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Husqvarna F2203P4, Repair Manual

The Husqvarna F2203P4 Repair Manual is a comprehensive and user-friendly guide designed to help you troubleshoot and repair your Husqvarna F2203P4 model with ease. This manual is available for free download on our website, where you can access step-by-step instructions and valuable maintenance tips to keep your equipment running smoothly.

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29  SERVICE SCHEDULE 

Every 30 operating  hours/after every race 

Every  15 operating  hours 

Once after  1 operating  hour 

Adjust the idle speed.  (

I!!) 

p.  274) 

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Check that the radiator fan is functioning properly. 

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Final check:  Check the vehicle for roadworthiness and take a test ride. 

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Read out the fault memory after the test ride using the  Husqvarna Motorcycles diagnostics tool. 

0 

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Make the service entry in the 

Husqvarna Motorcycles Dealer.net 

and in the Service and War-

0 

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I 

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ranty  Booklet. 

o

One-time interval

•

Periodic interval

29.2 

Service work (as additional order} 

I 

Annually 

Every  135 operating hours 

Every 70 operating  hours when used for motorsports 

Change the front brake fluid.  (

a 

p.  154) 

Change the rear brake fluid.  (

I!!,! 

p.  163) 

Change the hydraulic clutch fluid.  (

I!!) 

p.  253) 

Lubricate the steering head bearing.  (

!!JI 

p. 36) 

Clean the spark arrestor.  (

a 

p. 90) 

Perform a fork service.  (

I!!,! 

p.  19) 

Service the shock absorber.  (

I!!) 

p. 57) 

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. 

Check the transmission and shift mechanism. 
Check the oil pressure regulator valve. 

Change the suction pump. 

Check the force pump and lubrication system. 
Change the timing chain. 
Check the timing assembly. 
Change all engine bearings. 
Change the freewheel. 

o

One-time interval

•

Periodic interval

290 

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Every 45 operating  hours 

Once after  15 operating hours 

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Summary of Contents for F2203P4

Page 1: ...PIONEERING SINCE 1903 REPAIR MANUAL2016 FE 350 FE 350 S Art no 3403027en Husqvarna MOTORCYCLES ...

Page 2: ......

Page 3: ...al 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 partly co...

Page 4: ... rod 24 6 14 Disassembling the hydrostop unit 25 7 8 9 6 15 Disassembling the seal ring retainer 26 6 16 Checking the fork legs 26 6 17 Assembling the seal ring retainer 28 6 18 Assembling the hydrostop unit 28 6 19 Assembling the piston rod 29 6 20 Assembling the cartridge 30 6 21 Assembling the fork legs 32 6 22 Lubricating the steering head bearing 36 6 23 Removing the lower triple clamp 37 6 2...

Page 5: ...oving the right side cover 96 12 4 Installing the right side cover 96 12 5 Removing the seat 97 TABLE OF CONTENTS 12 6 Mounting the seat 97 12 7 Removing the fuel tank 98 12 8 Installing the fuel tank 100 12 9 Changing the fuel screen 101 12 10 Changing the fuel filter 103 12 11 Changing the fuel pump 105 12 12 Checking the fuel pressure 107 12 13 Removing the activated charcoal filter FE 350 S US...

Page 6: ...emoving the oil filter 182 Removing the spark plug 182 Removing the valve cover 183 Removing the alternator cover 183 18 3 9 Removing the torque limiter 184 18 3 10 Positioning the engine at ignition top dead center 184 18 3 11 Removing the timing chain tensioner 184 18 3 12 Removing the camshaft 185 18 3 13 Removing the cylinder head 185 18 3 14 Removing the piston 186 18 3 15 Removing the starte...

Page 7: ...stalling the timing chain 231 18 5 9 Installing the primary gear 232 18 5 1O Installing the force pump 232 18 5 11 Installing the suction pump 233 19 20 TABLE OF CONTENTS 18 5 12 Installing the locking lever 234 18 5 13 Installing the shift drum locating unit 234 18 5 14 Installing the shift shaft 234 18 5 15 Installing the clutch basket 234 18 5 16 Installing the clutch discs 235 18 5 17 Installi...

Page 8: ...n 286 28 STORAGE 287 28 1 Storage 287 28 2 Preparing for use after storage 288 29 SERVICE SCHEDULE 289 29 1 Service schedule 289 29 2 Service work as additional order 290 30 WIRING DIAGRAM 292 6 30 1 Page 1 of 8 EU 292 30 2 Page 2 of 8 EU 294 30 3 Page 3 of 8 EU 296 30 4 Page 4 of 8 EU 298 30 5 Page 5 of 8 EU 300 30 6 Page 6 of 8 EU 302 30 7 Page 7 of 8 EU 304 30 8 Page 8 of 8 EU 306 30 9 Page 1 o...

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: ...ering head on the right 4 2 T e label FE EU AU FE 350 S US 401946 10 M00650 10 10 FE EU AU Type label O is fixed to the front of the steering head FE 350 SUS Type label O is fixed to the front of the steering head The additional type label for Canada is fixed to the front of the front pipe ...

Page 13: ... for the steering lock is stamped onto the key connector FE 350 5 US Key number O for the ignition and steering lock is indicated on the KEYCODECARD Info I You need the key number to order a spare key Keep the KEYCODECARD in a safe place The engine number O is stamped on the left side of the engine under the engine sprocket The fork part number O is stamped on the inner side of the fork stub 11 ...

Page 14: ...4 SERIAL NUMBERS 4 6 Shock absorber article number 12 Shock absorber article number O is stamped on the top of the shock absorber above the adjusting ring towards the engine side ...

Page 15: ...ce Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle press side stand O to 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 401943 10 5 3 Startin Note Danger Danger of poisoning death Exhaust gases are toxic and inhaling them may result in unconsciousness and Alway...

Page 16: ...l lights up briefly as a functional con trol when starting 400733 01 5 4 Starting the motorcycle 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 Pres...

Page 17: ...e Compression damping Comfort Standard Sport Info 14 clicks 12 clicks 10 clicks I Turn clockwise to increase damping turn counter clockwise to reduce damping Adjusting the rebound dam ing of the fork Info The hydraulic rebound damping determines the fork suspension behavior Turn the red adjusting screw O all the way clockwise Info The adjusting screw O is located at the upper end of the right fork...

Page 18: ... a lift stand a p 13 Remove the fork protector a p 19 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 effec...

Page 19: ...e the front wheel llill p 121 Main work Remove screws O and take off the clamp Remove the cable tie s Remove screws 8 with the washers and take off the brake caliper Allow the brake caliper and brake line to hang loosely to the side FE EU AU FE 350 US Loosen screws i Take out the left fork leg Loosen screws e Take out the right fork leg FE 350 SUS Loosen screws i Take out the left fork leg Loosen ...

Page 20: ...crews D Guideline Screw bottom triple clamp FE 350 SUS Tighten screws Guideline MS Screw top triple MS clamp Tighten screws D Guideline Screw bottom triple clamp MS 17 Nm 12 5 lbf ft 15 Nm 11 1 lbf ft 17 Nm 12 5 lbf ft 15 Nm 11 1 lbf ft Position the brake caliper and mount and tighten screws C with the washers Guideline Screw front brake caliper MS 25 Nm 18 4 lbf ft Loctite 243 Mount the cable tie...

Page 21: ...iring harness and clamp Mount and tighten screws 8 Position the fork protector on the right fork leg Mount and tighten screws 6 Guideline Remaining screws chassis Condition M6 The fork legs have been removed Disassemble the fork legs a p 20 Remove the spring a p 22 Disassemble the cartridge a p 23 Disassemble the piston rod I p 24 10 Nm 7 4 lbf ft Disassemble the hydrostop unit I p 25 Disassemble ...

Page 22: ...e down the current state of compression damping 8 COMP white adjuster on the left fork leg Open the adjusters on the rebound and compression damp ing all the way Clamp the fork leg in the area of the lower triple clamp I Clamping stand T1403S 0 p 370 Remove screw fD Remove adjuster Loosen the screw cover C I Mounting tool T14047 0 p 370 Info The cartridge cannot be taken off yet Unclamp the fork l...

Page 23: ...m the cartridge usually requires the application of considerable force Remove dust boot D Remove fork protector ring f Info The fork protector ring does not necessarily need to be removed for repair work Remove lock ring Info The lock ring has a beveled end where a screwdriver can be applied Warm up the outer tube in area G of the lower sliding bush ing Guideline 1 so 0 c 122 F Pull the outer tube...

Page 24: ... dust boot Cs Unclamp the fork leg The operations are the same on both fork legs 22 Preparatory work Disassemble the fork legs p 20 Main work Pull the spring downward Mount the open end wrench on the hexagonal part Clamp the open end wrench in the vise Release screw cap O but do not remove it yet I Mounting tool T14047 a p 370 Pull the spring downward Remove the open end wrench Remove the screw ca...

Page 25: ...n work Degrease piston rod O and clamp using the special tool I Clamping stand T14049S p 370 Remove adjusting tube Unscrew spring guide 5 Remove spring seat C Pull the piston rod out of the cartridge Degrease the cartridge and clamp it with the special tool I Clamping stand T14049S a p 370 Release seal ring retainer 0 and remove with the washer Remove lock ring D Pull reservoir out of the cartridg...

Page 26: ...egs i I p 20 Remove the spring i I p 22 Disassemble the cartridge i I p 23 Main work Degrease hydrostop needle O and clamp using the special tool I Clamping stand T1202S i I p 367 Release hydrostop needle O and remove it from the piston rod Valve 8 usually remains in the hydrostop needle Info 6 silver hydrostop needle on compression damp ing side 0 red hydrostop needle on rebound damping side 24 e...

Page 27: ...can be used for this Disassembling the hydrostop unit Info The procedures are the same on both fork legs Preparatory work Disassemble the fork legs 0 p 20 Main work Clamp hydrostop unit using special tool to sleeve O and loosen I Clamping stand T1202S 0 p 367 Turn hydrostop unit mount on a fitting hexagon socket and clamp into a vice Remove sleeve O Remove shim stack 8 and washer 8 25 ...

Page 28: ...mbling the seal ring retainer Info The steps are identical for both fork legs R00013 10 Checking the fork legs Preparatory work Disassemble the fork legs i I p 20 Remove the spring i I p 22 Disassemble the cartridge i I p 23 Main work Remove pilot bushing support O Remove O ring 8 and seal ring Condition The fork legs have been disassembled ...

Page 29: ...he inner tube I Inner tube run out I s 0 20 mm s 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 s 49 20 mm S 1 937 in If the measured value is larger than the specified value Change the outer tube Check the outer tube for damage If there is damage Change the o...

Page 30: ...iner Info The steps are identical for both fork legs R00014 10 Mount and grease seal ring O I Lubricant T158 a p 354 Mount and grease O ring 8 I Lubricant T158 p 354 Position pilot bushing support Assemblin the hydrostop unit Info The procedures are the same on both fork legs Mount and grease O ring O I Lubricant T158 p 354 Mount washer 8 Mount shim stack with the smaller washers facing down ward ...

Page 31: ...l for both fork legs except for the hydrostop needle and valve 201790 10 R00033 10 R00031 10 Degrease the piston rod Clamp the piston rod with the special tool I Clamping stand T14049S a p 370 Grease O ring Mount valve needle O in the piston rod I Lubricant T158 a p 354 Mount spring 8 Mount and tighten adapter with spring 8 Guideline Adapter of piston rod Position the spring M6x0 5 12 Nm 8 9 lbf f...

Page 32: ... 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 fD Mount and tighten the hydrostop needle Guideline Hydrostop needle on M6x0 5 piston rod Info 8 Nm 5 9 lbf ft I e silver hydrostop needle on compression damp ing side G red hydrostop needle on rebound damping side Unclamp the piston rod The ope...

Page 33: ...eload 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 p 370 Slide reservoir 0 onto the cartridge Info Hold the sleeve in the reservoir to prevent it from slid ing out Mount lock ring C Mount seal ring retainer with the washer and tighten Guideline Seal ring retainer M23 5x0 75 46 Nm ...

Page 34: ...mping 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 Preparatory work Assemble the hydrostop unit I p 28 Main work Clamp the inner tube with the axle clamp Guideline I Use soft jaws Mount the special tool I Protecting sleeve T1401 p 369 Grease and push on dust boot O I Lubricant T14034 0 p 354 Info...

Page 35: ...e in area f of the lower sliding bush ing Guideline I 50 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 llill p 370 Press the sliding bushing all the way into the outer tube Position the support ring Hold the seal ring with the shorter side of the special tool I Mounting tool T14040S llill p 370 Press...

Page 36: ... the entire filling quantity of fork oil available Oil capacity per fork 630 ml Fork oil SAE 4 leg 21 3 fl oz 48601166S1 p 352 Add some of the fork oil while pulling out and pushing in the piston rod numerous times Guideline I Fork oil quantity I 510 ml 17 24 fl oz Mount and tighten hydrostop unit Guideline I Hydrostop unit I M30x1 Clamp the fork vertically Add the remaining quantity of fork oil I...

Page 37: ...ly 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 Guideline Screw cap on piston M8x0 75 rod I Mounting tool T14047 Ip 370 Push the outer tube upward 18 Nm 13 3 lbf ft Clamp ...

Page 38: ...rnative 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 within the recom mended range Ride slowly to start with after making adjustments to get the feel of the new handlin...

Page 39: ... holder O in front of the right radiator and detach the wiring harness FE 350 SUS Open cable holder O in front of the right radiator and detach the wiring harness Remove screw 8 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 O ring 8 Remove protective ring Take o...

Page 40: ...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 41: ... clamp Tighten screw C Guideline Screw top steering head M8 M8 M20x1 5 Mount and tighten screw Guideline Screw top steering stem M8 FE EU AU FE 350 US Tighten screws Guideline Screw top triple clamp M8 15 Nm 11 1 lbf ft 15 Nm 11 1 lbf ft 12 Nm 8 9 lbf ft 17 Nm 12 5 lbf ft Loctite 243 17 Nm 12 5 lbf ft Secure the wiring harness with cable holder Q 39 ...

Page 42: ... p 114 Check that the wiring harness throttle cables and brake and clutch lines can move freely and are routed correctly Check the play of the steering head bearing i I p 40 Remove the motorcycle from the lift stand l ll p 13 Check the headlight setting l ll p 169 Checkin the play of the steerin head bearin Warning Danger of accidents Incorrect steering head bearing play impairs the handling chara...

Page 43: ...d Adjust the steering head bearing play 0 p 42 Check the steering head bearing and replace if neces sary Finishing work Remove the motorcycle from the lift stand 0 p 13 Changing the steering head bearing Preparatory work Remove the headlight mask with the headlight p 113 Raise the motorcycle with a lift stand p 13 Remove the front wheel 0 p 121 Remove the fork legs 0 p 17 Remove front fender 0 p 1...

Page 44: ...he new bearing with a suitable tube as far as it will go Finishing work Install the lower triple clamp I p 38 Install front fender a p 112 Install the front wheel a p 122 Install the headlight mask with the headlight a p 114 Check that the wiring harness throttle cables and brake and clutch lines can move freely and are routed correctly Check the play of the steering head bearing p 40 Remove the m...

Page 45: ...ine Screw top steering stem MB 17 Nm 12 5 lbf ft Loctite 243 FE 350 SUS Loosen screws O Remove screw 8 Loosen and retighten screw Guideline Screw top steering M20x1 5 head 12 Nm 8 9 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid stresses Tighten screws O Guideline Screw top triple MB 17 Nm 12 5 lbf ft clamp Mount and tighten screw 8 Guideline Screw top steering stem M...

Page 46: ...ued 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 an...

Page 47: ...stance between the clutch 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 Checking the routing of the throttle cable Preparatory work Remove the seat p 97 Remove the fuel tank 8 p 98 Main work FE EU AU FE 350 US Check the throttle cable routing Both throttle cables must be routed to...

Page 48: ...tle grip back and forth slightly to ascertain play O in the throttle cable I Play in throttle cable I 3 5 mm 0 12 0 2 in If the throttle cable play does not meet specifications Adjust the play in the throttle cable a p 47 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 eng...

Page 49: ...r as possi ble Loosen nut 8 Turn adjusting screw 0 so that there is play 6 in the throttle cable at the throttle grip Guideline I Play in throttle cable I 3 5 mm 0 12 0 2 in Tighten nut 8 Press and hold the throttle grip in the closed setting Turn adjusting screw out until there is no play in throttle cable D Tighten nut 8 Push sleeves O on Check the throttle grip for smooth oper ation Finishing w...

Page 50: ...d on the frame 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 I Always replace a frame that has been damaged due to a mechanical impact Repair of the frame is not authorized by Husqvarna Motorcycles ...

Page 51: ...h Info I Do not loosen fitting 8 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 Adjusting the low speed compression damping of the shock absorber Caution Risk of injury Parts of the shoc...

Page 52: ...uce 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 correspon...

Page 53: ...rcycle from the lift stand a p 13 Checkin the static sa of the shock absorber Measure distance 6 of rear wheel unloaded l ll p 51 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 6 and G Check the static sag I Static sag 1 3 0 m...

Page 54: ...g I Riding sag 1100 mm 3 94 in If the riding sag differs from the specified measurement Adjust the riding sag a p 53 Adjusting the s ring reload of the shock absorber Caution Risk of injury rectly Parts of the shock absorber will fly off if the shock absorber is disassembled incor The shock absorber is filled with highly compressed nitrogen Please follow the description provided Info Before changi...

Page 55: ...necessary to increase or decrease the spring preload Tighten screw O Guideline Screw shock M5 absorber adjusting ring Finishing work Install the shock absorber p 55 Install the manifold a p 85 Mount the seat a p 97 Install the main silencer a p 87 Install the right side cover a p 96 5 Nm 3 7 lbf ft Remove the motorcycle from the lift stand l t I p 13 Preparatory work Raise the motorcycle with a li...

Page 56: ...hock absorber p 55 Install the manifold p 85 Mount the seat 11 p 97 Install the main silencer 11 p 87 Install the right side cover 11 p 96 Remove the motorcycle from the lift stand I p 13 Check the static sag of the shock absorber I p 51 Check the riding sag of the shock absorber p 52 Adjust the rebound damping of the shock absorber p 50 9 9 Removin the shock absorber 54 Preparatory work Raise the...

Page 57: ...unt the seat p 97 Install the main silencer p 87 Install the right side cover p 96 Remove the motorcycle from the lift stand p 13 Checkin the shock absorber linkage Preparatory work Raise the motorcycle with a lift stand p 13 Main work Remove screw O Remove fitting Info Raise the wheel slightly to be able to remove the screws more easily Remove fitting Take off the angle lever 55 ...

Page 58: ... 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 56 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 ...

Page 59: ...f ft I Raise the wheel slightly to be able to mount the screw more easily Tighten screws Q Guideline Screw bottom M10 shock absorber Tighten screw cap Ci 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 Parts of the shock absorber will fly off if the shock absorber is disassembled incor rectly The sh...

Page 60: ...ring retainer a p 65 Assemble the piston rod il l p 66 Assemble the damper il l p 68 Install the spring a p 74 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 il l p 367 Remove rin...

Page 61: ...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 C slowly The pressurized nitrogen escapes Remove locking cap 0 Press in seal ring retainer D using the special tool I Pressing tool T1216 p 369 Remove lock ring Info Do not scratch the inner surface 59 ...

Page 62: ...mediate washer Drain the oil Remove compression adjuster Remove the spring and piston Disassembling the piston rod Preparatory work Remove the spring p 58 Disassemble the damper p 59 Main work Clamp the piston rod with the fork in a vise Guideline I Use soft jaws Remove nut O Remove washer 411 ...

Page 63: ... I Place the compression shim stack onto a screwdriver and set it down as a unit Remove rebound washer D Remove seal ring retainer Remove locking cap D and rubber buffer Disassembling the seal ring retainer 201405 10 Preparatory work Remove the spring a p 58 Disassemble the damper a p 59 Disassemble the piston rod a p 60 Main work Remove spring O Remove O ring 8 Remove rebound rubber 8 61 ...

Page 64: ... I p 60 Disassemble the seal ring retainer ill p 61 Main work Press pilot bushing O out of seal ring retainer 8 with the special tool I Pressing tool T1504 ill p 371 Slide the new pilot bushing O onto the special tool I Pressing tool T1504 I p 371 Position the pilot bushing in the seal ring retainer using the special tool I Pressing tool T1504 a p 371 Support seal ring retainer 8 with sleeve O of ...

Page 65: ...e of the damper cartridge Damper cartridge Diameter 5 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 r...

Page 66: ...the vise using soft jaws for pro tection Remove the collar bushing of the heim joint I Drift T120 p 367 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 ll l p 368 Remove the second lock ring 8 Place special tool 6 underneath and press out heim joi...

Page 67: ...6 p 368 Press the heim joint all the way in Press the heim joint against the lock ring using the special tool I Pressing tool T1207S p 368 Mount the second lock ring 8 Mount seal rings fD on both sides Position both collar bushings 8 and press them in Mount dust boot O with the special tool I Mounting sleeve T1204 p 368 Grease the sealing lip of the dust boot I Lubricant T625 p 354 65 ...

Page 68: ...ount rebound rubber D Grease the 0 ring groove I Lubricant T158 0 p 354 Mount 0 ring Mount spring Preparatory work Assemble the seal ring retainer il l p 65 Main work Clamp the piston rod with the fork in a vise Guideline I Use soft jaws Mount rubber buffer O and locking cap 8 Position special tool on the piston rod I Mounting sleeve T1215 0 p 369 Grease the dust boot and push seal ring retainer 8...

Page 69: ...ck 0 with the smaller shims facing downward Sand both sides of piston D on a surface plate using 1200 grit sandpaper Clean the piston Assemble the piston Guideline Viewf 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 67 ...

Page 70: ...8 l l p 354 Lubricate the threads I Lubricant T159 a p 354 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 cartrid...

Page 71: ...ative 1 Turn adjusting screw 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 0 all the way clockwise with a socket wrench Turn counterclockwise by the number of turns corre sponding to...

Page 72: ...ents to get the feel of the new handling characteristic Turn adjusting screws and 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 Tig...

Page 73: ...th micrometer f1 07S a p 367 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 8 to Pressure Guideline 0 bar Oil...

Page 74: ...per control 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 vacu...

Page 75: ...w filling port I M10x1 14 Nm 10 3 lbf ft Mount screw O with the O ring and screw it in approx 2 full turns but do not tighten it fully yet Info The piston rod is fully extended Fix the special tool in the vise I Filling tool T170S1 p 371 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 1...

Page 76: ...that 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 and spring retainer Mount ring Alter...

Page 77: ...ew handling characteristic Tension the spring to the amount measured during dis mantling by turning the adjusting ring I Hook wrench T106S a p 367 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 swin...

Page 78: ...from one side to the other If there is detectable play Change the swingarm bearing il Jl p 79 FE 350 SUS Move the swingarm up and down If there is detectable play Change the swingarm bearing il Jl p 79 Move the swingarm from one side to the other If there is detectable play Change the swingarm bearing il Jl p 79 Finishing work Remove the motorcycle from the lift stand p 13 ...

Page 79: ... Main work Take the brake line out of the guide Push the brake caliper forward slip it out and hang it to the side Info Cover the components to protect them against dam age Remove screws O and Take off the engine sprocket cover Remove connecting link CD of the chain Info Cover the components to protect them against dam age Take off the chain 77 ...

Page 80: ...Mount the swingarm pivot Mount and tighten nut O Guideline I Nut swingarm pivot M16x1 5 Lift the swingarm Mount and tighten fitting 8 Guideline Nut angle lever on swingarm Mount the chain M14x1 5 100 Nm 73 8 lbf ft 80 Nm 59 lbf ft Connect the chain with connecting link 4D Guideline The closed side of the chain joint lock must face in the direction of travel ...

Page 81: ...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 126 Remove the motorcycle from the lift stand Ii p 13 Changing the swingarm bearing Preparatory work Raise the motorcycle with a lift stand Ii p 13 Remove the rear wheel Ii p 125 Remove the swingarm Ii p 77 79 ...

Page 82: ...m bearing Remove collar bushings O Remove bushing 8 Remove shaft seal rings D using a suitable tool Remove stop disks C Press out bearing 0 using a suitable tool Using a suitable tool press in new bearing 0 Position stop disks C Press in shaft seal rings D Mount bushing 8 ...

Page 83: ...grease ill p 354 Position collar bushings O with the shoulder facing inward Right swingarm bearing Remove collar bushings D Remove bushing Remove shaft seal rings using a suitable tool Press out bearing 0 using a suitable tool Using a suitable tool press in new bearing Press in shaft seal rings 81 ...

Page 84: ... 82 Mount bushing Grease the shaft seal rings I Long life grease p 354 Position collar bushings D with the shoulder facing inward Finishing work Install the swingarm p 78 Install the rear wheel p 126 Remove the motorcycle from the lift stand p 13 ...

Page 85: ...7 Remove the right side cover JI p 96 Remove the main silencer i I p 87 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 FE EU AU FE 350 US Lift the swingarm FE 350 SUS Lift the swingarm 83 ...

Page 86: ...10 EXHAUST 84 Remove screws 0 on both sides Loosen screws D on both sides Remove screw Raise the rear frame slightly and lower the shock absorber Remove springs I Spring hook 50305017000 l p 357 ...

Page 87: ...a sensor and remove the cable binder Take off the manifold FE AU FE US Remove screw 0 Take off the manifold Main work Position the manifold and mount springs O I Spring hook 50305017000 p 357 Mount and tighten screw Guideline Remaining screws chassis MS 25 Nm 18 4 lbf ft 85 ...

Page 88: ...move screws 0 on both sides 35 Nm 25 8 lbf ft Loctite 2701 TM Mount and tighten screws 0 on both sides Guideline Screw sub frame M8 FE EU AU FE 350US Lower the swingarm FE 350 SUS Lower the swingarm 35 Nm 25 8 lbf ft Loctite 2701 TM Position the angle lever and linkage lever Mount and tighten screw cap D Guideline Nut linkage lever on M14x1 5 angle lever Mount and tighten screw Guideline Screw bot...

Page 89: ...e lift stand I p 13 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 l ll p 96 Main work Disconnect spring O I Spring hook 50305017000 a p 357 Remove screws 8 and take off the main silencer Main work Mount the main...

Page 90: ...de cover l l p 96 Remove the main silencer l l p 87 Main work FE EU AU Remove all screws on the main silencer Take off silencer cap O and 0 ring Take off outer tube D and 0 ring 8 Remove glass fiber yarn filling 0 from inner tube D Clean the parts that need to be reinstalled and check for damage Fit the new glass fiber yarn filling onto the inner tube Mount 0 ring 8 onto connecting cap Position th...

Page 91: ...be G Mount and tighten screws Guideline Screws on the main silencer M5 Mount 0 ring D on the silencer cap 7 Nm 5 2 lbf ft Fit the new glass fiber yarn filling onto the perforated pipe Fit the connecting cap with the glass fiber yarn filling in the outer tube Info Press the glass fiber yarn filling into the outer tube using a blunt tool Mount and tighten screws O Guideline Screws on the main silenc...

Page 92: ...e right side cover 0 p 96 Remove the main silencer 0 p 87 Main work q 0 tf 0 Remove screws O and take off silencer cap with O ring fD Warning Danger to health Soot particles irritate the eyes and mucuous membranes 402269 10 Wear suitable breathing and eye protection when cleaning the main silencer and carbon screen Clean main silencer housing 8 and screen of the spark arrestor with compressed air ...

Page 93: ...Finishing work Install the main silencer ilill p 87 Install the right side cover l li p 96 10 EXHAUST 91 ...

Page 94: ...ithout an air filter Never start to use the vehicle without an air filter 92 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 92 Main work Push air filter holding bracket O toward the air fil...

Page 95: ...ard 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 M00303 01 Preparatory work Remove the air filter box cover a p 92 Remove the air filter a p 92 Main work Wash the air filter ...

Page 96: ...ishing work Install the air filter ilill p 93 Install the air filter box cover ilill p 92 Preparatory work Remove the air filter box cover ilill p 92 Main work Seal the air filter box in the marked area t Finishing work Install the air filter box cover ilill p 92 ...

Page 97: ...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 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 ...

Page 98: ...ithout kinks FE AU FE US Mount the filler cap and turn clockwise until the release button O locks in place Info Run the fuel tank breather hose without kinks Remove screw O Pull off the side cover in area f sideways and remove it toward the rear Position the side cover and engage in area f Mount and tighten screw O Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 411 411 411 ...

Page 99: ...ar 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 the seat fixing screws 0 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 97 ...

Page 100: ...o 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 I p 97 Main work Unplug connector O of the fuel ...

Page 101: ...rews i with the collar bushings and horn FE 350US Remove screws i with the collar bushings FE 350 SUS Remove screws i with the collar bushings and horn Remove screw 8 with the rubber bushing Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank 99 ...

Page 102: ...allow 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 I a H00188 11 Main work Check the routing of the throttle cable p 45 Position the fuel tank and fit the two spoilers to the sides of the radiator ...

Page 103: ...uel line with an air line Info Dirt should not be allowed to get into the fuel line under any circumstances Dirt in the fuel line clogs the injection valve Lubricate the 0 ring and connect plug in connection 8 for the fuel line Info Route the cable and fuel line at a safe distance from the exhaust system Finishing work Mount the seat l p 97 The fuel in the fuel tank expands when warm and can escap...

Page 104: ...Clean plug in connection O of the fuel line thoroughly with compressed air Info I Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Disconnect the plug in connection of the fuel line Info Remaining fuel may flow out of the fuel hose Pull fuel screen 8 out of the connecting piece Insert the new fuel screen all the way into the connecting pie...

Page 105: ...nsult 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 handlin...

Page 106: ...housing Mount the new fuel filter 0 Arrow f points away from the fuel pump Mount hose clamps C I Hose clamp plier 60029057000 i Jl p 361 Position the fuel pump Mount fuel connection 8 with the gasket but do not tighten yet Guideline Fuel connection on fuel pump MS 10 Nm 7 4 lbf ft Mount and tighten nut O with the gasket Guideline Nut fuel pump fixa M12 tion Tighten fuel connection 8 15 Nm 11 1 lbf...

Page 107: ...diately 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 consult a doctor in case of fuel contact with the eyes...

Page 108: ...e fuel pump Mount fuel connection 8 with the gasket but do not tighten yet Guideline Fuel connection on fuel pump M8 10 Nm 7 4 lbf ft Mount and tighten nut O with the gasket Guideline Nut fuel pump fixa M12 tion Tighten fuel connection 8 Guideline Fuel connection on fuel pump M8 Mount and tighten screws fD Guideline I Screw fuel pump I EJOT PT 15 Nm 11 1 lbf ft 10 Nm 7 4 lbf ft 12 3 Nm 1 7 lbf ft ...

Page 109: ...ughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Condition The fuel tank is full Ensure that the battery voltage does not drop below 12 5 V The diagnostics tool is disconnected Thoroughly clean the plug in connection of the fuel line using comp...

Page 110: ...ssure with the filler cap open 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 Check that the fuel line is clear Change the fuel filter p 103 Change the fuel pump p 105 Stop the Function test of fuel pump control actuator test by pressing the Quit button Remove the special tools Join the fuel hose connection 12 13 Removing the activated ...

Page 111: ...amp C Pull off the hose Remove fitting 0 Take off the retaining bracket Installing the activated charcoal filter FE 350 S US Main work Position the retaining bracket Mount and tighten fittings O Guideline Screw engine brace Mount the hose MB Position hose clamp 8 33 Nm 24 3 lbf ft Loctite 2701TM 109 ...

Page 112: ...12 FUEL TANK SEAT TRIM 110 Mount hoses D and C Position the activated charcoal filter Mount rubber band 0 Finishing work Install the fuel tank p 100 Mount the seat p 97 ...

Page 113: ...er 13 MASK FENDER Preparatory work Remove the headlight mask with the headlight p 113 Main work FE EU AU FE 350 US Remove screws O and 8 Take off the front fender FE 350 SUS Remove screws O and 8 Take off the front fender 111 ...

Page 114: ...s 0 and fj Guideline Remaining screws M6 10 Nm 7 4 lbf ft chassis FE 350 SUS Position front fender Mount and tighten screws 0 and fj Guideline Remaining screws M6 10 Nm 7 4 lbf ft chassis Finishing work Install the headlight mask with the headlight I p 114 Check the headlight setting I p 169 41 ...

Page 115: ...he engine is idling turn the key in the ignition lock to the position 9_ FE EU AU Detach brake line O and wiring harness 8 Release rubber bands 8 Slide the headlight mask up and swing it forward Detach plug in connectors C and take off the headlight mask with the headlight FE 350US Detach brake line O and wiring harness 8 Release rubber bands 8 Slide the headlight mask up and swing it forward Disc...

Page 116: ...h plug in connectors C and take off the headlight mask with the headlight 13 4 Installing the headlight mask with the headlight 114 Main work FE EU AU Connect plug in connectors O Position the headlight mask and secure it with rubber bands The holding lugs engage in the fender Position brake line 5 and wiring harness C in the brake line guide ...

Page 117: ...k and secure it with rubber bands The holding lugs engage in the fender Position brake line D and wiring harness 8 in the brake line guide FE 350 SUS Connect plug in connectors O Position the headlight mask and secure it with rubber bands The holding lugs engage in the fender 115 ...

Page 118: ...13 MASK FENDER K00261 10 116 Position brake line D and wiring harness C in the brake line guide Finishing work Check the headlight setting a p 169 ...

Page 119: ...on 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 especiall...

Page 120: ... Preparatory work Raise the motorcycle with a lift stand p 13 Place a load on the rear of the vehicle The front wheel is not in contact with the ground Main work FE EU AU FE 350 US 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 p 123 Place a load on the front of the vehicle The rear wheel is not in contact with the g...

Page 121: ...sc around the contact surface of the brake linings Brake discs wear limit front I 2 5 mm 0 098 in rear I 3 5 mm 0 138 in If the brake disc thickness is less than the specified value Change the front brake disc a p 123 Change the rear brake disc 11 l p 128 Check the front and rear brake discs for damage cracking and deformation If the brake disc exhibits damage cracking or deforma tion Change the f...

Page 122: ...I Torque wrench set 58429094000 p 360 Checking the rim run out Warning 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 wheel Other spokes will become looser as a result ...

Page 123: ...spoke nipple on the other side of the rim run out If there is sig nificant deformation change the rim Correct the spoke tension Preparatory work Raise the motorcycle with a lift stand i ll p 13 Main work Press the brake caliper onto the brake disc by hand in order to push back the brake pistons Info I Make sure that you do not press the brake caliper against the spokes when pushing back the brake ...

Page 124: ...ake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change front wheel bearing al p 123 Clean and grease shaft seal rings O and bearing surface f of the spacers I Long life grease p 354 Insert the spacers Lift the front wheel into the fork position it and insert the wheel spindl...

Page 125: ...with a lift stand p 13 Remove the front wheel l p 121 Main work Remove screws O Remove the brake disc Clean the contact surface of the brake disc Position the new brake disc with the label facing outward Mount and tighten screws O Guideline Screw front brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Finishing work Install the front wheel a p 122 14 7 4 Changing front wheel bearing Preparatory work Rai...

Page 126: ...tool Info Only press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in Position spacing tube C Press in new bearing D all the way using a suitable tool Info Only press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in Grease new shaft seal rings and O and press in until they are flush Finishing work Install the...

Page 127: ... spindle far enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Remove the chain from the rear sprocket Info Cover the components to protect them against damage Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Holding the rear wheel withdraw the wheel ...

Page 128: ... them against damage Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Holding the rear wheel withdraw the wheel spindle Take the rear wheel out of the swingarm Info Do not operate the foot brake lever when the rear wheel is removed Always lay the wheel down in such a way that the brake disc is not d...

Page 129: ...r Mount nut C but do not tighten it yet Make sure that chain adjusters s are fitted correctly on adjusting screws 0 Check the chain tension 0 p 129 Tighten nut C Guideline M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm 1 26 in enables different secondary ratios with the same chain length Chain adjusters s can be turned by 180 Operate the foot brake lever repeat...

Page 130: ...pressure point Finishing work Remove the motorcycle from the lift stand ll p 13 If the brake discs are changed the brake linings must also be changed 128 Preparatory work Raise the motorcycle with a lift stand l l p 13 Remove the rear wheel l l p 125 Main work FE EU AU FE 350 US Remove screws O Take off the brake disc Clean the contact surface of the brake disc Position the new brake disc with the...

Page 131: ... to measure chain tension 6 Info The lower chain section 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 129 Finishing work Remove the motorcycle from the lift stand a p 13 D...

Page 132: ...spindle Info M20x1 5 80 Nm 59 lbf ft I The wide adjustment range of the chain adjusters 32 mm 1 26 in enables different secondary ratios with the same chain length Chain adjusters C can be turned by 180 FE 350 SUS Loosen nut O Loosen nuts Adjust the chain tension by turning adjusting screws fD left and right Guideline Chain tension 1 55 58 mm 2 17 2 28 in Turn adjusting screws fD on the left and r...

Page 133: ...t and engine sprocket are worn Change the drivetrain kit a p 134 Info I The engine sprocket rear sprocket and chain should always be replaced together Pull at the top part of the chain with the specified weight f Guideline Weight of chain wear mea surement 10 15 kg 22 33 lb Measure distance G of 18 chain rollers in the lower chain section Info Chain wear is not always even so you should repeat thi...

Page 134: ...ng guard Check the chain sliding piece for wear 6 Nm 4 4 lbf ft Loctite 243 If the lower edge of the chain pins is in line with or below the chain sliding piece Change the chain sliding piece Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten the screw of the chain sliding piece Guideline Screw chain slid M8 ing piece Check the chain guide for wear Info...

Page 135: ... 8 7 Checking for chain dirt accumulation 400678 01 Check the chain for coarse dirt accumulation If the chain is very dirty Clean the chain p 133 14 8 8 Cleaning the chain A Warning Danger of accidents Oil or grease on the tires reduces the road grip Remove the lubricant from the tires using a suitable cleaning agent Warning Danger of accidents Oil or grease on the brake discs reduces the braking ...

Page 136: ...in and apply chain spray I Offroad chain spray J p 354 Finishing work Remove the motorcycle from the lift stand J p 13 Preparatory work Raise the motorcycle with a lift stand J p 13 Main work Remove screws O and Take off the engine sprocket cover Have an assistant operate the rear brake Remove screw with the washer Remove the rear wheel p 125 Remove connecting link 8 of the chain Info Cover the co...

Page 137: ...screw FE 350 SUS Remove fittings Cs Take off the rear sprocket Position the new rear sprocket Mount and tighten the fittings Guideline Nut rear M8 35 Nm 25 8 lbf ft sprocket Loctite 2701TM screw Slide new engine sprocket 0 onto the countershaft Mount the new chain Connect the chain with connecting link C Guideline The closed side of the chain joint lock must face in the direction of travel Install...

Page 138: ...ne Screw clutch slave cylinder M6 Mount and tighten screw 8 Guideline Remaining screws chassis Finishing work M8 10 Nm 7 4 lbf ft 25 Nm 18 4 lbf ft Remove the motorcycle from the lift stand a p 13 14 8 10 Changing the rear wheel bearing 136 Preparatory work Raise the motorcycle with a lift stand i p 13 Remove the rear wheel i p 125 Main work FE EU AU FE 350 US Remove shaft seal ring O Remove lock ...

Page 139: ...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 oth erwise the bearing will be damaged when it is pressed in Clean grease and mount spacing tube 0 I Long life grease p 354 Press new bearing C all the way in from the outside to the inside Info Only press the bearing in via the outer ring oth erwise the bearing will be...

Page 140: ...ove shaft seal ring O Remove lock ring 4i Remove shaft seal ring s Using a suitable tool press bearing 8 out from the inside to the outside Remove spacing tube 0 Using a suitable tool press bearing 3 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 ...

Page 141: ...ase Ii p 354 Press new bearing 8 all the way in from the outside to the inside Info Only press the bearing in via the outer ring oth erwise the bearing will be damaged when it is pressed in Grease new shaft seal ring CD and press it in until it is flush Mount lock ring 8 The lock ring engages audibly Grease new shaft seal ring O and press it in until it is flush Finishing work Install the rear whe...

Page 142: ...he ignition lock to the position 5 _ Remove the seat p 97 Main work FE EU AU FE 350US Open fuse box cover O Remove the defective fuse 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 burne...

Page 143: ...l light license plate lamp horn brake light turn signal radiator fan Fuses res 10 A spare fuses Info You can recognize a faulty fuse by a burned out fuse wire e Warning Fire hazard Incorrect fuses overload the electri cal system Only use fuses with the required ampere value Do not bypass or repair fuses Use spare fuses with the correct rating only I Fuse 75011088010 l l p 281 Tip Replace the spare...

Page 144: ...s FE 350US Press and hold the kill switch while the engine is idling until the engine stops FE 350 SUS While the engine is idling turn the key in the ignition lock to the position Remove the air filter box cover l p 92 Main work Take off protection caps O Remove faulty main fuse fj Info You can recognize a faulty fuse by a burned out fuse wiref A spare fuse D is located in the starter relay Instal...

Page 145: ...e figure Measure the resistance between the specified points I Resistance of open circuit I O Q If the value displayed does not meet specifications Change the starter relay 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 ...

Page 146: ...CD at the bottom Lift the battery up and out Main work Insert the battery into the battery compartment with the ter minals facing forward I Battery YTX5L BS p 281 Reconnect rubber band O Info Contact disks f must be mounted under screws 8 and cable sockets 0 with the claws toward the bat tery terminal Position the positive cable and mount and tighten the screw Guideline Screw battery termi M5 nal ...

Page 147: ...se environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Even when there is no load on the battery it discharges steadily The charging level and the method of charging are very important for the service life of the battery Rapid recharging with a high charging current shortens the service life of th...

Page 148: ...Main work Carry out the start procedure I p 13 V Measure the voltage between the specified points Measuring point Plus Measuring point Ground I Charging voltage 5 000 rpm 113 5 15 0 V If the displayed value is less than the specified value Check the plug in connections from the alternator to the voltage regulator Check the plug in connections from the voltage regu lator to the wiring harness Check...

Page 149: ...ery Measure the current between battery ground and the neg ative cable Info The value of the open circuit current only applies to vehicles in their original state without additional power consumers I Maximum open circuit cur rent I 1 0 mA If the measured value is greater than the specified value Disconnect the voltage regulator from the wiring har ness and perform the measurement again 147 ...

Page 150: ... 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 151: ...iance 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 FE EU AU FE 350 US Move the brake fluid reservoir mounted on the handlebar to a horizontal pos...

Page 152: ...th the brake disc and there is a pressure point FE EU AU FE 350 US Correct the brake fluid to level Q Guideline Level O brake fluid level 5 mm 0 2 in below container rim I Brake fluid DOT 4 a p 352 Position cover 8 with membrane 8 Mount and tighten screws O FE 350 SUS Info Clean up overflowed or spilled brake fluid immedi ately with water Correct the brake fluid to level O Guideline Level O brake ...

Page 153: ...ever p 152 FE 350 US Push the hand brake lever forward and check free travel f Free travel of hand brake lever 3 mm 0 12 in If the free travel does not match the specification Adjust the basic position of the hand brake lever p 151 Adjusting the basic osition of the hand brake lever FE 350 US H00198 10 Check the free travel of the hand brake lever p 151 Adjust the basic setting of the hand brake l...

Page 154: ...vel 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 Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is cha...

Page 155: ...th 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 front and rear brake is changed in accordance with the service schedule Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc cor...

Page 156: ...ation 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 and consult a doctor if...

Page 157: ...ng instructions of the bleeding device Ensure that the filling pressure is set on pressure gauge f Correct the filling pressure on pressure regulator G if necessary Guideline I Filling pressure I 2 2 5 bar 29 36 psi Pull off protection cap 0 of the brake caliper bleeder screw Connect the bleeder bottle hose I Bleeding device 00029013100 p 356 Open bleeder screw 0 by approx one half turn Info I Dra...

Page 158: ...rizontal position Cover painted parts Remove screws O Take off cover 8 with the membrane Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid Syringe 50329050000 ilel p 358 Brake fluid DOT 4 ilel p 352 Mount bleeder cover I Bleeder cover 00029013005 ilel p 356 Connect the bleeding device I Bleeding device 00029013100 p 356 Open shut off valve C ...

Page 159: ...ice Remove the bleeder cover Add brake fluid to level 8 Guideline I Level 8 I 5 mm 0 2 in I Brake fluid DOT 4 I p 352 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilled brake fluid immedi ately with water Check the hand brake lever for a firm pressure point Checking the rear brake linings Warning Danger of accidents Worn out brake linings reduce t...

Page 160: ...e braking effect Always keep the brake discs free of oil and grease Clean the brake discs 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 ...

Page 161: ... 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 162: ...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 163: ...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 164: ... 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 165: ...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 166: ... 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 356 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 167: ...t Correct the brake fluid up to marking I Brake fluid DOT 4 Ii p 352 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 165 ...

Page 168: ...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 169: ...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 170: ...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 01 168 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 171: ...tance 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 169 Preparatory work Check the headlight setting 0 p 169 Main work FE EU AU FE 350 US Loosen screw O Adju...

Page 172: ...g the headlight Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with driver instruc tions on how to apply the mark Checking the headlight setting Info I A change in weight on the vehicle may require a correction of the headlight range Tighten screw O ...

Page 173: ...Ii p 96 Remove the main silencer Ii p 87 FE EU AU FE 350 US Remove the seat a p 97 Remove the fuel tank Ii p 98 FE 350 SUS Remove the seat il I p 97 Remove the fuel tank il I p 98 Remove the activated charcoal filter il I p 108 Main work Remove screw O Disconnect the negative cable of the battery Loosen hose clip Pull back the protection cap Unplug connector 18 ENGINE 171 ...

Page 174: ...lamp C Pull off the vent hose Remove screws 0 Loosen screw D Repeat these steps on the opposite side Swing up the subframe and secure it Remove screw Swing back the shock absorber Remove springs fD I Spring hook 50305017000 a p 357 ...

Page 175: ... off the manifold Push back the cover Remove nut Ci Take off the cable Loosen hose clip 48 Pull off the radiator hose Disconnect spring G Remove screw 41 Remove screw 4D Take off the engine sprocket cover 18 ENGINE 173 ...

Page 176: ...e Info Do not kink the clutch line Do not activate the clutch lever while the clutch slave cylinder is removed Unplug connector 41 Unplug connector 41 Pull back the protection cap Unplug connector 41 Pull off the spark plug connector Loosen hose clip G Pull off the throttle valve body toward the rear Loosen hose clip Ci Pull off the radiator hose ...

Page 177: ...m toward the rear slightly Remove screws Lift out the engine sideways Info The help of an assistant is useful in this step Ensure that the motorcycle is sufficiently secured against falling over 18 ENGINE Protect the frame and attachments against damage Main work Position the engine in the frame 175 ...

Page 178: ...ngarm pivot I M16x1 5 Position the engine braces Mount and tighten fittings 5 Guideline Screw engine brace MB 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 C Mount the throttle valve body Position and tighten hose clip 0 1100 Nm 73 8 lbf ft I 33 Nm 24 3 lbf ft Loctite 2701TM 60 Nm 44 3 lbf ft 100 Nm...

Page 179: ... Screw clutch slave cylinder Mount the chain M6 10 Nm 7 4 lbf ft Connect the chain with connecting link 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 48 Guideline 10 Nm 7 4 lbf ft Remaining screws chassis MS 25 Nm 18 4 lbf ft Mount ...

Page 180: ...en nut Position the cover Position the manifold and mount springs CO I Spring hook 50305017000 p 357 Mount and tighten screw Guideline Remaining screws chassis MS Position the shock absorber Mount and tighten screw ti Guideline Screw top M10 shock absorber 25 Nm 18 4 lbf ft 60 Nm 44 3 lbf ft Loctite 2701TM ...

Page 181: ...G Guideline Screw sub frame Remove screw MB Mount and tighten screw Guideline Screw sub frame MB 35 Nm 25 8 lbf ft Loctite 2701 TM 35 Nm 25 8 lbf ft Loctite 2701 Repeat these steps on the opposite side Mount the vent hose Position hose clamp Plug in connector 9 Position the protection cap Position and tighten hose clip 179 ...

Page 182: ... up with engine oil Engine oil 1 0 I 1 1 qt Mount and tighten filler plug Danger Engine oil SAE 10W 50 a p 352 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 engi...

Page 183: ...and fitting for work stand 77229002000 I p 363 Engine work stand 80329001000 I p 366 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 181 ...

Page 184: ...ug 8 with the magnet Completely drain the engine oil Remove screws O Remove the oil filter cover 8 with the O ring Pull oil filter out of the oil filter housing I Lock ring plier 51012011000 ll l p 358 Remove the spark plug using special tool O I Spark plug wrench with link 77229172000 ll l p 366 ...

Page 185: ...the alternator cover Remove screws O Remove the valve cover with the valve cover seal Remove the spark plug shaft insert Remove screws O Remove the alternator cover Take off the alternator cover gasket Dowels 8 remain in the engine case 18 ENGINE 183 ...

Page 186: ...se until markings G on the cylinder head are located flush above the flat areas G of the camshafts Remove screw O with the washer Info 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 800421 10 184 Loosen screw O Remove screw with the seal ring ...

Page 187: ...g C Loosen screws O from the outside to the inside and remove Take off guide rail Take off the camshaft bearing bridge Take the timing chain off 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 18 ENGINE 185 ...

Page 188: ...h the cylinder as far up as necessary to take the piston pin out Remove the piston pin retainer O Remove the piston pin Take off the cylinder and piston Push the piston upward out of the cylinder Info If no further work is to be performed on the cylinder and piston the piston can remain in the cylinder Take off cylinder base gasket Remove screw O ...

Page 189: ...ht using the special tool and pull off the rotor by turning the screw in I Puller 58012009000 p 358 Info I Ensure that the woodruff key remains in place Remove lock ring C Take off the starter idler gear with the washer Remove freewheel gear 0 Remove screws CD Remove the inside alternator cover Take off gasket 18 ENGINE 187 ...

Page 190: ...18 ENGINE 18 3 16 Removing the suction pump 188 Remove screws Take off the starter motor Remove screws O Take off oil pump cover 8 Remove O ring 8 Remove suction pump 8 Remove needle roller C ...

Page 191: ...h cover 18 3 19 Removing the clutch discs Remove screws 0 Take off the water pump cover Remove nut 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 18 ENGINE 189 ...

Page 192: ...ension ring 8 Take off pressure cap 0 Completely remove clutch disc pack 0 Remove clutch pressure piece Bend open lock washer Hold the inner clutch hub with the special tool Loosen nut 0 1 Holding wrench 51129003000 l l p 358 Remove the nut with the lock washer Dispose of the lock washer ...

Page 193: ... Take off needle bearing 0 and collar sleeve C Push sliding plate O away from the shift drum locating unit Remove shift shaft 5 with the washer 18 3 22 Removing the shift drum locating unit Remove screw O 18 ENGINE Push away locking lever from shift drum locating unit 5 and remove the shift drum locating unit Relieve tension from the locking lever 191 ...

Page 194: ... sleeve and spring Remove lock ring O Take off washer Take off oil pump idler gear D with the washer Remove lock ring 8 Take off washer 0 Take off oil pump gear wheel D Remove pin Remove screws D Take off the oil pump cover Remove pin Push oil pump shaft inward and take it out of the engine from the alternator side Remove force pump 41 ...

Page 195: ...rimary gear Remove screws O Remove the timing chain tensioning rail 8 Remove the timing chain guide rail D Remove screw 8 18 ENGINE Take off balancer shaft 0 with the timing chain and timing chain securing guide Info If the timing chain is going to be used again mark its direction of travel Remove spacer O of the crankshaft Remove screw 8 193 ...

Page 196: ...haft I Protection cap 75029090000 p 362 Mount special tool 8 with the appropriate screws I Puller 77229048000 l l p 365 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 dowels Remove the...

Page 197: ...ove shift rail D together with upper spring C and the lower spring Tilt shift forks O to the side Info I 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 Remove lock ring O 195 ...

Page 198: ...kshaft Remove nozzle 8 Remove oil nozzle for conrod bearing lubrication Remove screw C Remove the oil nozzle for piston cooling Remove screws 0 Remove the bearing retainers Remove any sealing mass remnants and clean the engine case section thoroughly Warm the engine case section in an oven Guideline 11so C 302 F Knock the engine case section against a level wooden plate This will cause the bearing...

Page 199: ...n has cooled check that the bearings are firmly seated Info If the bearings are not firmly seated after cooling it is likely that they will rotate in the engine case when warm In this case the engine case must be 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 latio...

Page 200: ... in the engine case section must be removed using a suitable tool Insert the new cold bearings in the bearing seats of the heated section of the engine case if necessary use a suitable press drift to push them all the way in and make them flush Info 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 othe...

Page 201: ...unt and tighten oil nozzle D Guideline Oil nozzle pis ton cooling M5 Position all bearing retainers Mount and tighten screws C 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 D 199 ...

Page 202: ...ess the shaft seal ring D all the way in from the inside to the outside with the open side facing in Press the new bearing C all the way in from the inside to the outside using a suitable tool Press in shaft seal ring O all the way with the open side facing outward Remove lock ring 0 ...

Page 203: ...200155 10 305033 10 Remove screw plug O with sealing washer 8 Remove pressure spring CD and ball e Measure the spring length of the oil pressure regulator valve Oil pressure regulator valve Minimum length of pres 1 23 5 mm 0 925 in sure spnng If the measured value does not meet specifications Change the spring Check ball 8 and the sealing seat If there is damage or wear Change the ball and machine...

Page 204: ...t 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 202 Fix the crankshaft in the vise Info Use soft jaws Warm up special tool O Guideline 1150 C 302 F I Puller 58429037037 p 359 Push the warmed up special tool O onto the crankshaft bearing inner race press firmly together and pull jointly from the cr...

Page 205: ... new crankshaft bearing inner race is flush Info After replacing the crankshaft bearings the crankshaft end play must be measured 41 18 4 8 Changing the connecting rod conrod bearing and crank pin Main work Position crankshaft O in the press using special tool I Separator plate 77229009000 ill p 363 Press the crank pin with the special tool out of the upper crank web I Crankshaft pressing tool 750...

Page 206: ...g rod and bearing Posi tion the second crank web Position special tool with the heel pointing down I Crankshaft pressing tool insert 77229008000 p 363 Press in the upper crank web as far as possible Info The press mandrel must be positioned over the crank pin Take the crankshaft out of the special tool and check that the connecting rod can move freely Measure the axial play between the connecting ...

Page 207: ...hings Mount the left section of the engine case Mount and tighten the screws Guideline I Screw engine case I M6 110 Nm 7 4 lbf ft Mount the dial gauge support on the engine case and mea sure and note down the crankshaft end play Guideline Crankshaft axial play 0 50 0 60 mm 0 0197 0 0236 in If the measured value does not meet specifications Remove the crankshaft Remove the crankshaft bearing inner ...

Page 208: ...layer for a coating procedure developed by Mahle The name is derived from the two materials used in this procedure a layer of nickel into which is embedded the particularly hard silicone carbide The most important advantages of the Nikasil coating are very good heat conductivity resulting in much improved performance low wear and a lightweight cylinder 18 4 14 Checking measuring the cylinder 206 C...

Page 209: ...hange the piston and piston rings Check measure the cylinder p 206 Check the piston sliding surface for damage If the piston sliding surface is damaged Replace the piston and if necessary the cylinder Check that the piston rings move easily in the piston ring grooves If the piston ring is stiff Clean the piston ring groove Tip An old piston ring can be used to clean the piston ring groove Check th...

Page 210: ...ounting clearance equals the largest cylinder bore diameter minus the smallest piston diameter Guideline Piston cylinder mounting clearance Size I 0 025 0 047 mm 0 00098 0 00185 in Size II 0 027 0 049 mm 0 00106 0 00193 in Wear limit 0 070 mm 0 00276 in 18 4 17 Checking the piston ring end gap 302704 10 208 Remove the piston ring from the piston Place the piston ring in the cylinder and align with...

Page 211: ...ase the cone of the camshaft and camshaft gear Mount camshaft gear Mount screw 8 but do not tighten yet Guideline Screw M12x1 70 Nm 51 6 lbf ft camshaft drive Loctite 243 cone sprocket degreased Repeat these steps for the second camshaft 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 a...

Page 212: ...ge 0 Mount and tighten the screws Guideline Screw M7x1 14 Nm 10 3 lbf ft camshaft Lubricated with engine 308670 10 210 bearing bridge oil Info Ensure that the dowel pins are seated properly Do not turn the camshaft 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 ...

Page 213: ...built in position Pre tension the valve spring using the special tool Valve spring mounter 59029019000 a p 360 Insert for valve spring lever 77229060000 a p 365 Remove the valve keys and unload the valve spring Remove the valve spring retainer and valve springs Pull the valve down out of the valve guide Remove valve stem seal C with the special tool I Valve stem seals plier 77229010000 a p 363 Rem...

Page 214: ... Rework the valve seat Check the valve springs for breakage and wear visual check If the valve spring is broken or worn Change the valve spring Measure the length of the valve springs Valve spring Minimum length 42 00 mm 1 6535 in If the measured value does not meet specifications Change the valve springs 18 4 24 Checking the valve spring seat 305014 10 212 Check the valve spring seat for breakage...

Page 215: ...nd the valve seats from damage and cracking If there is damage or cracking Change the cylinder head Using a straightedge and the special tool check the sealing area of the cylinder for distortion I Feeler gauge 59029041100 I p 360 Cylinder cylinder head dis s 0 10 mm s 0 0039 in tortion of sealing area If the measured value does not meet specifications Change the cylinder head Check sealing seat f...

Page 216: ...er 59029019000 a p 360 Insert for valve spring lever 77229060000 I p 365 Mount valve keys fD Info When mounting the valve keys ensure that they are seated properly it is recommended to adhere the valve keys to the valves with a small amount of grease Position cam levers C in the positions they had before they were removed Mount the cam lever shafts Remove screw 0 Mount and tighten screw plugs D Gu...

Page 217: ...urning 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 Press expansion ring together with suitable pliers and take off Take freewheel 8 out of the primary gear 41 215 ...

Page 218: ...horoughly oil all parts Slide freewheel O into the primary gear Info Note the direction of rotation Mount spreader ring Ensure that all lugs of the expansion ring pass through slots O of the freewheel and engage in groove 0 of the primary gear Mount lock ring ...

Page 219: ...ear 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 D of the starter motor 18 ENGINE Connect the negative cable of a 12 volt power supply to the housing of the starter moto...

Page 220: ...ere is damage or wear Replace the timing chain guide rail Check the timing chain securing guide 8 for damage and wear If there is damage or wear Replace the timing chain securing guide Check camshaft gears 0 for damage and wear If there is damage or wear Change the camshaft gears Check timing chain D for damage and wear If there is damage or wear Replace the timing chain 305007 10 Let the timing c...

Page 221: ...n all the way Guideline Thickness of the compen sating disks 2 2 5 mm 0 08 0 098 in Release the timing chain tensioner The detent mechanism engages and the piston remains in place Final position of the pis ton after engagement Info 3 mm 0 12 in I This position is necessary for installation If the timing chain tensioner is now pressed again and is only extended a maximum of half way it is pre vente...

Page 222: ...tension ring 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 D for damage and wear If there is damage or wear Change th...

Page 223: ... 4D 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 o Check shift forks O on disc f for damage and wear visual check If there is damage or wear Change the shift fork Check shift grooves Cs of shift drum 8 for wear If the shift groove is worn Change the shif...

Page 224: ...there is severe grooving Change the sliding plate Check guide bolts for firm seating and wear If the guide bolts are loose or worn Change the sliding plate Preassemble the shift shaft p 222 1 l 305009 10 18 4 36 Preassembling the shift shaft 305010 10 222 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...

Page 225: ...ise Guideline I Use soft jaws Remove stop disk O and 2nd gear fixed gear 8 Remove 5th gear idler gear D and needle bearing 8 Remove stop disk 0 Remove lockring D Remove 3rd 4th gear sliding gear Remove lockring Remove stop disk Remove 6th gear idler gear Gi Remove needle bearing 41 18 ENGINE 305011 10 223 ...

Page 226: ...stop disk C Remove sixth gear sliding gear 0 Remove stop disk D Remove lock ring Remove third gear idler gear Remove needle bearing Remove fourth gear idler gear Ci Remove needle bearing 41 Remove stop disk 48 and lock ring Cl Remove fifth gear sliding gear 4I Remove lock ring e Remove stop disk 41 Remove the second gear idler gear 48 Remove needle bearing 4D 18 4 39 Checking the transmission Cond...

Page 227: ...ng 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 D for damage and wear If there is damage or wear Change the gear wheel pair Check the tooth profiles of sliding gears 0 for damage and wear If there is damage or wear Change the gear wheel pair Check sliding gears 0 for smooth operation in the p...

Page 228: ...n shaft in the vise with the gear teeth facing downward Guideline I Use soft jaws Mount needle bearing O Mount sixth gear idler gear Mount stop disk and lockring C 305011 11 Mount third fourth gear sliding gear 0 with the small gear wheel facing downward Mount lockring 0 Mount stop disk Mount needle bearing Mount fifth gear idler gear 0 Mount second gear fixed gear Gi and stop disk 48 Finally chec...

Page 229: ...nt second gear idler gear 8 Mount stop disk D and lockring C Mount fifth gear sliding gear 0 with the shift groove facing up Mount lockring D and stop disk Mount needle bearing Mount fourth gear idler gear Mount needle bearing Gi Mount third gear idler gear m Mount lockring 48 and stop disk G Mount sixth gear sliding gear 4D with the shift groove facing downward Mount stop disk e Mount needle bear...

Page 230: ...nkshaft 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 8 ...

Page 231: ...aft Mount shift fork in the lower shift groove of the counter shaft Mount shift fork D 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 in the shift drum Info Do not misplace the shift rollers Install shift rail O together with upper spring and the lower spring 22...

Page 232: ...urn 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 8 but do not tighten yet Guideline I Screw engine case I M6x65 110 Nm 7 4 lbf ft Mount screws D but do not tighten yet Guideline I Screw engine case I M6x85 Tighten screws 0 8 and D G...

Page 233: ...ore ensure it is run ning in the correct direction Mount and tighten screw Guideline Screw timing M6 chain securing guide Position timing chain guide rail CD Mount and tighten screw 8 Guideline Screw timing M6 chain guide rail 10 Nm 7 4 lbf ft Loctite 243 10 Nm 7 4 lbf ft Loctite 243 Position timing chain tensioning rail Mount and tighten screw 3 Guideline Screw timing MB chain tension ing rail 15...

Page 234: ...ar M18LHx1 5 100 Nm 73 8 lbf ft Loctite 243 41 Oil the oil pump shaft internal rotor and external rotor before assembly Position force pump O Info The rounded side of the force pump faces the engine case Mount oil pump shaft 8 from below Mount pin D Position the oil pump cover Marking f faces upward Mount and tighten screws C Guideline Screw oil pump M5 cover Insert pin C Position oil pump gear wh...

Page 235: ...ring G Insert needle roller O Position suction pump 8 The rounded sides of the external rotor face the engine case Crank the oil pump gear wheel and ensure that it can move easily Mount O ring 5 Position the oil pump cover C Mount and tighten screws 3 Guideline Screw oil pump M5 cover 6 Nm 4 4 lbf ft Loctite 243 233 ...

Page 236: ...rum locating unit and position the shift drum locating unit 8 Info The flat areas of the shift drum locating unit are not symmetric Relieve tension from the locking lever Mount and tighten screw 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 Insert the shift sh...

Page 237: ...nut 0 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 358 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 basket Mo...

Page 238: ...nt pretension ring D with marking Top facing up Position spring washer C Position spring retainer 0 with marking I Mount screws D and tighten in a crisscross pattern Guideline I Screw clutch spring MS I 6 Nm 4 4 lbf ft ...

Page 239: ...on 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 llill p 360 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 conve...

Page 240: ...stalling the water pump cover 238 Mount the two part water pump impeller O Mount and tighten nut 8 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 but do not tighten yet Guideline Screw water pump cover M6x25 10 Nm 7 4 lbf ft Mount screws C but do not tighten them yet Guide...

Page 241: ...ut do not tighten yet Guideline I Screw starter motor M6 Mount gasket 8 Position the inside alternator cover Mount and tighten screws 8 Guideline Screw inside alter nator cover Tighten screws O Guideline M6 I Screw starter motor M6 Position freewheel gear C 18 ENGINE 10 Nm 7 4 lbf ft 6 Nm 4 4 lbf ft 10 Nm 7 4 lbf ft 239 ...

Page 242: ...1 6 lbf ft Shift the joint of the piston rings by 120 Thread oiled with engine oil cone degreased Place the special tool on the oiled piston Compress the pis ton rings using the special tool I Piston ring mounting tool 60029015000 p 361 The piston rings are pushed together all the way Position the piston on the cylinder using the special tool Push the piston carefully into the cylinder from above ...

Page 243: ...10 Place the cylinder base gasket on Info Ensure that the dowel pins are seated properly Cover the engine case opening with a cloth Thread the tim ing chain through the chain shaft Mount the piston pin Info In order to present them more clearly the following steps are shown with a removed piston Position the piston pin retainer 241 ...

Page 244: ...ertion for piston ring lock 77229030000 i ll p 364 Ensure that the piston pin retainer is seated properly on both sides Remove the cloth Keep the timing chain taut Push the cylinder down carefully and let the dowel pins engage Position cylinder head gasket O Info I Ensure that the dowels are seated properly Put the cylinder head in place Mount nut 8 with the washers and tighten in a crisscross pat...

Page 245: ...timing chain and insert intake camshaft O oil Place the timing chain over the camshaft gear of the intake camshaft Markings f are aligned with the flat areas of the camshaft Lock ring G engages in groove 8 Ensure that bleeder are seated properly Slip in exhaust camshaft 8 Place the timing chain over the camshaft gear and position the camshaft in the bearing seat Clean all oil nozzles thoroughly an...

Page 246: ...00 p 365 Position special tool O I Adjustment bush bridge 77229050044 ra p 365 Check the valve timing I The special tool must be in full contact with the flat areas If the special tool is not in full contact Take off the special tool Remove the camshaft p 185 Pull the camshaft gears off the camshafts Adjust the valve timing ra p 244 Remove the special tool Adjustment bush bridge 77229050044 p 365 ...

Page 247: ...the cam shafts Mount and tighten screws Guideline Screw special M7x1 tool adjustment bush bridge Info 10 Nm 7 4 lbf ft Lubricated with engine oil Tighten the screws of the exhaust camshaft first Tighten screws C Guideline Screw M12x1 camshaft drive sprocket Remove screws Remove the special tool 70 Nm 51 6 lbf ft Loctite 243 cone degreased I Adjustment bush bridge 77229050044 a p 365 245 ...

Page 248: ...1 11 G00423 10 246 Prepare the timing chain tensioner for installation p 219 Main work Position timing chain tensioner O and insert it with new 0 ring Mount and tighten screw plug D with the seal ring Guideline Plug timing chain tensioner Remove screw 8 M24x1 5 40 Nm 29 5 lbf ft Press the timing chain tensioner toward the timing chain using special tool 0 Release device for timing chain tensioner ...

Page 249: ... the flat areas G of the camshafts Check the valve clearance at all valves between the camshaft and 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 a p 360 If the valve clearance does not meet specifications Adjust the valve clearance a p 248 Mount and tighten screw O with the washe...

Page 250: ...all the timing chain tensioner a p 246 Finishing work Check the valve clearance a p 247 Position torque limiter O 18 5 29 Installing the alternator cover Position alternator cover gasket O Position the alternator cover Mount screws and tighten once all of the alternator cover screws have been mounted Guideline Screw alternator cover M6x30 6 Nm 4 4 lbf ft Mount screws fD and tighten once all of the...

Page 251: ...f ft Grease the O rings and mount the spark plug shaft insert Apply a thin layer of sealing compound in area 6 I Loctite 5910 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 and tighten the spark plug with special tool O Guideline ISpark plug IM10x1 1 10 12 Nm 7 4 _ _ _ 8 9 lbf ft I Spark plug wrench with link 77229172000...

Page 252: ... fD Guideline I Screw oil filter cover I M6 110 Nm 7 4 lbf ft Mount and tighten the oil drain plug O with the magnet and the new seal ring Guideline Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Push the 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 en...

Page 253: ...ing Mount spacer O with the bevel facing inward Mount clutch push rod O 18 5 36 Removing the engine from the engine assembly stand Remove the screw connection from the special tool I Holder and fitting for work stand 77229002000 p 363 Remove the engine from the engine assembly stand Info Work with an assistant or a motorized hoist 41 251 ...

Page 254: ... 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 attacks paint...

Page 255: ...n 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 41 Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes I...

Page 256: ...e master cylinder reservoir to prevent overflow Remove the bleeding syringe Mount and tighten screws bleeder screw Correct the fluid level of the hydraulic clutch Guideline Fluid level below container 4 mm 0 16 in rim Position the cover with the membrane Mount and tighten the screws FE 350 SUS Inject the liquid into the system until it escapes from openings D of the master cylinder without bubbles...

Page 257: ...s extra cooling It is controlled by a ther moswitch 307532 10 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 d...

Page 258: ...e engine to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immed...

Page 259: ... the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing Condition The engine is cold FE EU AU FE 350 US Position the motorcycle upright ...

Page 260: ...immediately with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing Main work Make sure that the screw O is tightened Stand the vehicle upright Pour coolant in up to measurement 6 above the radiator fins Guideline 110 mm 0 39 in I Coolant Refit the...

Page 261: ...channel transmission lubrication 48 Timing chain tensioner 21 LUBRICATION SYSTEM 401362 60 21 2 Checking the engine oil level 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 lit I p 2...

Page 262: ...n the 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 Remo...

Page 263: ...n 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 a p 358 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 and ...

Page 264: ...r plug 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 a p 259 I...

Page 265: ...g 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 p 259 Check the engine oil level I p 259 Remove the release screw of the chain adjuster Mo...

Page 266: ... 80 C 176 F Engine speed 1 600 rpm Engine oil temperature 80 oc 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 gl...

Page 267: ...rk 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 kQ If the specification is not reached Change the spark plug connector Alternator checkin the stator windin EZ 601211 10 Condition The stator is disconnected Prepar...

Page 268: ...ge 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 4 266 If the value displayed does not meet specifications Change the stator Removing the stator and ignition ulse generator 305319 10 305320 10 Condition The alternator cover has been removed Remove ...

Page 269: ...ozzle for M4 2 Nm 1 5 lbf ft alternator cool Loctite 243 ing Position the stator in the alternator cover Mount and tighten screws Guideline Screw stator M5 Position cable retainer plate 8 6 Nm 4 4 lbf ft Loctite 243 Position cable support sleeve in the alternator cover Position the ignition pulse generator with the cable retainer plate in the alternator cover Position the retaining bracket Mount a...

Page 270: ...lter lll l p 108 Main work Push back cover O disconnect the connector Disconnect spark plug connector Remove the spark plug with special tool 8 I Spark plug wrench with link 77229172000 l l p 366 Remove right radiator shield 8 Remove screws 0 Pivot the radiator forward slightly on the right Remove fittings CD Take off the engine braces Push back hose clamp Pull off the air release hose Remove scre...

Page 271: ...h the hole to check that the position notch of the crankshaft is visible Mount and tighten screw 48 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 p 360 If the valve clearance...

Page 272: ...Mount and tighten screw 4D Guideline Screw alternator cover M24x1 5 Clean and degrease the sealing surface Apply a thin layer of sealant to area Loctite 5910 Mount gasket 10 Nm 7 4 lbf ft 18 Nm 13 3 lbf ft Pivot the radiator forward slightly on the right Position the valve cover with the gasket Mount and tighten screws Guideline I Screw valve cover M6 1 B Nm 5 9 lbf ft Mount the vent hose and hose...

Page 273: ...onnector 8 Plug in the connector and position cover 0 Finishing work FE EU AU FE 350 US Install the fuel tank p 100 Mount the seat p 97 FE 350 SUS Install the activated charcoal filter p 109 Install the fuel tank p 100 Mount the seat p 97 Ad usting the valve clearance Info For purposes of illustration the following operations are shown with the engine removed Removal is not necessary Preparatory w...

Page 274: ... on the results of the valve clearance check Finishing work Install the camshafts a p 243 Install the timing chain tensioner a p 246 Check the valve clearance a p 268 FE EU AU FE 350 US Install the fuel tank a p 100 Mount the seat a p 97 FE 350 SUS Install the activated charcoal filter a p 109 Install the fuel tank a p 100 Mount the seat a p 97 ...

Page 275: ...r has been removed Connect the negative cable of a 12 volt power supply to the housing of the starter motor Connect the positive cable of the power supply briefly to connector O of the starter motor If the starter motor does not turn when the circuit is closed Change the starter motor 273 ...

Page 276: ...ning the idle speed adjusting screw Guideline Idle speed 11 950 2 050 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 Coo...

Page 277: ... 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 I If the initialization is not completed or the initializa tion process is interrupted the entire process must be restarted 275 ...

Page 278: ...rod bearing Slide bearing Piston pin bearing No bearing bushes DLC coated piston pins 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 Damped multidisc clutch in oil bath hydraulically activated Transmission ratio 1st gear 14 32 2nd gear 16 26 3rd gear 20 25 4th g...

Page 279: ...00098 0 00185 in Size II 0 027 0 049 mm 0 00106 0 00193 in Wear limit 0 070 mm 0 00276 in Piston ring end gap Compression ring 0 40 mm 0 0157 in Oil scraper ring 0 80 mm 0 0315 in Connecting rod axial play of lower conrod bearing 0 20 0 45 mm 0 0079 0 0177 in Crankshaft axial play 0 50 0 60 mm 0 0197 0 0236 in Crankshaft run out at bearing pin 0 03 mm 0 0012 in Clutch facing discs thickness of tot...

Page 280: ...octite 243 Nut cylinder head M6 10 Nm 7 4 lbf ft Lubricated with 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 shi...

Page 281: ...12x1 5 M14x1 5 M18x1 5 M18LHx1 5 M20x1 5 M24x1 5 M24x1 5 11 0 I 1 1 qt 11 2 I 1 3 qt 26 TECHNICAL DATA 15 Nm 11 1 lbfft Loctite 243 60 Nm 44 3 lbfft Loctite 2701 15 Nm 11 1 lbfft Loctite 243 70 Nm 51 6 lbfft Thread oiled with engine oil cone degreased 10 Nm 7 4 lbfft 8 Nm 5 9 lbfft 10 12 Nm 7 4 8 9 lbfft Tightening sequence Tighten diagonally 1st tightening stage 10 Nm 7 4 lbfft 2nd tightening sta...

Page 282: ... height unloaded Ground clearance unloaded Weight without fuel approx FE 350 US Maximum permissible front axle load Maximum permissible rear axle load Maximum permissible overall weight 280 I 9 5 I 2 51 US gal I 8 5 I 2 25 US gal 11 5 I 1 6 qt 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 ...

Page 283: ... 350 S US 5 W 26 7 Tires Validity Front tire Rear tire FE EU AU FE 350 S US 90 90 21 M C 54R TT 140 80 18 M C 70R TT Michelin ENDURO COMPETI Michelin ENDURO COMPETI TION IV TION Ille FE 350 US 90 90 21 54M TT 110 100 18 64M TT Dunlop GEOMAX AT81F Dunlop GEOMAX AT81 The tires specified represent one of the possible series production tires Additional information is available in the Service section u...

Page 284: ... sag Riding sag Fitted length Shock absorber oil 26 10 Chassis tightening tor ues 4 2 N mm 24 lb in 4 4 N mm 25 1 lb in 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 Ip 352 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...

Page 285: ...hassis Screw bottom shock absorber Screw handlebar holder 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 26 TECHNICAL DATA 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 25...

Page 286: ...t rear wheel spindle Screw front wheel spindle Screw top steering head Screw in nozzles cooling system 284 M10 M12 M14x1 5 M14x1 5 M14x1 5 M16x1 5 M20x1 5 M20x1 5 M20x1 5 M20x1 5 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 ...

Page 287: ...gularly Avoid direct sunshine when cleaning the motorcycle 1 111111111111111 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 to...

Page 288: ...nst aggressive road salt If the vehicle was 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 285 Clean the brake system Info 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 s...

Page 289: ... waiting times at the start of the new season 1111 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Refuel Clean the motorcycle p 285 Change the engine oil and oil filter clean the oil screen p 260 Check the antifreeze and coolant level p 255 Check the tire air pressure a p 117 Remove the battery a p 143 Recharge the battery Guideline Storage...

Page 290: ...RAGE 28 2 288 Pre aring for use after storage 401059 01 Remove the motorcycle from the lift stand p 13 Install the battery p 144 Perform checks and maintenance measures when preparing for use Take a test ride ...

Page 291: ...on I p 119 0 I Check the chain rear sprocket engine sprocket and chain guide a p 131 I Check the chain tension J p 129 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 I p 252 I I Check the front brake fluid level a p 152 I I I Check the free travel of the hand brake lever a p 151 I Check the play o...

Page 292: ... p 253 Lubricate the steering head bearing JI p 36 Clean the spark arrestor a p 90 Perform a fork service I p 19 Service the shock absorber I p 57 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 pi...

Page 293: ...29 SERVICE SCHEDULE 291 ...

Page 294: ...M10 J K10 f A I n D X2 l 1 E C0 E a C nr F c I I z HUSQl l ma 1 2 a I 3 I II G10 1 X300 l 1 FE 350 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 8 A f B C f D f w rd a 2 E1 E f lW t b 2 F1 F I ha I 6 I 7 I 8 ...

Page 295: ...Components G10 Battery K10 Starter relay with main fuse M10 Electric starter system S21 E tip switch 30 WIRING DIAGRAM 293 ...

Page 296: ... 1 X10 1 1 rrDY 4 I 1 X9 1 5 t6 1 t3 J 2 i iEB 4 X295 F2 K30 a AP 6 e FJ 2 f EB 4 1 X 6 I 1 X3 1 1 1 1 EB aC wlHdl e 1 t L j __ 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 FJ 2 1 FJ 2 X39 1 xs X7 t 1 L_JI t IfI i b 3 E1 1 FB bC tr 0 tr t b 7 F1 HUSQl l ma FE 350 EU 2016 2 8 ...

Page 297: ...11 EFI control unit B33 Radiator fan temperature switch F2 Fuse F3 Fuse F4 Fuse G20 Alternator K12 Light relay K30 Power relay M14 Radiator fan T20 Voltage regulator X295 Diagnostics connector 30 WIRING DIAGRAM 295 ...

Page 298: ... S P13 I I n JiCX 2 X 50 il E wh t f 4 81 1 I I G i s 8 ttl BP 4 MjDG 4 1 l t 1 1 AC 6 BA 1 i 11 f d t 1 1 1 I I I 1 w m 11 I I I I I l f j f i 1r r 1 j j j 11 I y oo t 14 E1 l E 2 EB bC 0 c 4 E1 IE C0 0 I I C I ll ll HUSQl l ma FE 350 EU 2016 I l I 1 I I I ...

Page 299: ...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 297 ...

Page 300: ... ct C 1 X18 1 X19 l 1 i X 1 3 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 i_ 1 I I I I I f 3 EB et ye 00 E C0 a v C nr E 3 EB bC 0 E f F F C c I 1 z FE 350 EU 2016 hm HUSQl l ma 1 2 I 3 I 4 5 I 6 I 7 I 8 a ...

Page 301: ...Components B76 Front brake light switch B77 Rear brake light switch E60 License plate lamp P36 Brake tail light 30 WIRING DIAGRAM 299 ...

Page 302: ..._ C U X 42 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 fJ 3 i CX 2 l X 2 l X 2 l X 2 D X42 X23 X25 X41 X28 i i I I I I f E C0 a It C nr E E f F F c I IU FE 350 EU 2016 I hm HUSQl l ma 1 2 I 3 I 4 5 I 6 I 7 I 8 a ...

Page 303: ...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 301 ...

Page 304: ...a co C nr E F c I I FE 350 EU 2016 HUSQl l ma 1 2 I 3 I 4 5 a 1 Jl X15 X15 I B51 j 20 CU 4 M Y 4 M l i CU 4 X20 6 I I P13 3 A6 7 A2 1 X15 i 6 I 7 I S 1lY 3 lY 3 l cm M l cv J X51 X51 p i GN3 Jm Tl T 07 R rr D7 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 305: ...Components A11 EFI control unit B32 Fuel level sensor B51 Lambda sensor cylinder 1 F1 Fuse P13 Speedometer 30 WIRING DIAGRAM 303 ...

Page 306: ...if Y 3 X15 X15 X15 X15 X15 f X52 B70 5 l5 l5 e r j i f 1515 il 8 B I I i HHr 1 f il C U C 1 NDQ 2 NAT 2 GA 3 f f X295 X 3 01 r 7 6 D7 M f AP 6 n 16 Dl 1 0 0 t D X26 X29 D 5 l5 l5 1515 f E C0 a C nr E 6 EB g C er E f 2 FS b C t F F c I Ir FE 350 EU 2016 I hm HUSQl l ma 1 2 I 3 I 4 5 6 I 7 I 8 g a ...

Page 307: ...mponents A11 EFI control unit B70 Front wheel speed sensor M13 Fuel pump M51 Injection valve cylinder 1 R30 CAN bus terminating resistor 1 P13 Speedometer X295 Diagnostics connector 30 WIRING DIAGRAM 305 ...

Page 308: ... I I f 1 x3s AX12 B21 m AX 2 1 x35 3 4 l X15 11 X15 t 1 I I I 9 1 l X37 X36 N AU2 1 HT 2 R51 lJJ B37 FE 350 EU 2016 I 3 I 4 5 6 7 8 I IA 1 1 1 1 1 f X15 X15 X15 X15 X15 il 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 2 8 I il E E E I I I I I I IE I I I I I I I I I I I 6 7 I 5 ...

Page 309: ...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 307 ...

Page 310: ...2 l 1 a w E E C0 F a C nr tel HUSQ l ma 1 2 c I IO z a I 3 I 4 II G10 1 X300 l 1 FE 350 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 w rd a 2 E1 E f lW t b 2 F1 F I ha I 6 I 7 I 8 g ...

Page 311: ...Components G10 Battery K10 Starter relay with main fuse M10 Electric starter system S23 Emergency OFF switch tip switch 30 WIRING DIAGRAM 309 ...

Page 312: ...0 1 1 rrDY 4 I 1 X9 1 5 t6 1 t3 J 2 i iEB 4 X295 F2 K30 a AP 6 e FJ 2 f EB 4 1 X 6 I 1 X3 1 1 1 1 EB aC wlHdl e 1 t L j __ 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 FJ 2 1 FJ 2 X39 1 xs X7 t 1 L_JI t IfI C b 3 E1 1 FB bC tr 0 tr t b 7 F1 HUSQl l ma FE 350 AU 2016 2 8 0 ...

Page 313: ...11 EFI control unit B33 Radiator fan temperature switch F2 Fuse F3 Fuse F4 Fuse G20 Alternator K12 Light relay K30 Power relay M14 Radiator fan T20 Voltage regulator X295 Diagnostics connector 30 WIRING DIAGRAM 311 ...

Page 314: ...3 I I n JiCX 2 X50 il E I l wh c f 4 B1 1 f u i w I p 15 8 cru C 4 ___ _ _ 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 _ j 1r r 1 j I I E 2 EB bC 0 ____ C b 4 E1 IE C0 0 I I C _ I ll ll HUSQl l ma FE 350 AU 2016 I l I 1 I I I C II ...

Page 315: ...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 313 ...

Page 316: ... ic C 1X18 1X19 l 1 i X 1 3 C AH 2 AH 2 BY 4 D1 2 r X11 B76 B77 P36 CV 4 f 7 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 I I I I I f w 3 ES et ye OO E C0 a v C nr E 3 EB b C t E f F F I I z FE 350 AU 2016 hm HUSQl l ma 1 2 I 3 I 4 5 I 6 I 7 I 8 j a ...

Page 317: ...Components B76 Front brake light switch B77 Rear brake light switch E60 License plate lamp P36 Brake tail light 30 WIRING DIAGRAM 315 ...

Page 318: ..._ C U X 42 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 fJ 3 i CX 2 l X 2 l X 2 l X 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 FE 350 AU 2016 I hm HUSQl l ma 1 2 I 3 I 4 5 I 6 I 7 I 8 a ...

Page 319: ...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 317 ...

Page 320: ... D XS w E C0 a co C nr E F I I FE 350 AU 2016 HUSQl l ma 1 2 I 3 I 4 5 a TI X15 X15 ca l 7 1 1 rrrn CU 4 6 I I P13 3 A6 7 A2 1 X15 i 6 I 7 I S 1lY 3 lY 3 l cm 1cv3 X51 X51 p i GN3 Jm Tl T 07 R rr D7 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 321: ...Components A11 EFI control unit B32 Fuel level sensor F1 Fuse P13 Speedometer 30 WIRING DIAGRAM 319 ...

Page 322: ...J X15 X15 X15 X15 X15 f X52 B70 5 l5 l5 e r j i f 1515 il 8 B I I a a 1 S i P f f ll a il C C 1 NDQ 2 NAT 2 GA 3 f f X295 X301 r 7 6 D7 M f AP 6 n 16 Dl 1 0 0 t D X26 X29 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 tel FE 350 AU 2016 I hm HUSQ l ma 1 2 I 3 I 4 5 6 I 7 I 8 a ...

Page 323: ...mponents A11 EFI control unit B70 Front wheel speed sensor M13 Fuel pump M51 Injection valve cylinder 1 P13 Speedometer R30 CAN bus terminating resistor 1 X295 Diagnostics connector 30 WIRING DIAGRAM 321 ...

Page 324: ...5 X15 X15 X15 X15 I t 1 B f t B B f 9 t 9 C x34 I I X37 C DV 2 NAU2 S51 u2 AX 2 FU1 EX 3 AP 6 NDX 3 CM 2 B37 M f n El f fv e 0 F r n n w n m t D X35 X30 X33 X32 X38 D X34 B B f w E C0 a C0 C nr E E f 6 FB h I bl F F I I tel FE 350 AU 2016 I hm HUSQ l ma 1 2 I 3 I 4 5 I 6 I 7 I 8 a ...

Page 325: ...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 323 ...

Page 326: ...DIAGRAM 30 17 Page 1 of 6 FE 350 US I m i i i Tl m 0 C J 0 J S I m 324 I 0 I 0 I I l p J oo ro 4 h ro IJd 1 w d 20A wh rd G 3 9 1 i i i 11i ir J wh rd wh rd I i oo d c 2 b bl A _i _i A 0 I 0 I ro I ro I B00201 01 ...

Page 327: ...Components G10 Battery K10 Starter relay with main fuse M10 Electric starter system S21 E tip switch 30 WIRING DIAGRAM 325 ...

Page 328: ... I 1 X 10 1 1 rrDY 4 I 1 X9 1 5 t6 1 t3 J 2 i iEB 4 X295 F2 K30 a AP 6 e FJ 2 f EB 4 1 X6 I 1 X 3 1 1 1 1 EB aC wlHdl e 1 t L j __ 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 X19 111 FJ 2 1FJ 2 X23 1 xs X7 t 1 L_JI 1 t l l b 3 E1 1 FB bC tr 0 tr t b 5 F1 HUSQl l ma FE 350 US 2016 2 6 ...

Page 329: ...ntrol unit B33 Radiator fan temperature switch optional F2 Fuse 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 327 ...

Page 330: ...A3 A111 I 1 x 15 t B B I l 11 1 1 l C 1 X18 is 1 1 X17 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 Hu ma FE 350 US 2016 I 1 2 I J I 4 s I 6 I 1 I a ...

Page 331: ...Components A11 EFI control unit E11 Low beam P35 Parking light P37 Tail light S20 Kill switch S30 Light switch 30 WIRING DIAGRAM 329 ...

Page 332: ...f i m D XS w E 0 a v C nr E F I I FE 350 US 2016 HUSQl l ma 1 2 I 3 I 4 5 a TI X15 X15 ca l 7 1 1 rrrn CU 4 6 I I P13 5 A2 1 X15 i 6 I 7 I S 1lY 3 lY 3 l cm 1 cv 3 X14 X14 p i GN3 Jm Tl 15 07 R r i D7 I 7 I 8 A f B C f D f O t e 5 E1 E f bl f 6 F1 F 8 ...

Page 333: ...Components A11 EFI control unit B32 Fuel level sensor F1 Fuse P13 Speedometer 30 WIRING DIAGRAM 331 ...

Page 334: ...O iifY J X15 X15 X15 X15 X15 f X13 B70 5 l5 l5 e t j i f 1515 E B B I I i HHr 1 f E C U C 1 NDQ 2 NAT 2 GA 3 f f X295 X301 r 7 4 D7 M f AP 6 n 14 D7 1 0 0 t D X26 X29 D 5 l5 l5 1515 f w E 0 a It C nr E 4 EB et i r E f 2 FS b C t F F I 1 FE 350 US 2016 I HUSQl l ma 1 2 I 3 I 4 5 6 I 7 I 8 a ...

Page 335: ...mponents A11 EFI control unit B70 Front wheel speed sensor M13 Fuel pump M51 Injection valve cylinder 1 P13 Speedometer R30 CAN bus terminating resistor 1 X295 Diagnostics connector 30 WIRING DIAGRAM 333 ...

Page 336: ...X 2 1 x35 3 4 l X15 11 X15 t t I I I 9 1 l X28 X36 N AU2 1 HT 2 R51 lJJ B37 5 6 7 1 1 1 1 1 X15 X15 X15 X15 X15 B f t I I I I 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 B E E E 4 FB 11 bl 4 i I L HUSQ l ma FE 350 US 2016 1 I l I I I 8 I IA f Is I I ...

Page 337: ...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 335 ...

Page 338: ...B II 11 II I l l 1 1 l 1 M10 K10 G10 523 510 F3 n n X56 1i f V 8 v GT 6 o ii 1d 4 i is f s r o X4 X55 11 2 l a 1 1 X300 I i I 1 I rf7 rd a 2 E1 t 1 w rd b 2 E1 E E t ye tlr t c 2 E1 1 l d 2 F1 Ft F FE350SUS2016 I l_ HuSQl l ma I 1 8 1 2 I J I 4 s I 6 I 1 I a ...

Page 339: ...Components F3 Fuse G10 Battery K10 Starter relay with main fuse M10 Electric starter system S10 Ignition lock S23 Emergency OFF switch tip switch 30 WIRING DIAGRAM 337 ...

Page 340: ... I f X20 EB 4 X10 J l 1 ES aC rd I W DY 4 I 1 X9 11 1 t6 1 t3 fJ12 1 ies14 F2 w K3 0 a X295 AP 6 e FJ 2 iEB 4 1 X 6 I 1 X 3 1 l 1 1 EB bC WIHd J f 1 L 1 EB cC ye br l x2ss iBS 2 BV 2 M14 1 J th BV 28 18S 2 1 X285 ts i J 2 Ill w m m 00 _ 1 FB dC tr tr t d 7 F1 HUSQl l ma FE 350 SUS 2016 2 8 ...

Page 341: ...ts A11 EFI control unit B33 Radiator fan temperature switch F2 Fuse F4 Fuse G20 Alternator K12 Light relay K30 Power relay M14 Radiator fan T20 Voltage regulator X295 Diagnostics connector 30 WIRING DIAGRAM 339 ...

Page 342: ...4 I l I LAI MjDG 4 1CW 2 IAI JCXJ2 X46 t f X22 X50 X53 1 x i 1 0814 II 11 IYI 1 sp14 1 cXJ2 IYI 1 cw12 cR l iFF 1 iFF 1 i Dl 2 iF0 2 D 1 x12 X24 X21 X31 X54 ti i i i _a _a 2 EB IC L_J I LJ 1 1 I 11 I e E 2 EB dC 0 ____ _ _____ t C d 4 E1 IE C0 0 I l g g HUSQl l ma FE 350 SUS 2016 I l I 1 I I I g ...

Page 343: ...Components A11 EFI control unit E13 Low beam high beam P15 Horn P23 High beam indicator lamp P35 Parking light S29 Light switch horn button turn signal switch 30 WIRING DIAGRAM 341 ...

Page 344: ... E ct C 1 X18 1 X19 l 1 i X 1 3 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 i_ 1 I I I I I f w 3 EB It ye 00 E C0 a v C nr E 3 EB dC 0 E f F F I I z FE 350 SUS 2016 hm HUSQl l ma 1 2 I 3 I 4 5 I 6 I 7 I 8 a ...

Page 345: ...Components B76 Front brake light switch B77 Rear brake light switch E60 License plate lamp P36 Brake tail light 30 WIRING DIAGRAM 343 ...

Page 346: ...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 2 529 P42 P46 P41 P45 f 3 C3 f 13 W 2 W 2 W 2 W 2 i D X45 f J 3 l X 2 l X 2 l X 2 l X 2 D X42 X23 X25 X41 X28 u i i I I I I f w E C0 a It nr E E f F F I I z FE 350 SUS 2016 I hm HUSQl l ma 1 2 I 3 I 4 5 I 6 I 7 I 8 g a ...

Page 347: ...urn signal relay P21 Turn signal switch P41 Turn signal front left P42 Turn signal front right P45 Turn signal rear left P46 Turn signal rear right S29 Light switch horn button turn signal switch 30 WIRING DIAGRAM 345 ...

Page 348: ...J FJ 2 W f i m D XS u w E F E C0 a co C nr FE 350 SUS 2016 HUSQl l ma 1 2 I 3 I I I a 4 5 I 6 I I P13 7 A2 X15 i 4 5 I 6 I 7 l l i I S CY 3 1CY 3 CZ 3 1 CZ 3 X60 X60 X29 GN3 Tl 17 07 R rr D7 I 7 I 8 A f B C f D f O t h 7 E1 E f F hm 8 g ...

Page 349: ...Components A11 EFI control unit B32 Fuel level sensor F1 Fuse P13 Speedometer 30 WIRING DIAGRAM 347 ...

Page 350: ...l5 5 u w E C0 a C nr 6 EB h C er E 2 FS d C t F I I z FE 350 SUS 2016 HUSQl l ma 1 2 I 3 I 4 a 5 m ITT X15 j i I 9 9 9 9 r l1 o a AT 2 X295 AP 6 5 5 6 II DF 2 I X57 5 6 I 7 I 8 I A 1 ITT l oo TI ITT OO X15 X15 X15 f 1515 il B I f f il C GA 3 X 3 01 r 7 6 D7 M f 16 Dl t X29 D 1515 f E f F I hm I 7 I 8 g ...

Page 351: ...ontrol unit B70 Front wheel speed sensor M13 Fuel pump M20 Evaporate emission control valve M51 Injection valve cylinder 1 P13 Speedometer R30 CAN bus terminating resistor 1 X295 Diagnostics connector 30 WIRING DIAGRAM 349 ...

Page 352: ... I I f 1 x3s AX12 B21m AX 2 1 x35 3 4 l X15 11 X15 t 1 I I I 9 1 l X37 X36 N AU2 1 HT 2 R51 lJJ B37 FE 350 SUS 2016 I l 5 6 7 8 I IA 1 1 1 1 1 f X15 X15 X15 X15 X15 il 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 1 I I I ...

Page 353: ...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 351 ...

Page 354: ...otection 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 ine ...

Page 355: ...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 356: ...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 357: ...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 355 ...

Page 358: ...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 356 ...

Page 359: ...l H01065 01 Art no 00029095052 Feature UK safety plug Nominal voltage Mains fuse Power cable length approx Charger cable length approx rofessional H01065 01 H00973 01 Art no 00029095053 Feature CH plug Nominal voltage Mains fuse Power cable length approx Charger cable length approx Art no 50305017000 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...

Page 360: ...LS 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 Puller Art no 58012009000 58012009000 H00592 01 358 ...

Page 361: ...89000 Pressing tool 58429091000 Pressing tool 58429092000 H00596 01 H00603 01 H00604 01 H00605 01 Art no 58429037037 Feature I Inside diameter Art no 58429089000 Art no 58429091000 Art no 58429092000 33 SPECIAL TOOLS I 37 5 mm 1 476 in 359 ...

Page 362: ... H00627 01 360 Art no 58429094000 Feature Torque Open ended bit Open ended bit Open ended bit Open ended bit Bit diameter Art no 59029019000 Art no 59029041100 Feature I 5 piece Art no 60029012000 Feature 3 15 Nm 2 2 11 1 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 I 0 025 0 175 mm 0 00098 0 00689 in ...

Page 363: ...000 Testing hose 61029093000 Pressure testin tool 4x D 61029094000 H00628 01 H00650 01 H00659 01 H00660 01 33 SPECIAL TOOLS Art no 60029015000 Feature Height 80 mm 3 15 in Diameter 57 125 mm 2 24 4 92 in Art no 60029057000 Art no 61029093000 Art no 61029094000 361 ...

Page 364: ...iming chain tensioner Art no 61229021000 61229021000 H00675 01 Crankshaft ressing tool Art no 75029047000 0 v 75029047000 H00714 01 Protection ca Art no 75029090000 75029090000 H00726 01 Puller Art no 77229001044 77229001044 H00747 01 362 ...

Page 365: ... stand 2x Art no 77229002000 77229002000 H00748 01 Crankshaft ressing tool insert Art no 77229008000 77229008000 H00750 01 Se arator late Art no 77229009000 77229009000 H00751 01 Valve stem seals lier Art no 77229010000 77229010000 H00752 01 363 ...

Page 366: ... H00753 01 Insertion for iston ring lock 77229030000 H00754 01 Protection ca 0 77229031000 H00755 01 Se 0 77229032000 H00756 01 364 Art no 77229026000 Feature I Diameter Art no 77229030000 Art no 77229031000 Art no 77229032000 I 5 55 mm 0 2185 in ...

Page 367: ... tensioner Art no 77229035000 77229035000 H00757 01 Puller Art no 77229048000 77229048000 H00758 01 Adjustment bush bridge Art no 77229050044 2x 77229050044 H00759 01 Insert for valve s ring lever Art no 77229060000 77229060000 H00760 01 365 ...

Page 368: ...00 H00764 01 Engine work stand 80329001000 H01047 01 Lift stand 81329955100 H00985 01 366 Art no 77229172000 Feature Drive Hexagonal part Length Art no 77329006000 Art no 80329001000 Art no 81329955100 Feature Height Load 3 8 in 14 mm 0 55 in 130 mm 5 12 in 315 425 mm 12 4 16 73 in 150 kg 331 lb ...

Page 369: ...01 Drift T120 H00844 01 Clam ing stand T1202S H01149 01 Art no T106S Feature I Diameter Art no T107S Art no T120 Feature I Diameter Art no T1202S Feature Diameter Diameter 33 SPECIAL TOOLS I 68 75 mm 2 68 2 95 in I 8 mm 0 31 in 10 mm 0 39 in 18 mm 0 71 in 367 ...

Page 370: ...Pressing tool T1206 Pressing tool 61 T1207S 368 H00878 01 H00879 01 H00880 01 H00881 01 Art no T1204 Feature I Diameter Art no T1205 Feature I Diameter Art no T1206 Feature I Diameter Art no T1207S I25 5 30 5 mm 1 004 1 201 in 118 mm 0 71 in 115 30 mm 0 59 1 18 in ...

Page 371: ...1240S Protecting sleeve 6Y T1401 H00886 01 H00887 01 H00890 01 H00894 01 Art no T1215 Feature I Diameter Art no T1216 Feature I Diameter Art no T1240S Art no T1401 Feature I Diameter 33 SPECIAL TOOLS 118 mm 0 71 in 138 49 mm 1 5 1 93 in I 48 mm 1 89 in 369 ...

Page 372: ...896 01 H00922 01 H00923 01 H00924 01 Art no T1403S Feature Diameter Diameter Art no T14040S Feature I Diameter Art no T14047 Feature Drive Narrow diameter Wide diameter Art no T14049S Feature Diameter Diameter 48 mm 1 89 in 60 mm 2 36 in 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 ...

Page 373: ...1504 Mounting tool c0 T150S Filling tool 2x 3x T170S1 H00926 01 H00899 01 H00852 01 H00855 01 Art no T14051 Feature I Diameter Art no T1504 Feature I Diameter Art no T150S Art no T170S1 I 50 mm 1 97 in 118 mm 0 71 in 33 SPECIAL TOOLS 371 ...

Page 374: ... 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 375: ...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 373 ...

Page 376: ...cking 148 of rear brake changing 158 rear brake checking 157 374 Capacity coolant 258 279 Engine oil 180 262 279 fuel 280 Cartridge of fork legs disassembling 23 of the fork legs assembling 30 Chain checking cleaning 131 133 Chain guide checking 131 Chain tension adjusting 129 checking 129 Charging voltage checking 146 Chassis number 10 Clutch fluid level checking correcting 252 fluid changing 253...

Page 377: ...ork on the individual parts drive wheel of the balancer shaft installing 206 left engine case section 198 Engine working on the individual parts clutch checking 220 countershaft assembling 227 countershaft disassembling 224 main shaft assembling 226 Engine assembly alternator cover installing 248 camshafts installing 243 clutch basket installing 234 clutch cover installing 237 clutch discs install...

Page 378: ...e sprocket checking 131 F Figures 9 Filler cap closing 96 opening 95 Foot brake lever basic position adjusting 161 free travel checking 160 Fork legs assembling 32 bleeding 16 cartridge assembling 30 376 cartridge disassembling 23 checking 26 disassembling 20 dust boots cleaning 16 fork service performing 19 hydrostop unit assembling 28 hydrostop unit disassembling 25 installing 17 piston rod asse...

Page 379: ... screen cleaning 259 260 260 Open circuit current checking 146 Operating substances 9 p Piston rod of fork legs assembling 29 of fork legs disassembling 24 Play in throttle cable checking 46 Preparing for use after storage 288 R Rear sprocket checking 131 Rear wheel installing removing 126 125 Rebound damping fork adjusting 15 shock absorber adjusting 50 Riding sag adjusting 53 Right side cover in...

Page 380: ...g T changing 79 checking 75 Technical data capac es 279 chassis 280 chassis tightening torques 282 electrical system 281 engine 276 engine tolerance wear limits 277 378 engine tightening torques 277 fork 281 shock absorber 282 tires 281 Throttle cable play adjusting 47 Throttle cable routing checking 45 Tire air pressure checking 117 Tire condition checking 117 Type label 10 w Valve clearance chec...

Page 381: ...11111111111111111111IIIIIIIIIIII 3403027en 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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