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Husqvarna F2303P0, Repair Manual

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Husqvarna F2303P0 Repair Manual Download Page 6

TABLE OF CONTENTS 

15.5 

Checking the charging voltage .........  139 

15.6 

Checking the open-circuit current ....  139 

15. 7

Checking the capacitor .....................  140 

15.8

Checking the starter relay .................  141 

16  BRAKE SYSTEM ...........................................  142 

16.1 
16.2 
16.3 

16.4 

16.5 
16.6 

16.7 

16.8 
16.9 

Checking the front brake linings .......  142 
Changing the front brake linings .......  142 

Adjusting the basic position of the 

hand brake lever . . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .  144 
Checking the front brake fluid 

level ...................................................  145 

Adding front brake fluid ....................  145 
Changing the front brake fluid ..........  146 
Checking the brake linings of the 
rear brake..........................................  148 
Changing the rear brake linings ........  148 

Checking the free travel of foot 

brake lever . . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .  150 

16.10  Adjusting the basic position of the 

foot brake lever .................................  151 

16.11  Checking the rear brake fluid level ...  151 
16.12  Adding rear brake fluid .....................  152 
16.13  Changing the rear brake fluid ...........  153 

17  ENGINE .........................................................  156 

4 

17.1 

Removing the engine ........................  156 

17.2 

Installing the engine ..........................  163 

17 .3 

Engine disassembly ..........................  171 

17 .3.1 

Preparations .................................  171 

17.3.2 

Draining the engine oil. .................  171 

17.3.3 

Removing the clutch push rod .....  172 

17.3.4 

Removing the oil filter ...................  172 

17.3.5 

Removing the starter motor .........  173 

17.3.6 

Removing the spark plug .............  173 

17.3.7 

Removing the valve cover ............  173 

17.3.8 

Removing the alternator cover .....  173 

17.3.9 

Positioning the engine at 

ignition top dead center ...............  17 4 

17.3.10 

Removing the timing chain 
tensioner.......................................  17 4 

17 .3.11 

Removing the camshaft ...............  175 

17.3.12 

Removing the cylinder head .........  175 

17.3.13 

Removing the piston ....................  176 

17.3.14 

Removing the rotor .......................  176 

17.3.15 

Removing the timing chain ...........  177 

17.3.16 

Removing the suction pump ........  177 

17 .3.17 

Removing the gear position 

sensor ...........................................  178 

17.3.18 

Removing the water pump 

cover .............................................  178 

17.3.19 

Removing the clutch cover ...........  179 

17.3.20 

Removing the clutch discs ...........  179 

17.3.21 

Removing the outer clutch hub ....  180 

17.3.22 

Removing the torque limiter .........  181 

17.3.23 

Removing the starter idler gear ....  181 

17.3.24 

Removing the force pump ............  181 

17.3.25 

Removing the shift shaft ...............  182 

17.3.26 

Removing the shift drum 
locating unit.. ................................  183 

17.3.27 

Removing the locking lever ..........  183 

17.3.28 

Removing the primary gear ..........  183 

17.3.29 

Removing the freewheel gear .......  183 

17.3.30 

Removing the left engine case 

section..........................................  184 

17.3.31 

Removing the shift rails ................  185 

17.3.32 

Removing the shift drum ..............  185 

17.3.33 

Removing the shift forks ..............  185 

17.3.34 

Removing the transmission 

shafts ............................................  185 

17.3.35 

Removing the crankshaft .............  186 

17.4 

Working on individual parts ..............  186 

17.4.1 

Working on the right section of 

the engine case ............................  186 

17.4.2 

Working on the left section of 
the engine case ............................  188 

17.4.3 

Removing the oil pressure 
regulator valve ..............................  189 

17.4.4 

Checking spring length of oil 
pressure regulator valve ...............  189 

17.4.5 

Installing the oil pressure 

regulator valve ..............................  190 

17.4.6 

Changing the crankshaft seal 
ring in the clutch cover .................  190 

17.4. 7 

Removing the water pump ...........  190 

17.4.8 

Installing the water pump .............  191 

17.4.9 

Removing the crankshaft 
bearing inner race .........................  192 

17.4.10 

Installing the crankshaft bearing 

inner race ......................................  193 

17.4.11 

Changing the connecting rod, 
conrod bearing,  and crank pin .....  193 

17.4.12 

Checking crankshaft run-out at 

bearing pin ...................................  195 

17.4.13 

Measuring the crankshaft end 

play ...............................................  195 

17.4.14 

Cylinder - Nikasil

® 

coating ............  196 

17.4.15 

Checking/measuring the 

cylinder .........................................  196 

17.4.16 

Checking/measuring the piston ...  197 

17.4.17 

Checking the piston ring end 

gap ...............................................  198 

17.4.18 

Measuring the piston/cylinder 
mounting clearance......................  198 

17.4.19 

Checking the oil pumps ...............  199 

Summary of Contents for F2303P0

Page 1: ...PIONEERING SINCE 1903 REPAIR MANUAL2016 FS 450 Art no 3403034en Husqvarna MOTORCYCLES ...

Page 2: ......

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

Page 4: ...6 15 Disassembling the screw sleeve 27 6 16 Checking the fork legs 27 6 17 Checking the fork legs during a minor fork service 29 6 18 Changing the pilot bushing 31 6 19 Assembling the screw sleeve 32 6 20 Assembling the screw cap with the membrane holder 32 6 21 Assembling the piston rod 33 6 22 Assembling the cartridge 35 6 23 Assembling the fork legs 37 6 24 Bleeding and filling the cartridge 41...

Page 5: ...ing the air filter box 99 12 FUEL TANK SEAT TRIM 100 12 1 Opening the filler cap 100 TABLE OF CONTENTS 12 2 Closing the filler cap 100 12 3 Removing the right side cover 101 12 4 Installing the right side cover 101 12 5 Removing the seat 101 12 6 Mounting the seat 102 12 7 Removing the fuel tank 103 12 8 Installing the fuel tank 104 12 9 Checking the fuel pressure 106 12 10 Changing the fuel pump ...

Page 6: ... 178 17 3 18 Removing the water pump cover 178 17 3 19 Removing the clutch cover 179 17 3 20 Removing the clutch discs 179 17 3 21 Removing the outer clutch hub 180 17 3 22 Removing the torque limiter 181 17 3 23 Removing the starter idler gear 181 17 3 24 Removing the force pump 181 17 3 25 Removing the shift shaft 182 17 3 26 Removing the shift drum locating unit 183 17 3 27 Removing the locking...

Page 7: ... 17 5 11 Installing the shift shaft 224 17 5 12 Installing the force pump 224 17 5 13 Installing the starter idler gear 225 17 5 14 Installing the torque limiter 226 TABLE OF CONTENTS 17 5 15 Installing the clutch basket 226 17 5 16 Installing the clutch discs 227 17 5 17 Installing the clutch cover 228 17 5 18 Installing the water pump cover 228 17 5 19 Installing the gear position sensor 229 17 ...

Page 8: ... 25 2 Tolerance engine wear limits 266 25 3 Engine tightening torques 266 25 4 Capacities 268 25 4 1 Engine oil 268 25 4 2 Coolant 268 25 4 3 Fuel 268 25 5 Chassis 268 25 6 Electrical system 269 25 7 Tires 269 25 8 Fork 270 25 9 Shock absorber 270 25 10 Chassis tightening torques 271 26 CLEANING PROTECTIVE TREATMENT 273 26 1 Cleaning the motorcycle 273 27 STORAGE 275 27 1 Storage 275 27 2 Preparin...

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

Page 11: ...ment 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 ...

Page 12: ...art number 401947 10 10 The chassis number O is stamped on the right side of the steer ing head The type label O is fixed to the front of the steering head The engine number O is stamped on the left side of the engine under the engine sprocket The fork part number O is stamped on the inside of the axle clamp ...

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

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

Page 15: ... cle to check the function Danger Danger of poisoning death Exhaust gases are toxic and inhaling them may result in unconsciousness and Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space 400733 01 Shift the transmission to idle Press the electric starter button Cl _ Info I Pres...

Page 16: ... clicks 12 clicks 10 clicks I Turn clockwise to increase damping turn counter clockwise to reduce damping Ad ustin the rebound dam ing of the fork Info The hydraulic rebound damping determines the fork suspension behavior Take off protection caps O Turn adjusting screws clockwise all the way Info Adjusting screws are located at the bottom end of the fork legs Make the same adjustment on both fork ...

Page 17: ...of both fork legs downward Info The dust boots remove dust and coarse dirt parti cles from the inside fork tubes Over time dirt can accumulate behind the dust boots If this dirt is not removed the oil seals behind can start to leak Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with br...

Page 18: ... side Release screws Take out the left fork leg Release screws D Take out the right fork leg Main work Position the fork legs Bleeder screws O are positioned toward the front Info Grooves are milled into the side of the upper end of the fork legs The second milled groove from the top must be flush with the top edge of the upper triple clamp Tighten screws Guideline Screw top triple clamp Tighten s...

Page 19: ...ff the right fork protector 6 8 Installing the fork protector S00564 11 Position the fork protector on the left fork leg Mount and tighten screws 0 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake line and clamp Mount and tighten screws Position the fork protector on the right fork leg Mount and tighten screws CD Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Condu...

Page 20: ...0 p 27 Change the pilot bushing a p 31 Assemble the screw sleeve a p 32 Assemble the screw cap with the membrane holder p 32 Assemble the piston rod 0 p 33 Assemble the cartridge 0 p 35 Assemble the fork legs 0 p 37 Conductin minor fork service Info The steps are identical for both fork legs 0 Condition The fork legs are disassembled Disassemble the fork legs 0 p 19 Check the fork legs during a mi...

Page 21: ...p f Make a note of the present state of rebound O and com pression damping 8 Open the adjusters of the rebound and compression damp ing completely Clamp the fork leg in the area of the lower triple clamp I Clamping stand T1403S ll l p 308 Remove the screw Remove adjuster of the compression damping Loosen cartridge 8 I Ring wrench T14017 8 p 306 Info The cartridge cannot be taken off yet 19 ...

Page 22: ...act wrench Place a container underneath as oil runs out in most cases The rebound adjustment cannot be removed yet Press the cartridge against the spring and mount special tool D on the piston rod I Support tool T14020 a p 306 Hold nut and remove the rebound adjuster Press the cartridge against the spring and remove special tool D Remove the cartridge from the fork leg Unclamp the fork leg Remove ...

Page 23: ...arm up outer tube in area of the lower sliding bushing Guideline I so 0 c 122 F Pull the outer tube from the inner tube with a jerk Info Lower sliding bushing ai must be pulled from its bearing seat Remove upper sliding bushing G Info Without using a tool pull the stack slightly apart by hand Take off lower sliding bushing ai Take off support ring 48 Take off seal ring 48 Take off lock ring Take o...

Page 24: ...5 10 200836 10 Preparatory work Disassemble the fork legs a p 19 Main work Remove adjusting tube O and nut 8 Clamp the cartridge into a vise Info Use soft jaws Remove filling screw 8 Pierce the membrane with the needle of the special tool I Filling tool T14019 a p 306 The pressurized nitrogen is bled off ...

Page 25: ...Pin wrench T103 a p 303 Unclamp the cartridge Empty the cartridge Reclamp the cartridge upside down Guideline I Use soft jaws Heat the cartridge in area O of pilot bushing 0 Guideline 1100 C 212 F Loosen the screw sleeve and remove the piston rod Remove spring guide D and ring Remove guide ring 23 ...

Page 26: ...d Info The steps are identical for both fork legs 200856 10 201160 10 Preparatory work Disassemble the fork legs i I p 19 Disassemble the cartridge i I p 22 Main work Remove screw sleeve O and washer 8 from the piston rod Degrease the piston rod Clamp the piston rod with the special tool as far up as possi ble I Clamping stand T14016S i I p 306 Remove nut D ...

Page 27: ...bound shim stack C Remove rebound piston 0 Remove the piston ring from the piston Remove compression shim stack D Remove spring Remove tap rebound Remove spring with the sleeve Remove the valve with the spring from tap rebound Remove the O rings 41 25 ...

Page 28: ...lamp the screw cap with the membrane holder and the spe cial tool into a vise Guideline I Use soft jaws I Pin wrench T103 a p 303 Info I Only tighten the vise lightly Remove compression holder O Remove membrane 8 Unclamp the special tool Remove 0 ring 8 Clamp the open end wrench in a vise Position compression holder O Remove nut e Remove spring 0 Remove rebound washer D Remove compression piston R...

Page 29: ...orklegs ll p 19 Disassemble the cartridge I p 22 Disassemble the piston rod I p 24 Main work Remove 0 ring O Remove lockring 8 Remove ring D Screw the special tool onto the screw sleeve I Threaded bushing T14023 ll p 307 The special tool must have an overhang to protect the thread I Overhang I 1 mm 0 04 in Pry out seal ring 8 being sure only to brace the lever against the special tool Condition Th...

Page 30: ...the inner tube I Inner tube run out I s 0 20 mm 0 0079 in If the measured value is greater than the specified value Change the inner tube Measure the inside diameter of the outer tube at several loca tions Inside diameter of the outer s 49 20 mm 1 937 in tube If the measured value is greater than the specified value Change the outer tube Check the outer tube for damage If there is damage Change th...

Page 31: ...ecified value Change the spring Check the piston rod for damage If there is damage Replace the piston rod Measure the outside diameter of the piston rod at several locations Outside diameter of the pis 2 11 965 mm 2 0 47106 in ton rod If the measured value is less than the specified value Replace the piston rod Measure the run out of the piston rod I Run out of the piston rod I 5 0 40 mm 5 0 0157 ...

Page 32: ...everal loca tions Inside diameter of the outer 49 20 mm 5 1 937 in tube If the measured value is greater than the specified value Change the outer tube Check the outer tube for damage If there is damage Change the outer tube Check the surface of the sliding bushing If the bronze colored layer f under the sliding layer is visible or the surface is rough Replace the sliding bushing Check the spring ...

Page 33: ... T14022B I p 307 Ensure that special tool f is mounted and that there is an overhang to protect the thread Guideline I Overhang 11 mm 0 04 in I Threaded bushing T14023 a p 307 Position the pilot bushing in the screw sleeve with the special tool and press it in all the way I Pressing tool T14022B I p 307 Lubricate the special tool Fork oil SAE 4 48601166S1 iJI p 286 Calibrating unit T14021 iJI p 30...

Page 34: ... fork legs 200874 10 Preparatory work Check the fork legs I p 27 Main work Lubricate and mount 0 ring O I Lubricant T158 I p 288 Clamp the open end wrench in a vise Position compression holder Mount the compression shim stack 8 with the smaller shims facing downward Grind compression piston on both sides on a surfacing plate using 1200 grit sandpaper Clean the compression piston Mount and grease 0...

Page 35: ... the spring Secure the nut by locking Mount and grease O ring I Lubricant T158 p 288 Clamp the screw cap with the membrane holder and the spe cial tool into a vise I Pin wrench T103 I p 303 Info I Only tighten the vise lightly Mount membrane Mount and tighten compression holder Guideline Compression holder M9x1 Unclamp the special tool 8 Nm 5 9 lbf ft Loctite 241 The steps are identical for both f...

Page 36: ...k C with the smaller washer facing downward Grind the rebound piston on both sides on a surface plate with 1200 grit sandpaper Clean the rebound piston Wrap the piston ring around the shaft of a screwdriver before mounting Mount the piston ring Lubricate the piston ring I Fork oil SAE 4 48601166S1 p 286 Mount rebound piston 0 Guideline Viewt ViewG Mount rebound shim stack D Info Rebound piston fro...

Page 37: ...legs p 27 Assemble the screw cap with the membrane holder p 32 Assemble the piston rod p 33 Main work Lubricate and mount O ring O I Lubricant T158 p 288 Mount the spring and O ring on check valve I Lubricant T158 a p 288 Mount the check valve with the special tool I Tweezers T14033 l I p 308 Mount guide ring Mount spring guide C and ring 0 Clamp the cartridge into a bench vise Guideline I Use sof...

Page 38: ...e I Lubricant T158 I p 288 Tighten the screw sleeve Guideline Screw sleeve M24x1 on the cartridge 40 Nm 29 5 lbf ft Loctite 241 Mount filling screw with the O ring Clamp the cartridge vertically and fill with fork oil to lower edge f of the upper part of the cartridge I Fork oil SAE 4 48601166S1 I p 286 The piston rod is fully extended Mount the screw cap with the membrane holder and tighten with ...

Page 39: ... membrane holder a p 32 Assemble the piston rod a p 33 Assemble the cartridge a p 35 Main work Clamp the inner tube using the axle clamp Guideline I Use soft jaws Mount the special tool I Protecting sleeve T1401 a p 305 Grease and push on dust boot O I Lubricant T14034 a p 288 Info Always change the dust boot seal ring lock ring and support ring Mount the sealing lip with the spring expander facin...

Page 40: ...stack slightly apart by hand Warm up the outer tube in area f of the lower sliding bush ing Guideline I 50 oc 122 OF Push the outer tube on Hold the lower sliding bushing with the longer side of the special tool I Mounting tool T1 4040S l ll p 308 Press the outer tube all the way in Position the support ring Hold the seal ring with the shorter side of the special tool I Mounting tool T1 4040S l ll...

Page 41: ...uster I Lubricant T158 a p 288 Mount the rebound adjuster The rebound adjuster must reach the stop before the piston rod turns with it If the threads on the piston rod are tight it must be held to keep it from turning X If the rebound adjuster is not turned all the way to the stop the rebound damping cannot be correctly adjusted Hold nut and tighten the rebound adjuster Guideline Rebound adjuster ...

Page 42: ...ighten the cartridge Guideline Cartridge on the outer tube M51x1 5 I Ring wrench T14017 a p 306 50 Nm 36 9 lbf ft Mount adjuster 41 of the compression damping Mount and tighten the screw Guideline Screw compression M4x0 5 1 5 Nm 1 11 lbf ft adjuster Alternative 1 Turn compression adjusting screw G and rebound adjusting screw 48 clockwise all the way Turn counterclockwise by the number of clicks co...

Page 43: ...ismantling Mount protection cap 48 Bleeding and filling the cartridge Info Before working with the vacuum pump carefully read the vacuum pump operating manual Clamp the cartridge as shown in the figure Guideline I Use soft jaws Info I Clamp the cartridge only lightly The filling port must be located at the highest point During the filling procedure the cartridge must be lower than the oil tank of ...

Page 44: ...0 mbar When the vacuum gauge reaches the required value turn control lever Oil reservoir 0 to Equalize pressure Guideline 110 mbar The pressure gauge increases to the required value 0 bar When the pressure gauge reaches the required value turn control lever Damper C to Pressure Guideline 0 bar Oil is pumped into the cartridge The pressure gauge increases to the required value 3 bar When the pressu...

Page 45: ... cartridge only lightly Connect the connector of the special tool to the pressure regulator of the nitrogen bottle Filling tool T14019 p 306 Filling gas nitrogen Adjust the pressure regulator of the nitrogen bottle Guideline I Gas pressure 11 2 bar 17 psi Pierce the membrane with the needle of the special tool Open valve O Fill the cartridge for at least 15 seconds Guideline I Gas pressure 11 2 ba...

Page 46: ...ion of the lower triple clamp Removing the lower triRle clamR Preparatory work Raise the motorcycle with a lift stand l l p 12 Remove the handlebar cushion Remove the front wheel a p 119 Remove the fork legs a p 16 Remove the start number plate a p 115 Remove front fender p 114 Main work Remove the holder with Fl warning lamp Take off cable holder O in front of the left and right radiator Remove s...

Page 47: ...sert the lower triple clamp with the steering stem Mount the upper steering head bearing Check whether upper steering head seal O is correctly posi tioned Slide on protective ring and O ring 8 Position the upper triple clamp with the handlebar Mount screw C but do not tighten yet Position the fork legs Bleeder screws 0 are positioned toward the front Info I Grooves are milled into the side of the ...

Page 48: ...w top triple clamp M8 17 Nm 12 5 lbf ft Secure the wiring harness left and right with cable holders Mount the holder with Fl warning lamp Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position brake line and bracket on fork protector and mount and tighten screws Finishing work Mount the handlebar cushion Install front fender a p 114 Install the start number plate a p 115 Install the front...

Page 49: ... travel I No play should be noticeable in the steering head bearing If there is noticeable play present Adjust the steering head bearing play p 49 Move the handlebar to and fro over the entire steering range The handlebar must be able to move easily over the entire steering range No resting locations should be noticeable If click positions are noticeable Adjust the steering head bearing play p 49 ...

Page 50: ... bearing ring C with special tool 8 Tool bracket 58429089000 p 293 Pressing tool 58429092000 a p 294 Press the new bearing ring up to the stop with special tool Tool bracket 58429089000 ta l p 293 Pressing tool 58429091000 p 294 Remove lower steering head bearing 8 Remove the seal ring Grease and mount the new seal ring Press on the new bearing with a suitable tube as far as it will go Finishing w...

Page 51: ... motorcycle with a lift stand p 12 Remove the handlebar cushion Main work Loosen screws O Remove screw Loosen and retighten screw fD Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid stresses Mount and tighten screw Guideline Screw top M8 steering stem 20 Nm 14 8 lbf ft Loctite 243 Tighten screws O Guideline Screw top t...

Page 52: ...sition B00375 10 Remove screws O Take off the handlebar clamps Take off the handlebar and lay it to one side Info Protect the components against damage by covering them Do not bend the cables and lines Remove screws 8 Remove the handlebar supports Place the handlebar supports in the required position Mount and tighten screws 8 Guideline Screw handle M10 bar support 40 Nm 29 5 lbf ft Loctite 243 In...

Page 53: ...ake any adjustments while riding Check the rubber grips on the handlebar for damage wear and looseness Info The rubber grips are vulcanized onto a sleeve on the left and onto the handle tube of the throttle grip on the right The left sleeve is clamped onto the handlebar The rubber grip can only be replaced with the sleeve or the throttle tube If a rubber grip is damaged or worn Change the rubber g...

Page 54: ...Install the right side cover tl l p 101 7 6 Checking the play in the throttle cable 52 Check the throttle grip for smooth operation Move the handlebar to the straight ahead position Turn the throttle grip back and forth slightly and determine the play in throttle cable 6 I Play in throttle cable I 3 5 mm 0 12 0 2 in If the throttle cable play does not meet the specified value Adjust the play in th...

Page 55: ...ready been secured the fuel tank does not need to be removed Preparatory work Remove the right side cover 0 p 101 Remove the air filter box cover 0 p 97 Remove the seat 0 p 101 Remove the fuel tank p 103 Check the throttle cable routing p 51 Main work Move the handlebar to the straight ahead position Push back sleeve O Loosen nut 8 Turn adjusting screw in as far as possi ble Loosen nut C Push cold...

Page 56: ...le cables and take off the grip tube Remove guide plate 8 from handle tube G Position the required guide plate on the grip tube Guideline The label OUTSIDE must be visible Marking f must be positioned at marking G I Grey guide plate 79002014000 Alternative 1 I Black guide plate 79002014100 Info I The gray guide plate opens the throttle valve more slowly The black guide plate opens the throttle val...

Page 57: ...ion half shells CD mount and tighten screws 4i Guideline I Screw throttle grip I M6 I 5 Nm 3 7 lbf ft Slide on sleeve O and check the throttle grip for ease of movement Finishing work Check the play in the throttle cable p 52 55 ...

Page 58: ...ir of the frame is not authorized by Husqvarna Motorcycles The procedures are the same on both footrests D00725 10 Condition The frame protectors have been removed on the left and right Remove split pin O and take off the washer Press the spring with special tool 8 I Footrest spring plier 79029083000 p 300 The special tool is applied to area f on the footrest Remove pin fD Position the new footres...

Page 59: ...g as shown Spring G engages in area Press the spring with special tool I Footrest spring plier 79029083000 l l p 300 The special tool is applied to area f on the footrest Mount pin 6 Mount the washer and split pin O 8 FRAME 57 ...

Page 60: ...nfo I Do not loosen fitting Turn counterclockwise by the number of turns corresponding to the shock absorber type Guideline Compression damping high speed Comfort Standard Sport Info 2 5 turns 2 turns 1 5 turns I Turn clockwise to increase damping turn counter clockwise to reduce damping 9 2 Adjusting the low speed compression damping of the shock absorber A 58 Caution Risk of injury rectly Parts ...

Page 61: ...ping 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 K00269 10 Turn counterclockwise by the number of clicks corres...

Page 62: ...motorcycle from the lift stand p 12 Checking the static sag of the shock absorber Measure dimension 6 of rear wheel unloaded i l p 60 Hold the motorcycle upright with the aid of an assistant Again measure the distance between the rear axle and mark ing SAG on the rear fender using the sag gauge Note down the value as dimension G Info The static sag is the difference between measure ments 6 and 0 C...

Page 63: ...n 0 Info The riding sag is the difference between measure ments G and 0 Check the riding sag Guideline I Riding sag 1 ao mm 3 15 in If the riding sag differs from the specified measurement Adjust the riding sag a p 62 reload of the shock absorber 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 compr...

Page 64: ...bsorber adjusting ring Finishing work Install the shock absorber p 64 5 Nm 3 7 lbf ft Remove the motorcycle from the lift stand ll p 12 Check the free travel of the foot brake lever 11 l p 150 Preparatory work Raise the motorcycle with a lift stand p 12 Remove the shock absorber p 63 After removing the shock absorber clean it thoroughly Main work Choose and mount a suitable spring Guideline Spring...

Page 65: ... absorber K00269 11 Preparatory work Raise the motorcycle with a lift stand I p 12 Main work Remove the cable tie s Remove screws O Remove screws 8 with the washers Remove the frame protector on the left and right Remove screw fD Remove fitting C Info I Raise the wheel slightly to be able to remove the screws more easily Press angle lever 0 toward the rear Press linkage lever D downward Remove scr...

Page 66: ...t Push the swingarm back and secure it against falling over Hold the shock absorber and remove screw Remove the shock absorber carefully at the bottom Main work Carefully position the shock absorber into the vehicle from the bottom Mount and tighten screw O Guideline Screw top M10 shock absorber 60 Nm 44 3 lbf ft Loctite 2701 TM ...

Page 67: ...e foot brake cylinder The push rod D engages in the foot brake cylinder Info I Ensure that the dust boot is correctly seated Mount and tighten screws C Guideline Remaining screws chassis M6 Position the angle lever and linkage lever Mount and tighten fitting 0 Guideline Nut linkage lever to M14x1 5 angle lever Info I Pay attention to flat area 0 Mount and tighten screw C Guideline 10 Nm 7 4 lbf ft...

Page 68: ... pro tector M5 Mount the new cable ties Finishing work 3 Nm 2 2 lbf ft Remove the motorcycle from the lift stand p 12 Check the free travel of the foot brake lever p 150 Checking the shock absorber linka e Preparatory work Raise the motorcycle with a lift stand p 12 Main work Remove screw O Remove fitting 8 Info Raise the wheel slightly to be able to remove the screws more easily Remove fitting fD...

Page 69: ...ear Change the spacers Check the shaft seal rings for damage and wear If there is damage or wear Change the shaft seal rings Check dimension f 303096 10 I 54 91 55 00 mm 2 1618 2 1654 in If dimension f is below the specified value Add the necessary spacing washers Position the angle lever Mount fitting D but do not tighten yet Guideline Nut linkage lever on M14x1 5 swingarm 80 Nm 59 lbf ft 67 ...

Page 70: ... be able to mount the screw more easily Tighten screws O Guideline Screw bottom M10 shock absorber Tighten fitting CD Guideline Nut linkage lever on M14x1 5 swingarm Finishing work 60 Nm 44 3 lbf ft Loctite 2701 TM 80 Nm 59 lbf ft Remove the motorcycle from the lift stand el p 12 Servicing the shock absorber Caution Risk of injury Parts of the shock absorber will fly off if the shock absorber is d...

Page 71: ... heim joint a p 76 Assemble the seal ring retainer p 76 Assemble the piston rod p 77 Assemble the damper p 79 Install the spring p 85 Condition The shock absorber has been removed Clamp the shock absorber into the vise with soft jaws Measure and note down the spring length in the preloaded state Loosen screw O Turn the adjusting ring until the spring is completely without tension I Hook wrench T10...

Page 72: ...nt state of rebound O and com pression damping 8 Open the adjusters of the rebound and compression damp ing completely Slowly open screw The nitrogen pressure dissipates Remove locking cap 8 Press in seal ring retainer 0 using the special tool I Pressing tool T1216 lll l p 305 Remove lock ring Q Info Do not scratch the inside surface ...

Page 73: ...ate washer Drain the oil Remove compression adjuster Remove the spring and piston Disassembling the piston rod Preparatory work Remove the spring a p 69 Disassemble the damper a p 70 Main work Clamp the piston rod with the fork in a vise Guideline I Use soft jaws Remove nut O Remove washer 8 71 ...

Page 74: ...fo I Place the compression shim stack onto a screwdriver and set it down as a unit Remove rebound washer CD Remove seal ring retainer Remove locking cap fD and rubber buffer Disassembling the seal ring retainer 201405 10 Preparatory work Remove the spring 0 p 69 Disassemble the damper 0 p 70 Disassemble the piston rod 0 p 71 Main work Remove spring O Remove O ring 8 Remove rebound rubber ...

Page 75: ... 71 Disassemble the seal ring retainer l JI p 72 Main work Press pilot bushing O out of seal ring retainer 8 with the special tool I Pressing tool T1504 l JI p 309 Slide the new pilot bushing O onto the special tool I Pressing tool T1504 p 309 Position the pilot bushing in the seal ring retainer using the special tool I Pressing tool T1504 p 309 Support seal ring retainer 8 with sleeve f of the sp...

Page 76: ...the damper cartridge Damper cartridge Diameter s 50 08 mm 5 1 9716 in If the measured value is greater than the specified value Change the damper cartridge Check the damper cartridge for damage and wear If there is damage or wear Change the damper cartridge Check the heim joint for damage and wear If there is damage or wear Change the heim joint Measure the diameter of the piston rod Piston rod Di...

Page 77: ...oved Clamp the shock absorber into the vise with soft jaws Remove the collar bushing of the heim joint I Drift f120 0 p 303 Turn the shock absorber and remove the second collar bush ing of the heim joint Press the heim joint against a lock ring using the special tool I Pressing tool T1207S I p 304 Remove lock ring O Place special tool 6 underneath and press out heim joint 8 using special tool G I ...

Page 78: ...the way in Press the heim joint against the lock ring using the special tool I Pressing tool T1207S a p 304 Mount lock ring 8 Position both collar bushings fD and press in retainer I 201409 10 Mount dust boot O with the special tool I Mounting sleeve T1204 ill p 304 Grease the sealing lip of the dust boot I Lubricant T625 a p 288 Mount washer 8 Position washer fD on seal ring C ...

Page 79: ...58 p 288 Mount 0 ring Mount spring C Preparatory work Assemble the seal ring retainer p 76 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 p 305 Grease the dust boot and push seal ring retainer D onto the piston rod I Lubricant T625 p 288 Remove the special tool ...

Page 80: ...plate using 1200 grit sandpaper Clean the piston Assemble the piston Guideline View6 Piston from above View CD Piston from below Mount the rebound shim stack with the smaller shims facing upward Mount washer with the collar facing downward Grease the thread of the piston rod I Lubricant T152 p 288 Mount and tighten nut Guideline I Nut piston rod I M16x1 I 45 Nm 33 2 lbf ft ...

Page 81: ...per 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 has been mounted Fill the damper cartridge about half full I Shock absorber fluid SAE 2 5 50180751S1 p 287 Lubricate O ring D of the seal ring retainer I Lubricant T158 p 288 Mount the piston rod carefully Mount seal ring...

Page 82: ...ession damping low speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Turn adjusting screw D all the way clockwise with a socket wrench Turn counterclockwise by the number of turns corre sponding to the shock absorber type Guideline Compression damping high speed Comfort 2 5 turns Standard 2 turns Sport 1 5 turns Turn adjusting screw clockwise up to the last percep tible click Turn counter...

Page 83: ...he location 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 I Tighten only hand tight without the use of tools Connect the adapter O to connector 8 o...

Page 84: ... Depth micrometer T107S a p 303 The floating piston is positioned all the way at the bot tom When the vacuum pressure gauge reaches the specified value turn the Oil reservoir control lever 0 to Equalize pressure Guideline 14 mbar The pressure gauge increases to the specified value 0 bar When the pressure gauge reaches the specified value turn the Damper control lever C to Pressure Guideline 0 bar ...

Page 85: ...l lever 8 to Pressure Guideline 0bar Oil is pumped into the damper The pressure gauge increases to the specified value 3 bar When the pressure gauge reaches the specified value turn the Damper 8 control lever to Vacuum Guideline 3 bar The pressure gauge drops to the specified value 0bar When the pressure gauge reaches the specified value oper ate the On Off switch Guideline 0bar The vacuum pump is...

Page 86: ... 114 Nm 10 3 lbf ft 411 Filling the damper with nitrogen G02088 10 Screw in screw O by approx 2 rotations but do not tighten Info The piston rod is fully extended Clamp the special tool in the vise I Filling tool T170S1 ilill p 309 Connect the special tool to the pressure regulator of the filling cylinder I Filling gas nitrogen Adjust the pressure regulator Guideline I Gas pressure 110 bar 145 psi...

Page 87: ... Ensure 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 the spring Guideline Spring rate Weight of rider 65 75 kg 143 165 lb Weight of rider 75 85 kg 165 187 lb Weight of rider 85 95 kg 187 209 lb Mount spring retainer 8 Mount ring 8 Alternative 1 45 N mm 257 lb in 48 N mm 274 lb in 51 N mm 291 lb in...

Page 88: ...the new handling characteristic Tension the spring to the length measured during disas sembly by turning the adjusting ring I Hook wrench T106S p 303 Tighten screw 8 Guideline Screw shock M5 5 Nm 3 7 lbf ft absorber adjusting ring Check the swingarm for damage cracking and deformation If the swingarm shows signs of damage cracking or deformation Change the swingarm Info I Always change a damaged s...

Page 89: ...garm bearing 0 p 90 Finishing work Remove the motorcycle from the lift stand a p 12 Preparatory work Raise the motorcycle with a lift stand a p 12 Remove the rear wheel a p 123 Remove the air filter box cover 0 p 97 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 screw...

Page 90: ...move fitting C Lower the swingarm Remove the cable ties Remove screws 0 Remove screws D with the washers Remove the frame protectors on the left and right Remove nut Remove the swingarm pivot Remove the swingarm Main work Position the swingarm Mount the swingarm pivot Mount and tighten nut O Guideline Nut swingarm pivot M16x1 5 100 Nm 73 8 lbf ft ...

Page 91: ...ngarm M5 Mount and tighten fitting C Guideline Nut linkage lever on M14x1 5 swingarm Mount the chain 3 Nm 2 2 lbf ft 80 Nm 59 lbf ft Connect the chain with connecting link 0 Guideline The closed side of the chain joint lock must face in the direction of travel Position the engine sprocket cover Mount and tighten screws 3 and Guideline Screw clutch slave M6 cylinder Remaining screws M8 chassis 10 N...

Page 92: ... ll l p 124 Remove the motorcycle from the lift stand ll l p 12 9 31 Changing the swingarm bearing R02757 10 R02758 10 90 Preparatory work Raise the motorcycle with a lift stand p 12 Remove the rear wheel I p 123 Remove the air filter box cover I p 97 Remove the swingarm I p 87 Left swingarm bearing Remove collar bushings O Remove bushing 8 ...

Page 93: ... 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 Grease the shaft seal rings I Long life grease ll ll p 288 Position collar bushings O with the shoulder facing inward Right swingarm bearing Remove collar bushings D 91 ...

Page 94: ...Using a suitable tool press in new bearing Q Press in shaft seal rings Q Mount bushing Grease the shaft seal rings I Long life grease a p 288 Position collar bushings D with the shoulder facing inward Finishing work Install the swingarm ll p 88 Install the air filter box cover ll p 97 Install the rear wheel ll p 124 Remove the motorcycle from the lift stand 0 p 12 ...

Page 95: ...ht side cover a p 101 Remove the main silencer a p 95 Main work Remove screw O Remove fitting 8 Info Raise the link fork slightly to be able to remove the screws more easily Press angle lever 8 toward the rear Press linkage lever C downward Detach springs 0 I Spring hook 50305017000 a p 292 Remove screw D Lift the swingarm 93 ...

Page 96: ...the shock absorber and mount and tighten screw O Guideline Screw top M10 shock absorber 60 Nm 44 3 lbf ft Loctite 2701 TM Mount screw 8 but do not tighten yet Guideline Remaining screws chassis Attach springs 8 MS I Spring hook 50305017000 p 292 Tighten screw 8 Guideline Remaining screws chassis Lower the swingarm MS 25 Nm 18 4 lbf ft 25 Nm 18 4 lbf ft ...

Page 97: ... the lift stand il l p 12 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down before performing any work on the vehicle Preparatory work Remove the right side cover l i p 101 Main work Detach spring O I Spring hook 50305017000 a p 292 Remove screws with the washers and take off the main silencer Instal...

Page 98: ...ht side cover l l p 101 Remove the main silencer l l p 95 Main work Remove all the screws on the main silencer Take off silencer cap 0 Take off outer tube Remove glass fiber yarn filling from the inner tube with connecting cape Clean the parts that need to be reinstalled and check for damage Mount the new glass fiber yarn filling with connecting cap onto the inner tube Position the inner tube with...

Page 99: ... areas 6 Ce and 9 Engine damage Unfiltered intake air has a negative effect on the service life of the engine Dust and dirt will enter the engine without an air filter Never start to use the vehicle without an air filter Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with t...

Page 100: ...he bottom retaining pin with holding tab 8 Info If the air filter is not mounted correctly dust and dirt may enter the engine and result in damage Finishing work Install the air filter box cover p 97 Cleaning the air filter and air filter box Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly an...

Page 101: ...er to dry it never wring it out Oil the dry air filter with a high quality filter oil I Oil for foam air filter a p 289 Clean the air filter box Check the intake flange for damage and looseness Finishing work Install the air filter p 98 Install the air filter box cover p 97 Preparatory work Remove the air filter box cover a p 97 Main work Seal the air filter box in marked area 6 Finishing work Ins...

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

Page 103: ...r sideways in areas f and G and remove toward the front Position the side cover on collar bushings O and 8 and push toward the rear Engage the side cover in areas f and Cs Mount and tighten screw 6 Guideline Remaining screws chassis Preparatory work M5 Remove the air filter box cover il l p 97 5 Nm 3 7 lbf ft 101 ...

Page 104: ...Main work Mount the front of the seat on the collar bushing of the fuel tank and the rear in the bracket Push the seat forward Make sure that the seat is locked in correctly Mount and tighten screw O Guideline Remaining screws chassis Finishing work M6 Install the air filter box cover p 97 10 Nm 7 4 lbf ft ...

Page 105: ...kin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Preparatory work Remove the right side cover il ll p 101 Remove the air filter box cover il ll p 97 Remove the seat il...

Page 106: ...itch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of s...

Page 107: ...Guideline Remaining screws chassis M6 Plug in connector fD for the fuel pump 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft Remove the wash cap set and thoroughly clean the plug in connection of the fuel line using compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Lubricate the O ring and connect plug in connection 8 for the fuel lin...

Page 108: ...tact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Condition The fuel tank is completely full Ensure that the battery voltage does not drop below 12 5 V The diagnostic tool is ...

Page 109: ...han A Danger Fire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling...

Page 110: ...e soil or the sewage system Preparatory work Drain the fuel from the fuel tank into a suitable container Remove the right side cover p 101 Remove the air filter box cover p 97 Remove the seat p 101 Remove the fuel tank p 103 Main work Remove nut O with the gasket Remove fuel connection 8 with the gasket Remove screws Pull out the fuel pump D00571 11 108 ...

Page 111: ...l tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Av...

Page 112: ...age system D00571 10 Preparatory work Drain the fuel from the fuel tank into a suitable container Remove the right side cover p 101 Remove the air filter box cover p 97 Remove the seat p 101 Remove the fuel tank p 103 Main work Remove nut O with the gasket Remove fuel connection 8 with the gasket Remove screws Pull out the fuel pump Remove hose clamps C Remove fuel filter 0 ...

Page 113: ...ints away from the fuel pump Mount hose clamps C I Hose clamp plier 60029057000 p 296 Position the fuel pump Mount fuel connection 8 with the gasket but do not tighten yet Mount and tighten nut O with the gasket Guideline Nut fuel pump fas tener M12x1 75 15 Nm 11 1 lbf ft Tighten fuel connection 8 Guideline Fuel connection on fuel tank M8x1 25 10 Nm 7 4 lbf ft 111 ...

Page 114: ...lled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water 12 3 N...

Page 115: ...ose Pull fuel screen 8 out of the connecting piece Insert the new fuel screen all the way into the connecting piece Lubricate the O ring and connect plug in connection of the fuel line Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extracti...

Page 116: ...ve the start number plate a p 115 Main work Remove screws O and 8 Take off the front fender Main work Position front fender Mount and tighten screws O and 8 Guideline Remaining screws chassis Finishing work M6 Install the start number plate ilill p 115 10 Nm 7 4 lbf ft ...

Page 117: ...e and start number plate Installing the start number late Position the brake line and brake line guide on the start num ber plate Mount and tighten screw O Position the start number plate The holding lugs engage in the fender Mount and tighten screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 115 ...

Page 118: ...f the tire pressure does not meet specifications Correct the tire pressure Mount the protection cap Checkin the tire condition Info 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 ...

Page 119: ... the tires Checking the wheel bearing for la Preparatory work Raise the motorcycle with a lift stand I p 12 Place a load on the rear of the vehicle The front wheel is not in contact with the ground Main work Move the front wheel from side to side Info Hold the fork leg to check it If there is detectable play Change front wheel bearing a p 121 Place a load on the front of the vehicle The rear wheel...

Page 120: ...deformation If the brake disc exhibits damage cracking or deforma tion Change the front brake disc l ll p 121 Change the rear brake disc I p 125 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 r...

Page 121: ...ng of the brake caliper on the brake disc Pull the brake caliper carefully back from the brake disc and hang it to one side loosely Info I Do not pull the hand brake lever while the brake caliper is removed Loosen screw 8 by several rotations Loosen screws 8 Press on screw 8 to push the wheel spindle out of the axle clamp Remove screw 8 Warning Danger of accidents Damaged brake discs reduce the br...

Page 122: ...cer on the brake disc side Insert the narrow spacer on the opposite side Clean and grease the wheel spindle I Long life grease I p 288 Position the front wheel and insert the wheel spindle Mount and tighten screw Guideline Screw front wheel spindle M24x1 5 45 Nm 33 2 lbf ft Position the brake caliper Mount screws 8 with wash ers C but do not tighten yet The brake linings are correctly positioned O...

Page 123: ...k Raise the motorcycle with a lift stand a p 12 Remove the front wheel a p 119 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 120 14 6 4 Changing front wheel bea...

Page 124: ...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 125: ...and other spokes may loosen within a short period If the spokes are too tight they can break due to local overload Check the spoke tension regularly especially on a new motorcycle 400998 01 Rear wheel Check for lateral and radial run out of the rims Lateral runout Outside the rim joint 1 8 mm 0 071 in Radial runout Outside the rim joint 1 8 mm 0 071 in If the measured value is greater than the spe...

Page 126: ... Info Cover the components to protect them against dam age Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged 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 Remove spacers 8 e e H00936 10...

Page 127: ...tighten it yet Make sure that chain adjusters D are fitted correctly on adjusting screws Check the chain tension a p 126 Tighten nut 8 Guideline Nut rear wheel spin M25x1 5 die Info 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 D can be turned by 180 Operate the foot brake lever repeate...

Page 128: ...more quickly Some components may break if overloaded If the chain is too loose the chain may fall off the engine sprocket or the rear sprocket As a result the rear wheel locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the specification Preparatory work Raise the motorcycle with a lift stand il l p 12 Main work Pull the chain at the end...

Page 129: ... nut O Loosen nuts 8 Adjust the chain tension by turning adjusting screws left and right Guideline Chain tension 1 55 58 mm 2 17 2 28 in Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks 6 The rear wheel is then correctly aligned Tighten nuts 8 Make sure that chain adjusters C are fitted corre...

Page 130: ...should repeat this measurement at different chain positions Maximum distance G at the longest chain section 272 mm 10 71 in If the distance G is greater than the specified measure ment Change the drivetrain kit a p 130 Info When the chain is replaced the rear sprocket and engine sprocket should also be changed New chains wear out faster on an old worn rear sprocket or engine sprocket Check the cha...

Page 131: ...ding piece Guideline Screw chain slid M8 ing piece 15 Nm 11 1 lbf ft Check the chain guide with a slide gauge for dimension 9 Minimum thickness 9 of the chain guide 6 mm 0 24 in If the measured value is less than the specification Change the chain sliding piece Check that the chain guide is firmly seated If the chain guide is loose Tighten the screws on the chain guide Guideline Remaining screws c...

Page 132: ...brake cleaner when necessary Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info The service life of the chain depends largely on its maintenance 400725 01 Preparatory work Raise the motorcycle with a lift stand a p 12 Main work Rinse off loo...

Page 133: ...the rear wheel a p 123 Remove connecting link C of the chain Info Cover the components to protect them against dam age Take off the chain Remove engine sprocket 0 Remove fittings D Take off the rear sprocket Position the new rear sprocket Mount and tighten the fit tings Guideline Nut rear MB sprocket screw 35 Nm 25 8 lbf ft Loctite 2701TM 131 WHEELS ...

Page 134: ... washer Guideline Screw engine sprocket M10 60 Nm 44 3 lbf ft Loctite 2701TM Position the engine sprocket cover Mount and tighten screw O Guideline Screw clutch slave cylinder M6 Mount and tighten screw 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 p 12 Install the air filter box cover p 97 14 7 10 Changing the r...

Page 135: ... Using a suitable tool press bearing Q out from the inside to the outside Check spacer washer for damage and wear If the spacer washer is damaged or worn Replace the spacer washer Position spacer washer Press new bearing Q all the way in from the outside to the inside Info Only press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in 133 ...

Page 136: ... the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in Grease new shaft seal ring 8 and press it in until it is flush Mount lock ring 8 The lock ring engages audibly Grease new shaft seal ring O and press it in until it is flush Finishing work Install the rear wheel 0 p 124 Remove the motorcycle from the lift stand p 12 ...

Page 137: ...emove the air filter box cover l l p 97 Remove the seat l l p 101 Main work Pull starter relay O from the holder Take off protection caps Remove faulty main fuse D Info You can recognize a faulty fuse by a burned out fuse wiref A spare fuse 8 is located in the starter relay Install a new main fuse I Fuse 5801110911O a p 269 Check that the electrical system is functioning properly Tip I Insert a sp...

Page 138: ...e is already below the minimum voltage Minimum voltage before the start of the charge 9 V Dispose of batteries with less than the minimum voltage correctly Preparatory work Press and hold the kill switch while the engine is idling until the engine stops Remove the air filter box cover p 97 Remove the seat p 101 Main work J i f_ I 1 i _lIr1 Pull back the negative terminal cover O and disconnect neg...

Page 139: ...ry termi MS nal 2 5 Nm 1 84 lbf ft Info I Contact disks e must be mounted under the screw and the cable lug C with the claws toward the battery terminal Slide negative terminal cover fD over the negative terminal Finishing work Recharging the battery Warning Mount the seat 0 p 102 Install the air filter box cover p 97 Risk of injury Batteries contain harmful substances Keep batteries out of the re...

Page 140: ...battery will be destroyed If the battery is depleted from starting the vehicle repeatedly the battery must be charged immediately If the battery is left in a discharged state for an extended period it will become over discharged and sul fated destroying the battery The battery is maintenance free 311910 10 Preparatory work Remove the air filter box cover 0 p 97 Remove the seat 0 p 101 Main work Co...

Page 141: ...ck the plug in connections from the alternator to the voltage regulator Check the plug in connections from the voltage regu lator to the wiring harness Check the stator winding of the alternator 1ll p 256 If the displayed value is greater than the specified value Change the voltage regulator Finishing work Mount the seat 1ll p 102 Install the air filter box cover 1ll p 97 15 6 Checking the open ci...

Page 142: ...dging the two contacts Connect the capacitor with a 12 V test lamp on one connec tor and connect it to the battery as shown in the figure Info As the charge of the capacitor increases the test lamp becomes dimmer The lamp lights up for 0 5 2 0 s The capacitor is functional The lamp lights up for 0 5 s Change the capacitor The lamp lights up for 2 0 s Change the capacitor Discharge the capacitor wi...

Page 143: ...ector Pull back the cover Detach cable D from the starter relay Connect the starter relay to a 12 V power supply as per the figure Measure the resistance between the specified points I Resistance of open circuit I0 n If the value displayed does not meet specifications Change the starter relay Clamp cable D on the starter relay Plug in connector 8 Connect the negative cable of the battery Mount the...

Page 144: ...w brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning ...

Page 145: ... Remove screws 8 Remove cover 8 with membrane 0 Press the brake piston back into the basic position and ensure that brake fluid does not flow out of the brake fluid reservoir if necessary draw some off Press together brake linings D and remove them from the brake caliper Clean the brake caliper and leaf spring Ensure that the leaf spring is correctly positioned Info The arrow on the leaf spring po...

Page 146: ...g I Brake fluid DOT 4 p 286 Position cover C with membrane 0 Mount and tighten screws Info Clean up overflowed or spilled brake fluid immediately with water Adjusting the basic osition of the hand brake lever 144 Adjust the basic position of the hand brake lever to your hand size by turning adjusting wheel Q Info Push the hand brake lever forward and turn the adjusting wheel Turn the adjusting whe...

Page 147: ...id l lll p 145 Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the brake system is leaking or the brake linings are worn down Check the brake system and do not continue riding until the problem is eliminated Warning Skin irritation Brake fluid causes skin irritation Keep brak...

Page 148: ... 4 llill p 286 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilled brake fluid immediately with water Changing the front brake fluid Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with the skin...

Page 149: ...Connect the bleeding device I Bleeding device 00029013100 p 290 Open shut off valve 8 Info Follow the operating instructions of the bleeding device Ensure that the filling pressure is set on pressure gauge f Adjust the filling pressure on pressure regulator if neces sary 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 hose...

Page 150: ...hand brake lever for a firm pressure point Checking the brake linings of the rear brake Warning Danger of accidents Worn out brake linings reduce the braking effect Ensure that worn out brake linings are replaced immediately Check the brake linings for minimum thickness f I Minimum thickness e I 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings I p 148 Chec...

Page 151: ...arning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake...

Page 152: ...nt and tighten screw cap O with membrane 8 and the O ring Info Clean up overflowed or spilled brake fluid immediately with water Checking the free travel of foot brake lever Warning Danger of accidents The brake system fails in the event of overheating If there is no free travel on the foot brake lever pressure builds up in the brake system on the rear brake Set the free travel on the foot brake l...

Page 153: ...necessary adjust the basic position of the foot brake lever Guideline K00308 10 Free travel at foot brake lever 3 5 mm 0 12 0 2 in Hold push rod 0 and tighten nut 8 Guideline Remaining nuts chassis M6 Hold screw 8 and tighten nut Guideline 10 Nm 7 4 lbf ft Nut foot brake lever M8 stop 20 Nm 14 8 lbf ft Attach spring O Checking the rear brake fluid level Warning Danger of accidents An insufficient ...

Page 154: ...Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make su...

Page 155: ...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 Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid ...

Page 156: ...e 00029013100 I p 290 Open bleeder screw 0 by approx one half turn Info I Drain until the fresh brake fluid emerges from the hose of the bleeder bottle without bubbles Tighten the bleeder screw Close shut off valve Open the bleeder screw again until brake fluid stops emerg ing Info I This prevents overfilling of the brake fluid reservoir Tighten the bleeder screw Remove the hose of the bleeder bot...

Page 157: ...16 BRAKE SYSTEM Check the foot brake lever for a firm pressure point 155 ...

Page 158: ... Remove the air filter box cover p 97 Remove the seat p 101 Remove the fuel tank p 103 Remove the main silencer p 95 Main work Remove the cable ties Remove screw O Remove screws 8 with the washers Remove the frame protectors on the left and right Disconnect the negative cable of the battery Loosen hose clip s Push back protection cap C Unplug the connector ...

Page 159: ...ne side Push back hose clamp D and pull off the vent hose Remove screw Loosen screw C Repeat these steps on the opposite side Pivot up the subframe and secure it Remove screw 0 17 ENGINE Pivot the shock absorber toward the rear and twist it slightly 157 ...

Page 160: ...8 Remove springs 41 I Spring hook 50305017000 I p 292 Remove screw 4D with the washer Take off the manifold Remove screws 48 Take off the engine brace Disconnect plug in connector 41 Disconnect plug in connectors C ...

Page 161: ... 48 Remove the cable tie s Remove the cable clamps and expose the cable Push back protection cap CO Unplug the connector Loosen hose clip 4D Pull off the radiator hose Loosen hose clips G Pull off the radiator hoses 17 ENGINE 159 ...

Page 162: ... Take off the engine sprocket cover Remove screws Take off the slave cylinder of the clutch and hang it to one side Info Do not kink the clutch line Do not activate the clutch lever while the slave cylin der of the clutch is removed Activate the foot brake lever Loosen screw e Info The help of an assistant is useful in this step ...

Page 163: ...e engine sprocket Remove screw Ci with the washers Take off the shift lever Loosen hose clip 17 ENGINE Pull the throttle valve body off of the cylinder head toward the rear and hang it to one side Push back protection cap and remove the nut Hang the positive cable to the side 161 ...

Page 164: ... fitting G Remove screws D Remove the foot brake cylinder and allow it to hang tension free to the side Take the brake line out of the guide Remove nut G Remove the swingarm pivot Carefully pull the swingarm back and secure the swingarm ...

Page 165: ...k Position the engine in the frame Info The help of an assistant is useful in this step Make sure that the engine is sufficiently secured against falling over Protect the frame and attachments against damage Mount screws O but do not tighten yet Guideline Engine carrying screw M10 Position the swingarm Mount the swingarm pivot Mount and tighten nut 8 Guideline 60 Nm 44 3 lbf ft I Nut swingarm pivo...

Page 166: ...emaining screws chassis M6 Position the linkage lever Mount and tighten fitting Guideline Nut linkage lever to M14x1 5 angle lever Info 10 Nm 7 4 lbf ft 80 Nm 59 lbf ft Raise the wheel slightly to be able to mount the screw more easily Mount spring Q Position the positive cable on the starter motor Mount and tighten the nut Guideline Remaining nuts chassis M6 Position protection cap 10 Nm 7 4 lbf ...

Page 167: ...gine Mount screw Ci with the washer but do not tighten yet Guideline Screw engine sprocket Mount the chain M10 60 Nm 44 3 lbf ft Loctite 2701TM Connect the chain with connecting link a Guideline The closed side of the chain joint lock must face in the direction of travel Activate the foot brake lever Tighten screw Ci Guideline Screw engine sprocket M10 60 Nm 44 3 lbf ft Loctite 2701TM Info I The h...

Page 168: ...er M6 Position the engine sprocket cover Mount and tighten screw I Guideline Screw clutch slave cylinder M6 Mount and tighten screw 4D Guideline Remaining screws chassis M8 Mount spark plug connector Qi Mount capacitor Mount the radiator hoses Position and tighten hose clips 48 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 25 Nm 18 4 lbf ft ...

Page 169: ...n cap Ci 17 ENGINE Route the cable without tension and secure with cable clips and cable ties Connect plug in connector of the gear position sensor Connect plug in connector D of the crankshaft position sensor Connect plug in connectors fa of the alternator Route the cable without tension 167 ...

Page 170: ...ft Loctite 2701 TM 60 Nm 44 3 lbf ft Mount screw ewith the washer but do not tighten yet Guideline Remaining screws chassis Mount springs M8 25 Nm 18 4 lbf ft I Spring hook 50305017000 l p 292 Tighten screw e Guideline Remaining screws chassis M8 Position the shock absorber Mount and tighten screw Guideline Screw top M10 shock absorber 25 Nm 18 4 lbf ft 60 Nm 44 3 lbf ft Loctite 2701 TM ...

Page 171: ... screw Guideline Screw sub frame Remove screw MB Mount and tighten screw Guideline Screw sub frame MB 30 Nm 22 1 lbf ft Loctite 2701 TM 30 Nm 22 1 lbf ft Loctite 2701 Repeat the operation on the opposite side Mount the vent hose and hose clamp Mount rollover sensor Ii Plug in the connector Mount protection cap 0 169 ...

Page 172: ...the frame protectors on the left and right Mount and tighten screw Guideline Screw frame pro tector M5 3 Nm 2 2 lbf ft Mount and tighten screws G with the washers Guideline Screw frame pro tector Mount the cable ties M5 3 Nm 2 2 lbf ft Remove filler plug G and add engine oil Engine oil 1 20 I 1 27 qt Mount and tighten filler plug G Finishing work Install the main silencer I p 95 Install the fuel t...

Page 173: ... Read out the fault memory using the Husqvarna Motorcycles diagnostics tool Check the engine for leak tightness Check the engine oil level I p 249 Check the coolant level 0 p 246 Mount the special tool on the engine assembly stand Holder and fitting for work stand 79429002000 0 p 300 Engine work stand 80329001000 p 302 Mount the engine on the special tool Info Work with an assistant or a motorized...

Page 174: ... screw plug C with the short oil screen Removing the clutch push rod Removing the oil filter Remove clutch push rod 0 Remove screws O Remove the oil filter cover with the O ring Pull oil filter out of the oil filter housing I Lock ring plier 51012011000 OJ p 293 ...

Page 175: ...lve cover Remove screws O and take off the starter motor Remove the spark plug using the special tool I Spark plug wrench with link 77229172000 p 299 Remove screws O Take off the valve cover with the valve cover seal Removing the alternator cover Remove screws O Take off the alternator cover 17 ENGINE 173 ...

Page 176: ...ignition top dead center Align camshaft marking f with the center of screw 4D on the cylinder head Remove screw O with the washer Screw in special tool 8 Locking screw 113080802 ilill p 291 17 3 10 Removing the timing chain tensioner Remove screw O with the washer and spring 174 ...

Page 177: ...er with the gasket Remove screw O Remove the camshaft support plate Pull the camshaft out of the bearing seats Take the timing chain off the camshaft gear Remove the camshaft Remove screw O Unscrew screws in a crisscross pattern and remove Remove the cylinder head Take off dowels i Remove cylinder head gasket C 175 ...

Page 178: ...piston ring lock 0 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 Remove cylinder base gasket D Info Ensure locating pins 8 remain in place Remove timing chain guide rail C from the top Remove nut O with the spring washer ...

Page 179: ...special tool and pull off the rotor by turning the screw in Remove the woodruff key Remove screw O Remove timing chain tensioning rail 8 toward the top Remove screw 8 Remove the timing chain securing guide Take off the timing chain Info If the timing chain is to be reused mark the direction of travel Remove screws O Take off oil pump cover 8 of the suction pump 177 ...

Page 180: ...e off pin 0 Remove pin D upward Remove O ring 17 3 17 Removing the gear position sensor Remove screws O Take off the gear position sensor 17 3 18 Removing the water pump cover 178 Remove screws 0 Take off the water pump cover Take off the water pump cover seal ...

Page 181: ...er Remove dowels 8 Take off clutch cover gasket Clamp the antihopping clutch with special tool O I Assembly screws 75029033000 a p 297 Info I Apply the special tool by hand only do not use another tool Remove screws 8 with the spring retainers and clutch springs Remove pressure cap fD Remove clutch throw out C Bend up lock washer 0 Remove special tool D I Locking screw 113080802 p 291 17 ENGINE 17...

Page 182: ...he lock washer I Gear segment 80029004000 l ll p 302 Remove clutch disc pack 0 entirely Take off washer O Info The washer usually sticks to the inner clutch hub Lock the outer clutch hub and primary gear using special tool I Gear segment 80029004000 l ll p 302 Remove nut 8 Info Left handed thread Take off C 180 ...

Page 183: ...s 0 and collar bushing 0 Remove screw O with the washer Take off the torque limiter 17 3 23 Removing the starter idler gear 17 3 24 Removing the force pump Take off starter idler gear O Remove lock ring O Take off washer 8 Remove oil pump idler gear fs 17 ENGINE 181 ...

Page 184: ...ar wheel D Remove pin Remove screws Take off oil pump cover Remove internal rotor Gi and external rotor 48 Remove the pin Push oil pump shaft 48 inward and take it out of the engine from the ignition side 411 Push sliding plate O away from the shift drum locating unit Remove shift shaft with the washer 411 ...

Page 185: ...lieve tension from the locking lever Unscrew O and remove together with locking lever 8 washer sleeve and spring Insert special tool O in the crankshaft I Protection cap 75029090000 p 298 Install special tool 8 I Puller 75029021000 p 296 Hold it using the special tool and pull off the primary gear by turning the screw in Remove the special tools 17 3 29 Removing the freewheel gear Remove woodruff ...

Page 186: ...nfo I Use the 794 drill hole Tilt the left section of the engine case upward and remove the fitting of the engine fixing arm Pull off the section of the engine case Info Ensure that washer f is not damaged Do not tension the section of the engine case Remove the special tool Take off the left section of the engine case Remove spacer 8 Remove dowel C ...

Page 187: ...rks Remove shift rails O together with upper springs 8 and lower springs Swing shift forks O to one side Info I Do not misplace the shift rollers Remove shift drum Take shift forks O out of the shift grooves Info Do not misplace shift rollers 8 17 3 34 Removing the transmission shafts Remove O ring O 185 ...

Page 188: ... sure not to misplace the washers 17 3 35 Removing the crankshaft 17 4 17 4 1 186 Remove crankshaft O Info I Ensure that washer 8 is not damaged Take off the right section of the engine case Working on individual arts Working on the right section of the engine case Preparatory work Remove the oil pressure regulator valve a p 189 ...

Page 189: ...e new cold bearings into the bearing seats of the hot engine case section and if necessary use a suitable press drift to push the bearings from the inside to the outside all the way to the stop or so it is flush Info When pressing the bearings in ensure that the engine case section is level to prevent damage Only press the bearings in via the outer bearing race otherwise the bearings will be damag...

Page 190: ...n in an oven Guideline 11so 0 c 302 F Knock the engine case section against a level wooden board This will cause the bearings to drop out of the bearing seats Info Any bearings that remain in the engine case section must be removed using a suitable tool Remove washer D Warm the engine case section again Guideline 11so C 302 F Position washer D Insert the new cold bearings in the bearing seats of t...

Page 191: ...Position the bearing retainers Mount and tighten screws Guideline Screw bearing MS retainer Position oil spray tube 8 Mount and tighten screw O Guideline Screw oil spray M4 tube Mount the dowels 6 Nm 4 4 lbf ft Loctite 243 5 Nm 3 7 lbf ft Loctite 243 Blow compressed air through all oil channels and check that they are clear 17 4 3 Removing the oil pressure regulator valve e 8 s 0 I 310047 10 Remov...

Page 192: ...nstall ball O and pressure spring 8 Mount and tighten plug with sealing washer C Guideline Plug oil pressure regulator valve M12x1 5 20 Nm 14 8 lbf ft Changing the crankshaft seal ring in the clutch cover B03798 10 Removing the water pump Remove lock ring O Remove crankshaft seal ring 8 Press the new crankshaft seal ring into the clutch cover with the open side facing inward until it is flush Moun...

Page 193: ...ool Info Suitably support the clutch cover while pressing it out Press bearing O of the water pump shaft up to the stop with a suitable tool I Pressing tool 79429006000 p 301 Info I Provide suitable support for the clutch cover while pressing in Press shaft seal ring 8 all the way in I Pressing tool 60029043040 a p 295 The narrower chamfer faces the balancer shaft 191 ...

Page 194: ... 0 Mount and tighten nut D Guideline Nut water pump wheel M6 8 Nm 5 9 lbf ft Loctite 243 Removing the crankshaft bearing inner race 310069 10 Fix the crankshaft in the vise Info Use soft jaws Warm up special tool 0 Guideline 1150 C 302 F I Puller 58429037043 p 293 Push the warmed up special tool O onto the crankshaft bearing inner race press firmly together and pull jointly from the crankshaft Tak...

Page 195: ...ether Guideline 1120 C 248 F I Puller 58429037043 0 p 293 Repeat these steps on the opposite side Ensure that the new crankshaft bearing inner race is flush Info After replacing the crankshaft bearings the crankshaft end play must be measured Finishing work Measure the crankshaft end play 0 p 195 17 4 11 Changing the connecting rod conrod bearing and crank pin Main work Position the crankshaft wit...

Page 196: ...il channel f is aligned with oil channel G X If the oil channels are not correctly aligned the conrod bearing will not be supplied with oil Blow compressed air through the oil channels to check that they are clear Mount new connecting rod Q Info Thoroughly lubricate the bearing Position special tools and on the press Crankshaft pressing tool 75029047000 a p 297 Crankshaft pressing tool insert 7942...

Page 197: ...d value Finishing work Check the crankshaft run out at bearing pin ill p 195 17 4 12 Checking crankshaft run out at bearing pin Position the crankshaft on a roller block Turn the crankshaft slowly Check the crankshaft run out on both bearing pins Crankshaft run out on bearing pin 0 03 mm 0 0012 in If the crankshaft run out at the bearing pin is larger than the specification 17 4 13 Measuring the c...

Page 198: ...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 17 4 15 Checking measuring the cylinder 310059 10 196 Check the cylinder bearing surface for damage If the cylinder bea...

Page 199: ... llill p 196 Check the piston bearing surface for damage If the piston bearing 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 the piston rings for damage If the piston ring is damage...

Page 200: ... in cylinder Using special tool O measure the end gap Guideline Piston ring end gap Compression ring I 5 1 00 mm 5 0 0394 in Oil scraper ring I 5 1 20 mm 5 0 0472 in I Feeler gauge 59029041100 p 295 If the end gap is greater than the specified value Check measure the cylinder p 196 If cylinder wear lies within the specified tolerance Change the piston ring Mount the piston ring with the marking fa...

Page 201: ... 295 Oil pump External rotor engine case clearance I 0 20 mm 0 0079 in If the measured value does not meet specifications Change the oil pump and if necessary the engine case Use special tool O to measure the play between the exter nal rotor and the internal rotor I Feeler gauge 59029041100 0 p 295 Oil pump External rotor internal rotor clearance I 0 20 mm 0 0079 in If the measured value does not ...

Page 202: ... 304674 11 304673 11 200 Insert long flange O of the autodecompression spring in the hole push the autodecompression spring over bearing bolt 8 and hook it into autodecompression weight C Mount autodecompression shaft C in the camshaft Mount new lock ring 0 Perform a function check The autodecompression spring does not turn the autode compression shaft back to the stop Pre tension the autodecompre...

Page 203: ...he camshaft 17 4 23 Checking the timing assembly ll Y Clean all parts well e Check the timing chain gear timing chain sprocket O for damage and wear If there is damage or wear Change the camshaft timing chain sprocket Check the timing chain tensioning rail 8 for damage and wear If there is damage or wear Replace the timing chain tensioning rail Check the timing chain guide rail for damage and wear...

Page 204: ...ove plugs 8 with the O rings Screw appropriate screw C into the rocker arm shafts Pull out rocker arm shafts 0 Take off rocker arm 3 Take the shims out of the valve spring retainers and lay them to one side according to their normal built in position Pretension the valve springs using the special tool Valve spring mounter 59029019000 0 p 294 Insert for valve spring lever 77029041200 0 p 298 Remove...

Page 205: ... valves are removed and the exhaust flange is removed Mount the cylinder head I Clamping plate 75029050000 l l p 298 Remove the large camshaft bearing using special tool O I Pressing tool 75029051000 l l p 298 Remove small camshaft bearing 8 using the special tool Bearing puller 15112017000 ill p 292 Internal bearing puller 15112018100 p 292 Remove shaft seal ring using a suitable tool Press the n...

Page 206: ...cial tool Pressing tool 75029044010 JI p 297 The valve stem is hard chrome plated wear generally appears at the valve guide 302808 10 204 Check the valve plate for run out Valve Run out at valve plate s 0 05 mm 5 0 002 in If the measured value does not meet specifications Change the valve Check sealing seat 6 on valve for damage and wear If the sealing surface is damaged or worn Machine the valve ...

Page 207: ... wear visual check If the valve spring seat is broken or worn Change the valve spring seat Measure the thickness of the valve spring seat Valve spring Valve spring seat 1 8 mm 0 071 in If the measured value does not meet specifications Change the valve spring seat Check exhaust valve guides O using the special tool I Limit plug gauge 59029026006 l l p 295 If the special tool is easy to insert in t...

Page 208: ...0787 in Valve Exhaust sealing seat width 1 2 00 mm 0 0787 in If the measured value does not meet specifications Rework the valve seat Blow compressed air through all oil channels and check that they are clear 17 4 31 Checking the rocker arm shafts 306609 10 17 4 32 Installing the valves i 6 310048 10 206 Check the rocker arm shafts for damage and wear If there is damage or wear Change the rocker a...

Page 209: ...ts 8 The rocker arm shaft with marking O is installed on the intake side Marking O faces upward Info Make sure that the tapped hole of the rocker arm shaft is facing outward Align drill holes CD of the rocker arm shafts with drill holes C of the cylinder head Use special tool 0 to set the distance of the intake rocker arm Guideline I Rocker arm axial play I 0 10 mm 0 0039 in I Feeler gauge 5902904...

Page 210: ...8 10 306629 10 208 Clamp clutch O into a vise Info I Use soft jaws Carefully loosen special tool 8 in steps and remove it Take the clutch out of the vise and place it on a clean work bench with the outside inner clutch hub facing down ward Take the inside inner clutch hub C and release springs 0 out of the outer inner clutch hub Remove clutch facing discs D from the outer inner clutch hub Remove s...

Page 211: ...s D in the inside inner clutch hub Slide on the outside inner clutch hub watching out for the markings Align markings 0 and Ci Push together both inner clutch hubs firmly and have a helper screw in the special tool I Assembly screws 75029033000 p 297 Info I Apply the special tool by hand only do not use another tool Only tighten the special tool to the point where the clutch facing discs cannot be...

Page 212: ...pecified Change all clutch springs Check the contact surface of pressure cap C for damage and wear If there is damage or wear Change the pressure cap Check inner clutch hub 0 for damage and wear If there is damage or wear Change the inner clutch hub Check sleeves D for damage and wear If there is damage or wear Change the sleeves Check outer clutch hub for damage and wear If there is damage or wea...

Page 213: ...scs Check the thickness of the clutch pack Clutch pack thickness Wear limit 26 4 mm 1 039 in If the clutch pack does not meet specifications Change the clutch pack Check intermediate clutch discs 41 for damage and wear If the intermediate clutch discs are not level and are pitted Change all intermediate clutch discs 17 4 37 Checking the shift mechanism Check shift forks O on plate 6 for damage and...

Page 214: ...t areas 9 for wear If the sliding plate is worn Change the sliding plate Check return surface Ci on the sliding plate for wear If deep notches are present Change the sliding plate Check guide pin for looseness and wear If the guide pin is loose and or worn Change the sliding plate Preassemble the shift shaft p 212 304682 10 17 4 38 Preassembling the shift shaft 304683 10 212 Check clearance O betw...

Page 215: ...the gear teeth facing downward Guideline I Use soft jaws Remove stop disk O and second gear fixed gear 8 Remove lock ring fD Remove distance sleeve C Remove third fourth gear sliding gear 0 Remove lock ring D and stop disk Remove fifth gear idler gear Remove needle bearing 17 ENGINE 310083 10 213 ...

Page 216: ...stop disk 8 Remove the fifth gear sliding gear 0 and lock ring D Remove stop disk and third gear idler gear fD Remove needle bearing CD and fourth gear idler gear Remove needle bearing 48 and stop disk 48 Remove lock ring G and second fourth gear shift collar 4D Remove lock ring e and stop disk 40 Remove second gear idler gear 48 and needle bearing G i 17 4 41 Checking the transmission Condition T...

Page 217: ...amage 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 gear 0 for smooth operation in the profile of main sh...

Page 218: ...lly before assembling Check the transmission ill p 214 Main work Secure the main shaft in the vise with the gear teeth facing downward Guideline I Use soft jaws 310084 10 Mount needle bearing O and mount fifth gear idler gear 8 with the shift dogs facing up Mount stop disk D and lock ring C Mount third fourth gear sliding gear 0 with the small gear wheel facing downward Mount distance sleeve D Mou...

Page 219: ...ding collar facing downward Mount stop disk D and lockring C Mount second fourth gear shift collar 0 with the shift groove facing up Mount lockring D and stop disk Mount needle bearing D and the fourth gear idler gear with the collar facing up Mount needle bearing Gi and the third gear idler gear 48 with the collar facing down Mount stop disk and lockring G Mount the fifth gear sliding gear 4D wit...

Page 220: ... there is damage or wear Change the freewheel gear or bearing Check freewheel C for damage and wear when it is disassembled If there is damage or wear Change the freewheel Check the gear mesh of starter motor 0 for damage and wear If there is damage or wear Change the starter motor Change the O ring D of the starter motor Connect the negative cable of a 12 volt power supply to the housing of the s...

Page 221: ...rimary gear clockwise do not wedge Check the locking action of freewheel gear O If the primary gear does not turn clockwise or if it does not lock counterclockwise Change the freewheel Press expansion ring O together with suitable pliers and take off Take the freewheel 8 out of the primary gear Thoroughly oil all parts Push the freewheel O into the primary gear Info Note the direction of rotation ...

Page 222: ... all lugs of the spreader ring pass through slots f of the freewheel and engage in groove Cs of the primary gear Position the right section of the engine case in the engine work stand Oil the bearing I Engine oil SAE 1 0W 50 p 286 Slide crankshaft O into the bearing seat Info Ensure that washer 8 is not damaged ...

Page 223: ...e not to misplace the washers Mount lock ring O Lubricate all parts thoroughly Mount shift fork O in the upper shift groove of the main shaft 17 ENGINE Mount shift fork 8 in the lower shift groove of the counter shaft Mount shift fork fD in the upper shift groove of the counter shaft Mount shift rollers 8 Info Fix the shift rollers in the shift forks with grease 221 ...

Page 224: ...shift rollers Install shift rails O together with upper springs 8 and lower springs Info Fix the springs in the shift rails with grease Installing the left engine case Install dowel O Degrease the sealing surfaces Apply sealing compound to the left section of the engine case I Loctite 591 O Info I To prevent sealing compound from entering into the oil channel dowel O must be mounted first ...

Page 225: ...rew engine case I M6x60 10 Nm 7 4 lbf ft Mount screws fD but do not tighten yet Guideline I Screw engine case I M6x70 110 Nm 7 4 lbf ft Mount screws 8 and tighten all screws in a crisscross pat tern Guideline I Screw engine case I M6x80 Mount the O ring on the countershaft Lightly grease and mount spacer 0 Mount freewheel gear O Mount woodruff key O 10 Nm 7 4 lbf ft Degrease the cone and thinly ap...

Page 226: ...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 and insert the shift shaft all the way Let the sliding plate engage in the shift drum locating unit Shif...

Page 227: ...pressure M6 pump cover Insert pin D Position oil pump gear wheel Position washers Mount lock washer Mount oil pump idler gear Mount washer G and lock ring 48 17 ENGINE 10 Nm 7 4 lbf ft Loctite 243 Crank the oil pump gear wheels and ensure that they can move easily Slide on starter idler gear O with the collar facing the engine case 225 ...

Page 228: ...bf ft bolt torque lim Loctite 243 iter Mount collar bushing O and both needle bearings 8 Slide clutch basket CD onto the gearbox main shaft Turn oil pump gear wheel C until the gear teeth of the clutch basket engage Lock the clutch basket and primary gear using special tool 0 I Gear segment 80029004000 a p 302 Mount and tighten nut D Guideline Nut primary gear Mount washer M20LHx1 5 100 Nm 73 8 lb...

Page 229: ...er clutch hub I M18x1 5 I 80 Nm 59 lbf ft I Gear segment 80029004000 p 302 Info I Make sure that the crankshaft is not locked Secure the nut with the lock washer Insert clutch throw out C Position crankshaft to TDC and lock with special tool 0 1 Locking screw 113080802 l l p 291 Position pressure cap D Install and tighten screws with the spring retainers and clutch springs Guideline Screw clutch s...

Page 230: ...ighten yet Guideline I Screw clutch cover I M6x55 110 Nm 7 4 lbf ft Mount screw 3 and tighten all screws in a crisscross pat tern Guideline I Screw clutch cover I M6x30 Remove the special tool 110 Nm 7 4 lbf ft I Marking mandrel 78129032000 JI p 299 17 5 18 Installing the water pump cover Put the water pump cover seal in place Mount the water pump cover Mount screw O with the sealing washer but do...

Page 231: ...nd tighten screws O Guideline Screw gear M5 position sensor 5 Nm 3 7 lbf ft Loctite 243 Oil the internal rotor and external rotor before mounting Insert O ring O Position pin fj into the oil pump shaft from above Position pin 8 Mount internal rotor 8 and external rotor The rounded sides of the external rotor face the engine case Position oil pump cover D Mount and tighten screws Guideline Screw su...

Page 232: ...timing chain securing guide Mount and tighten screw O Guideline Screw timing M6 10 Nm 7 4 lbf ft chain securing Loctite 243 guide Thread in timing chain tensioning rail from above Mount and tighten screw Guideline Screw timing M6 chain tension ing rail Mount the woodruff key Mount the rotor 10 Nm 7 4 lbf ft Loctite 243 Mount and tighten nut O with the spring washer Guideline Nut rotor M12x1 60 Nm ...

Page 233: ...ng mounting tool from above with a plastic hammer so that it lies flush with the cylinder The special tool must press the piston rings together properly and lie flush with the cylinder Drive the piston into the cylinder by striking it carefully with the hammer handle The piston rings should not catch or they will be dam aged Mount timing chain guide rail O from above Catch G engages in recess The ...

Page 234: ...perly Ensure that piston marking C faces the exhaust side Cover the engine case opening with a cloth Feed the timing chain through the timing chain shaft and mount the piston pin Info For purposes of illustration the following operations are shown on the removed piston Position the piston ring lock ...

Page 235: ...the groove I Insertion for piston ring lock 77329030100 ll JI p 299 Ensure that the piston ring lock is in the correct position on both sides Remove the cloth Keep the timing chain taut Carefully push the cylinder downward letting the dowels engage Mount dowels O and fit cylinder head gasket Put the cylinder head in place Mount screws D with the washers and tighten them in a crisscross pattern 233...

Page 236: ...in over the camshaft gear Push the camshaft into the bearing seats oil Marking CD on the camshaft and hole e on the cylinder head are lined up with each other Info Make sure that the crankshaft is at top dead center Position the camshaft support plate Mount and tighten screw O Guideline Screw M6 camshaft support plate 10 Nm 7 4 lbf ft Loctite 243 17 5 26 Installing the timing chain tensioner 30635...

Page 237: ...Remove special tool O M8 I Locking screw 113080802 p 291 Crank the engine several times 8 Nm 5 9 lbf ft Position the engine at ignition top dead center p 174 41 Check the valve clearance at all valves between the valve and rocker arm 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 12 0 17 mm 0 0047 0 0067 in I Feeler gauge 59029041100 p 295 If the...

Page 238: ...the installation position Correct the shims based on the results of the valve clearance check Insert suitable shims Install the camshaft p 234 Install the timing chain tensioner p 234 Finishing work Check the valve clearance p 235 17 5 29 Installing the alternator cover 236 Position alternator cover gasket O Position the alternator cover Mount screws 8 with the washers but do not tighten yet Guide...

Page 239: ...I M6 I10Nm 7 41bfft Mount and tighten the spark plug using the special tool Guideline ISpark plug IM10x1 1 10 12Nm 7 4 8 9 lbfft I Spark plug wrench with link 77229172000 p 299 Grease the O ring Insert the starter motor I Long li fe grease il p 288 Mount and tighten screws O Guideline I Screw starter motor I M6 110Nm 7 4 lbfft Tilt the motorcycle to one side andfill the oilfilter housing to ab out...

Page 240: ... Mount and tighten screw plug O with the short oil screen and the O ring Guideline Screw plug oil screen M20x1 5 15 Nm 11 1 lbf ft Position the long oil screen with the O rings on a pin wrench Position the pin wrench through the drilled hole of the screw plug in the opposite section of the engine case Push the oil screen all the way into the engine case Mount and tighten screw plug 8 with the O ri...

Page 241: ... plug with magnet M12x1 5 17 5 36 Removing the engine from the engine assembly stand Remove the fitting from the special tool 20 Nm 14 8 lbf ft I Holder and fitting for work stand 79429002000 IE p 300 Remove the engine from the engine assembly stand Info Work with an assistant or a motorized hoist 239 ...

Page 242: ...nge the clothing Info I The fluid level rises with increasing wear of the clutch facing discs 240 Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and clutch lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container Move the clutch fluid reservoir mounte...

Page 243: ...substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and clutch lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean b...

Page 244: ...ity Ride stability is enhanced as the engine braking effect causes less slip on the rear wheel thanks to the antihopping system The antihopping system uses a two part inner clutch hub The individual parts are connected via helical gears The clutch spring preload can be adjusted if necessary Low preload with out washer f Moderate preload with washer G condition at deliv ery Washer 59032000101 High ...

Page 245: ...ect The clutch also engages differently when starting the differences are considerably less pro nounced than when braking The clutch then behaves somewhat more aggressively M01377 10 Preparatory work Place the motorcycle on its left side with the aid of an assis tant Main work Detach spring O Remove screws 8 fD and C Take off the clutch cover Remove screw 0 Info I Never remove more than one screw ...

Page 246: ...ew 8 but do not tighten yet Tighten all screws in a crisscross pattern Guideline I Screw clutch cover I M6 Attach spring O Finishing work Stand the motorcycle upright Danger 110 Nm 7 4 lbf ft 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 extracti...

Page 247: ...es or other cooling system components if the engine or the cooling system are at operating temperature Allow the cooling system and the engine to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coo...

Page 248: ...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 249: ...y 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 Refilling coolant Warning Condition The engine is cold Position the motorcycle upright Place a suitable container under the water pump cover Remove screw O Take off radiator cap 8 Completely...

Page 250: ...Position the motorcycle upright Pour coolant in up to measurement 6 above the radiator fins Guideline Dimension 6 over the radi 10 mm 0 39 in ator fins Coolant Mount the radiator cap Take a short test ride 1 20 I 1 27 qt Check the coolant level a p 246 Coolant ll l p 286 ...

Page 251: ...Oil channel transmission lubrication Checkin Info 20 LUBRICATION SYSTEM 401628 60 The engine oil level can be checked when the engine is cold or warm Preparatory work Stand the motorcycle upright on a horizontal surface Condition The engine is cold Check the engine oil level The engine oil reaches the middle of level viewer f If the engine oil does not reach the middle of the level viewer Add engi...

Page 252: ...r oil get very hot when the motorcycle is ridden Wear suitable protective clothing and safety gloves In the event of scalding rinse the area affected immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Check th...

Page 253: ...s Guideline Screw plug oil screen M20x1 5 15 Nm 11 1 lbf ft Position long oil screen C with the O rings on a pin wrench Position the pin wrench through the drilled hole of the screw plug in the opposite section of the engine case Push the oil screen all the way into the engine case Mount and tighten screw plug 8 with the O ring Guideline Screw plug oil screen M20x1 5 15 Nm 11 1 lbf ft Mount and ti...

Page 254: ...crews Guideline I Screw oil filter cover I M6 Stand the motorcycle upright 110 Nm 7 4 lbf ft Remove filler plug and the O ring from the clutch cover and fill up with engine oil Engine oil Info 1 20 I 1 27 qt Engine oil SAE 10W 50 p 286 I Too little engine oil or poor quality engine oil results in premature wear of the engine Install and tighten the oil filler plug with O ring Danger Danger of pois...

Page 255: ...o not mix different types of engine oil If appropriate change the engine oil Install and tighten the oil filler 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 encl...

Page 256: ...on system when starting or running the engine in an enclosed space Start the engine and let it warm up Check the engine oil pressure Engine oil pressure Engine oil temperature 80 C 176 F Engine speed 1 600 rpm Engine oil temperature 80 C 176 F Engine speed 6 000 rpm 1 0 bar 15 psi 1 7 bar 25 psi If the measured value is less than the specification Check the oil pumps for wear Check all oil channel...

Page 257: ...20 LUBRICATION SYSTEM Guideline I Screw oil filter cover I M6 Finishing work Check the engine oil level I p 249 110 Nm 7 4 lbf ft 255 ...

Page 258: ... Change the ignition coil Checking the spark plug connector 1 601170 10 Condition Spark plug connector cylinder 1 has been removed 0 Measure the resistance between the specified points Measuring point 1 Measuring point 2 Spark plug connector Resistance at 20 C 68 F 1 3 75 6 25 kQ If the specification is not reached Change the spark plug connector Alternator checkin stator windin Condition The alte...

Page 259: ...dition The alternator cover has been removed Remove screws O Remove the retaining bracket Remove screws 8 Remove cable support sleeve fD from the alternator cover Take the stator out of the alternator cover Position the stator in the alternator cover Mount and tighten screws O Guideline Screw stator 0 M5 6 Nm 4 4 lbf ft Loctite 243 D00343 11 Position the retaining bracket Mount and tighten screws ...

Page 260: ...ter box cover p 97 Remove the seat p 101 Remove the fuel tank p 103 Main work Pull capacitor O off of the holder and hang to one side Disconnect spark plug connector Remove the spark plug using the special tool I Spark plug wrench with link 77229172000 il l p 299 Push back hose clamp Pull off the air release hose Remove screws C Remove the valve cover with the gasket ...

Page 261: ...Check the valve clearance at all valves between the valve and rocker arm 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 12 0 17 mm 0 0047 0 0067 in Feeler gauge 59029041100 aJ p 295 If the valve clearance does not meet specifications Adjust the valve clearance aJ p 236 Remove locking screw 0 Crank the engine several times Check the valve clearanc...

Page 262: ...stall the fuel tank a p 104 Mount the seat a p 102 Install the air filter box cover a p 97 Install the right side cover a p 101 Remove the motorcycle from the lift stand a p 12 Ad ustin the valve clearance Info For purposes of illustration the following operations are shown with the engine removed Removal is not necessary Preparatory work Raise the motorcycle with a lift stand a p 12 Remove the ri...

Page 263: ...ance check Finishing work Install the camshaft p 234 Install the timing chain tensioner I p 234 Check the valve clearance I p 258 Install the fuel tank 0 p 104 Mount the seat 0 p 102 Install the air filter box cover p 97 Install the right side cover p 101 Remove the motorcycle from the lift stand p 12 261 ...

Page 264: ...otor has been removed Connect the negative cable of a 12 volt power supply to the housing of the starter motor Connect the positive cable of the power supply briefly with connector O of the starter motor If the starter motor does not turn when the circuit is closed Change the starter motor ...

Page 265: ...he engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Set the idle speed by turning the idle speed adjusting screw Q Guideline I Idle speed I 2 250 2 350 rpm I Tachometer 45129075000 p 292 Executing the initialization run Info I Turning counterclockwise lowers the idle speed Turning clockwise raises the idle speed Condition The diagnostic too...

Page 266: ...closed space Start the engine without operating the throttle grip Guideline I Coolant temperature I 25 C 77 F Let the engine idle until it reaches the specified temperature Guideline I Coolant temperature 1 ao 90 c 176 194 F Info 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...

Page 267: ...ring Piston pin bearing Not a bearing bush DLC plated 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 31 76 Clutch Multidisc clutch in oil bath hydraulically activated Gearbox 5 gear claw shifted Transmission ratio First gear 16 32 Second gear 18 30 Third gear 20 ...

Page 268: ...Compression ring 5 1 00 mm 5 0 0394 in Oil scraper ring 5 1 20 mm 5 0 0472 in Connecting rod end play of lower conrod bearing 0 20 0 45 mm 0 0079 0 0177 in Crankshaft run out on bearing pin 5 0 03 mm 5 0 0012 in Clutch facing disc thickness 1 9 mm 2 0 075 in Clutch spring length 45 60 46 80 mm 1 7953 1 8425 in Thrust surface clutch facing discs in outer clutch 5 0 5 mm 5 0 02 in hub Oil pressure r...

Page 269: ... location Plug oil channel Screw engine sprocket M5 M5 M5 M5 M5 M5 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6x0 75 M7 M7 M8 M8 M10 M10 25 TECHNICAL DATA 6 Nm 4 4 lbf ft 8 Nm 5 9 lbf ft 5 Nm 3 7 lbf ft 6 Nm 4 4 lbf ft 6 Nm 4 4 lbf ft 6 Nm 4 4 lbf ft 8 Nm 5 9 lbf ft 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 10...

Page 270: ...Brake system front rear 268 10 12 Nm 7 4 8 9 lbf ft 12 Nm 8 9 lbf ft 10 Nm 7 4 lbf ft Step 1 10 Nm 7 4 lbf ft Step 2 30 Nm 22 1 lbf ft Step 3 50 Nm 36 9 lbf ft Lubricated with engine oil 60 Nm 44 3 lbf ft Thread oiled with engine oil cone degreased 20 Nm 14 8 lbf ft 20 Nm 14 8 lbf ft 80 Nm 59 lbf ft 100 Nm 73 8 lbf ft Loctite 243 15 Nm 11 1 lbf ft I Engine oil SAE 10W 50 0 p 286 I Coolant 0 p 286 ...

Page 271: ...90 mm 11 42 in Seat height unloaded 890 mm 35 04 in Weight without fuel approx 105 3 kg 232 1 lb Maximum permissible front axle load 145 kg 320 lb Maximum permissible rear axle load 190 kg 419 lb Maximum permissible overall weight 335 kg 739 lb 25 6 Electrical s stem Battery C22S Lithium ion battery Battery voltage 12 V Nominal capacity 2 2Ah maintenance free Fuse 58011109110 10A I Fl warning lamp...

Page 272: ...195 ml 6 59 fl oz Fork oil SAE 4 48601166S1 p 286 Oil capacity fork leg without car 380 ml 12 85 fl oz Fork oil SAE 4 48601166S1 tridge 0 p 286 25 9 Shock absorber Shock absorber article number 18 15 7P 08 Shock absorber WP Performance Systems 5018 DCC Link Compression damping low speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping high speed Comfort 2 5 turns Standard 2...

Page 273: ...t bracket M6 Screw chain sliding guard M6 Screw electric starter cable con M6 nection Screw front brake disc M6 Screw rear brake disc M6 Screw throttle grip M6 Fuel connection on fuel tank M8 Nut foot brake lever stop M8 Nut rear sprocket screw M8 Nut rim lock M8 Remaining nuts chassis M8 Remaining screws chassis M8 Screw bottom triple clamp M8 Screw chain sliding piece M8 25 TECHNICAL DATA Shock ...

Page 274: ...ng system Screw front wheel spindle Nut rear wheel spindle 272 MS MS MS MS MS MS M10 M10 M10 M10 M10 M10 M10x1 25 M12 M14x1 5 M14x1 5 M14x1 5 M16x1 5 M20x1 5 M20x1 5 M24x1 5 M25x1 5 25 Nm 18 4 lbf ft 15 Nm 11 1 lbf ft 20 Nm 14 8 lbf ft 30 Nm 22 1 lbf ft 20 Nm 14 8 lbf ft 17 Nm 12 5 lbf ft 60 Nm 44 3 lbf ft 45 Nm 33 2 lbf ft 45 Nm 33 2 lbf ft 60 Nm 44 3 lbf ft 40 Nm 29 5 lbf ft 60 Nm 44 3 lbf ft 45...

Page 275: ...r a long period Avoid direct sunshine on the motorcycle during cleaning 1 111111111111111 401061 01 Close off the exhaust system to prevent water from entering First remove coarse dirt particles with a gentle spray of water Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply ...

Page 276: ...4 Treat bare metal parts except for brake discs and the exhaust system with a corrosion inhibitor Treat all plastic parts and powder coated parts with a mild cleaning and care agent Preserving materials for paints metal and rubber p 289 ...

Page 277: ...ce repairs or replacements are necessary you should do this during the storage period less workshop overload In this way you can avoid long workshop waiting times at the start of the new season 1111 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Refuel Clean the motorcycle p 273 Change the engine oil and oil filter and clean the oil screens...

Page 278: ... short time only Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and the exhaust system to rust Preparin for use after stora e 401059 01 Install the battery p 137 Remove the motorcycle from the lift stand p 12 Perform checks and maintenance measures when preparing for use Make a test ride ...

Page 279: ...the tire air pressure 0 p 116 I O I I I Check the wheel bearing for play 0 p 117 I I I I Check the wheel hubs I I I I Check the rim run out a p 123 0 I I Check the spoke tension 0 p 118 0 I I I I Check the chain rear sprocket engine sprocket and chain guide 0 p 127 I I Check the chain tension I p 126 0 I I Grease all moving parts e g hand lever chain and check for smooth operation I I I I Check co...

Page 280: ...e fluid 0 p 146 Change the rear brake fluid 0 p 153 Change the hydraulic clutch fluid p 241 Lubricate the steering head bearing p 44 Conduct a major fork service 0 p 17 Service the shock absorber 0 p 68 Change the fuel filter p 109 Perform minor engine service engine has been installed Change spark plug and spark plug connector Change piston check and measure cylinder check cylin der head Check th...

Page 281: ...28 SERVICE SCHEDULE 279 ...

Page 282: ...i X16 1 j X7 NfC 2 S 2 C10 S 2 1FC 2 X7 1 I m lll P 6 5 6 I I 521 l x19 r R 4 K 4 r K 4 rBR 4 1 X19 M10 II I iAF 4 i X17 II G101 1 1 I X30 2 i I lZ 3 1 X18 I 1 1 t X1 N iEB 4 ij EB 4 I 6 1 l a 2 F1 4 l a 2 F1 HlJSCl l rna FS 450 HQV 2016 1 3 re ...

Page 283: ... control unit C10 Capacitor G10 Battery G20 Alternator K10 Starter relay with main fuse K30 Power relay M10 Starter motor T20 Voltage regulator S21 Electric starter button X295 Diagnostics connector 29 WIRING DIAGRAM 281 ...

Page 284: ... HY 33 t t HY 33 HY 33 520 1 X16 6 I 1 X16 6 1 X16 I I 6 1 X16 t i i f is I I t X S BF 1 dA 1 E I X295 l11AP 6 1 t4 i fr12 a P25 l x2 iCX 2 W 2 W 2 CX 2 1 X2 1 xJ f1 2 Hl 2 1 x 3 f 0 0 X 3 0 1 rh 151515 I 1 xs l GA 3 GA 3 1 x 5 l l 1 FS a 1 FB at FS 450 HQV 2016 HUSQ l rna I l I I I I I ...

Page 285: ...Components A11 EFI control unit M13 Fuel pump M51 Injection valve cylinder 1 P25 Fl warning lamp MIL R30 CAN bus terminating resistor S20 Kill switch X295 Diagnostics connector 29 WIRING DIAGRAM 283 ...

Page 286: ...ru l X16 X16 X16 a I t I I J a f t t 1 x12 l x11 _841 fV 2 1CR 1 B21 EE 1 t R51 I f1 x1l I HV 2 11 X12 _il s I I FS 450 HQV 2016 I 3 I 4 5 11 X16 i I I 1 1 t l X10 NIF 2 AT 2 B37 e 5 I 6 7 8 l l X16 X16 t I 1 m 11 ru X16 X16 r I I I J l i r x20 X14 X9 NJM 3 AP B NCM 2 U3 B26 B12 r B34 AP 6 lM 2 1 r u3 I 4 l g B B I I I I 11 I I IA f Is I IE I I I 6 7 I II ...

Page 287: ... Crankshaft position sensor B41 Manifold absolute pressure sensor cylinder 1 B43 Throttle position sensor R51 Ignition coil cylinder 1 S51 Map Select switch for ride mode optional S55 Map Select switch optional Cable colors bl Black br Brown bu Blue gn Green gr Gray lbu Light blue or Orange pk Pink pu Violet rd Red wh White ye Yellow 29 WIRING DIAGRAM 285 ...

Page 288: ...protection to at least I 25 C 13 F The mixture ratio must be adjusted to the necessary antifreeze protection Use distilled water if the coolant needs to be diluted The use of premixed coolant is recommended Observe the coolant manufacturer specifications for antifreeze protection dilution and miscibility compatibility with other coolants Recommended supplier Bel Ray Moto Chill Racing Coolant En in...

Page 289: ...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 290: ...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 291: ...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 31 AUXILIARY SUBSTANCES 289 ...

Page 292: ...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 290 ...

Page 293: ...al H01065 01 Art no 00029095052 Feature UK safety plug Nominal voltage Mains fuse Power cable length approx Charger cable length approx rofessional H01065 01 H00944 01 Art no 00029095053 Feature CH plug Nominal voltage Mains fuse Power cable length approx Charger cable length approx Art no 113080802 32 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 294: ...000 Internal bearing uller p 15112018100 Tachometer M 45129075000 s ring hook 50305017000 292 H00520 01 H00522 01 H00525 01 H00973 01 Art no 15112017000 Art no 15112018100 Feature 118 23 mm 0 71 0 91 in Art no 45129075000 Art no 50305017000 ...

Page 295: ...51012011000 Puller 58429037043 Tool bracket 58429089000 H00565 01 H00572 01 H00598 01 H00603 01 Art no 50329050000 Art no 51012011000 Art no 58429037043 Feature I Inside diameter Art no 58429089000 32 SPECIAL TOOLS I 43 9 mm 1 728 in 293 ...

Page 296: ...0606 01 Valve s ring mounter 59029019000 H00610 01 294 Art no 58429091000 Art no 58429092000 Art no 58429094000 Feature Torque Open ended bit Open ended bit Open ended bit Open ended bit Bit diameter Art no 59029019000 3 15 Nm 2 2 11 1 lbf ft 3 9 mm 0 154 in 4 9 mm 0 193 in 5 5 mm 0 217 in 6 8 mm 0 268 in 5 9 mm 0 232 in ...

Page 297: ...0029015000 H00628 01 Pressing tool 60029043040 H00639 01 Art no 59029026006 Feature I Diameter Art no 59029041100 Feature 15 piece Art no 60029015000 Feature Height Diameter Art no 60029043040 32 SPECIAL TOOLS I 6 05 mm 0 2382 in I 0 10 0 25 mm 0 0039 0 0098 in 80 mm 3 15 in 57 125 mm 2 24 4 92 in 295 ...

Page 298: ...clam lier Art no 60029057000 60029057000 H00650 01 Testing hose Art no 61029093000 61029093000 H00659 01 Pressure testing tool Art no 61029094000 4x D 61029094000 H00660 01 Puller Art no 75029021000 75029021000 H00707 01 296 ...

Page 299: ...crews 4x Art no 75029033000 75029033000 H00708 01 Pressing tool Art no 75029044010 75029044010 H00712 01 Pressing tool Art no 75029044020 75029044020 H00713 01 Crankshaft ressing tool Art no 75029047000 75029047000 H00714 01 297 ...

Page 300: ...ate Art no 75029050000 75029050000 H00719 01 Pressing tool Art no 75029051000 75029051000 H00721 01 Protection ca Art no 75029090000 75029090000 H00726 01 Insert for valve s ring lever Art no 77029041200 77029041200 H00746 01 298 ...

Page 301: ...77329030100 H00768 01 Marking mandrel 78129032000 H00796 01 Crankshaft ressing tool insert 78929008000 H01016 01 Art no 77229172000 Feature Drive Hexagonal part Length Art no 77329030100 Art no 78129032000 Art no 78929008000 32 SPECIAL TOOLS 3 8 in 14 mm 0 55 in 130 mm 5 12 in 299 ...

Page 302: ...g lier 79029083000 H00804 01 Extractor 79229032044 H00808 01 Puller 79229048000 H00809 01 Holder and fittin for work stand 2xffiffi 79429002000 H01081 01 300 Art no 79029083000 Art no 79229032044 Art no 79229048000 Art no 79429002000 ...

Page 303: ...Art no 79429006000 79429006000 H01018 01 Crankshaft ressing tool insert Art no 79429008000 79428008000 H01169 01 Se arator late Art no 79429009000 79429009000 H00812 01 Oil ressure ada ter Art no 79429094000 79429094000 H01045 01 301 ...

Page 304: ...work stand 80329001000 Lift stand 80329955100 Protection ca 0 90129005000 302 H00813 01 H01047 01 H02016 01 H00816 01 Art no 80029004000 Art no 80329001000 Art no 80329955100 Feature Height Load Art no 90129005000 260 370 mm 10 24 14 57 in 150 kg 331 lb ...

Page 305: ...1 01 De th micrometer T107S H00842 01 Drift T120 H00844 01 Art no T103 Feature I adjustable Diameter Art no T106S Feature I Diameter Art no T107S Art no T120 Feature I Diameter 32 SPECIAL TOOLS 14 mm 0 16 in I 68 75 mm 2 68 2 95 in 1 s mm 0 31 in 303 ...

Page 306: ...Pressing tool T1206 Pressing tool 61 T1207S 304 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 307: ...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 32 SPECIAL TOOLS 118 mm 0 71 in 138 49 mm 1 5 1 93 in I 48 mm 1 89 in 305 ...

Page 308: ...6S Ring wrench T14017 Filling tool 2x T14019 Su ort tool T14020 306 H01036 01 H00904 01 H00906 01 H00907 01 Art no T14016S Feature I Diameter Art no T14017 Feature I Hexagonal part Art no T14019 Art no T14020 I 12 mm 0 47in I 50 mm 1 97in ...

Page 309: ...4023 H00911 01 Mounting sleeve T14029 H00917 01 Art no T14021 Feature I Diameter Art no T14022B Feature I Diameter Art no T14023 Feature I Diameter Art no T14029 Feature I Diameter 32 SPECIAL TOOLS 112 mm 0 47 in 111 95 21 4 mm 0 4705 0 843 in I 24 5 mm 0 965 in 112 45 mm 0 4902 in 307 ...

Page 310: ...lam ing stand 2x T1403S Mounting tool T14040S 308 H00918 01 H00921 01 H00896 01 H00922 01 Art no T14030 Feature Art no T14033 Art no T1403S Feature Diameter Diameter Art no T14040S Feature I Diameter 116 mm 0 63 in 48 mm 1 89 in 60 mm 2 36 in I 48 mm 1 89 in ...

Page 311: ...Pressing tool T1504 Mounting tool o T150S Filling tool 2x 3x T170S1 H00899 01 H00852 01 H00855 01 Art no T1504 Feature I Diameter Art no T150S Art no T170S1 118 mm 0 71 in 32 SPECIAL TOOLS 309 ...

Page 312: ... 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 313: ...34 LIST OF ABBREVIATIONS Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly 311 ...

Page 314: ...g 148 Capacitor checking 140 312 Capacity coolant 248 268 engine oil 170 252 268 Cartridge fork legs disassembling 22 of the fork legs assembling 35 Chain checking cleaning 127 130 Chain guide checking 127 Chain tension adjusting 127 checking 126 Characteristic map of the throttle response adjusting 54 Charging voltage checking 139 Chassis number 10 Clutch 242 adjusting 243 fluid level checking co...

Page 315: ...working on the individual parts clutch checking 204 206 202 190 210 countershaft assembling 217 countershaft disassembling 214 main shaft assembling 216 main shaft disassembling 213 water pump installing Engine assembly 191 alternator cover installing 236 camshaft installing 234 clutch basket installing 226 clutch cover installing 228 clutch discs installing 227 clutch push rod installing 238 cran...

Page 316: ...oot brake lever 100 100 basic position adjusting 151 free travel checking 150 Fork legs assembling 37 bleeding 15 cartridge assembling 35 cartridge bleeding and filling 41 cartridge disassembling 22 314 cartridge filling with nitrogen 43 checking 27 compression damping adjusting 14 disassembling 19 dust boots cleaning 15 installing 16 major fork service conducting 17 minor fork service checking 29...

Page 317: ...tle cable adjusting 53 checking 52 Preparing for use after storage 276 R Rear sprocket checking 127 Rear wheel installing removing 124 123 Rebound damping fork adjusting 14 shock absorber adjusting 59 Riding sag adjusting 62 Right side cover installing 101 removing Rim run out 101 checking 123 Rubber grips checking 51 s Screw cap with membrane holder fork legs assembling 32 fork legs disassembling...

Page 318: ... Stator installing 257 removing 257 Steering head bearing changing 47 lubricating 44 Steering head bearing play adjusting 49 checking 47 Storage 275 Swingarm checking 86 installing 88 removing 87 Swingarm bearing T changing 90 checking 86 Technical data capac es 268 316 chassis 268 chassis tightening torques 271 electrical system 269 engine 265 engine tolerance wear limits 266 engine tightening to...

Page 319: ...11111111111111111111IIIIIIIIIIII 3403034en 06 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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