fro...

Page 147: ...o contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Environmental hazard Haza...

Page 148: ... pressure gauge 6 If necessary adjust the filling pressure at pressure regulator Ci Guideline I Filling pressure I 2 2 5 bar 29 36 psi Pull off protection cap 8 of the bleeder screw Connect the hose of the bleeder bottle I Bleeding device 00029013100 p 318 Open bleeder screw 0 by approx one half turn Info I Bleed until new brake fluid emerges from the bleeder bottle hose without bubbles Tighten th...

Page 149: ...t Correct the brake fluid up to marking I Brake fluid DOT 4 Ii p 314 Fit and tighten plug with oil screen and 0 ring Info Clean up overflowed or spilt brake fluid immediately with water Check the foot brake lever for a firm pressure point 147 ...

Page 150: ...changes to the next menu item The 0 symbol flashes Press one of the buttons to select the 24h or 12h display of the clock Wait for 5 seconds Combination instrument changes to the next menu item The 0 symbol flashes Resetting the time Press the left button The value decreases Advancing the time Press the right button The value increases Wait for 5 seconds Combination instrument changes to the next ...

Page 151: ...the buttons to select UNIT for the speed in kilo meters KM H or miles M H um II KM H 401909 01 17 3 Adjusting the clock 401911 01 401912 01 Condition The motorcycle is stationary Press and hold both buttons for 3 5 seconds The Setup menu is displayed The UNIT display flashes Wait for the menu of the clock 0 to flash Press one of the buttons to select the 24h or 12h display of the clock Wait for 5 ...

Page 152: ...alue decreases Enlarging the wheel circumference Press the right button The value increases Finishing work Disconnect speedometer connector CZ 17 5 Ad usting the service dis la l 7 _ _ 15 nn ART I I LIU 401913 01 150 Condition The motorcycle is stationary Press and hold both buttons for 3 5 seconds The Setup menu is displayed The UNIT display flashes Wait for the menu of the service display to fla...

Page 153: ...ine I Distance e 15 m 16 ft The rider now sits down on the motorcycle Switch on the low beam Check the headlight setting The boundary between light and dark must be exactly on the lower mark for a motorcycle with rider If the light dark border does not meet specifications Adjust the headlight range 0 p 151 Preparatory work Check the headlight setting 0 p 151 Main work Loosen screw O Adjust the hea...

Page 154: ...with a lift stand Jl p 12 Remove the right side cover Jl p 91 Remove the main silencer Jl p 82 Remove the seat Jl p 92 Remove the fuel tank p 93 Main work Remove screw O Disconnect the negative cable of the battery Loosen hose clip Pull back the protection cap Unplug connector 8 Push back hose clamp C Pull off the air release hose ...

Page 155: ...rew D on both sides Repeat these steps on the opposite side Pivot up the subframe and secure it Remove screw Swing the shock absorber to the rear Remove springs I Spring hook 50305017000 p 320 Remove screw Take off the manifold 18 ENGINE 153 ...

Page 156: ... cover Remove nut Ci Take off the cable Loosen hose clip 4D Pull off the radiator hose Detach spring 48 Remove screw G Remove screw 4D Take off the engine sprocket cover Remove the connecting link of the chain Take off the chain ...

Page 157: ...the clutch lever while the slave cylin der of the clutch is removed Unplug connector Gs Unplug connector D Pull back the protection cap Unplug connector Gi Detach the spark plug connector Loosen hose clip 41 Pull off the throttle valve body to the rear Loosen hose clip 6i Pull off the radiator hose Remove fittings Take off the engine braces 155 ...

Page 158: ... engine sideways Info The help of an assistant is useful in this step Make sure that the engine is sufficiently secured against falling over Protect the frame and attachments against damage Main work Position the engine in the frame Mount screws O but do not tighten yet Guideline Engine attachment bolt M10 60 Nm 44 3 lbf ft ...

Page 159: ... Tighten screws O and nut 8 Guideline Engine attachment bolt Nut swingarm pivot Mount the radiator hose M10 M16x1 5 Position and tighten hose clip 8 Mount the throttle valve body Position and tighten hose clip 0 Plug in connector 3 Position the protection cap Plug in connector Plug in connector C Mount the spark plug connector I 100 Nm 73 8 lbf ft I 33 Nm 24 3 lbf ft Loctite 2701TM 60 Nm 44 3 lbf ...

Page 160: ...ith connecting link Gi Guideline The closed side of the chain joint lock must face in the direction of travel Position the engine sprocket cover Mount and tighten screw 48 Guideline Screw clutch slave cylinder M6 Mount and tighten screw G Guideline Remaining screws chassis Mount spring G Mount the radiator hose MS Position and tighten hose clip 4D 10 Nm 7 4 lbf ft 25 Nm 18 4 lbf ft ...

Page 161: ...n the manifold and mount springs 4D I Spring hook 50305017000 a p 320 Mount and tighten screw 48 Guideline Remaining screws chassis M8 Position the shock absorber Mount and tighten screw G Guideline Screw top M10 shock absorber 25 Nm 18 4 lbf ft 60 Nm 44 3 lbf ft Loctite 2701 TM 159 ...

Page 162: ...ws G Guideline Screw sub frame Remove screw M8 Mount and tighten screw Guideline Screw sub frame M8 35 Nm 25 8 lbf ft Loctite 2701TM 35 Nm 25 8 lbf ft Loctite 2701TM Repeat these steps on the opposite side Mount the vent hose Position hose clamp m Plug in connector 9 Position the protection cap Position and tighten hose clip ...

Page 163: ...W 50 0 p 314 Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Start the engine and check that it is oil tight Switch off the engine Check the engine oil level a p 238 Check t...

Page 164: ...for work stand 77229002000 p 325 Engine work stand 80329001000 a p 328 Mount the engine on the special tool Info Work with an assistant or a motorized hoist Removing the clutch push rod Removing the spacer Draining the engine oil Remove clutch push rod O Remove spacer O of the countershaft Remove 0 ring Remove plug O with oil screen and the 0 rings ...

Page 165: ...ring Remove oil drain plug D with the O ring Completely drain the engine oil Remove screws O Remove the oil filter cover 8 with the O ring Pull oil filter D out of the oil filter housing I Lock ring plier 51012011000 I p 320 Remove the spark plug using special tool O I Spark plug wrench with link 77229172000 I p 327 41 41 163 ...

Page 166: ...Remove screws O Remove the valve cover with the valve cover seal Remove gasket Remove spark plug shaft insert D Removing the alternator cover Remove screws O Take off the alternator cover Take off alternator cover gasket D Dowels remain in the engine case ...

Page 167: ... counterclockwise until marking O is flush with the edge of the cylinder head Remove screw O Info 18 ENGINE Check through the hole whether the position notch of the crankshaft is visible Mount and tighten screw O without the washer 18 3 11 Removing the timing chain tensioner 309267 10 Loosen screw O Remove screw 8 with the seal ring 165 ...

Page 168: ...nd remove screws O from the outside to the inside Take off guide rail Take off the camshaft bearing bridge Info Ensure that the dowel pins remain in place Take the timing chain from the camshaft gear Remove the camshafts Remove nut O with the washer Loosen nuts 8 in a crisscross pattern and remove them with the washers Remove the cylinder head 41 41 ...

Page 169: ...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 Take off cylinder base gasket 8 Remove screw O 167 ...

Page 170: ...pecial tool and pull off the rotor by turning the screw in Puller 58012009000 I p 321 Info I Ensure that the woodruff key remains in place Remove screws 8 Take off the alternator cover Take off gasket 0 Info Ensure that the dowel pins remain in place Remove screws D and the starter motor Remove lock ring Take off the starter idler gear with the washer ...

Page 171: ...18 3 16 Removing the suction pump Remove freewheel gear D Remove screws O Take off oil pump cover 8 Remove O ring Take off suction pump C Remove needle roller 0 18 ENGINE 169 ...

Page 172: ...the clutch cover 18 3 19 Removing the clutch discs 170 Remove screws 0 Take off the water pump cover Remove nut 8 Take off the two part water pump impeller Remove screws O Take off the clutch cover Remove the clutch cover seal Remove screws O Take off spring retainer ...

Page 173: ...on ring C Take off pressure cap 0 Remove clutch disc pack Q entirely Remove clutch pressure piece Bend up the lock washer Hold the inner clutch hub with the special tool Loosen nut 0 1 Holding wrench 51129003000 ll I p 320 Remove the nut with the lock washer Dispose of the lock washer 171 ...

Page 174: ...basket 8 Take off needle bearing 0 and collar sleeve D Push sliding plate O away from the shift drum locating unit 8 Remove shift shaft CD with the washer 18 3 22 Removing the shift drum locating unit 172 Remove screw O Push away locking lever 8 from shift drum locating unit CD and remove the shift drum locating unit Relieve tension from the locking lever ...

Page 175: ...er sleeve and spring Remove lock ring O Take off washer Take off oil pump idler gear D with the washer Remove lock ring C Take off washer Remove oil pump gear C Remove pin Remove screws Take off the oil pump cover Remove pin Push oil pump shaft Ci inward and take it out of the engine from the ignition side Remove force pump 8 173 ...

Page 176: ...p 75029090000 a p 325 Pull off primary gear 8 using the special tool I Puller 46129021000 p 319 Remove screw CD Remove screws O Remove timing chain guide rail 8 Remove timing chain tensioning rail CD Remove screw C Take off balancer shaft 0 together with the timing chain and timing chain securing guide Info I If the timing chain is to be reused mark the direction of travel Remove spacer O of the c...

Page 177: ...90000 p 325 Mount special tool 8 with the appropriate screws I Puller 77229048000 I p 327 Info I Use the drill hole marked with 772 Take off the section of the engine case Info Do not subject the section of the engine case to any stress The washer of the main shaft usually adheres to the bearing Take off the left section of the engine case Remove the special tool Remove shift rail O together with ...

Page 178: ...Tilt shift forks O to the side Info Do not misplace the shift rollers Remove shift drum 8 Remove shift forks O Info Do not misplace shift rollers 8 18 3 32 Removing the transmission shafts 176 Remove lock ring O Pull both transmission shafts 8 out of the bearing seats together ...

Page 179: ... and clean the engine case section thoroughly Warm the engine case section in an oven Guideline 11so 0 c 302 F Knock the engine case section against a level wooden plate This will cause the bearings to drop out of the bearing seats Info Any bearings that remain in the engine case section must be removed using a suitable tool Blow out oil nozzle D with compressed air and check that it is clear Guid...

Page 180: ...renewed Mount the dowels Press in shaft seal ring O of the crankshaft with the open side facing out so it is flush Mount and tighten nozzle 8 Guideline Nozzle crank M4 chamber venti lation Mount and tighten the oil nozzle D Guideline Oil nozzle for M4 conrod bearing lubrication 2 Nm 1 5 lbf ft Loctite 243 2 Nm 1 5 lbf ft Loctite 243 Mount the oil nozzle for piston cooling Mount and tighten screw C...

Page 181: ...sary use a suitable press drift to push them all the way in and make them flush Info When pressing the bearing in ensure that the engine case section is level to prevent damage Only press the bearings in via the outer bearing race otherwise the bearings will be damaged when they are pressed in After the engine case section has cooled check that the bearings are firmly seated Info If the bearings a...

Page 182: ... Position all bearing locks Mount and tighten screws D Guideline Locking screw for bearing M5 2 Nm 1 5 lbf ft Loctite 243 6 Nm 4 4 lbf ft Loctite 243 Blow out the oil channel with compressed air and check that it is clear Remove shaft seal ring O Remove lock ring 8 Remove shaft seal ring 5 Press out bearing C toward the inside ...

Page 183: ...ool Press in shaft seal ring O all the way with the open side facing outward Remove lock ring 0 Remove shaft seal ring Q 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 Blow out the oil channel with...

Page 184: ... valve Oil pressure regulator valve Minimu 7 length of pres 1 23 5 mm 0 925 in sure spring If the measured value does not meet specifications Change the spring Check ball C and the sealing seat If there is damage or wear Change the ball and machine the sealing seat Install ball C and pressure spring D Mount and tighten screw plug O with sealing washer 8 Guideline Plug oil pressure regulator valve ...

Page 185: ...Check the oil pump cover for damage and wear If there is damage or wear Change the oil pump cover 18 4 6 Removing the crankshaft bearing inner race Fix the crankshaft in the vise Info Use soft jaws Warm up special tool O Guideline 1150 C 302 F I Puller 58429037037 p 321 18 ENGINE Push the warmed up special tool O onto the crankshaft bearing inner race press firmly together and pull jointly from th...

Page 186: ...nd mount together Guideline 1120 C 248 F I Puller 58429037037 p 321 Repeat the operation 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 p 186 Changing the connecting rod conrod bearing and crank pin Main work Position crankshaft O in ...

Page 187: ...hly oil bearing Ci Position special tool 3 on the press Crankshaft pressing tool 75029047000 p 324 Crankshaft pressing tool insert 77029008000 0 p 325 Insert the crank web with connecting rod and bearing Posi tion the second crank web Position special tool with the heel pointing down I Crankshaft pressing tool insert 77029008000 lll l p 325 Press in the upper crank web as far as possible Info The ...

Page 188: ... bearing pin 5 0 03 mm 5 0 0012 in If the crankshaft run out at the bearing pin is larger than the specification Align the crankshaft 18 4 10 Measuring the crankshaft end play 186 Insert the crankshaft into the right section of the engine case Info I Do not forget the fitted bushings Mount the left section of the engine case Mount and tighten screws Guideline I Screw engine case I M6 110 Nm 7 4 lb...

Page 189: ...4 12 Installing the drive wheel of the balancer shaft 303077 10 18 4 13 Cylinder Nikasil coating 308787 10 Ensure that woodruff key O is seated properly Warm drive wheel 8 of the balancer shaft and push it onto the balancer shaft Guideline 1100 oc 212 OF 41 Nikasil is a surface protection layer for a coating procedure developed by Mahle The name is derived from the two materials used in this proce...

Page 190: ...auge 59029041100 a p 322 Cylinder cylinder head dis 5 0 10 mm 5 0 0039 in tortion of sealing area If the measured value does not meet specifications Change the cylinder 18 4 15 Checking measuring the piston 188 e 400995 10 308788 10 Use the special tool to measure clearance t of the piston rings in the piston ring groove Guideline Piston ring groove clear ance 5 0 08 mm 5 0 0031 in I Feeler gauge ...

Page 191: ...es to the piston pin at a distance G Guideline Distance 0 27 mm 1 06 in Piston diameter Size I 77 955 77 965 mm 3 06909 3 06948 in Size II 77 965 77 975 mm 3 06948 3 06988 in Info Piston dimensions O are marked on the piston head 18 4 16 Measuring the piston cylinder mounting clearance 308787 10 Check measure the cylinder I p 188 Check measure the piston I p 188 The smallest piston cylinder mounti...

Page 192: ...is greater than the specified measurement Check measure the cylinder il l p 188 If cylinder wear lies within the specified tolerance Replace the piston ring Mount the piston ring with the marking facing toward the pis ton head Check the camshaft for damage and wear If there is damage or wear Change the camshaft If the surface of the cams is damaged check the oil supply to the camshaft and cam leve...

Page 193: ...bearing bridge 0 Mount and tighten the screws Guideline Screw M7x1 14 Nm 10 3 lbf ft camshaft Lubricated with engine bearing bridge Info Ensure that the dowel pins are seated properly Do not turn the camshaft oil Remove camshaft bearing bridge O again Compare the Plastigauge clearance gauge with the specifications on the packaging Guideline Camshaft bearing sleeve bearing Radial clearance 0 020 0 ...

Page 194: ... the valve spring using the special tool Valve spring mounter 59029019000 fl p 322 Insert for valve spring lever 77229060000 fl p 327 Remove the valve keys and unload the valve spring Remove the valve spring retainer and valve springs Mark the valve spring according to its normal built in posi tion Pull the valve down out of the valve guide Remove valve stem seal C with the special tool I Valve st...

Page 195: ... in If the sealing seat is not centered on the valve seat or deviates from the specification Rework the valve seat Check the valve springs for breakage and wear visual check Info 18 ENGINE Intake valves are marked with a green color coding Exhaust valves are marked with a brown color coding If the valve spring is broken or worn Change the valve spring Measure the length of the valve springs Valve ...

Page 196: ...am 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 p 326 If the special tool is easy to insert in the valve guide Change the valve guide and valve Check the sealing area of the spark plug thread and the valve seats from damage and cracking If there is damage or crack...

Page 197: ...orresponding to its installation position Mount the valve spring with the tighter coil facing downward according to the built in position Info Intake valves are marked with a green color coding Exhaust valves are marked with a brown color coding Mount the valve spring retainers Pre tension the valve spring using the special tool Valve spring mounter 59029019000 0 p 322 Insert for valve spring leve...

Page 198: ...ug 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 starter wheel O If the freewheel gear does not turn clockwise or if it does not lock counterclockwise Change the free wheel Remove lock ring O ...

Page 199: ...ry gear Thoroughly oil all parts Slide freewheel O into the primary gear Info Note the direction of rotation Mount spreader ring 8 18 ENGINE Ensure that all lugs of the expansion ring pass through slots 6 of the free wheel and engage in groove 0 of the primary gear Mount lock ring 8 197 ...

Page 200: ...mage and wear If there is damage or wear Change the freewheel gear or bearing Check freewheel C for damage and wear If there is damage or wear Change the free wheel Check the gear mesh of starter motor 0 for damage and wear If there is damage or wear Change the starter motor Change O ring C of the starter motor Connect the negative cable of a 12 volt power supply to the housing of the starter moto...

Page 201: ... 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 8 for damage and wear If there is damage or wear Change the camshaft Check timing chain 0 for damage and wear If there is damage or wear Change the timing chain 306753 10 Let the timing chain hang dow...

Page 202: ... go in all the way Guideline Thickness of the compen sating disks 2 2 5 mm 0 08 0 098 in Release the timing chain tensioner The detent mechanism engages and the piston remains in place Final position of the pis ton after engagement Info 3 mm 0 12 in This position is necessary for installation If the timing chain tensioner is now pressed again and is only extended a maximum of half way it is pre ve...

Page 203: ...ing Check spring washer 0 for damage and wear If there is damage or wear Change the spring washer Check the contact surface of pressure cap D for damage and wear If there is damage or wear Change the pressure cap Check clutch center for damage and wear If there is damage or wear Change the clutch center Check damping rubber pieces fD for damage and wear If there is damage or wear Change the dampin...

Page 204: ...facing discs CD I Clutch facing discs thickness of total package I 26 4 mm 1 039 in If the clutch facing disc does not meet specifications Change all clutch facing discs 18 4 35 Checking the shift mechanism Check shift forks Q on disc 6 for damage and wear visual check If there is damage or wear Change the shift fork Check shift grooves G of shift drum 8 for wear If the shift groove is worn Change...

Page 205: ...ere is severe grooving Change the sliding plate Check guide bolts 4 for firm seating and wear If the guide bolts are loose or worn Change the sliding plate Preassemble the shift shaft p 203 305009 10 18 4 36 Preassembling the shift shaft 305010 10 Check clearance O between the sliding plate and the shift quadrant Shift shaft sliding plate shift quadrant clearance 0 40 0 80 mm 0 0157 0 0315 in If t...

Page 206: ...d in the bench vise Guideline I Use soft jaws Remove stop disk O and second gear fixed gear f Remove sixth gear idler gear D Remove needle bearing C and stop disk 0 Remove lock ring D Remove third fourth gear sliding gear Remove lock ring fD Remove stop disk 0 and fifth gear idler gear Remove needle bearing 48 204 ...

Page 207: ...isk C Remove sixth gear sliding gear 0 Remove lockring D Remove stop disk Remove third gear idler gear and needle bearing Remove fourth gear idler gear Gi Remove needle bearing a Remove stop disk 48 Remove lockring 41 Remove fifth gear sliding gear I Remove lockring 48 Remove stop disk Remove second gear idler gear G and needle bearing 18 4 39 Checking the transmission Condition The transmission h...

Page 208: ...8 and sliding gears 0 for damage and wear If there is damage or wear Change the gear wheel pair Check the tooth faces of idler gears 8 sliding gears 0 and fixed gear 3 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 operati...

Page 209: ...aring 0 and mount fifth gear idler gear 8 with the shift dogs facing up Mount stop disk CD and lock ring e Attach third fourth gear sliding gear 0 with the small gear wheel facing downward and mount lock ring D Mount stop disk and needle bearing fD Mount sixth gear idler gear Q with the shift dogs facing downward Mount second gear fixed gear 41 with the collar facing downward and mount stop disk 4...

Page 210: ...op disk and lockring C Mount the sixth gear sliding gear 0 with the shift groove facing up Mount lockring D and stop disk Mount needle bearing D and the fourth gear idler gear with the collar facing up Mount needle bearing i and the third gear idler gear 48 with the collar facing down Mount stop disk 48 and lockring 41 Mount the fifth gear sliding gear e with the shift groove facing down and stop ...

Page 211: ...haft Position the right section of the engine case in the engine work stand Oil the bearing Push crankshaft O into the bearing seat Installing the transmission shafts Oil the bearing Slide both transmission shafts O into the bearing seats together Mount lock ring 209 ...

Page 212: ...haft Mount shift fork 8 in the lower shift groove of the counter shaft Mount shift fork 8 in the upper shift groove of the counter shaft Slide on shift rollers C Tip Fix the shift rollers in the shift forks with grease Push shift drum O into the bearing seat Put shift forks 8 in the shift drum Info Do not misplace the shift rollers Install shift rail O together with upper spring 8 and the lower sp...

Page 213: ...y with a rubber mallet and turn the transmission shafts Info I Do not use the screws to pull the two sections of the engine case together Mount screws O but do not tighten yet Guideline I Screw engine case I M6x55 110 Nm 7 4 lbf ft Mount screws but do not tighten yet Guideline I Screw engine case I M6x65 10 Nm 7 4 lbf ft Mount screws D and tighten all screws in a crisscross pat tern Guideline I Sc...

Page 214: ... before ensure it is run ning in the correct direction Mount and tighten screw Guideline Screw timing M6 10 Nm 7 4 lbf ft chain securing Loctite 243 guide Position timing chain guide rail D Mount and tighten screw C Guideline Screw timing M6 chain guide rail 10 Nm 7 4 lbf ft Loctite 243 Position timing chain tensioning rail 0 Mount and tighten screw D Guideline Screw timing MB chain tension ing ra...

Page 215: ... Oil the oil pump shaft internal rotor and external rotor before assembly Position force pump O The rounded side of the force pump faces the engine case Mount the oil pump shaft from the ignition side Mount pin 5 Position the oil pump cover Marking 6 faces upward Mount and tighten screws C Guideline Screw oil pump M5 cover 6 Nm 4 4 lbf ft Loctite 243 Insert pin 0 Position oil pump gear D Mount was...

Page 216: ...ock ring m 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 Mount O ring s Position the oil pump cover C Mount and tighten screws 0 Guideline Screw oil pump M5 cover 6 Nm 4 4 lbf ft Loctite 243 ...

Page 217: ...cating unit and position the shift drum locating unit Info I The flat areas of the shift drum locating unit are not symmetric Relieve tension from the locking lever Mount and tighten screw 8 Guideline Screw shift drum locating M6 10 Nm 7 4 lbf ft Loctite 243 Slide shift shaft O with the washer into the bearing seat Push sliding plate 8 away from the shift drum locating unit 8 Insert the shift shaf...

Page 218: ...ount nut D Tighten the nut holding the inner clutch hub with a special tool Guideline Nut inner clutch hub M18x1 5 100 Nm 73 8 lbf ft Loctite 243 I Holding wrench 51129003000 a p 320 Secure the nut with the lock washer Thoroughly oil the clutch facing discs Beginning with an intermediate clutch disc alternately insert all other clutch facing discs and intermediate clutch discs into the clutch bask...

Page 219: ...ring D with marking Top facing up Position spring washer C Position spring retainer 0 with marking I Mount screws s and tighten in a crisscross pattern Guideline I Screw clutch spring M5 I 6 Nm 4 4 lbf ft 18 ENGINE 217 ...

Page 220: ...rtion 0 0 10 mm 0 0 0039 in If the specified value is not reached Remove screws CD and mount the spring retainer with marking Ill Using a straightedge and the special tool check the spring washer for distortion I Feeler gauge 59029041100 ll l p 322 Spring washer distortion 0 0 10 mm 0 0 0039 in If the specified value is not reached Change the clutch facing discs Create the tool special screw A con...

Page 221: ...s pattern 18 5 18 Installing the water pump cover Mount the two part water pump impeller O Mount and tighten nut Guideline Nut water pump wheel M6 5 Nm 3 7 lbf ft Loctite 243 Mount the water pump cover with the seal ring Info Ensure that the dowel pins are seated properly Mount screw D with the seal ring but to not tighten yet Guideline Screw water pump cover M6x25 Mount screw 8 but do not tighten...

Page 222: ...0 Nm 7 4 lbf ft Mount the starter idler gear with the washer Mount lock ring 8 Grease the O ring Position the starter motor Mount screws D but do not tighten yet Guideline I Screw starter motor M6 Position gasket 8 Info 10 Nm 7 4 lbf ft I Ensure that the dowel pins are seated properly Position the alternator cover 41 ...

Page 223: ... Mount the rotor Info To simplify installation turn the starter idler gear coun terclockwise Mount and tighten screw D Guideline Rotor screw M10x1 70 Nm 51 6 lbf ft Shift the gap of the piston rings by 120 Thread oiled with engine oil cone degreased Place the special tool onto the oiled piston Clamp the piston rings together using the special tool I Piston ring mounting tool 60029015000 a p 323 Th...

Page 224: ...ston marking G 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 Feed the timing chain through the chain shaft Mount the piston pin Info For purposes of illustration the following operations are shown on the removed piston Position the piston ...

Page 225: ...r piston ring lock 77729030100 ll JI p 328 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 Position cylinder head gasket 0 Info I Ensure that the dowel pins are seated properly Put the cylinder head in place Mount nuts 8 with the washers and tighten in a crisscr...

Page 226: ...d tighten nut fD Guideline Nut cylinder M6 10 Nm 7 4 lbf ft head Lubricated with engine oil Pull up the timing chain and insert the intake camshaft O Place the timing chain over the camshaft gear of intake camshaft 411 Marking O is positioned and is aligned with the edge of the cylinder head Ensure that bleeder 8 is correctly positioned Slip in exhaust camshaft fD Place the timing chain over the c...

Page 227: ...ridge 18 5 23 Installing the timing chain tensioner oil Position timing chain tensioner O and insert it with new 0 ring Mount and tighten screw plug with the seal ring Guideline Plug timing chain tensioner M24x1 5 40 Nm 29 5 lbf ft Remove screw C Press the timing chain tensioner toward the timing chain using special tool 0 Release device for timing chain tensioner 61229021000 p 324 The timing chai...

Page 228: ...cam levers Guideline Valve clearance Intake at 20 C 68 F 0 10 0 15 mm 0 0039 0 0059 in Exhaust at 20 C 68 F 0 13 0 18 mm 0 0051 0 0071 in I Feeler gauge 59029041100 p 322 If the valve clearance does not meet specifications Adjust the valve clearance p 226 Mount and tighten screw O with the washer Guideline Screw plug crankshaft location M8 10 Nm 7 4 lbf ft 18 5 25 Adjusting the valve clearance 226...

Page 229: ...alve clearance a p 226 Position torque limiter O Position the alternator cover gasket O Position the alternator cover Mount screws 8 and tighten once all of the alternator cover screws have been mounted Guideline Screw alternator cover M8x30 6 Nm 4 4 lbf ft Mount screws 8 and tighten once all of the alternator cover screws have been mounted Guideline Screw alternator cover M8x50 6 Nm 4 4 lbf ft Mo...

Page 230: ... M8x25 6 Nm 4 4 lbf ft Grease O rings and mount spark plug shaft insert 0 Position gasket 8 Apply a thin layer of sealing compound in area G I Loctite 5910 Position the valve cover with the gasket Mount and tighten screws fD Guideline I Screw valve cover I M6 I 8 Nm 5 9 lbf ft 41 41 ...

Page 231: ...plug wrench with link 77229172000 p 327 Tilt the motorcycle to one side and fill the oil filter housing to about full with engine oil Insert oil filter O into the oil filter housing Oil the O ring of the oil filter cover Mount oil filter cover 8 Mount and tighten screws Guideline I Screw oil filter cover I M6 110 Nm 7 4 lbf ft Mount and tighten screw plug O with the O ring Guideline I Oil drain pl...

Page 232: ...oil screen with O rings onto a pin wrench Push the pin wrench through the opening into the drill hole of the opposite engine case wall and push the oil screen as far as possible into the engine case Mount and tighten screw plug D with the O ring Guideline Screw plug oil screen M20x1 5 15 Nm 11 1 lbf ft Grease the shaft seal ring before mounting Position the O ring Mount spacer O with the bevel fac...

Page 233: ...engine assembly stand Remove the screw connection from the special tool 18 ENGINE I Holder and fitting for work stand 77229002000 p 325 Remove the engine from the engine assembly stand Info I Work with an assistant or a motorized hoist 231 ...

Page 234: ... of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info The fluid level rises with increasing wear of the clutch facing discs Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and clutch lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attac...

Page 235: ...C with the appropriate hydraulic fluid Syringe 50329050000 l p 320 Brake fluid DOT 4 l p 314 On the clutch slave cylinder remove bleeder screw 0 and mount bleeding syringe C Inject the liquid into the system until it escapes from open ings D of the master cylinder without bubbles To prevent overflow drain fluid occasionally from the master cylinder reservoir Remove the bleeding syringe Mount and t...

Page 236: ...n provides extra cooling It is controlled by a ther moswitch Checking the antifreeze and coolant level Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not open the radiator the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature Allow the cooling system and the engine to cool do...

Page 237: ...gine to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediate...

Page 238: ...iately with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing Condition The engine is cold Position the motorcycle upright Place a suitable container under the water pump cover Remove screw O Take off radiator cap Completely drain the coolant Moun...

Page 239: ...w O is tightened Stand the vehicle upright Pour coolant in up to measurement 6 above the radiator fins Guideline I 10 mm 0 39 in I Coolant 11 2 I 1 3 qt I Coolant p 314 Refit the radiator cap Finishing work Take a short test ride Check the coolant level p 235 237 ...

Page 240: ...ion Suction pump 41 Oil channel transmission lubrication 48 Timing chain tensioner 401362 60 21 2 Checking the engine oil level 238 Preparatory work Stand the motorcycle upright on a horizontal surface Condition The engine is cold Check the engine oil level The engine oil reaches the lower edge of level viewer e If the engine oil does not reach the lower edge of the level viewer Add engine oil a p...

Page 241: ...e event of scalding rinse the area affected immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Drain the engine oil only when the engine is warm Preparatory work Park the motorcycle on a level surface Remove t...

Page 242: ...ain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Remove screws C Remove the oil filter cover with the O ring Pull oil filter 0 out of the oil filter housing I Lock ring plier 51012011000 I p 320 Completely drain the engine oil Thoroughly clean the parts and sealing area Lay the motorcycle on its side and fill the oil filter housing to about full with engine oil Fill the oil filter with engine oil an...

Page 243: ...g with 0 ring Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Start the engine and check that it is oil tight Finishing work Check the engine oil level JI p 238 Insta...

Page 244: ...esult in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Start the engine and check that it is oil tight Finishing work Check the engine oil level Ip 238 21 5 ine oil pressure 242 Check the engine oil level p 238 Remove the release screw of the chai...

Page 245: ... C 176 F Engine speed 1 600 rpm Engine oil temperature 80 C 176 F Engine speed 6 000 rpm 0 9 bar 13 psi 2 5 bar 36 psi If the measured value is less than the specification Check the oil pumps for wear Check that all oil holes are clear Switch off the engine Warning Danger of burns Some vehicle components get very hot when the machine is driven Wear appropriate protective clothing and safety gloves...

Page 246: ...spark plug connector 1 601170 10 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 checkin the stator windin EZ 601211 10 Condition The stator is disconnected Pre...

Page 247: ...e the stator Stator winding check for a short circuit to ground terminal 31 Measure the resistance between the specified points Stator connector EZ pin 1 Measuring point Ground I Resistance I oo Q 22 4 If the value displayed does not meet specifications Change the stator Removing the stator and crankshaft osition sensor 305319 10 305320 10 Condition The alternator cover has been removed Remove scr...

Page 248: ...e Oil nozzle for M4 2 Nm 1 5 lbf ft alternator cool Loctite 243 ing Position the stator in the alternator cover Mount and tighten screws 8 Guideline Screw stator M5 Position cable retainer plate 6 Nm 4 4 lbf ft Loctite 243 Position the cable sleeve in the alternator cover Position the crankshaft position sensor with the cable retainer plate in the alternator cover Position the retaining bracket Mo...

Page 249: ...ect spark plug connector Remove the spark plug with special tool 8 I Spark plug wrench with link 77229172000 p 327 Remove right radiator shield e Remove screws 0 Pivot the radiator forward slightly on the right Remove fittings 0 Take off the engine braces Push back hose clamp Pull off the air release hose Remove screws Remove the valve cover with the gasket to the right 247 ...

Page 250: ...le to check that the position notch of the crankshaft is visible Mount and tighten screw a without the washer On all valves check the valve clearance between the camshaft and cam lever with the special tool Guideline Valve clearance Intake at 20 C 68 F 0 10 0 15 mm 0 0039 0 0059 in Exhaust at 20 C 68 F 0 13 0 18 mm 0 0051 0 0071 in I Feeler gauge 59029041100 l l p 322 If the valve clearance does n...

Page 251: ...and tighten screw Gi Guideline 10 Nm 7 4 lbf ft Screw alternator cover M24x1 5 18 Nm 13 3 lbf ft Clean and degrease the sealing surface Apply a thin layer of sealant to area I Loctite 5910 Mount gasket 0 Pivot the radiator forward slightly on the right Position the valve cover with the gasket Mount and tighten screws Guideline I Screw valve cover I M6 I 8 Nm 5 9 lbf ft Mount the vent hose and hose...

Page 252: ...m 7 4 8 9 lbf ft I Spark plug wrench with link 77229172000 0 p 327 Plug in spark plug connector 8 Plug in the connector and position cover O Finishing work Install the fuel tank 0 p 94 Mount the seat 0 p 92 Adjusting the valve clearance Info For purposes of illustration the following operations are shown with the engine removed Removal is not necessary Preparatory work Remove the seat 0 p 92 Remov...

Page 253: ... O Correct the shims based on the results of the valve clearance check Finishing work Install the camshafts a p 224 Install the timing chain tensioner I p 225 Check the valve clearance I p 247 Install the fuel tank 0 p 94 Mount the seat 0 p 92 251 ...

Page 254: ...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 to connector O of the starter motor If the starter motor does not turn when the circuit is closed Change the starter motor ...

Page 255: ...the idle speed adjusting screw Guideline I Idle speed I 2 050 2 150 rpm Executing the initialization run Condition Info Turn counterclockwise to increase the idle speed Turn clockwise to decrease the idle speed The diagnostics tool is connected and running Execute Engine electronics Functions Delete adaptation values The adaptation values are deleted Select Engine electronics Measured values Coola...

Page 256: ...aches the specified temperature Guideline I Coolant temperature Info I so 90 c 176 194 F I Do not operate the throttle grip during the initialization process As soon as the specified temperature is reached switch off the ignition Info If the initialization is not completed or the initializa tion process is interrupted the entire process must be restarted ...

Page 257: ...nder bearings 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 Transmission ratio 1st gear 13 32 2nd gear 16 30 3rd gear 16 24 4th gear 23 28 5th gear...

Page 258: ...ylinder mounting clearance Size I 0 035 0 057 mm 0 00138 0 00224 in Size II 0 037 0 060 mm 0 00146 0 00236 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 Connecting rod axial play of lower conrod bearing 0 20 0 45 mm 0 0079 0 0177 in Crankshaft run out at bearing pin s 0 03 mm s 0 0012 in Clutch facing discs thick...

Page 259: ... engine oil Nut water pump wheel M6 5 Nm 3 7 lbf ft Loctite 243 Screw alternator cover M6 8 Nm 5 9 lbf ft Screw clutch cover M6 10 Nm 7 4 lbf ft Screw clutch slave cylinder M6 10 Nm 7 4 lbf ft Screw engine case M6 10 Nm 7 4 lbf ft Screw exhaust flange M6 10 Nm 7 4 lbf ft Loctite 243 Screw oil filter cover M6 10 Nm 7 4 lbf ft Screw shift drum locating M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift lev...

Page 260: ... 5 M20x1 5 M24x1 5 M24x1 5 11 0 I 1 1 qt 11 2 I 1 3 qt Total fuel tank capacity approx FE EU AU Super unleaded ROZ 95 RON 95 PON 91 p 315 258 15 Nm 11 1 lbf ft Loctite 243 60 Nm 44 3 lbf ft Loctite 2701 15 Nm 11 1 lbf ft Loctite 243 70 Nm 51 6 lbf ft Thread oiled with engine oil cone degreased 10 Nm 7 4 lbf ft 8 Nm 5 9 lbf ft 10 12 Nm 7 4 8 9 lbf ft Tightening sequence Tighten diagonally 1st tight...

Page 261: ...arance unloaded Homologated weight without fuel approx FEEU AU Weight without fuel approx FE US Maximum permissible front axle load Maximum permissible rear axle load Maximum permissible overall weight Central tube frame made of chrome molybdenum steel tubing WP Performance Systems Up Side Down 4860 MXMA4CS 300 mm 11 81 in 330 mm 12 99 in 22 mm 0 87 in WP Performance Systems 5018 DCC Disc brakes b...

Page 262: ...T 140 80 18 M C 70R TT Michelin ENDURO COMPETI Michelin ENDURO COMPETI TION IV TION Ille FE US 90 90 21 54M TT 110 100 18 64M TT Dunlop GEOMAX AT 81 F Dunlop GEOMAX AT 81 The tires specified represent one of the possible series production tires Additional information is available in the Service section under www husqvarna motorcycles com 26 8 Fork Fork part number 24 18 7P 67 Fork WP Performance S...

Page 263: ...ICAL DATA 4 6 N mm 26 3 lb in 932 mm 36 69 in 100 mm 3 94 in 18 15 7P 67 Fork oil SAE 4 48601166S1 p 314 WP Performance Systems 5018 DCC 20 clicks 18 clicks 16 clicks 2 5 turns 2 turns 1 5 turns 20 clicks 18 clicks 16 clicks 17 mm 0 67 in 51 N mm 291 lb in 54 N mm 308 lb in 57 N mm 325 lb in 260 mm 10 24 in 10 bar 145 psi 30 mm 1 18 in 100 mm 3 94 in 490 mm 19 29 in Shock absorber fluid SAE 2 5 50...

Page 264: ...maining screws chassis Screw bottom shock absorber Screw handlebar holder 262 M5 M5x12 M6 M6 M6 M6 M6 M6 M6 M6 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8x20 M8x30 M8 M8 M10 M10 M10 M10 M10 5 Nm 3 7 lbf ft 1 5 Nm 1 11 lbf ft 4 Nm 3 lbf ft 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 6 Nm 4 4 lbf ft 14 Nm 10 3 lbf ft 14 Nm 10 3 lbf ft 5 Nm 3 7 lbf ft 10 Nm 7 4 lbf ft 20 Nm 14 8 lbf ft 35 Nm ...

Page 265: ...ngarm pivot M16x1 5 Nut rear wheel spindle M20x1 5 Screw front wheel spindle M20x1 5 Screw top steering head M20x1 5 Screw in nozzles cooling system M20x1 5 26 TECHNICAL DATA 60 Nm 44 3 lbf ft 15 Nm 11 1 lbf ft 80 Nm 59 lbf ft 80 Nm 59 lbf ft 80 Nm 59 lbf ft 100 Nm 73 8 lbf ft 80 Nm 59 lbf ft 35 Nm 25 8 lbf ft 12 Nm 8 9 lbf ft 12 Nm 8 9 lbf ft Loctite 2701 TM Loctite 243 263 ...

Page 266: ...t regularly Avoid direct sunshine when cleaning the motorcycle 7 11111111111111 401061 01 Close off the exhaust system to keep water from entering Remove coarse dirt particles with a gentle water jet Spray dirty parts with a normal commercial engine cleaner and then brush off with a soft brush Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner...

Page 267: ...operated in road salt clean it with cold water after riding Warm water would enhance the corrosive effects of salt 401060 01 Clean the motorcycle p 264 Clean the brake system Info I After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings in the cooled down and installed state with cold water and dry carefully After riding on salted roads thoroughly wash the vehi cle w...

Page 268: ...ing 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 Refuel Clean the motorcycle a p 264 Change the engine oil and oil filter clean the oil screen a p 239 Check the antifreeze and coolant level a p 234 Check the tire air pressure a p 107 401058 01 266 Remove the battery a p 128 Recharge the battery Guideline St...

Page 269: ...GE Pre aring for use after storage 401059 01 Remove the motorcycle from the lift stand illll p 12 Install the battery lillll p 129 Perform checks and maintenance measures when preparing for use Take a test ride 267 ...

Page 270: ... I I I Check the chain rear sprocket engine sprocket and chain guide I p 118 I Check the chain tension I p 117 0 I Grease all moving parts e g side stand hand lever chain and check for smooth operation I I Check correct the fluid level of the hydraulic clutch a p 232 I I Check the front brake fluid level I p 136 I I I Check the free travel of the hand brake lever a p 134 I I I Check the play of th...

Page 271: ...3 Lubricate the steering head bearing a p 35 Clean the spark arrestor FE US p 85 Perform a fork service a p 18 Service the shock absorber p 54 Change the spark plug and spark plug connector Change the piston Check measure the cylinder Check the cylinder head Change the valves valve springs and valve spring seats Check camshaft and cam lever Change the connecting rod conrod bearing and crank pin Ch...

Page 272: ...10 f A I n D X2 l 1 w w E C0 E a C nr F c I I z tel HUS Yl 1 2 a I 3 I II G10 1 X300 l 1 FE 250 EU 2016 I 3 I 4 521 4 n 5 BR 4 l x4 l K 4 i i R 4 X4 1 s 5 I 6 I 7 I I I 6 I 7 I 8 1Wl rd a 2 E1 lW t b 2 F1 ha 8 A f B C f D f E f F 0 r 11 ...

Page 273: ...Components G10 Battery K10 Starter relay with main fuse M10 Electric starter system S21 E tip switch 30 WIRING DIAGRAM 271 ...

Page 274: ...I 1 X10 1 1 rrDY 4 I 1 X9 1 5 1 X295 AP 6 1 t3 i iEB 4 ij f EB 4 I 1 X3 1 1 1 EB aC wlHdl e i t 1 B33 Lf l M1 4 4 2 N BV 2o J C l BS 2 1 X285 l I i xs t7 j J i j F 4 J 2 F J J 2 X 40 111 F J 2 1FJ 2 X39 1 xs X7 t 1 L_JI t IfI l b 3 E1 1 FB bC tr 0 _ tr t b 7 F1 tel HUS Yl FE 250 EU 2016 2 8 C II r C II ...

Page 275: ...ts A11 EFI control unit B33 Radiator fan temperature switch F3 Fuse F4 Fuse G20 Alternator K12 Light relay K30 Power relay M14 Radiator fan T20 Voltage regulator X295 Diagnostics connector 30 WIRING DIAGRAM 273 ...

Page 276: ... EB bl 11 _ f ma I 274 1 1 I S22 3 I I jJ AC 6 I BC 6 I I E E JJ tf X48 X47 X48 0 1t I I FE 250 EU 2016 I 3 I 4 4 5 l C 0 o I l l FP 1 D1 2 I J m m 1 BP 4 1 DG 4 X46 i m t i w C 0 o IILJ X24 X21 X31 i I I 5 I 6 6 I I I 8 P13 6 AI 0 ww12 1 XSO E1s B lll t 4 BI C X46 DG 4 BP 4 X22 D z z l Ol l e l4EI 11 b 14EI E f 318 I I I 8 D00153 01 ...

Page 277: ...Components A11 EFI control unit E13 Low beam high beam P13 Speedometer P15 Horn P35 Parking light S22 Light switch horn button kill switch 30 WIRING DIAGRAM 275 ...

Page 278: ...f H 2 f H 2 X18 X19 l sl w w 3 ES et ye OO E C0 a v C nr E 3 EB b C t F C c I 1 z FE 250 EU 2016 HUSQl l ma 1 2 I 3 I 4 5 I a 6 I I I l 1 X13 BY 4 P36 7 l X11 V 4 i i Y 4 X13 I I I I 6 I 7 I I D1 2 I X14 I 7 I 8 A f B I 1y bu 1 e 5 B1 E ic C X11 CV 4 f r X17 D 1 f E f F hm 8 0 r 11 ...

Page 279: ...Components B76 Front brake light switch B77 Rear brake light switch E60 License plate lamp P36 Brake tail light 30 WIRING DIAGRAM 277 ...

Page 280: ...2 R 13 i D X45 f J 3 X42 i i w w E C0 a It C nr E F C c I IU z tel FE 250 EU 2016 HUS Yl 1 2 I 3 I a 4 5 I l I I j X23 j X25 j X41 CX 2 CX 2 CX 2 P46 P41 W 2 W 2 W 2 i CX 2 l X 2 l X 2 X23 X25 X41 I I 4 5 I 6 I I X28 CX 2 P45 W 2 i CX 2 X28 I 6 I 7 I 8 I I 7 I 8 A f B C f D f E f F hm C0 r 11 ...

Page 281: ...nts K20 Turn signal relay P21 Turn signal indicator lamp P41 Turn signal front left P42 Turn signal front right P45 Turn signal rear left P46 Turn signal rear right S25 Turn signal switch 30 WIRING DIAGRAM 279 ...

Page 282: ...X29 t w w E C0 a co C nr E F c I I z FE 250 EU 2016 HUSQl l ma 1 2 I 3 I a 4 5 l X15 Ja 4 5 1 Jl X15 X15 I B51 j 20 CU 4 M Y 4 M l i CU 4 X20 6 I I l X15 i 6 I P13 3 A6 7 A2 7 I S 1lY 3 lY 3 l cm M l cv J X51 X51 p i GN3 Jm 6 03 R D3 I 7 I 8 A f B C f D f O t g 7 E1 E f bl t h 8 F1 F hm 8 re ...

Page 283: ...Components A11 EFI control unit B32 Fuel level sensor B51 Lambda sensor cylinder 1 F1 Fuse F2 Fuse M13 Fuel pump P13 Speedometer 30 WIRING DIAGRAM 281 ...

Page 284: ... m 1 TI iifY J X15 X15 X15 X15 f X52 B70 5 l5 l5 e r j i f 1515 8 B I I i HHr 1 f C U C 1 NDQ 2 NAT 2 X295 X 3 01 r 7 f AP 6 n 1 0 0 D X26 D 5 l5 l5 1515 f w w E C0 a C nr E 6 EB g C er E f 2 FS b C t F F c I Ir FE 250 EU 2016 I hm HUSQl l ma 1 2 I 3 I 4 5 6 I 7 I 8 a ...

Page 285: ...Components A11 EFI control unit B70 Front wheel speed sensor M51 Injection valve cylinder 1 P13 Speedometer R30 CAN bus terminating resistor 1 X295 Diagnostics connector 30 WIRING DIAGRAM 283 ...

Page 286: ...15 I f 1 x35 AX12 B21m AX 2 1 x35 3 4 l X15 1l X15 t t I I I 9 1 l X37 X36 N AU2 1 H T 2 R51 lJJ B37 FE 250 EU 2016 I 3 I 4 5 6 7 8 I IA l l l 1 l f X15 X15 X15 X15 X15 B f t I I I I Is to i_X33 i_X32 t38 iEX 3 fP 6 rX 3 cM 2 M f EX 3 AP 6 oX 3 cM 2 I 0 I 1 X33 I 1 X32 1 X38 I il E E E I I I I I I IE I I I I I I I I I I 6 7 I II 5 ...

Page 287: ...sor B37 Crankshaft position sensor B41 Induction manifold pressure sensor cylinder 1 R51 Ignition coil cylinder 1 S51 Map Select switch for ride mode optional S55 Map Select switch for basic position optional Cable colors bl Black br Brown bu Blue gn Green gr Gray lbu Light blue or Orange pk Pink pu Violet rd Red wh White ye Yellow 30 WIRING DIAGRAM 285 ...

Page 288: ... X2 l 1 a w E C0 E a C nr F c I IO z tel HUS Yl 1 2 a I 3 I 4 II G10 1 X300 l 1 FE 250 AU 2016 I 3 I 4 523 3 C2 n 5 l x4 BR 4 I BK 4 J E 1 fv j 1 D2 I BK 4 I i i R 4 X4 1 s 5 I 6 I 7 I 8 A f B C f D f 1Wl rd a 2 E1 E f lW t b 2 F1 F I ha I 6 I 7 I 8 ...

Page 289: ...Components G10 Battery K10 Starter relay with main fuse M10 Electric starter system S23 Emergency OFF switch tip switch 30 WIRING DIAGRAM 287 ...

Page 290: ...I 1 X10 1 1 rrDY 4 I 1 X9 1 5 1 X295 AP 6 1 t3 i iEB 4 ij f EB 4 I 1 X3 1 1 1 EB aC wlHdl e i t 1 B33 Lf l M1 4 4 2 N BV 2o J C l BS 2 1 X285 l I i xs t7 j J i j F 4 J 2 F J J 2 X 40 111 F J 2 1FJ 2 X39 1 xs X7 t 1 L_JI t IfI l b 3 E1 1 FB bC tr 0 _ tr t b 7 F1 tel HUS Yl FE 250 AU 2016 2 8 re ...

Page 291: ...ts A11 EFI control unit B33 Radiator fan temperature switch F3 Fuse F4 Fuse G20 Alternator K12 Light relay K30 Power relay M14 Radiator fan T20 Voltage regulator X295 Diagnostics connector 30 WIRING DIAGRAM 289 ...

Page 292: ... I I N S P13 I I n JiCX 2 X50 B I l wh c f 4 B1 1 f u i w I P15 8 cru _ _ _ ttlBP 4 M j DG 4 1 X44 l DG 4 I BP 4 X46 X22 1 1 _ 1 1 l l l J c 2 EB dC I I 11LJ 1 1 I I I E 2 EB bC 0 l b 4 E1 IE C0 0 I I C I ll ll HUSQl l ma FE 250 AU 2016 I l I 1 I I I ...

Page 293: ...Components A11 EFI control unit E13 Low beam high beam P13 Speedometer P15 Horn P35 Parking light S22 Light switch horn button kill switch S23 Emergency OFF switch tip switch 30 WIRING DIAGRAM 291 ...

Page 294: ...1 E ct C 1 X18 1 X19 l 1 X13 C AH 2 AH 2 BY 4 D1 2 r X11 B76 B77 P36 CV 4 f f r l X17 AK 2 K 2 X11 V 4 I D f H 2 f H 2 ii Y 4 X14 D X18 X19 X13 l sl 1 1 I I I I I f w 3 EB et ye OO E C0 a v C nr E 3 EB b C t E f F F I I z tel FE 250 AU 2016 hm HUS Yi ma 1 2 I 3 I 4 5 I 6 I 7 I 8 a ...

Page 295: ...Components B76 Front brake light switch B77 Rear brake light switch E60 License plate lamp P36 Brake tail light 30 WIRING DIAGRAM 293 ...

Page 296: ... C U X42 j X23 j X25 j X41 X28 C J N AJ 3 H CX 2 CX 2 CX 2 CX 2 AH 2 NF0 2 525 P42 P46 P41 P45 R f 13 W 2 W 2 W 2 W 2 i D X45 f J 3 i CX 2 l X 2 l X 2 i CX 2 D X42 X23 X25 X41 X28 i i I I I I f w E C0 a It C nr E E f F F I I z tel FE 250 AU 2016 I hm HUS Yl 1 2 I 3 I 4 5 I 6 I 7 I 8 a ...

Page 297: ...nts K20 Turn signal relay P21 Turn signal indicator lamp P41 Turn signal front left P42 Turn signal front right P45 Turn signal rear left P46 Turn signal rear right S25 Turn signal switch 30 WIRING DIAGRAM 295 ...

Page 298: ... 2 I 3 I A111 7 A4 I I j j m FJ 2 GN3 6 07 M D7 I r X6 X29 t FE 250 AU 2016 2 I 3 I 4 5 l X15 Ja 4 5 1 TI X15 X15 ca I 7 1 1 rrrn CU 4 6 I I P13 3 A6 7 A2 l X15 i 6 I 7 I S 1lY 3 lY 3 l cm 1 cv3 X51 X51 p i GN3 Jm 6 03 R D3 I 7 I 8 A f B C f D f O t g 7 E1 E f bl t h 8 F1 F hm 8 ...

Page 299: ...Components A11 EFI control unit B32 Fuel level sensor F1 Fuse F2 Fuse M13 Fuel pump P13 Speedometer 30 WIRING DIAGRAM 297 ...

Page 300: ... 1 m 1 TI iifY J X15 X15 X15 X15 f X52 B70 5 l5 l5 e r j i f 1515 8 B I I i HHr 1 f C U C 1 NDQ 2 NAT 2 X295 X 3 01 r 7 f AP 6 n 1 0 0 D X26 D 5 l5 l5 1515 f w E C0 a C nr E 6 EB g C er E f 2 FS b C t F F I I FE 250 AU 2016 I hm HUSQl l ma 1 2 I 3 I 4 5 6 I 7 I 8 a ...

Page 301: ...Components A11 EFI control unit B70 Front wheel speed sensor M51 Injection valve cylinder 1 P13 Speedometer R30 CAN bus terminating resistor 1 X295 Diagnostics connector 30 WIRING DIAGRAM 299 ...

Page 302: ... 2 l X15 I 1 x3s AX12 B21m AX 2 1 x35 3 4 l X15 1l X15 t t I I I 9 1 l X37 X36 N AU2 1 H T 2 R51 lJJ B37 FE 250 AU 2016 3 4 5 6 7 8 I IA l l l 1 l f X15 X15 X15 X15 X15 B f t I I I I Is to i_X33 i_X32 t38 iEX 3 fP 6 rX 3 cM 2 M f EX 3 AP 6 oX 3 cM 2 l o I 3 l 2 8 I il E E E I I I I I I IE I I I I I I I I I 0 0 5 6 7 ...

Page 303: ...sor B37 Crankshaft position sensor B41 Induction manifold pressure sensor cylinder 1 R51 Ignition coil cylinder 1 S51 Map Select switch for ride mode optional S55 Map Select switch for basic position optional Cable colors bl Black br Brown bu Blue gn Green gr Gray lbu Light blue or Orange pk Pink pu Violet rd Red wh White ye Yellow 30 WIRING DIAGRAM 301 ...

Page 304: ...M10 J K10 f A I n D X2 l 1 w E 0 E a nr F I I z tel HUS Yi ma 1 2 a I 3 I II G10 1 X300 l 1 FE 250 US 2016 I 3 I 4 521 4 n 5 BR 4 l x4 l K 4 i i R 4 X4 1 s 5 I 6 I 7 I 8 A f B C f D f w rd a 2 E1 E f lW t b 2 F1 F I hm I 6 I 7 I 8 ...

Page 305: ...Components G10 Battery K10 Starter relay with main fuse M10 Electric starter system S21 E tip switch 30 WIRING DIAGRAM 303 ...

Page 306: ... EB 4 I 1 X 10 1 1 rrDY 4 I 1 X9 1 5 1 X295 AP 6 1 t3 i iEB 4 ij f EB 4 I 1 X3 1 1 1 EB aC wlHdl e i t 1 B33 Lf l M14 4 2 N BV 2o J C l BS 2 1 X285 l I i xs t7 j j J 2 J 2 F4 F3 X 19 111 FJ 2 1FJ 2 X23 1 xs X7 t 1 L_JI 1 t l i b 3 E1 1 FB bC tr 0 _ tr t b 5 F1 tel HUS Yl FE 250 US 2016 2 6 g ...

Page 307: ...I control unit B33 Radiator fan temperature switch optional F3 Fuse F4 Fuse G20 Alternator K12 Light relay K30 Power relay M14 Radiator fan optional T20 Voltage regulator X295 Diagnostics connector 30 WIRING DIAGRAM 305 ...

Page 308: ...A3 A11 1 I 1 x 15 t B B I l 11 1 1 l C 1 X18 is 1 1 X1 7 is 1 C BF 1 X12 M BY 4 X1 X31 FF 1 FP 1 Dl 2 BA 1 V 4 i BP 4 M DG 4 J v 1 0814 I BP 4 V 4 X16 X22 l l c ii l l 1 CNOH l j jr 1 j E 2 EB bC 0 E Ft iF H ma FE 250 US 2016 I 1 2 I J I 4 s I 6 I 1 I a ...

Page 309: ...Components A11 EFI control unit E11 Low beam P35 Parking light P37 Tail light S20 Kill switch S30 Light switch 30 WIRING DIAGRAM 307 ...

Page 310: ...I 3 I A11 1 l5 A4 I I j j m FJ 2 GN3 14 07 M 14 D7 I r X6 X29 t FE 250 US 2016 2 I 3 I 4 5 l X15 Ja 4 5 1 TI X15 X15 ca I 7 1 1 rrrn CU 4 6 I I P13 5 A2 l X15 i 6 I 7 I S 1lY 3 lY 3 N1l 3 l 3 X14 X14 p i GN3 Jm l 14 03 R goJ I 7 I 8 A f B C f D f O t e 5 E1 E f bl f 6 F1 F 8 g ...

Page 311: ...Components A11 EFI control unit B32 Fuel level sensor F1 Fuse F2 Fuse M13 Fuel pump P13 Speedometer 30 WIRING DIAGRAM 309 ...

Page 312: ...1 m 1 TI iifY J X15 X15 X15 X15 f X13 B70 5 l5 l5 e r j i f 1515 B B I I i HHr 1 f C U C 1 NDQ 2 NAT 2 X295 X301 r 7 f AP 6 n 1 0 0 D X26 D 5 l5 l5 1515 f w E 0 a It C nr 4 EB e C er E E f 2 FS b C t F F I 1 FE 250 US 2016 I HUSQl l ma 1 2 I 3 I 4 5 6 I 7 I 8 a ...

Page 313: ...Components A11 EFI control unit B70 Front wheel speed sensor M51 Injection valve cylinder 1 P13 Speedometer R30 CAN bus terminating resistor 1 X295 Diagnostics connector 30 WIRING DIAGRAM 311 ...

Page 314: ... x35 AX12 B21m AX 2 1 x35 3 4 l X15 1l X15 t t I I I 9 1 l X28 X36 N AU2 1 H T 2 R51 lJJ B37 FE 250 US 2016 I 3 I 4 5 6 7 8 I IA l l l 1 l f X15 X15 X15 X15 X15 B f t I I I I Is to i_X33 i_X32 t25 iEX 3 fP 6 rX 3 cM 2 M f EX 3 AP 6 oX 3 cM 2 I 0 I 1 X33 I 1 X32 1 X25 I il E E E I I I I I I IE I I I I I I I I I C II I 6 7 I 5 ...

Page 315: ...sor B37 Crankshaft position sensor B41 Induction manifold pressure sensor cylinder 1 R51 Ignition coil cylinder 1 S51 Map Select switch for ride mode optional S55 Map Select switch for basic position optional Cable colors bl Black br Brown bu Blue gn Green gr Gray lbu Light blue or Orange pk Pink pu Violet rd Red wh White ye Yellow 30 WIRING DIAGRAM 313 ...

Page 316: ...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 antifreeze protection dilution and miscibility compatibility with other coolants Recommended supplier Bel Ray Moto Chill Racing Coolant En in...

Page 317: ...that exhibit the corresponding properties Super 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 use Info I Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100...

Page 318: ...Waterproof Grease Lubricant I158 Recommended supplier Lubcon Turmogrease PP 300 Lubricant 14034 Recommended supplier WP Performance Systems WP Racing Grease IPR 2 Lubricant 625 Recommended supplier Molykote 33 Medium Lubricant T152 Recommended supplier Bel Ray Molylube Anti Seize Lubricant T159 Recommended supplier Bel Ray MC 11 Offroad chain spray Guideline Recommended supplier Bel Ray Blue Tac C...

Page 319: ...nded supplier Bel Ray Foam Filter Oil Preserving materials for aints metal and rubber Recommended supplier Bel Ray Silicone Detailer Protectant Spray Universal oil s ra Recommended supplier Bel Ray 6 in 1 32 AUXILIARY SUBSTANCES 317 ...

Page 320: ...0029013006 I 00029013006 H00505 01 Bleeding device Art no 00029013100 00029013100 H00518 01 EU batte charger XCharge rofessional Art no 00029095050 Feature EU safety plug Nominal voltage 230 V Mains fuse 16A Power cable length 5 m 16 ft approx Charger cable 5 m 16 ft H01065 01 length approx 318 ...

Page 321: ...H01065 01 Art no 00029095052 Feature UK safety plug Nominal voltage Mains fuse Power cable length approx Charger cable length approx rofessional H01065 01 H01519 01 Art no 00029095053 Feature CH plug Nominal voltage Mains fuse Power cable length approx Charger cable length approx Art no 46129021000 33 SPECIAL TOOLS 120V 32 A 5 m 16 ft 5 m 16 ft 230V 16 A 5 m 16 ft 5 m 16 ft 230V 16 A 5 m 16 ft 5 m...

Page 322: ... S ring hook Art no 50305017000 50305017000 H00973 01 S ringe Art no 50329050000 50329050000 H00565 01 Lock ring lier Art no 51012011000 51012011000 H00572 01 Holding wrench Art no 51129003000 51129003000 H00575 01 320 ...

Page 323: ...r 58429037037 H00596 01 Tool bracket 58429089000 H00603 01 Pressing tool 58429091000 H00604 01 Art no 58012009000 Art no 58429037037 Feature I Inside diameter Art no 58429089000 Art no 58429091000 33 SPECIAL TOOLS I 37 5 mm 1 476 in 321 ...

Page 324: ... 01 H00606 01 H00610 01 H00616 01 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 Art no 59029041100 Feature I 5 piece 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 I 0 10 0 25 mm 0 0039 0 0098 in ...

Page 325: ...0029015000 Hose clam lier 60029057000 H00627 01 H00628 01 H00650 01 33 SPECIAL TOOLS Art no 60029010000 Feature I Driver system tip 11 2 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 323 ...

Page 326: ...93000 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 Crankshaft ressing tool Art no 75029047000 75029047000 H00714 01 324 ...

Page 327: ...75029090000 75029090000 H00726 01 Crankshaft ressing tool insert Art no 77029008000 77029008000 H00737 01 Se arator late Art no 77029009001 77029009001 H00738 01 Holder and fitting for work stand Art no 77229002000 77229002000 H00748 01 325 ...

Page 328: ...7229010000 Limit lug gauge 77229026000 Protection ca 0 77229031000 Se 0 77229032000 326 H00752 01 H00753 01 H00755 01 H00756 01 Art no 77229010000 Art no 77229026000 Feature I Diameter Art no 77229031000 Art no 77229032000 I 5 55 mm 0 2185 in ...

Page 329: ...0 H00760 01 S ark lug wrench with link 77229172000 H00761 01 Oil ressure ada ter 77329006000 H00764 01 Art no 77229048000 Art no 77229060000 Art no 77229172000 Feature Drive Hexagonal part Length Art no 77329006000 33 SPECIAL TOOLS 3 8 in 14 mm 0 55 in 130 mm 5 12 in 327 ...

Page 330: ...e work stand 80329001000 H01047 01 Lift stand 81329955100 H00985 01 Hook wrench T106S H00841 01 328 Art no 77729030100 Art no 80329001000 Art no 81329955100 Feature Height Load Art no T106S Feature I Diameter 315 425 mm 12 4 16 73 in 5 150 kg 5 331 lb I 68 75 mm 2 68 2 95 in ...

Page 331: ...stand T1202S H01149 01 Mounting sleeve T1204 H00878 01 Art no T107S Art no T120 Feature I Diameter Art no T1202S Feature Diameter Diameter Art no T1204 Feature I Diameter 33 SPECIAL TOOLS I 8 mm 0 31 in 10 mm 0 39 in 18 mm 0 71 in I 25 5 30 5 mm 1 004 1 201 in 329 ...

Page 332: ...1206 Pressing tool 61 T1207S Mounting sleeve T1215 330 H00879 01 H00880 01 H00881 01 H00886 01 Art no T1205 Feature I Diameter Art no T1206 Feature I Diameter Art no T1207S Art no T1215 Feature I Diameter 118 mm 0 71 in 115 30 mm 0 59 1 18 in 118 mm 0 71 in ...

Page 333: ...lam ing stand 2x T1403S Art no T1216 Feature I Diameter H00887 01 Art no T1240S H00890 01 Art no T1401 Feature I Diameter H00894 01 Art no T1403S Feature Diameter Diameter H00896 01 33 SPECIAL TOOLS 1 38 49 mm 1 5 1 93 in I 48 mm 1 89 in 48 mm 1 89 in 60 mm 2 36 in 331 ...

Page 334: ...00924 01 Pressing tool T14051 H00926 01 332 Art no T14040S Feature I Diameter Art no T14047 Feature Drive Narrow diameter Wide diameter Art no T14049S Feature Diameter Diameter Art no T14051 Feature I Diameter I 48 mm 1 89 in 1 2 in 34 mm 1 34 in 42 7 mm 1 681 in 8 mm 0 31 in 24 8 mm 0 976 in I 50 mm 1 97 in ...

Page 335: ...Pressing tool T1504 Mounting tool o T150S Filling tool 2x 3x T170S1 H00899 01 H00852 01 H00855 01 Art no T1504 Feature I Diameter Art no T150S Art no T170S1 118 mm 0 71 in 33 SPECIAL TOOLS 333 ...

Page 336: ... 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 MA standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to thei...

Page 337: ...35 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 335 ...

Page 338: ...legs disassembling 21 336 of the fork legs assembling 29 Chain checking cleaning 118 121 Chain guide checking 118 Chain tension adjusting 117 checking 117 Charging voltage checking 131 Chassis number 10 Clutch fluid level checking correcting 232 fluid changing 233 Clutch lever basic position adjusting 42 Combination instrument adjusting 148 adjusting the clock 149 adjusting the kilometers or miles...

Page 339: ...embly alternator cover installing 227 camshafts installing 224 clutch basket installing 215 clutch cover installing 218 clutch discs installing 216 clutch push rod installing 230 crankshaft installing 209 cylinder head installing 223 engine removing from the engine assembly stand 231 force pump installing 213 left engine case installing 211 locking lever installing 215 oil filter installing 229 oi...

Page 340: ... unit assembling 26 hydrostop unit disassembling 24 installing 16 piston rod assembling 27 piston rod disassembling 22 removing 16 seal ring retainer assembling 26 seal ring retainer disassembling 24 338 spring removing 20 Fork protector installing 17 removing 17 Fork service performing 18 Frame checking 45 Front fender installing removing Front wheel installing removing Fuel filter 103 103 112 11...

Page 341: ...checking 118 Rear wheel installing removing 115 114 Rebound damping fork adjusting 14 shock absorber adjusting 47 Riding sag adjusting 50 Right side cover installing 91 removing 91 Rim run out checking 110 s Seal ring retainer fork legs assembling 26 fork legs disassembling 24 Seat mounting 92 removing 92 Service schedule 268 269 Servicing the shock absorber 54 Shock absorber damper assembling 65 ...

Page 342: ... 255 engine tolerance wear limits 256 engine tightening torques 256 fork 260 shock absorber 261 tires 260 Throttle cable play adjusting 43 Throttle cable routing checking 42 Tire air pressure checking 107 340 Tire condition checking 107 Type label 1 0 w Valve clearance chec ng 247 w Warranty 9 Wheel bearing checking 108 of the front wheel changing 113 of the rear wheel changing 123 Winter operatio...

Page 343: ...11111111111111111111IIIIIIIIIIII 3403024en 07 2017 Husqvarna MOTORCYCLES Husqvarna Motorcycles GmbH fiiiHiAvl StallhofnerstraBe 3 5230 Mattighofen Austria llmi LZZa O www husqvarna motorcycles com __ __ Photo Mitterbauer Husqvarna Motorcycles GmbH ...

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Husqvarna F2103P4, Repair Manual

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