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Husqvarna F2303P4, Repair Manual

The Husqvarna F2303P4 Repair Manual is a comprehensive guide for troubleshooting and fixing issues with this powerful outdoor equipment. Available for free download on manualshive.com, this user-friendly manual provides step-by-step instructions and illustrations, ensuring seamless repair and maintenance of your Husqvarna F2303P4.

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33  SPECIAL TOOLS 

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 

Clam 

Art.  no.:  75029050000 

75029050000 

H00719-01 

359 

Summary of Contents for F2303P4

Page 1: ...PIONEERING SINCE 1903 REPAIR MANUAL2016 FE 450 FE 501 FE 501 S Art no 3403030en leJ Husqvarna MOTORCYCLES ...

Page 2: ......

Page 3: ...lors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice Husqvarna accepts no liability for delivery options deviations from figures and descriptions as well as misprints and other errors The models portrayed partly contain special equipment tha...

Page 4: ...dge 24 6 13 Disassembling the piston rod 25 7 8 9 6 14 Disassembling the hydrostop unit 26 6 15 Disassembling the seal ring retainer 27 6 16 Checking the fork legs 27 6 17 Assembling the seal ring retainer 29 6 18 Assembling the hydrostop unit 29 6 19 Assembling the piston rod 30 6 20 Assembling the cartridge 31 6 21 Assembling the fork legs 33 6 22 Lubricating the steering head bearing 37 6 23 Re...

Page 5: ...box 95 12 F UEL TANK SEAT TRIM 96 12 1 Opening the filler cap 96 12 2 Closing the filler cap 97 TABLE OF CONTENTS 12 3 Removing the right side cover 97 12 4 Installing the right side cover 97 12 5 Removing the seat 98 12 6 Mounting the seat 98 12 7 Removing the fuel tank 99 12 8 Installing the fuel tank 101 12 9 Changing the fuel screen 103 12 10 Changing the fuel filter 104 12 11 Changing the fue...

Page 6: ... 2 18 3 3 18 3 4 Draining the engine oil 181 Removing the clutch push rod 182 Removing the oil filter 182 18 3 5 18 3 6 18 3 7 18 3 8 18 3 9 18 3 10 18 3 11 18 3 12 18 3 13 18 3 14 Removing the starter motor 183 Removing the spark plug 183 Removing the valve cover 183 Removing the alternator cover 184 Positioning the engine at ignition top dead center 184 Removing the timing chain tensioner 185 Re...

Page 7: ...ain shaft 222 TABLE OF CONTENTS 18 4 39 Disassembling the countershaft 224 18 4 40 Assembling the countershaft 224 18 4 41 Checking the transmission 225 18 4 42 Checking the starter drive 227 18 4 43 Removing the freewheel 228 18 4 44 Checking the freewheel 228 18 4 45 Installing the freewheel 228 18 5 Engine assembly 229 18 5 1 Installing the crankshaft 229 18 5 2 Installing the transmission shaf...

Page 8: ...the starter motor 270 25 THROTTLE VALVE BODY 271 6 25 1 Adjusting the idle speed 271 25 2 Executing the initialization run 271 26 TECHNICAL DATA 273 26 1 26 2 26 3 26 4 26 4 1 26 4 2 26 4 3 Engine 273 Tolerance engine wear limits 274 engine tightening torques 275 Capacities 277 Engine oil 277 Coolant 277 Fuel 277 26 5 Chassis 277 26 6 26 7 26 8 26 9 Electrical system 278 Tires 279 Fork 279 Shock a...

Page 9: ...501 S US 338 30 27 Page 5 of 8 FE 501 S US 340 30 28 Page 6 of 8 FE 501 S US 342 30 29 Page 7 of 8 FE 501 S US 344 30 30 Page 8 of 8 FE 501 S US 346 31 SUBSTANCES 348 32 AUXILIARY SUBSTANCES 350 33 SPECIAL TOOLS 352 34 STANDARDS 370 35 LIST OF ABBREVIATIONS 371 INDEX 372 TABLE OF CONTENTS 7 ...

Page 10: ...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 8 Indicates a proprietary name Indicates a protected name Ind...

Page 11: ...ermanent injury if the appropriate measures are not taken Warning Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken Caution Indicates a danger that may lead to minor injuries if the appropriate measures are not taken Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken Wa...

Page 12: ...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 13: ...head on the right 4 2 T e label FE EU AU FE 501 S US 401946 10 M00650 10 FE EU AU The type label O is fixed to the front of the steering head FE 501 SUS The type label O is fixed to the front of the steering head The additional type label for Canada fj is fixed to the front of the front pipe 11 ...

Page 14: ... number O for the steering lock is stamped onto the key connector FE 501 SUS Key number O for the ignition and steering lock is indicated on the KEYCODECARD Info I You need the key number to order a spare key Keep the KEYCODECARD in a safe place The engine number O is stamped on the left side of the engine under the engine sprocket The fork part number O is stamped on the inner side of the fork st...

Page 15: ...4 6 Shock absorber article number 4 SERIAL NUMBERS Shock absorber article number O is stamped on the top of the shock absorber above the adjusting ring towards the engine side 13 ...

Page 16: ...rface 401943 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle press side stand Oto the ground with your foot and lean the motorcycle on it Info When you are riding the side stand must be folded up and secured with the rubber band 5 3 Startin Note Danger Danger of poisoning death Exhaust gases are toxic and inhaling them may result in unconsciousness and Alw...

Page 17: ...ol when starting 400733 01 5 4 Starting the motorcycle to check the function Danger Danger of poisoning death Exhaust gases are toxic and inhaling them may result in unconsciousness and Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Shift transmission to neutral FE 501 SUS ...

Page 18: ...pression damping Comfort Standard Sport Info 14 clicks 12 clicks 10 clicks I Turn clockwise to increase damping turn counter clockwise to reduce damping Ad usting the rebound dam ing of the fork Info The hydraulic rebound damping determines the fork suspension behavior Turn the red adjusting screw O all the way clockwise Info The adjusting screw O is located at the upper end of the right fork leg ...

Page 19: ...ift stand a p 14 Remove the fork protector a p 20 Main work Push dust boots O of both fork legs downward Info The dust boots remove dust and coarse dirt parti cles from the inside fork tubes Over time dirt can accumulate behind the dust boots If this dirt is not removed the oil seals behind can start to leak Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Al...

Page 20: ...ve the front wheel l ll p 122 Main work Remove screws O and take off the clamp Remove the cable tie s Remove screws with the washers and take off the brake caliper Allow the brake caliper and brake line to hang loosely to the side FE EU AU FE 450 501 US Loosen screws 5 Take out the left fork leg Loosen screws C Take out the right fork leg FE 501 SUS Loosen screws 5 Take out the left fork leg Loose...

Page 21: ...5 lbf ft clamp Tighten screws D Guideline Screw bottom M8 15 Nm 11 1 lbf ft triple clamp FE 501 SUS Tighten screws Guideline Screw top triple M8 17 Nm 12 5 lbf ft clamp Tighten screws D Guideline Screw bottom M8 15 Nm 11 1 lbf ft triple clamp Position the brake caliper and mount and tighten screws C with the washers Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Mount the cab...

Page 22: ...tion the brake line wiring harness and clamp Mount and tighten screws 8 Position the fork protector on the right fork leg Mount and tighten screws D Guideline Remaining screws chassis Condition M6 The fork legs have been removed Disassemble the fork legs a p 21 Remove the spring a p 23 Disassemble the cartridge a p 24 Disassemble the piston rod l p 25 10 Nm 7 4 lbf ft Disassemble the hydrostop uni...

Page 23: ... the current state of compression damping 8 COMP white adjuster on the left fork leg Open the adjusters on the rebound and compression damp ing all the way Clamp the fork leg in the area of the lower triple clamp I Clamping stand T1403S ll l p 367 Remove screw 8 Remove adjuster Loosen the screw cover 8 I Mounting tool T14047 ll l p 367 Info The cartridge cannot be taken off yet Unclamp the fork le...

Page 24: ...he cartridge usually requires the application of considerable force Remove dust boot 3 Remove fork protector ring f Info The fork protector ring does not necessarily need to be removed for repair work Remove lock ring Info The lock ring has a beveled end where a screwdriver can be applied Warm up the outer tube in area C of the lower sliding bush ing Guideline 1 50 oc 122 OF Pull the outer tube fr...

Page 25: ...t boot CS Unclamp the fork leg The operations are the same on both fork legs 201722 11 Preparatory work Disassemble the fork legs p 21 Main work Pull the spring downward Mount the open end wrench on the hexagonal part Clamp the open end wrench in the vise Release screw cap O but do not remove it yet I Mounting tool T14047 p 367 Pull the spring downward Remove the open end wrench Remove the screw c...

Page 26: ... Main work Degrease piston rod O and clamp using the special tool I Clamping stand T14049S p 368 Remove adjusting tube Unscrew spring guide Ci Remove spring seat 8 Pull the piston rod out of the cartridge Degrease the cartridge and clamp it with the special tool I Clamping stand T14049S p 368 Release seal ring retainer and remove with the washer Remove lock ring D Pull reservoir out of the cartrid...

Page 27: ...le the fork legs p 21 Remove the spring p 23 Disassemble the cartridge p 24 Main work Degrease hydrostop needle O and clamp using the special tool I Clamping stand T1202S p 365 Release hydrostop needle O and remove it from the piston rod Valve usually remains in the hydrostop needle Info f silver hydrostop needle on compression damp ing side 0 red hydrostop needle on rebound damping side Turn pist...

Page 28: ...tube can be used for this Disassembling the hydrostop unit Info The procedures are the same on both fork legs Preparatory work Disassemble the fork legs 0 p 21 Main work Clamp hydrostop unit using special tool to sleeve O and loosen I Clamping stand T1202S 0 p 365 Turn hydrostop unit mount on a fitting hexagon socket and clamp into a vice Remove sleeve O Remove shim stack 8 and washer ...

Page 29: ...ssembling the seal ring retainer Info The steps are identical for both fork legs R00013 10 Checking the fork legs Preparatory work Disassemble the fork legs p 21 Remove the spring p 23 Disassemble the cartridge p 24 Main work Remove pilot bushing support O Remove O ring 8 and seal ring s Condition The fork legs have been disassembled 27 ...

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

Page 31: ...The steps are identical for both fork legs R00014 10 Mount and grease seal ring Q I Lubricant T158 p 350 Mount and grease 0 ring 8 I Lubricant T158 lit I p 350 Position pilot bushing support fD Assemblin the hydrostop unit Info The procedures are the same on both fork legs Mount and grease 0 ring Q I Lubricant T158 lit I p 350 Mount washer 8 Mount shim stack fD with the smaller washers facing down...

Page 32: ...tical for both forklegs except for the hydrostop needle and valve 201790 10 R00033 10 R00031 10 30 Degrease the piston rod Clamp the piston rod with the special tool I Clamping stand T14049S a p 368 Grease O ring Mount valve needle O in the piston rod I Lubricant T158 a p 350 Mount spring Mount and tighten adapter CD with spring e Guideline Adapter of piston rod Position the spring M6x0 5 12 Nm 8 ...

Page 33: ... Info Note the setting list Press the piston downward against the spring Info Make sure the pistons do not squeeze the shims Position valve in hydrostop needle Mount and tighten the hydrostop needle Guideline Hydrostop needle on M6x0 5 piston rod Info 8 Nm 5 9 lbf ft I e silver hydrostop needle on compression damp ing side 4D red hydrostop needle on rebound damping side Unclamp the piston rod The ...

Page 34: ... preload spacers Position the spring with the preload spacers in the reservoir Position sleeve 8 in the reservoir Clamp cartridge with special tool I Clamping stand T14049S p 368 Slide reservoir 0 onto the cartridge Info Hold the sleeve in the reservoir to prevent it from slid ing out Mount lock ring D Mount seal ring retainer with the washer and tighten Guideline Seal ring retainer M23 5x0 75 Unc...

Page 35: ...de screw cap with mark COMP brake caliper holder white adjuster Rebound damping side screw cap with mark REB no brake caliper holder red adjuster B 8 8 R00037 10 Preparatory work Assemble the hydrostop unit I p 29 Main work Clamp the inner tube with the axle clamp Guideline I Use soft jaws Mount the special tool I Protecting sleeve T1401 a p 367 Grease and push on dust boot O I Lubricant T14034 a ...

Page 36: ...tube in area f of the lower sliding bush ing Guideline I 50 oc 122 OF Slide the outer tube onto the inner tube Hold the lower sliding bushing with the longer side of the special tool I Mounting tool T14040S l ll p 367 Press the sliding bushing all the way into the outer tube Position the support ring Hold the seal ring with the shorter side of the special tool I Mounting tool T14040S l ll p 367 Pr...

Page 37: ... the entire filling quantity of fork oil available Oil capacity per fork 630 ml Fork oil SAE 4 leg 21 3 fl oz 48601166S1 p 348 Add some of the fork oil while pulling out and pushing in the piston rod numerous times Guideline I Fork oil quantity I 510 ml 17 24 fl oz Mount and tighten hydrostop unit Guideline I Hydrostop unit I M30x1 Clamp the fork vertically Add the remaining quantity of fork oil I...

Page 38: ...rectly mounted according to the hydrostop needles Rebound damping side red hydrostop needle screw cap with mark REB Compression damping side silver hydrostop needle screw cap with mark COMP Mount the open end wrench on the hexagonal part Hold the open end wrench Tighten screw cap Guideline Screw cap on piston M8x0 75 rod I Mounting tool T14047 a p 367 Push the outer tube upward 18 Nm 13 3 lbf ft C...

Page 39: ...ive 2 Warning Danger of accident Modifications to the sus pension setting may seriously alter the handling characteristic Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components Only make adjustments within the recom mended range Ride slowly to start with after making adjustments to get the feel of the new handling ch...

Page 40: ...ront of the right radiator and detach the wiring harness Remove screw 8 Remove screw 8 take off the upper triple clamp with the handlebar and set it aside Info I Cover the components to protect them against damage Do not kink the cables and lines FE 501 SUS Open cable holder O in front of the right radiator and detach the wiring harness Remove screw 8 Remove screw 8 take off the upper triple clamp...

Page 41: ...damage and grease I High viscosity grease a p 350 Position 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 Mount protective ring 8 and O ring fD Position the upper triple clamp with the handlebar Mount screw C but do not tighten yet Position the clutch line in the guide above the voltage regula to...

Page 42: ...s The second milled groove from the top must be flush with the upper edge of the upper triple clamp FE EU AU FE 450 501 US Tighten screws 3 Guideline Screw bottom triple clamp FE 501 SUS Tighten screws 3 Guideline Screw bottom triple clamp Tighten screw C Guideline Screw top steering head MS MS M20x1 5 Mount and tighten screw Guideline Screw top steering stem MS 15 Nm 11 1 lbf ft 15 Nm 11 1 lbf ft...

Page 43: ...nt fender a p 113 Install the front wheel Ip 123 Install the headlight mask with the headlight I p 115 Check that the wiring harness throttle cables and brake and clutch lines can move freely and are routed correctly Check the play of the steering head bearing Ip 41 Remove the motorcycle from the lift stand p 14 Check the headlight setting p 169 Checking the la of the steering head bearing Warning...

Page 44: ...tent positions are detected Adjust the steering head bearing play 0 p 43 Check the steering head bearing and replace if neces sary Finishing work Remove the motorcycle from the lift stand a p 14 6 26 Changing the steering head bearing 42 Preparatory work Remove the headlight mask with the headlight 0 p 114 Raise the motorcycle with a lift stand a p 14 Remove the front wheel a p 122 Remove the fork...

Page 45: ...ss on the new bearing with a suitable tube as far as it will go Finishing work Install the lower triple clamp 0 p 39 Install front fender a p 113 Install the front wheel a p 123 Install the headlight mask with the headlight a p 115 Check that the wiring harness throttle cables and brake and clutch lines can move freely and are routed correctly Check the play of the steering head bearing p 41 Remov...

Page 46: ... steering stem FE 501 SUS M8 Loosen screws O Remove screw 8 Loosen and retighten screw 8 Guideline Screw top steering M20x1 5 head 17 Nm 12 5 lbf ft 17 Nm 12 5 lbf ft Loctite 243 12 Nm 8 9 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid stresses Tighten screws O Guideline Screw top triple clamp M8 Mount and tighten screw Guideline Screw top steering stem Finishing work...

Page 47: ... The handlebar may break as a result Change the handlebar if the handlebar is damaged or bent 101860 10 Remove screws O Take off the handlebar clamps Take off the handlebar and lay it to one side Info Cover the components to protect them against dam age Do not bend the cables and lines Remove screws 8 Take off the handlebar supports Place the handlebar supports in the required position Mount and t...

Page 48: ...ce between the clutch lever and the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding Checking the routing of the throttle cable Preparatory work Remove the seat il l p 98 Remove the fuel tank il l p 99 Main work FE EU AU FE 450 501 US Check the throttle cable routing Both throttle cables must be r...

Page 49: ...le grip back and forth slightly to ascertain play f in the throttle cable I Play in throttle cable I 3 5 mm 0 12 0 2 in If the throttle cable play does not meet specifications Adjust the play in the throttle cable p 48 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...

Page 50: ...rn adjusting screw CD in as far as pos sible Loosen nut C Turn adjusting screw 0 so that there is play f in the throttle cable at the throttle grip Guideline I Play in throttle cable I 3 5 mm 0 12 0 2 in Tighten nut C Press and hold the throttle grip in the closed setting Turn adjusting screw CD out until there is no play in throttle cable D Tighten nut 8 Slide on sleeves O Check the throttle grip...

Page 51: ...grip Guideline I Play in throttle cable I 3 5 mm 0 12 0 2 in Tighten nut D Press and hold the throttle grip in the closed setting Turn adjusting screw 0 out until there is no play in throttle cable D Tighten nut C Slide on sleeves D Check the throttle grip for smooth operation Position activated charcoal filter 8 Reconnect rubber band O Finishing work Install the fuel tank p 101 Mount the seat p 9...

Page 52: ... guard on the frame at the rear and swing up at the front Turn quick release O clockwise all the way Check the frame for cracks and deformation If the frame exhibits cracks or deformation due to a mechanical impact Change the frame Info I Always replace a frame that has been damaged due to a mechanical impact Repair of the frame is not authorized by Husqvarna Motorcycles ...

Page 53: ...h Info I Do not loosen fitting 8 Turn counterclockwise by the number of turns corresponding to the shock absorber type Guideline Compression damping high speed Comfort Standard Sport Info 2 5 turns 2 turns 1 5 turns I Turn clockwise to increase damping turn counter clockwise to reduce damping Adjusting the low speed compression damping of the shock absorber Caution Risk of injury Parts of the shoc...

Page 54: ...uce damping Ad usting the rebound dam ing of the shock absorber Caution Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incor rectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Turn adjusting screw O clockwise up to the last perceptible click Turn counterclockwise by the number of clicks correspon...

Page 55: ...orcycle from the lift stand a p 14 Checkin the static sa of the shock absorber Measure distance 6 of rear wheel unloaded l ll p 53 Hold the motorcycle upright with the aid of an assistant Measure the distance between the rear axle and the fixed point again Note down the value as dimension G Info The static sag is the difference between measure ments 6 and G Check the static sag I Static sag 130 mm...

Page 56: ...g 1100 mm 3 94 in If the riding sag differs from the specified measurement Adjust the riding sag a p 55 Adjusting the s ring reload of the shock absorber Caution Risk of injury rectly Parts of the shock absorber will fly off if the shock absorber is disassembled incor The shock absorber is filled with highly compressed nitrogen Please follow the description provided Info Before changing the spring...

Page 57: ...r decrease the spring preload Tighten screw O Guideline Screw shock M5 absorber adjusting ring Finishing work Install the shock absorber p 57 Install the manifold 0 p 86 Install the fuel tank 0 p 101 Mount the seat 0 p 98 Install the main silencer 0 p 88 Install the right side cover I p 97 5 Nm 3 7 lbf ft Remove the motorcycle from the lift stand I p 14 Preparatory work Raise the motorcycle with a...

Page 58: ...ll the manifold p 86 Install the fuel tank 11 p 101 Mount the seat 11 p 98 Install the main silencer 11 p 88 Install the right side cover 0 p 97 Remove the motorcycle from the lift stand p 14 Check the static sag of the shock absorber p 53 Check the riding sag of the shock absorber p 54 Adjust the rebound damping of the shock absorber 0 p 52 9 9 Removing the shock absorber 56 Preparatory work Rais...

Page 59: ...ount the seat p 98 Install the main silencer l ell p 88 Install the right side cover l ell p 97 Remove the motorcycle from the lift stand l ell p 14 Checking the shock absorber linkage Preparatory work Raise the motorcycle with a lift stand l ell p 14 Main work Remove screw O Remove fitting Info Raise the wheel slightly to be able to remove the screws more easily Remove fitting Take off the angle ...

Page 60: ... wear Change the spacers Check the shaft seal rings for damage and wear If there is damage or wear Change the shaft seal rings Check dimension f 303096 10 I 54 91 55 00 mm 2 1618 2 1654 in 58 If dimension f is below the specified value Add the necessary spacing washers Position angle lever Mount fitting D but do not tighten yet Guideline Nut angle lever on swingarm M14x1 5 80 Nm 59 lbf ft ...

Page 61: ...f ft I Raise the wheel slightly to be able to mount the screw more easily Tighten screws Q Guideline Screw bottom M10 shock absorber Tighten screw cap Ci Guideline Nut angle lever on swingarm M14x1 5 60 Nm 44 3 lbf ft Loctite 2701 TM 80 Nm 59 lbf ft Servicing the shock absorber Caution Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incor rectly The sh...

Page 62: ...ring retainer a p 67 Assemble the piston rod il l p 68 Assemble the damper il l p 70 Install the spring a p 76 Condition The shock absorber has been removed Clamp the shock absorber in the vise using soft jaws for pro tection Measure and note spring length in its preloaded state Loosen screw O Turn adjusting ring until the spring is no longer under tension I Hook wrench T106S il l p 364 Remove rin...

Page 63: ...mping O and compression damping 8 Completely open the adjusters of the rebound and compres sion damping Remove rubber cap 8 of the reservoir Open screw C slowly The pressurized nitrogen escapes Remove locking cap 0 Press in seal ring retainer D using the special tool I Pressing tool T1216 p 366 Remove lock ring Info Do not scratch the inner surface 61 ...

Page 64: ...mediate washer Drain the oil Remove compression adjuster Remove the spring and piston Disassembling the piston rod Preparatory work Remove the spring p 60 Disassemble the damper p 61 Main work Clamp the piston rod with the fork in a vise Guideline I Use soft jaws Remove nut O Remove washer 411 ...

Page 65: ... I Place the compression shim stack onto a screwdriver and set it down as a unit Remove rebound washer D Remove seal ring retainer Remove locking cap D and rubber buffer Disassembling the seal ring retainer 201405 10 Preparatory work Remove the spring a p 60 Disassemble the damper a p 61 Disassemble the piston rod a p 62 Main work Remove spring O Remove O ring 8 Remove rebound rubber 8 63 ...

Page 66: ... I p 62 Disassemble the seal ring retainer ill p 63 Main work Press pilot bushing O out of seal ring retainer 8 with the special tool I Pressing tool T1504 ill p 368 Slide the new pilot bushing O onto the special tool I Pressing tool T1504 I p 368 Position the pilot bushing in the seal ring retainer using the special tool I Pressing tool T1504 a p 368 Support seal ring retainer 8 with sleeve O of ...

Page 67: ...e of the damper cartridge Damper cartridge Diameter 5 50 08 mm 5 1 9716 in If the measured value is greater than the specified value Change the damper cartridge Check the damper cartridge for damage and wear If there is damage or wear Change the damper cartridge Check the heim joint for damage and wear If there is damage or wear Change the heim joint Measure the diameter of the piston rod Piston r...

Page 68: ...the vise using soft jaws for pro tection Remove the collar bushing of the heim joint I Drift T120 p 364 Turn the shock absorber and remove the second collar bush ing of the heim joint Remove seal rings O on both sides Press the heim joint against a lock ring using the special tool I Pressing tool T1207S ll l p 366 Remove the second lock ring 8 Place special tool 6 underneath and press out heim joi...

Page 69: ...6 p 365 Press the heim joint all the way in Press the heim joint against the lock ring using the special tool I Pressing tool T1207S p 366 Mount the second lock ring 8 Mount seal rings fD on both sides Position both collar bushings 8 and press them in Mount dust boot O with the special tool I Mounting sleeve T1204 p 365 Grease the sealing lip of the dust boot I Lubricant T625 p 350 67 ...

Page 70: ...ount rebound rubber D Grease the 0 ring groove I Lubricant T158 0 p 350 Mount 0 ring Mount spring Preparatory work Assemble the seal ring retainer il l p 67 Main work Clamp the piston rod with the fork in a vise Guideline I Use soft jaws Mount rubber buffer O and locking cap 8 Position special tool on the piston rod I Mounting sleeve T1215 0 p 366 Grease the dust boot and push seal ring retainer 8...

Page 71: ...ck 0 with the smaller shims facing downward Sand both sides of piston D on a surface plate using 1200 grit sandpaper Clean the piston Assemble the piston Guideline Viewf Piston from above View Piston from below Mount the rebound shim stack with the smaller shims facing upward Mount washer fD with the collar facing downward 69 ...

Page 72: ...8 l l p 350 Lubricate the threads I Lubricant T159 a p 350 Mount the piston with the spring Mount and tighten the compression adjuster 0 Guideline Compression adjuster M31x1 Clamp the damper in a bench vise Guideline I Use soft jaws 45 Nm 33 2 lbf ft Mount adjusting ring 8 with the intermediate washer Info The adjusting ring cannot be mounted after the piston rod is mounted Fill the damper cartrid...

Page 73: ...ative 1 Turn adjusting screw clockwise with a screwdriver up to the last perceptible click Turn counterclockwise by the number of clicks corre sponding to the shock absorber type Guideline Compression damping low speed Comfort 20 clicks Standard 18 clicks Sport 16 clicks Turn adjusting screw 0 all the way clockwise with a socket wrench Turn counterclockwise by the number of turns corre sponding to...

Page 74: ...ents to get the feel of the new handling characteristic Turn adjusting screws and to the position determined during disassembly Bleeding and filling the dam er Info Before working with the vacuum pump be sure to read the operating instructions carefully Completely open the adjusters of the rebound and compression damping Remove the screw of the filling port Install adapter O on the damper Info Tig...

Page 75: ...th micrometer T1 07S a p 364 The floating piston is positioned all the way at the bot tom When the vacuum pressure gauge reaches the specified value turn the Oil reservoir control lever 0 to Equalize pressure Guideline 14 mbar The pressure gauge increases to the specified value 0 bar When the pressure gauge reaches the specified value turn the Damper control lever 8 to Pressure Guideline 0 bar Oil...

Page 76: ...per control lever 8 to Pressure Guideline 0bar Oil is pumped into the damper The pressure gauge increases to the specified value 3 bar When the pressure gauge reaches the specified value turn the Damper 8 control lever to Vacuum Guideline 3 bar The pressure gauge drops to the specified value 0bar When the pressure gauge reaches the specified value oper ate the On Off switch Guideline 0bar The vacu...

Page 77: ...w filling port I M10x1 14 Nm 10 3 lbf ft Mount screw O with the O ring and screw it in approx 2 full turns but do not tighten it fully yet Info The piston rod is fully extended Fix the special tool in the vise I Filling tool T170S1 p 369 Connect the special tool to the pressure regulator of the filling cylinder I Filling gas nitrogen Adjust the pressure regulator Guideline I Gas pressure 110 bar 1...

Page 78: ...that adjusting ring O is screwed on with the interme diate washer Measure the overall spring length while the spring is not under tension Position spring Guideline Spring rate Weight of rider 65 54 N mm 308 lb in 75 kg 143 165 lb Weight of rider 75 57 N mm 325 lb in 85 kg 165 187 lb Weight of rider 85 60 N mm 343 lb in 95 kg 187 209 lb Mount intermediate washer and spring retainer Mount ring Alter...

Page 79: ...ew handling characteristic Tension the spring to the amount measured during dis mantling by turning the adjusting ring I Hook wrench T106S a p 364 Tighten screw 0 Guideline Screw shock M5 5 Nm 3 7 lbf ft absorber adjusting ring Check the swingarm for damage cracking and deformation If the swingarm shows signs of damage cracking or deformation Change the swingarm Info I Always change a damaged swin...

Page 80: ... play Change the swingarm bearing I p 81 Finishing work Remove the motorcycle from the lift stand e I p 14 Preparatory work Raise the motorcycle with a lift stand ll1ll p 14 Remove the rear wheel ll1ll p 125 Main work Take the brake line out of the guide Push the brake caliper forward slip it out and hang it to the side Info Cover the components to protect them against dam age Remove screws O and ...

Page 81: ...ve fitting C Lower the swingarm Remove nut 0 Remove the swingarm pivot Take off the swingarm Main work Position the swingarm Mount the swingarm pivot Mount and tighten nut 0 Guideline I Nut swingarm pivot I M16x1 5 Lift the swingarm Mount and tighten fitting Guideline Nut angle lever on swingarm M14x1 5 I 100 Nm 73 8 lbf ft I 80 Nm 59 lbf ft 79 ...

Page 82: ...ngine sprocket cover and mount in the holder Mount and tighten screws C Guideline Screw clutch slave cylinder M6 Mount and tighten screws 0 Guideline Remaining screws chassis M8 10 Nm 7 4 lbf ft 25 Nm 18 4 lbf ft Position the brake caliper and pull it back Position the brake line in the guide Finishing work Install the rear wheel el p 127 Remove the motorcycle from the lift stand el p 14 ...

Page 83: ...and a p 14 Remove the rear wheel a p 125 Remove the swingarm a p 78 Left swingarm bearing Remove collar bushings O Remove bushing 8 Remove shaft seal rings using a suitable tool Remove stop disks C Press out bearing 0 using a suitable tool Using a suitable tool press in new bearing 0 Position stop disks C Press in shaft seal rings 81 ...

Page 84: ...758 10 R02763 10 R02760 10 R02761 10 82 Mount bushing 8 Grease the shaft seal rings I Long life grease p 350 Position collar bushings O with the shoulder facing inward Right swingarm bearing Remove collar bushings Q Remove bushing ...

Page 85: ...ble tool Using a suitable tool press in new bearing Press in shaft seal rings Mount bushing Grease the shaft seal rings I Long life grease ll ll p 350 Position collar bushings D with the shoulder facing inward Finishing work Install the swingarm a p 79 Install the rear wheel a p 127 Remove the motorcycle from the lift stand a p 14 83 ...

Page 86: ...he right side cover p 97 Remove the main silencer p 88 Remove the fuel tank p 99 Main work Remove fitting O Remove screw 8 Info Raise the wheel slightly to be able to remove the screws more easily Press angle lever 8 toward the rear Press linkage lever 8 downward FE EU AU FE 450 501 US Lift the swingarm FE 501 SUS Lift the swingarm ...

Page 87: ...Remove screws 0 on both sides Loosen screws D on both sides Remove screw 10 EXHAUST Raise the rear frame slightly and lower the shock absorber Remove springs I Spring hook 50305017000 p 354 85 ...

Page 88: ...or and remove cable binder Take off the manifold FE AU FE 450 501 US FE 501 S US Remove screw Take off the manifold Main work Position the manifold and mount springs 0 1 Spring hook 50305017000 p 354 Mount and tighten screw 8 Guideline Remaining screws chassis M8 25 Nm 18 4 lbf ft ...

Page 89: ...screws 0 on both sides 35 Nm 25 8 lbf ft Loctite 2701 TM Mount and tighten screws 0 on both sides Guideline Screw sub frame MB FE EU AU FE 450 501 US Lower the swingarm FE 501 SUS Lower the swingarm 35 Nm 25 8 lbf ft Loctite 2701 TM Position the angle lever and linkage lever Mount and tighten fitting D Guideline Nut linkage lever on M14x1 5 angle lever Mount and tighten screw Guideline Screw botto...

Page 90: ...ove the motorcycle from the lift stand a p 14 Removin the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down before performing any work on the vehicle Preparatory work Remove the right side cover p 97 Main work Disconnect spring O I Spring hook 50305017000 p 354 Remove screws 8 and take off the main silencer Main ...

Page 91: ...Preparatory work Remove the right side cover p 97 Remove the main silencer E 1 p 88 Main work FE EU AU Remove all screws on the main silencer Take off silencer cap O and 0 ring Take off outer tube fD and 0 ring 8 Remove glass fiber yarn filling 0 from inner tube 3 Clean the parts that need to be reinstalled and check for damage Fit the new glass fiber yarn filling onto the inner tube Mount 0 ring ...

Page 92: ...pad in outer tube a Mount and tighten screws Guideline Screws on the main silencer M5 Mount O ring CD on the silencer cap 7 Nm 5 2 lbf ft Fit the new glass fiber yarn filling onto the perforated pipe Fit the connecting cap with the glass fiber yarn filling in the outer tube Info Press the glass fiber yarn filling into the outer tube using a blunt tool Mount and tighten screws 0 Guideline Screws on...

Page 93: ...e the right side cover I p 97 Remove the main silencer I p 88 Main work l 0 0 Remove screws O and take off silencer cap 8 with O ring D Warning Danger to health Soot particles irritate the eyes and mucuous membranes 10 EXHAUST 402269 10 Wear suitable breathing and eye protection when cleaning the main silencer and carbon screen Clean main silencer housing 8 and screen 0 of the spark arrestor with ...

Page 94: ...10 EXHAUST Finishing work Install the main silencer p 88 Install the right side cover p 97 92 ...

Page 95: ...without an air filter Never start to use the vehicle without an air filter Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Preparatory work Remove the air filter box cover a p 93 Main work Push air filter holding bracket O toward the air filte...

Page 96: ...tal hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Do not clean the air filter with fuel or petroleum since these substances attack the foam Preparatory work Remove the air filter box cover a p 93 Remove the air filter p 93 Main work Wash the air filter thoro...

Page 97: ...rk Install the air filter p 94 Install the air filter box cover 1ll p 93 Preparatory work Remove the air filter box cover 1ll p 93 Main work Seal the air filter box in the marked area f Finishing work Install the air filter box cover p 93 11 AIR FILTER 95 ...

Page 98: ...g contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Warning Env...

Page 99: ...450 501 US FE 501 S US Replace the filler cap and turn clockwise until the release button O locks in place Info Run the fuel tank breather hose without kinks Remove screw O Pull off the side cover in area 6 sideways and remove it toward the rear Position the side cover and engage in area 6 Mount and tighten screw O Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 97 ...

Page 100: ...r of the seat push the seat back and lift it off Mount the front of the seat on the collar bushing of the fuel tank lower the seat at the rear while pushing it forward The seat is correctly engaged Mount and tighten the seat fixing screws 0 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 411 411 ...

Page 101: ...l Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Preparatory work Remove the seat p 98 Main work Unplug connector O of the fuel...

Page 102: ...th the collar bushings and horn FE 450 501US Remove screws D with the collar bushings FE 501 SUS Remove screws D with the collar bushings and horn Remove screw 8 with the rubber bushing FE EU AU FE 450 501US Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank ...

Page 103: ...f poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Main work Ch...

Page 104: ...and horn and mount and tighten screws Guideline Remaining screws M6 chassis Connect the connector of the horn Plug in connector for the fuel pump Remove the wash cap set 10 Nm 7 4 lbf ft 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 a...

Page 105: ... 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 Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system Clean plug in connection O of t...

Page 106: ...arts 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 Rinse the eyes thoroughly with water...

Page 107: ... TRIM Main work Remove nut O with the gasket Remove fuel connection with the gasket Remove screws 8 Pull out the fuel pump Remove hose clamps e Remove fuel filter 0 Press lock 0 Pull back fuel pump housing Change fuel screen fD Mount the fuel pump housing 105 ...

Page 108: ...connection on fuel pump M8 Mount and tighten screws D Guideline I Screw fuel pump I EJOT PT Finishing work Install the fuel tank p 101 Mount the seat ll J p 98 15 Nm 11 1 lbf ft 10 Nm 7 4 lbf ft 1 2 3 Nm 1 7 lbf ft 12 11 Changing the fuel um 106 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 vici...

Page 109: ...en Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system 305313 10 305314 10 Preparatory work Drain the fuel from the fuel tank into a suitable container Remove the seat I p 98 Remove the fuel tank I p 99 Main work Remove nut O with the gasket Remove fuel connection 8 with the gasket Remove scr...

Page 110: ...el is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a ...

Page 111: ...on of the actuator test 3 min Check the fuel pressure with the filler cap closed Fuel pressure When the fuel pump is active 1 3 35 3 65 bar 48 6 52 9 psi If the specification is not reached Open the filler cap p 96 Check the tank air vent system Check the fuel pressure with the filler cap open Fuel pressure When the fuel pump is active 1 3 35 3 65 bar 48 6 52 9 psi If the specification is not reac...

Page 112: ...er FE 501 S US 110 Preparatory work Remove the seat a p 98 Remove the fuel tank a p 99 Main work Remove the cable binder s Push back hose clamp O Remove the hose Detach rubber strap Detach hoses and 8 Remove the activated charcoal filter Main work Mount hoses O and 8 ...

Page 113: ...ANK SEAT TRIM Position the activated charcoal filter Reconnect rubber band 8 Mount the hose and secure with a cable binder Position hose clamp C Finishing work Install the fuel tank p 101 Mount the seat p 98 111 ...

Page 114: ...ving front fender 112 Preparatory work Remove theheadlight m ask with theheadlight a p 114 Main work FE EU AU FE 450 501 US Remove scr ews O and Takeoff the front fender FE 501 SUS Remove scr ews O and Takeoff the front fender ...

Page 115: ...crews 0 and Guideline Remaining screws M6 10 Nm 7 4 lbf ft chassis FE 501 SUS Position front fender Mount and tighten screws 0 and Guideline Remaining screws M6 10 Nm 7 4 lbf ft chassis Finishing work Install the headlight mask with the headlight p 115 Check the headlight setting p 169 113 ...

Page 116: ...l the engine stops FE EU AU FE 450 US Detach brake line O and wiring harness f Release rubber bands D Slide the headlight mask up and swing it forward Detach plug in connectors 8 and take off the headlight mask with the headlight FE 450 501 US Detach brake line O and wiring harness f Release rubber bands D Slide the headlight mask up and swing it forward Disconnect plug in connector 8 and take off...

Page 117: ...Detach plug in connectors 8 and take off the headlight mask with the headlight Installing the headlight mask with the headlight Main work FE EU AU Connect plug in connectors O Position the headlight mask and secure it with rubber bands The holding lugs engage in the fender Position brake line D and wiring harness 8 in the brake line guide 115 ...

Page 118: ...ht mask and secure it with rubber bands The holding lugs engage in the fender Position brake line D and wiring harness C in the brake line guide FE 501 SUS Connect plug in connectors O Position the headlight mask and secure it with rubber bands The holding lugs engage in the fender ...

Page 119: ...K00261 10 13 MASK FENDER Position brake line CD and wiring harness e in the brake line guide Finishing work Check the headlight setting p 169 117 ...

Page 120: ...nt the protection cap Checking 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 the front and rear wheels must have a similar profile Worn tires have a negat...

Page 121: ... the tires Checking the wheel bearing for la Preparatory work Raise the motorcycle with a lift stand I p 14 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 124 Place a load on the front of the vehicle The rear wheel...

Page 122: ...deformation If the brake disc exhibits damage cracking or deforma tion Change the front brake disc l ll p 123 Change the rear brake disc I p 128 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 123: ...me looser as a result Check spoke tension regularly and in particular on a new vehicle Info A loose spoke can unbalance the wheel and other spokes may loosen within a short period If the spokes are too tight they can break due to local overload Check the spoke tension regularly especially on a new motorcycle 400998 01 Check for lateral and radial run out of the rims Lateral runout Outside the rim ...

Page 124: ...against the spokes when pushing back the brake pis tons Loosen screw O by several rotations Loosen screws 8 Press on screw O to push the wheel spindle out of the axle clamp Remove screw O Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Holding the front wheel withdraw the wheel spindle Take the fro...

Page 125: ...se a p 350 Position the front wheel and insert the wheel spindle The brake linings are correctly positioned Mount and tighten screw 8 Guideline Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Operate the hand brake lever several times until the brake linings are seated correctly against the brake disc Remove the motorcycle from the lift stand il ll p 14 Operate the front brake and compress the...

Page 126: ... wheel bearing Preparatory work 14 Nm 10 3 lbf ft Loctite 243 Raise the motorcycle with a lift stand a p 14 Remove the front wheel a p 122 Main work Remove shaft seal rings O and 8 Press out bearing 8 using a suitable tool Info I Spacing tube e can be pushed aside Remove the spacing tube Press out bearing 0 using a suitable tool Press in new bearing 0 all the way using a suitable tool Info Only pr...

Page 127: ...123 Preparatory work Raise the motorcycle with a lift stand JI p 14 Main work FE EU AU FE 450 501 US Press the brake caliper onto the brake disc by hand in order to push back the brake piston Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove nut O Remove chain adjuster Pull out wheel spindle 8 far enough to allow the rear wheel to b...

Page 128: ... by hand in order to push back the brake piston Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove nut O Remove chain adjuster 8 Pull out wheel spindle fD far enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Remove the chain from the rear sprocket Info Cover the components to protect ...

Page 129: ...0 501 US Clean and grease the wheel spindle I Long life grease ill p 350 Position the rear wheel and insert wheel spindle Mount the chain The brake linings are correctly positioned Position chain adjuster fD Mount nut C but do not tighten it yet Make sure that chain adjusters 8 are fitted correctly on adjusting screws 0 Check the chain tension i I p 129 Tighten nut C Guideline M20x1 5 80 Nm 59 lbf...

Page 130: ...2 mm 1 26 in enables different secondary ratios with the same chain length Chain adjusters 8 can be turned by 180 Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Finishing work Remove the motorcycle from the lift stand p 14 If the brake discs are changed the brake linings must also be changed 128 Preparatory work Rais...

Page 131: ...ar more quickly Some components may break if overloaded If the chain is too loose the chain may fall off the engine sprocket or the rear sprocket As a result the rear wheel locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the specification Preparatory work Raise the motorcycle with a lift stand p 14 Main work Pull the chain at the end o...

Page 132: ...ise the motorcycle with a lift stand p 14 Check the chain tension p 129 Main work FE EU AU FE 450 501 US Loosen nut 0 Loosen nuts Adjust the chain tension by turning adjusting screws CD left and right Guideline Chain tension 1 55 58 mm 2 17 2 28 in Turn adjusting screws CD on the left and right so that the markings on the left and right chain adjusters are in the same position relative to referenc...

Page 133: ...Guideline Info M20x1 5 80 Nm 59 lbf ft The wide adjustment range of the chain adjusters 32 mm 1 26 in enables different secondary ratios with the same chain length Chain adjusters C can be turned by 180 Finishing work Remove the motorcycle from the lift stand p 14 14 8 6 Checking the chain rear sprocket engine sprocket and chain guide 400227 01 Preparatory work Raise the motorcycle with a lift sta...

Page 134: ...mm 10 71 in If distance 0 is greater than the specified measurement Change the drivetrain kit p 134 Info I When a new chain is mounted the rear sprocket and engine sprocket should also be changed New chains wear out faster on old worn sprockets Check the chain sliding guard for wear If the lower edge of the chain pins is in line with or below the chain sliding guard Change the chain sliding guard ...

Page 135: ...e front of the chain guide If the light part of the chain guide is worn Change the chain guide FE EU AU FE 450 501 US Check that the chain guide is firmly seated If the chain guide is loose Tighten the fitting on the chain guide Guideline Remaining M6 10 Nm screws chassis 7 4 lbf ft Remaining nuts M6 10 Nm chassis 7 4 lbf ft FE 501 SUS Check that the chain guide is firmly seated If the chain guide...

Page 136: ...e brake discs with brake cleaner when necessary Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info The service life of the chain depends largely on its maintenance 400725 01 Preparatory work Raise the motorcycle with a lift stand a p 14 Main...

Page 137: ...rear wheel a p 125 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 FE EU AU FE 450 501 US Remove fittings D Take off the rear sprocket Position the new rear sprocket Mount and tighten the fittings Guideline Nut rear M8 35 Nm 25 8 lbf ft sprocket Loctite 2701TM screw 135 ...

Page 138: ...closed side of the chain joint lock must face in the direction of travel Install the rear wheel 1 1 p 127 Have an assistant operate the rear brake Mount and tighten screw fs with the washer Guideline Screw engine sprocket M10 60 Nm 44 3 lbf ft Loctite 2701 TM Position the engine sprocket cover Mount and tighten screw O Guideline Screw clutch slave cylinder M6 Mount and tighten screw fj Guideline R...

Page 139: ...U FE 450 501 US Remove shaft seal ring O Remove lock ring Remove shaft seal ring Using a suitable tool press bearing C out from the inside to the outside Remove spacing tube 0 Using a suitable tool press bearing D out from the inside to the outside Check spacer washer for damage and wear If the spacer washer is damaged or worn Replace the spacer washer 137 ...

Page 140: ...g tube 3 I Long life grease il l p 350 Press new bearing C all the way in from the outside to the inside Info Only press the bearing in via the outer ring oth erwise the bearing will be damaged when it is pressed in Grease new shaft seal ring 4D and press it in until it is flush Mount lock ring f The lock ring engages audibly Grease new shaft seal ring O and press it in until it is flush FE 501 SU...

Page 141: ...or worn Replace the spacer washer Position spacer washer Press new bearing D all the way in from the outside to the inside Info Only press the bearing in via the outer ring oth erwise the bearing will be damaged when it is pressed in Clean grease and mount spacing tube 0 1 Long life grease p 350 Press new bearing C all the way in from the outside to the inside Info Only press the bearing in via th...

Page 142: ...ng D and press it in until it is flush Mount lock ring 8 The lock ring engages audibly Grease new shaft seal ring O and press it in until it is flush Finishing work Install the rear wheel p 127 Remove the motorcycle from the lift stand p 14 ...

Page 143: ... seat p 98 Main work FE EU AU FE 450 501 US Open fuse box cover O Remove the defective fuse Guideline Fuse 1 10 A EFI control unit Fuse 2 10 A fuel pump Fuse 3 10 A high beam low beam parking light tail light license plate lamp Fuse 4 10 A horn brake light turn signal radiator fan Fuses res 10 A spare fuses Info You can recognize a faulty fuse by a burned out fuse wire e Warning Fire hazard Incorr...

Page 144: ...l light license plate lamp horn brake light turn signal radiator fan Fuses res 10 A spare fuses Info I You can recognize a faulty fuse by a burned out fuse wire e Warning Fire hazard Incorrect fuses overload the electri cal system Only use fuses with the required ampere value Do not bypass or repair fuses Use spare fuses with the correct rating only I Fuse 75011088010 l I p 278 Tip I Replace the s...

Page 145: ...ngine is idling until the engine stops FE 450 501 US Press and hold the kill switch while the engine is idling until the engine stops Remove the air filter box cover p 93 Main work Take off protection caps O Remove faulty main fuse Info You can recognize a faulty fuse by a burned out fuse wireG A spare fuse D is located in the starter relay Install a new main fuse I Fuse 58011109120 p 278 Check th...

Page 146: ...ed does not meet specifications Change the starter relay 144 601201 10 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns Keep batteries out of the reach of children Wear suitable protective clothing and safety glasses Avoid contact with battery acid and battery gases Keep sparks or open flames away from the battery Only charge batteries in well...

Page 147: ...ew Guideline Screw battery termi MS nal 2 5 Nm 1 84 lbf ft Slide positive terminal cover over the positive terminal Position the negative cable and mount and tighten the screw Guideline Screw battery termi MS nal 2 5 Nm 1 84 lbf ft Slide negative terminal cover over the negative terminal Finishing work Mount the seat p 98 Risk of injury Battery acid and battery gases cause serious chemical burns K...

Page 148: ...ded the battery will be destroyed If the battery is depleted by repeated starting the battery must be charged immediately If the battery is left in a discharged state for an extended period it will become over discharged and sul fated destroying the battery The battery is maintenance free 311910 10 Preparatory work Remove the seat l I p 98 Main work Connect the battery charger to the battery Adjus...

Page 149: ...ternator lit I p 263 If the displayed value is greater than the specified value Change the voltage regulator Checking the o en circuit current Preparatory work FE EU AU Press and hold the kill switch 5 while the engine is idling until the engine stops FE 450 501 US Press and hold the kill switch 5 while the engine is idling until the engine stops Remove the seat a p 98 Main work Disconnect the neg...

Page 150: ... fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately...

Page 151: ...th the applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container FE EU AU FE 450 501 US Move the brake fluid reservoir mounted on the handlebar to a horizontal positio...

Page 152: ...e disc and there is a pressure point FE EU AU FE 450 501 US Correct the brake fluid quantity to level 6 Guideline Level O brake fluid level 5 mm 0 2 in below reservoir rim I Brake fluid DOT 4 a p 348 Position cover 8 with membrane 8 Mount and tighten screws O FE 501 SUS Info Clean up overflowed or spilled brake fluid immedi ately with water Correct the brake fluid quantity to level 6 Guideline Lev...

Page 153: ...and brake lever p 151 FE 450 501 US Push the hand brake lever forward and check free travel f Free travel of hand brake lever 3 mm 0 12 in If the free travel does not match the specification Adjust the basic position of the hand brake lever p 152 Adjusting free travel of hand brake lever FE EU AU FE 501 S US Check the free travel of the hand brake lever p 151 Adjust the free travel of the hand bra...

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

Page 155: ... the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc corre...

Page 156: ...ation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if...

Page 157: ...s in the Owner s Manual of the bleeding device Ensure that the filling pressure is set on pressure gauge f Correct the filling pressure on pressure regulator G if necessary Guideline I Filling pressure I 2 2 5 bar 29 36 psi Pull off protection cap 0 of the brake caliper bleeder screw Connect the bleeder bottle hose I Bleeding device 00029013100 p 352 Open bleeder screw 0 by approx one half turn In...

Page 158: ...al position Cover painted parts Remove screws O Take off cover 8 with the membrane Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid Syringe 50329050000 ilel p 354 Brake fluid DOT 4 ilel p 348 Mount bleeder cover I Bleeder cover 00029013005 ilel p 352 Connect the bleeding device I Bleeding device 00029013100 p 352 Open shut off valve C Info I...

Page 159: ...ice Remove the bleeder cover Add brake fluid to level 8 Guideline I Level 8 I 5 mm 0 2 in I Brake fluid DOT 4 I p 348 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilled brake fluid immedi ately with water Check the hand brake lever for a firm pressure point Checking the rear brake linings Warning Danger of accidents Worn out brake linings reduce t...

Page 160: ...e braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Warning Danger of accidents Brake linings which have not been approved alter the braking efficiency Not all brake linings are tested and approved for Husqvarna motorcycles The structure and friction coefficient of the brake linings and thus their brake power may vary greatly ...

Page 161: ... pins pull out pin C and remove the brake linings Clean the brake caliper and brake caliper support Check that leaf spring 0 in the brake caliper and sliding plate D in the brake caliper support are seated correctly The arrow on the leaf spring points in the rotation direc tion of the brake disc Insert the new brake linings insert pin C and mount cotter pins Info I Always change the brake linings ...

Page 162: ...o free travel on the foot brake lever pressure builds up in the brake system on the rear brake Set the free travel on the foot brake lever in accordance with the specification l 402026 10 Disconnect spring O Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel f Guideline Free travel at foot brake lever 3 5 mm 0 12 0 ...

Page 163: ...ssary adjust the basic position of the foot brake lever Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in Hold screw D and tighten nut Guideline Nut foot brake lever MB stop 20 Nm 14 8 lbf ft Hold push rod 0 and tighten nut 8 Guideline Remaining nuts chassis Reconnect spring O M6 Checking the rear brake fluid level Warning 10 Nm 7 4 lbf ft Danger of accidents An insufficient brake fluid...

Page 164: ... brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the fro...

Page 165: ...o contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Environmental hazard Haza...

Page 166: ... pressure gauge 6 If necessary adjust the filling pressure at pressure regulator Ci Guideline I Filling pressure I 2 2 5 bar 29 36 psi Pull off protection cap 8 of the bleeder screw Connect the hose of the bleeder bottle I Bleeding device 00029013100 p 352 Open bleeder screw 0 by approx one half turn Info I Bleed until new brake fluid emerges from the bleeder bottle hose without bubbles Tighten th...

Page 167: ...t Correct the brake fluid up to marking I Brake fluid DOT 4 Ii p 348 Fit and tighten plug with oil screen and 0 ring Info Clean up overflowed or spilt brake fluid immediately with water Check the foot brake lever for a firm pressure point 165 ...

Page 168: ...changes to the next menu item The 0 symbol flashes Press one of the buttons to select the 24h or 12h display of the clock Wait for 5 seconds Combination instrument changes to the next menu item The 0 symbol flashes Resetting the time Press the left button The value decreases Advancing the time Press the right button The value increases Wait for 5 seconds Combination instrument changes to the next ...

Page 169: ...the buttons to select UNIT for the speed in kilo meters KM H or miles M H um II KM H 401909 01 17 3 Adjusting the clock 401911 01 401912 01 Condition The motorcycle is stationary Press and hold both buttons for 3 5 seconds The Setup menu is displayed The UNIT display flashes Wait for the menu of the clock 0 to flash Press one of the buttons to select the 24h or 12h display of the clock Wait for 5 ...

Page 170: ...alue decreases Enlarging the wheel circumference Press the right button The value increases Finishing work Disconnect speedometer connector CZ 17 5 Ad usting the service dis la l 7 _ _ 15 nn ART I I LIU 401913 01 168 Condition The motorcycle is stationary Press and hold both buttons for 3 5 seconds The Setup menu is displayed The UNIT display flashes Wait for the menu of the service display to fla...

Page 171: ... m 16 ft The rider now sits down on the motorcycle Switch on the low beam Check the headlight setting The boundary between light and dark must be exactly on the lower mark for a motorcycle with rider If the light dark border does not meet specifications Adjust the headlight range 0 p 169 Preparatory work Check the headlight setting 0 p 169 Main work FE EU AU FE 450 501 US Loosen screw O Adjust the...

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

Page 173: ...silencer Ii p 88 FE 501 SUS Remove the seat a p 98 Remove the fuel tank Ii p 99 Remove the activated charcoal filter p 110 FE EU AU FE 450 501 US Remove the seat p 98 Remove the fuel tank p 99 Main work Remove screw O Disconnect the negative cable of the battery Loosen hose clip Pull back the protection cap Unplug connector Remove screws C Take off the intake air temperature sensor 18 ENGINE 171 ...

Page 174: ...0 Pull off the air release hose Remove screws D Loosen screw Repeat these steps on the opposite side Pivot up the subframe and secure it Remove screw Swing the shock absorber to the rear Remove springs C I Spring hook 50305017000 a p 354 ...

Page 175: ... the manifold Push back the cover Remove nut D Take off the cable Loosen hose clips Pull off the radiator hoses Detach spring 48 Pull back the protection cap Unplug connector e Disconnect the spark plug connector 18 ENGINE 173 ...

Page 176: ...in Remove the cable ties Remove screws 48 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 Loosen hose clip 4E Pull off the throttle valve body to the rear Loosen hose clip G Pull off the radiator hose ...

Page 177: ...Remove nut Remove the swingarm pivot Pull the swingarm slightly toward the rear Remove screws Lift out the engine sideways Info The help of an assistant is useful in this step Make sure that the engine is sufficiently secured against falling over 18 Protect the frame and attachments against damage 175 ENGINE ...

Page 178: ... attachment bolt Position the swingarm M10 Mount the swingarm pivot 60 Nm 44 3 lbf ft Mount nut 8 but do not tighten it yet Guideline I Nut swingarm pivot I M16x1 5 Join plug in connector 8 Join plug in connector C Position the engine braces Mount and tighten fittings 0 Guideline Screw engine brace MB Tighten screws O and nut 8 Guideline Engine attachment M10 bolt Nut swingarm pivot M16x1 5 1100 N...

Page 179: ...Guideline Screw clutch slave cylinder Mount the chain M6 10 Nm 7 4 lbf ft Connect the chain with connecting link Guideline The closed side of the chain joint lock must face in the direction of travel Position the engine sprocket cover Mount and tighten screw Ci Guideline Screw clutch slave cylinder M6 Mount and tighten screw 48 Guideline 10 Nm 7 4 lbf ft Remaining screws chassis M8 25 Nm 18 4 lbf ...

Page 180: ...ection cap Plug in the spark plug connectors Mount spring G Mount the radiator hoses Position and tighten hose clips 4D Position the cable Mount and tighten nut 48 Position the cover Position the manifold and mount springs I Spring hook 50305017000 p 354 ...

Page 181: ... 44 3 lbf ft Loctite 2701TM Remove the locking piece and position the subframe Info Watch out for the intake flange Mount and tighten screws G Guideline Screw sub frame Remove screw fl MB Mount and tighten screw fl Guideline Screw sub frame M8 35 Nm 25 8 lbf ft Loctite 2701TM 35 Nm 25 8 lbf ft Loctite 2701TM Repeat these steps on the opposite side Mount the vent hose Position hose clamp G 179 ...

Page 182: ...5 nal Info 2 5 Nm 1 84 lbf ft I Contact disk e must be mounted between screw and cable lug with the claws facing downward Refill the coolant a p 256 Install the main silencer a p 88 Remove the motorcycle from the lift stand a p 14 FE 501 5 US Install the activated charcoal filter a p 110 Install the fuel tank a p 101 Mount the seat a p 98 Remove oil filler plug on the clutch cover and fill up with...

Page 183: ...e oil level l I p 257 Check the coolant level l I p 254 Execute the initialization run l I p 271 Finishing work Take a test ride Read out the fault memory using the Husqvarna Motorcycles diagnostics tool Check the engine for leak tightness Check the engine oil level l I p 257 Check the coolant level 0 p 254 Install the engine guard 0 p 50 Mount the special tool on the engine assembly stand Holder ...

Page 184: ...e oil screen plug Completely drain the engine oil Remove engine oil screen Remove engine oil screen plug 8 Removing the clutch push rod Removing the oil filter Remove clutch push rod 0 Remove screws 0 Remove oil filter cover 8 with the O ring ...

Page 185: ... Pull oil filter D out of the oil filter housing I Lock ring plier 51012011000 i l p 355 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 361 18 ENGINE Remove screws O Remove the valve cover with the valve cover seal 183 ...

Page 186: ...over Remove centering pins 8 Take off the alternator cover gas ket Positioning the engine at ignition top dead center Turn the crankshaft counterclockwise until the markings G are flush with the marking 0 on the cylinder head Remove screw O Screw in special tool 8 Locking screw 113080802 ill p 353 ...

Page 187: ...e screw O Remove screw 8 Take off the chain adjuster with the gasket 18 3 11 Removing the camshaft Remove screw O Remove the camshaft support plate 8 Pull the camshaft out of the bearing seats Take the timing chain off the camshaft gear Remove the camshaft 185 ...

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

Page 189: ...Remove the woodruff key 18 3 15 Removing the timing chain guide rail Remove screw O Take off timing chain guide rail 4i toward the top 18 3 16 Removing the timing chain tensioning rail Remove screw O Remove the timing chain tensioning rail from above 18 3 17 Removing the timing chain securing guide Remove screws O Take off the timing chain securing guide 41 187 ...

Page 190: ...travel 18 3 19 Removing the ignition pulse generator 18 3 20 Removing the suction pump 188 Remove screws O Pull the cable support sleeve from the engine case Take off the crankshaft position sensor Remove screws O Take off oil pump cover 8 of the suction pump Remove external rotor and internal rotor C ...

Page 191: ...ing the clutch cover Remove screws O Take off the water pump cover Take off the water pump cover seal Remove screws O Take off the clutch cover Info I If work is to be performed on the water pump unscrew the nut of the water pump impeller Take out dowels Take off clutch cover gasket 8 18 ENGINE 189 ...

Page 192: ...3 23 Removing the clutch discs 190 Remove screws O Take off spring retainer Take off spring washer Take off pretension ring C Take off pressure cap 0 Completely remove clutch disc pack D Remove clutch pressure piece ...

Page 193: ... LH thread Remove nut 8 18 3 25 Removing the outer clutch hub Bend up the lock washer Hold the inner clutch hub with the special tool Loosen nut O I Holding wrench 51129003000 p 355 Remove the nut with the lock washer Dispose of the lock washer Take off inner clutch hub 8 and washer Info The washer usually sticks to the inner clutch hub Take off 8 Take off both needle bearings 0 and collar bushing...

Page 194: ...he shift shaft Remove the lock ring Take off the washer Take off starter idler gear O Push sliding plate O away from the shift drum locating unit Remove shift shaft with the washer 18 3 29 Removing the shift drum locating unit 192 Remove screw O Push away locking lever from shift drum locating unit D and remove the shift drum locating unit Relieve tension from the locking lever ...

Page 195: ...ve together with locking lever washer sleeve and spring 18 3 31 Removing the oil pump gear wheels Remove lock ring O Take off washer Remove oil pump idler gear s Remove lock washer 8 Take off washer Take off oil pump gear wheel C Remove pin 18 ENGINE 193 ...

Page 196: ...shaft 0 inward and take it out of the engine from the ignition side Insert special tool O in the crankshaft I Protection cap 75029090000 a p 360 Install special tool 8 I Puller 75029021000 a p 358 Hold it using the special tool and pull off the primary gear by turning the screw in Remove the special tools 18 3 34 Removing the freewheel gear 194 Remove woodruff key O Take off freewheel gear ...

Page 197: ...Use the drill hole with marking 781 18 ENGINE 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 I Do not tension the section of the engine case Remove the special tool Take off the left section of the engine case Remove spacer Remove dowels 8 195 ...

Page 198: ...rks Remove shift rails O together with upper springs 8 and the lower springs Tilt shift forks O to the side Info 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 18 3 39 Removing the transmission shafts Remove O ring O 196 ...

Page 199: ...ial tool to the crankshaft I Protection cap 75029090000 p 360 Mount special tool O onto the engine case with suitable screws I Puller 90129048100 p 364 Press the crankshaft out of the bearing seat Take out crankshaft Remove the special tools Take off the right section of the engine case Working on individual parts Work on the right section of the engine case Preparatory work Remove the oil pressur...

Page 200: ... collar on the inside Press in the shaft seal ring from the outside toward the inside with the open side facing outward Warm the engine case section again Guideline 1150 C 302 F Insert the new cold bearings into the bearing seats of the hot engine case section and if necessary use a suitable press drift to push the bearing from the inside to the outside all the way to the stop or so it is flush In...

Page 201: ... all remaining dowels Remove screw O Remove oil spray tube 8 Remove screws Remove membrane support plate C and the membrane Remove countershaft shaft seal ring 0 and shift shaft C Info The shaft seal ring of crankshaft can only be removed after the crankshaft bearing has been taken out because of a small external collar Remove screws 8 Remove membrane support plate 0 and the membrane Remove any re...

Page 202: ...s flat in order prevent damage Only press the bearings in using the outer bearing race otherwise the bearings will be damaged when they are pressed in After the section of the engine case has cooled check that the bearings are firmly seated Info If the bearings are not firmly seated after cooling it is likely that they will rotate in the engine case when warm In this case the engine case must be r...

Page 203: ...r 8 Remove pressure spring CD and ball e 18 4 4 Checking spring length of oil pressure regulator valve 200155 10 Preparatory work Remove the oil pressure regulator valve l p 201 Main work Measure the spring length of the oil pressure regulator valve Oil pressure regulator valve Minimum length of pres 1 24 5 mm 0 965 in sure spnng If the measured value does not meet specifications Change the spring...

Page 204: ...n the clutch cover 18 4 7 18 4 8 202 309242 10 Remove the crankshaft seal ring in clutch cover O Installing the crankshaft seal ring in the clutch cover 309242 10 Removing the water pump 309243 10 Press crankshaft seal ring O into the clutch cover with the open side flush toward the inside Grease the sealing lip Remove nut O Remove water pump impeller Info If the water pump impeller cannot be deta...

Page 205: ...water pump shaft bearing 0 toward the inside with an appropriate tool Info Suitably support the clutch cover while pressing it out Press water pump shaft bearing O in until it is flush using the appropriate tool Info Support the clutch cover sufficiently when pressing in Press shaft seal ring 8 all the way in 203 ...

Page 206: ...243 309243 11 18 4 10 Removing the timing chain sprocket Warm up the timing chain sprocket O with a blow dryer Pull off the timing chain sprocket with the special tool I Puller 60029033000 I p 357 Info I The timing chain sprocket is usually damaged by the disassembly and must be replaced 304702 10 I E 18 4 11 Installing the timing chain sprocket Info I Never clamp the crankshaft with a crankshaft ...

Page 207: ... bearing and crank pin 304715 10 Main work Position the crankshaft with special tool O in the press I Separator plate 78029009100 ll l p 362 Press the crank pin out of the upper crankweb with special tool I Crankshaft pressing tool 75029047000 p 359 Info I Hold the lower crankweb Remove the connecting rod and bearing Press crank pin fD out of the lower crankweb 41 205 ...

Page 208: ...ls to check that they are clear Mount new connecting rod CD Info Lubricate bearing thoroughly Position special tools and 0 on the press Crankshaft pressing tool 75029047000 p 359 Crankshaft pressing tool insert 78029008000 l I p 362 Insert the crankweb with the connecting rod and bearing Position the second crankweb Position special tool C with the heel pointing down I Crankshaft pressing tool ins...

Page 209: ...rankshaft run out at the bearing pin is larger than the specification Align the crankshaft Nikasil is a surface protection layer for a coating procedure developed by Mahle The name is derived from the two materials used in this procedure a layer of nickel into which is embedded the particularly hard silicone carbide The most important advantages of the Nikasil coating are very good heat conductivi...

Page 210: ...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 damaged Replace the piston ring Info I Mount the piston ring with the marking facing upward Chec...

Page 211: ...ton ring end gap Compression ring I S 1 00 mm S 0 0394 in Oil scraper ring I S 1 20 mm S 0 0472 in I Feeler gauge 59029041100 il ll p 357 If the end gap is greater than the specified value Check measure the cylinder il l p 207 If cylinder wear lies within the specified tolerance Change the piston ring Mount the piston ring with the marking facing upward 18 4 18 Measuring the piston cylinder mounti...

Page 212: ...8 p 357 Oil pump External rotor engine case clearance I s 0 20 mm S 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 p 357 Oil pump External rotor internal rotor clearance I s 0 20 mm s 0 0079 in If the measured value ...

Page 213: ...1 304674 11 304673 11 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 fD Mount autodecompression shaft 8 in the camshaft Mount new lock ring Perform a function check The autodecompression spring does not turn the autode compression shaft back to the stop Pre tension the autodecompressio...

Page 214: ...65 in Camshaft cam height FE 501 EU FE 501 AU FE 501US FE 501 SUS Intake 1 34 40 34 60 mm 1 3543 1 3622 in If the measured value does not meet specifications Change the camshaft 18 4 23 Checking the timing assembly 0 v 8 Clean all parts well 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 ...

Page 215: ... straight line Replace the timing chain 18 4 24 Removing the rocker arm 308885 10 308886 10 18 4 25 Removing the valves Remove screws O and 8 of the rocker arm shafts Remove plugs with the O rings Screw appropriate screw C into the rocker arm shafts Pull out rocker arm shafts 0 Take off rocker arm 0 Take the shims out of the valve spring retainers and lay them to one side according to their normal...

Page 216: ...tion position and label them 200189 10 18 4 26 Changing the camshaft bearing Condition 214 Valves are removed Mount the cylinder head I Clamping plate 75029050000 l l p 359 Remove the large camshaft bearing using the special tool I Pressing tool 75029051000 p 360 Remove small camshaft bearing O using the special tool Bearing puller 15112017000 p 354 Internal bearing puller 15112018100 p 354 Press ...

Page 217: ...asured value does not meet specifications Change the valve Check sealing seat 6 on the valve Valve Intake sealing seat width 2 00 mm 0 0787 in Valve Exhaust sealing seat width 1 2 00 mm 0 0787 in If the sealing area is not in the center of the valve seat or deviates from the specified value Rework the valve seat Check the valve springs for breakage and wear visual check If the valve spring is brok...

Page 218: ...st valve guides O using the special tool I Limit plug gauge 77029026000 ill p 360 If the special tool is easy to insert in the valve guide Change the valve guide and valve Check intake valve guides 8 using the special tool I Limit plug gauge 59029026006 ill p 357 If the special tool is easy to insert in the valve guide Change the valve guide and valve Check the sealing area of the spark plug threa...

Page 219: ...8 4 31 Checking the rocker arm shafts 301119 10 18 4 32 Installing the valves 304686 11 308887 10 Check the rocker arm shafts for damage and wear If there is damage or wear Change the rocker arm shafts Position valve spring seats 0 Mount the new valve stem seals Mount the valves according to their normal built in position Mount the springs and spring retainers CD Pretension the valve springs using...

Page 220: ...tallation position Position rocker arm O and push in rocker arm shafts Markings f face upward Info Make sure that the tapped hole of the rocker arm shaft is facing outward Align drill holes D in the rocker arm shafts with drill holes C in the cylinder head Install and tighten screws and D of the rocker arm shafts Guideline Screw rocker arm bearing M7x1 15 Nm 11 1 lbf ft Install and tighten screw p...

Page 221: ...ing Check spring washer 0 for damage and wear If there is damage or wear Change the spring washer Check the contact surface of pressure cap D for damage and wear If there is damage or wear Change the pressure cap Check clutch center for damage and wear If there is damage or wear Change the clutch center Check damping rubber pieces fD for damage and wear If there is damage or wear Change the dampin...

Page 222: ...ge all clutch facing discs Check the thickness of clutch facing discs CD I Clutch facing disc thickness I 1 9 mm 0 075 in If the clutch facing disc does not meet specifications Change all clutch facing discs 18 4 35 Checking the shift mechanism e Check shift forks O at leaf G for wear Shift fork J0 304687 10 Thickness at leaf 4 85 4 95 mm 0 1909 0 1949 in If the measured value does not meet specif...

Page 223: ...liding plate is worn Change the sliding plate Check return surface 0 on the sliding plate for wear If there is severe grooving Change the sliding plate Check guide bolts for firm seating and wear If the guide bolts are loose or worn Change the sliding plate Preassemble the shift shaft l JJ p 221 Check clearance 4 between the sliding plate and the shift 304682 10 18 4 36 Preassembling the shift sha...

Page 224: ...6th gear idler gear D Remove the split needle bearing 8 and stop disk t Remove lock ring D Remove 3rd 4th gear sliding gear Remove lock ring fD Remove stop disk 0 and 5th gear idler gear Remove split needle bearing 48 18 4 38 Assembling the main shaft Info Use new lock rings with every repair Preparatory work Lubricate all parts carefully before assembling Check the transmission p 225 222 304684 1...

Page 225: ...ith the shift dogs facing up Mount stop disk and lockring e Push on the third fourth gear sliding gear 0 with the small gear wheel facing downward and mount lock ring i Push on stop disk and split needle bearing Attach sixth gear idler gear with the shift dog facing downward Attach second gear fixed gear Ci with the collar facing downward and stop disk 48 Finally check all the gear wheels for smoo...

Page 226: ... 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 sixth gear sliding gear 4D Remove lock ring e and stop disk 40 Remove second gear idler gear 48 and needle bearing G i 18 4 40 Assembling the countershaft Info Use new lock rings with every repair Preparat...

Page 227: ...oove facing up Mount lockring D and stop disk Mount needle bearing C and the fourth gear idler gear with the collar facing up Mount needle bearing Ci and the third gear idler gear 48 with the collar facing down Mount stop disk 48 and lockring G Mount the fifth gear sliding gear 4D with the shift groove facing down and stop disk e Mount needle bearing Gs first gear idler gear 49 with the recess fac...

Page 228: ...s 8 and sliding gears 0 for damage and wear If there is damage or wear Change the gear wheel pair Check the tooth faces of idler gears e sliding gears 0 and fixed gear CD 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 opera...

Page 229: ...ear If there is damage or wear Change the freewheel gear or bearing Check freewheel 8 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 18 ENGINE Connect the negative cable of a 12 volt power supply to the ...

Page 230: ...heel 8 out of the primary gear Insert freewheel gear O into primary gear turning the primary 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 Remove the freewheel ll J p 228 Turn the freewheel 180 Install the freewheel p 228 Thoroughly oil all parts Push the freewheel O into the primary gear...

Page 231: ...ine assembly stand Heat the crankshaft bearing Guideline 1 ao 0 c 176 F Info I Do not damage the seal ring Mount the special tool on the clutch end of the crankshaft I Protection cap 78029005000 a p 362 Push the crankshaft all the way into the bearing seat of the right section of the engine case Remove the special tool Installing the transmission shafts Lubricate all bearings Slide both transmissi...

Page 232: ...mount this in the shift groove of the main shaft Mount shift fork 8 in the lower shift groove of the counter shaft Mount shift fork 8 in the upper shift groove of the counter shaft Slide on shift rollers 8 Info Fix the shift rollers to the shift forks with grease Push shift drum O into the bearing seat Put shift forks 8 in the shift drum Info Do not misplace the shift rollers ...

Page 233: ...t Mount the left engine casing If necessary strike it lightly with a rubber mallet Info Do not use the screws to pull the two sections of the engine case together Mount screws but do not tighten them yet Guideline I Screw engine case I M6x40 I10 Nm 7 4 lbf ft Mount screws D but do not tighten them yet Guideline I Screw engine case I M6x60 110 Nm 7 4 lbf ft Mount screws C but do not tighten them ye...

Page 234: ... the cone and thinly apply thread locker to it I Loctite 648 Mount primary gear 8 Info Turn the freewheel gear to ease engagement Oil the oil pump shaft internal rotor and external rotor before assembly I Engine oil SAE 1 0W 50 l p 348 Mount oil pump shaft O Mount pin 8 Slide on the internal rotor with the marking facing outward Mount external rotor 8 with the marking facing inward Info The markin...

Page 235: ...nstalling the locking lever Insert pin O Position oil pump gear wheel Position washers D Mount lock washer C Mount oil pump idler gear 0 Mount washer D and lock ring Crank the oil pump gear wheels and ensure that they can move easily Mount locking lever O with the washer sleeve and spring Mount and tighten screw Guideline 41 Screw locking lever M5 6 Nm 4 4 lbf ft Loctite 243 41 233 ...

Page 236: ...e 243 Slide shift shaft O with the washer into the bearing seat Push sliding plate 8 away from the shift drum locating unit Insert the shift shaft all the way Let sliding plate 8 engage in the shift drum locating unit Shift through the transmission 18 5 14 Installing the starter idler gear 18 5 15 Installing the torque limiter 234 Slide on starter idler gear O with the collar facing the engine cas...

Page 237: ...tion the new lock washer and mount nut Tighten the nut holding the inner clutch hub with a special tool Guideline I Nut inner clutch hub I M18x1 5 I 80 Nm 59 lbf ft I Holding wrench 51129003000 a p 355 Secure the nut with the lock washer 18 5 17 Installing the primary gear nut Lock the outer clutch hub and primary gear using special tool O I Gear segment 80029004000 Ii p 363 Mount and tighten nut ...

Page 238: ...ng screw 113080802 llill p 353 Thoroughly oil the clutch facing discs Beginning with an intermediate clutch disc alternately insert all other clutch facing discs and intermediate clutch discs into the clutch basket Mount clutch throw out O Position pressure cap 8 Mount pretension ring D with marking Top facing up Position spring washer C ...

Page 239: ... Remove screws D and mount the spring retainer with marking II Using a straightedge and the special tool check the spring washer for distortion I Feeler gauge 59029041100 I p 357 Spring washer distortion 0 0 10 mm 0 0 0039 in If the specified value is not reached Remove screws D and mount the spring retainer with marking Ill Using a straightedge and the special tool check the spring washer for dis...

Page 240: ... lbf ft Mount screw 0 and tighten once all of the clutch cover screws have been mounted Guideline I Screw clutch cover I M6x55 110 Nm 7 4 lbf ft Mount screw D 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 p 362 18 5 20 Installing the water pump cover 238 Put the water pump cover seal in...

Page 241: ...ion pin into the oil pump shaft from above Position pin fD Mount internal rotor 8 and external rotor G The rounded sides of the external rotor face the engine case Position oil pump cover 0 Mount and tighten screws Guideline Screw oil pump M5 cover 6 Nm 4 4 lbf ft Loctite 243 18 5 22 Installing the ignition pulse generator Position the ignition pulse generator Info I Use the outer drill hole pair ...

Page 242: ...timing chain securing guide Mount and tighten screws O Guideline Screw timing M6 10 Nm 7 4 lbf ft chain securing Loctite 243 guide 18 5 25 Installing the timing chain tensioning rail Thread in the timing chain tensioning rail from the top Mount and tighten screw O Guideline Screw timing M6 10 Nm 7 4 lbf ft chain tension Loctite 243 ing rail 18 5 26 Installing the timing chain guide rail 240 Slip i...

Page 243: ...led piston on the cylinder Compress the piston rings using the special tool I Piston ring mounting tool 60029015000 a p 357 Tap lightly on the piston ring 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 Carefully tap the piston into the cylinder using the handle of ...

Page 244: ... toward the exhaust side Cover the engine case opening with a cloth Thread the tim ing chain through the chain shaft Mount the piston pin Info I In order to present them more clearly the following steps are shown with a removed piston Position the piston pin retainer ...

Page 245: ...Keep the timing chain taut Carefully push the cylinder downward letting the dowels engage Mount the dowels Put the new cylinder head gasket in place Put the cylinder head in place Put on the cylinder head bolt washers Mount cylinder head bolts O and tighten in a crisscross pat tern Guideline Screw cylinder M10x1 25 head Mount and tighten screw 8 Tightening sequence Tighten diagonally beginning wit...

Page 246: ...ach 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 10 Nm 7 4 lbf ft camshaft Loctite 243 bearing support 18 5 31 Installing the timing chain tensioner 244 Activate release f and push the timing chain tensioner all the way back Position the timing chain tensioner with the gasket Mount and tighten screws...

Page 247: ...een the valve and rocker arm Guideline Valve clearance Exhaust at 20 C 68 F 0 12 0 17 mm 0 0047 0 0067 in Intake at 20 C 68 F 0 10 0 15 mm 0 0039 0 0059 in I Feeler gauge 59029041100 llill p 357 If the valve clearance does not meet specifications Adjust the valve clearance llill p 245 Remove the special tool I Locking screw 113080802 llill p 353 Mount and tighten screw with washer 18 5 33 Adjustin...

Page 248: ... alternator cover 18 5 35 Installing the valve cover 246 Mount locating pins Q Position alternator cover gasket Position the alternator cover Mount screws CD with washer and tighten after all of the alternator cover screws have been mounted Guideline Screw alternator cover M6x25 10 Nm 7 4 lbf ft Mount screws C and tighten all screws in a crisscross pat tern Guideline Screw alternator cover M6x25 P...

Page 249: ...nch with link 77229172000 p 361 Grease the O ring Position the starter motor Mount and tighten screws O Guideline I Screw starter motor I M6 110 Nm 7 4 lbf ft Tilt the motorcycle to one side and fill the oil filter housing to about 1 3 full with engine oil Insert oil filter O into the oil filter housing Oil the O ring of the oil filter cover Mount oil filter cover 8 Mount and tighten screws Guidel...

Page 250: ...een with O rings onto a pin wrench Push the pin wrench through the opening into the drill hole of the opposite engine case wall and push the oil screen as far as possible into the engine case Mount and tighten engine oil screen plug with the O ring Guideline Screw plug engine oil screen M20x1 5 15 Nm 11 1 lbf ft Mount and tighten the oil drain plug 8 with the magnet and the new seal ring Guideline...

Page 251: ...the engine assembly stand Remove the fitting from the special tool 18 ENGINE I Holder and fitting for work stand 78029002000 p 361 Remove the engine from the engine assembly stand Info I Work with an assistant or a motorized hoist 249 ...

Page 252: ...id level Fluid level below container 4 mm 0 16 in rim If the fluid level does not meet specifications Correct the fluid level of the hydraulic clutch I Brake fluid DOT 4 a p 348 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilled brake fluid immedi ately with water FE 501 SUS Move the clutch fluid reservoir mounted on the handlebar to a horizontal ...

Page 253: ...change the clothing 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 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 a...

Page 254: ...the hydraulic clutch Guideline Fluid level below container 4 mm 0 16 in rim Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilled brake fluid immedi ately with water FE 501 SUS Now inject the fluid into the system until it emerges from drill hole CD of the master cylinder without bubbles Now and then extract fluid from the master cylinder reservoir t...

Page 255: ...s extra cooling It is controlled by a ther moswitch 307532 10 Checking the antifreeze and coolant level Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not open the radiator the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature Allow the cooling system and the engine to cool d...

Page 256: ...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 257: ...eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing Condition The engine is cold FE EU AU FE 450 501 US Position the motorcycle upright P...

Page 258: ...immediately with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing Main work Make sure that the screw O is tightened Stand the vehicle upright Pour coolant in up to measurement 6 above the radiator fins Guideline 110 mm 0 39 in I Coolant Refit the...

Page 259: ...e engine is at operating temperature Preparatory work Stand the motorcycle upright on a horizontal surface Main work Check the engine oil level Info After switching off the engine wait one minute before checking the level I The engine oil level is between G and 0 When the engine oil level is below the G marking Add engine oil I p 260 When the engine oil level is at or above the 0 marking Correct t...

Page 260: ...ose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Drain the engine oil only when the engine is warm Preparatory work Remove the engine guard 0 p 50 Park the motorcycle on a level surface Main work Place a suitable container under the engine Remove oil drain plug O with the magnet and seal ring Remove screw plug 8 with t...

Page 261: ...ush the oil screen all the way into the engine case Mount and tighten screw plug D with the O ring Guideline Screw plug engine oil screen M20x1 5 15 Nm 11 1 lbf ft Mount and tighten the oil drain plug O with the magnet and a new seal ring Guideline Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Remove screws 0 Remove the oil filter cover with the O ring Pull oil filter D out of the oil filte...

Page 262: ...o 1 50 I 1 59 qt Engine oil SAE 10W 50 8 p 348 I Too little engine oil or poor quality engine oil results in premature wear to the engine Install and tighten the oil filler plug with O 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 ext...

Page 263: ...lation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Start the engine and check that it is oil tight Finishing work Check the engine oil level a p 257 Main work Place a suitable container under the engine Remove screws O Remove the oil filter cover with the O ring Remove the oil filter I Lock ring plier 51012011000 a p 3...

Page 264: ...emperature 1 7 bar 25 psi 80 oc 176 F Engine speed 6 000 rpm If the measured value is less than the specification Check the oil pumps for wear Check all oil channels for free flow Switch off the engine Warning Danger of burns Some vehicle components get very hot when the machine is driven Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water ...

Page 265: ...rk plug connector 1 601170 10 Condition Spark plug connector cylinder 1 has been removed 0 Measure the resistance between the specified points Measuring point 1 Measuring point 2 Spark plug connector Resistance at 20 C 68 F 1 3 75 6 25 kQ If the specification is not reached Change the spark plug connector Alternator checkin the stator windin EZ 601211 10 Condition The stator is disconnected Prepar...

Page 266: ...ns Change the stator Stator winding check for a short circuit to ground terminal 31 Measure the resistance between the specified points Stator connector EZ pin 1 Measuring point Ground I Resistance I oo Q 22 4 264 If the value displayed does not meet specifications Change the stator Removing the stator Condition The alternator cover has been removed Remove screw O and take off the cable holder Rem...

Page 267: ...rnator cover Mount and tighten screws O Guideline Screw stator MS 6 Nm 4 4 lbf ft Loctite 243 Position cable support sleeve 8 in the alternator case Position the cable holder Mount and tighten screw Guideline Screw cable M4 4 Nm 3 lbf ft holder in alter Loctite 243 nator cover 41 265 ...

Page 268: ...al filter JI p 110 Main work Disconnect spark plug connector O Remove the spark plug using the special tool I Spark plug wrench with link 77229172000 l JI p 361 Push back hose clamp 8 Pull off the air release hose Remove screws 8 Remove the valve cover with the gasket FE EU AU FE 450 501 US Engage the highest gear Turn the rear wheel until the engine is at ignition top dead center The markings f o...

Page 269: ...out the washer Check the valve clearance at all valves between the valve and rocker arm Guideline Valve clearance Exhaust at 20 C 0 12 0 17 mm 0 0047 68 F 0 0067 in Intake at 20 C 68 F 0 10 0 15 mm 0 0039 0 0059 in I Feeler gauge 59029041100 0 p 357 If the valve clearance does not meet specifications Adjust the valve clearance 0 p 245 Remove locking screw C Crank the engine several times Check the...

Page 270: ... motorcycle from the lift stand a p 14 FE 501 SUS Install the activated charcoal filter a p 110 Install the fuel tank a p 101 Mount the seat a p 98 Remove the motorcycle from the lift stand il p 14 For purposes of illustration the following operations are shown with the engine removed Removal is not necessary Preparatory work FE EU AU FE 450 501 US Raise the motorcycle with a lift stand a p 14 Rem...

Page 271: ...nstall the timing chain tensioner I p 244 Check the valve clearance I p 266 FE EU AU FE 450 501 US Install the fuel tank I p 101 Mount the seat I p 98 Remove the motorcycle from the lift stand I p 14 FE 501 SUS Install the activated charcoal filter I p 110 Install the fuel tank I p 101 Mount the seat I p 98 Remove the motorcycle from the lift stand I p 14 269 ...

Page 272: ...motor has been removed Connect the negative cable of a 12 volt power supply to the housing of the starter motor Connect the positive cable of the power supply briefly to connector O of the starter motor If the starter motor does not turn when the circuit is closed Change the starter motor ...

Page 273: ... the idle speed adjusting screw Guideline I Idle speed 1 800 1 900 rpm Executing the initialization run Condition Info Turn counterclockwise to increase the idle speed Turn clockwise to decrease the idle speed The diagnostics tool is connected and running Execute Engine electronics Functions Delete adaptation values The adaptation values are deleted Select Engine electronics Measured values Coolan...

Page 274: ...aches the specified temperature Guideline I Coolant temperature Info I so 90 c 176 194 F I Do not operate the throttle grip during the initialization process As soon as the specified temperature is reached switch off the ignition Info If the initialization is not completed or the initializa tion process is interrupted the entire process must be restarted ...

Page 275: ... Intake at 20 C 68 F 0 10 0 15 mm 0 0039 0 0059 in Crankshaft bearing 2 grooved ball bearings Conrod bearing Slide bearing Piston pin bearing No bearing bushes DLC plated piston pins Pistons Forged light alloy Piston rings 1 compression ring 1 oil scraper ring E ngine lubrication Pressure circulation lubrication with two rotary pumps Primary transmission 32 76 Clutch Multidisc clutch in oil bath h...

Page 276: ...le diameter Size I 95 000 95 012 mm 3 74015 3 74062 in Size II 95 013 95 025 mm 3 74066 3 74113 in Piston cylinder mounting clearance Size I 0 040 0 082 mm 0 00157 0 00323 in Size II 0 043 0 085 mm 0 00169 0 00335 in Wear limit 0 120 mm 0 00472 in Piston ring end gap Compression ring 5 1 00 mm 5 0 0394 in Oil scraper ring 5 1 20 mm 5 0 0472 in Conrod bearing axial clearance 0 20 0 45 mm 0 0079 0 0...

Page 277: ...rew exhaust flange M6 Screw idler M6 Screw kick starter spring hanger M6 Screw kick starter stop M6 Screw oil pump cover M6 26 TECHNICAL DATA 1 5 Nm 1 11 lbf ft 2 Nm 1 5 lbf ft 4 Nm 3 lbf ft 2 Nm 1 5 lbf ft 2 Nm 1 5 lbf ft 6 Nm 4 4 lbf ft 6 Nm 4 4 lbf ft 6 Nm 4 4 lbf ft 6 Nm 4 4 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 2 5 Nm 1 84 lbf ft 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf...

Page 278: ...6 M6 M6 M6 M6x25 M6x55 M6x0 75 M6x0 75 M7 M7x1 M8 M8 M8x1 M10 M10 M10x1 25 M12x1 M12x1 25 M12x1 5 M12x1 5 M12x1 5 M12x1 5 10 Nm 7 4 lbf ft 14 Nm 10 3 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 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 4 Nm 3 lbf ft 4 Nm 3 lbf ft 9 Nm 6 6 lbf ft 15 Nm 11 1 lbf ft 10 Nm 7 4 lbf ft 25 Nm 18 4 ...

Page 279: ...al fuel tank capacity approx FE 450 501 US FE 501 S US Super unleaded ROZ 95 RON 95 PON 91 p 349 I Fuel reserve approx 26 5 Chassis Frame Fork Suspension travel front Suspension travel rear Fork offset Shock absorber Brake system Brake discs diameter front rear Brake discs wear limit front rear Tire air pressure off road front rear Road tire pressure FE EU AU FE 450 US 11 s I 1 6 qt I 8 5 I 2 25 U...

Page 280: ...out fuel approx FE 450 US 112 8 kg 248 7 lb Weight without fuel approx FE 501 US 113 3 kg 249 8 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 26 6 Electrical s stem Battery YTX5L BS Battery voltage 12 V Nominal capacity 4 Ah Maintenance free Combination instrument battery CR 2032 Battery voltag...

Page 281: ...ring length with preload spacer s 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 Fork length Air chamber length Oil capacity per fork leg 26 9 Shock absorber Shock absorber article number Shock absorber Compression damping low speed Comfort Standard Sport Compression damping high speed Comfort Standard Sport 630 ml 21 3 fl oz...

Page 282: ...rature sen sor Screw shock absorber adjusting ring Screw spoiler on fuel tank FE 450 501 US Screws on the main silencer Nut cable on starter motor Remaining nuts chassis Remaining screws chassis Screw ball joint of push rod on foot brake cylinder Screw chain sliding guard Screw front brake disc Screw rear brake disc Screw throttle grip Fuel connection on fuel pump Nut foot brake lever stop Nut rea...

Page 283: ...d Screw in nozzles cooling system M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8x20 M8x30 M8 M8 M10 M10 M10 M10 M10 M10 M12 M14x1 5 M14x1 5 M14x1 5 M16x1 5 M20x1 5 M20x1 5 M20x1 5 M20x1 5 26 TECHNICAL DATA 25 Nm 18 4 lbf ft 25 Nm 18 4 lbf ft 15 Nm 11 1 lbf ft 15 Nm 11 1 lbf ft 33 Nm 24 3 lbf ft 15 Nm 11 1 lbf ft 25 Nm 18 4 lbf ft 20 Nm 14 8 lbf ft 15 Nm 11 1 lbf ft 45 Nm 33 2 lbf ft 30 Nm 22 1 lbf ft 30 Nm 22 1...

Page 284: ...t regularly Avoid direct sunshine when cleaning the motorcycle 7 11111111111111 401061 01 Close off the exhaust system to keep water from entering Remove coarse dirt particles with a gentle water jet Spray dirty parts with a normal commercial engine cleaner and then brush off with a soft brush Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner...

Page 285: ...ggressive road salt If the vehicle was operated in road salt clean it with cold water after riding Warm water would enhance the corrosive effects of salt 401060 01 Clean the motorcycle p 282 Clean the brake system Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings in the cooled down and installed state with cold water and dry carefully After riding on salted...

Page 286: ... times at the start of the new season 1111 When refueling for the last time before taking the motorcycle out of service add fuel additive Refuel Clean the motorcycle a p 282 Change the engine oil and oil filter and clean the oil screens a p 258 Check the antifreeze and coolant level a p 253 Check the tire air pressure a p 118 401058 01 284 Remove the battery a p 144 Recharge the battery Guideline ...

Page 287: ...GE Pre aring for use after storage 401059 01 Remove the motorcycle from the lift stand illll p 14 Install the battery lillll p 145 Perform checks and maintenance measures when preparing for use Take a test ride 285 ...

Page 288: ...ke tension a p 120 0 I I I Check the chain rear sprocket engine sprocket and chain guide I p 131 I Check the chain tension I p 129 0 I Grease all moving parts e g side stand hand lever chain and check for smooth operation I I Check correct the fluid level of the hydraulic clutch a p 250 I I Check the front brake fluid level I p 152 I I I Check the free travel of the hand brake lever a p 151 I I I ...

Page 289: ...63 I I I I I Change the hydraulic clutch fluid p 251 I I I I I Lubricate the steering head bearing a p 37 I I I I I Clean the spark arrestor FE 450 501 US FE 501 S US p 91 I I I Perform a fork service a p 20 Service the shock absorber p 59 Change the spark plug and spark plug connector Change the piston Check measure the cylinder Check the cylinder head Change the valves valve springs and valve sp...

Page 290: ...K10 f A I n D X2 l 1 w w E E C0 F a C nr HUSQl l ma 1 2 c I I z a I 3 I II G10 1 X300 l 1 FE 450 501 EU 2016 I 3 I 4 521 4 n 5 BR 4 l x4 l K 4 i i R 4 X4 1 s 5 I 6 I 7 I 8 A f B C f D f w rd a 2 E1 E f lW t b 2 F1 F I ha I 6 I 7 I 8 re ...

Page 291: ...Components G10 Battery K10 Starter relay with main fuse M10 Electric starter system S21 E tip switch 30 WIRING DIAGRAM 289 ...

Page 292: ... X10 1 1 rrDY 4 I 1 X9 1 5 t6 1 t3 J 2 i iEB 4 X295 F2 K30 a AP 6 e FJ 2 f EB 4 1 X 6 I 1 X3 1 1 1 1 EB aC wlHdl e 1 t L j __ B33 Lf l M1 4 4 2 N BV 2o J C l BS 2 1 X285 l I i xs t7 j J i j F 4 J 2 F J J 2 X 40 111 FJ 2 1 FJ 2 X39 1 xs X7 t 1 L_JI t IfI C b 3 E1 1 FB bC tr 0 tr t b 7 F1 HUSQl l ma FE 450 501 EU 2016 2 8 ...

Page 293: ...11 EFI control unit B33 Radiator fan temperature switch F2 Fuse F3 Fuse F4 Fuse G20 Alternator K12 Light relay K30 Power relay M14 Radiator fan T20 Voltage regulator X295 Diagnostics connector 30 WIRING DIAGRAM 291 ...

Page 294: ...5 0 B f wh t f 4 81 1 I I G i s 8 ttl BP 4 MjDG 4 1 t l AC 6 BN1 i 11 1 f t 1 1 I I I 1 w m 11 I I I I w 2 EB dC I I s r I r i jl r 1 I 2 EB et Y lxJ Y lxJ C e 4 E1 E 2 EB bC 0 _______________ _____ _ ______ c 4 E1 IE C0 0 I I C I ll ll HUSQl l ma FE 450 501 EU 2016 I l I 1 l I l ...

Page 295: ...Components A11 EFI control unit E13 Low beam high beam P13 Speedometer P15 Horn P35 Parking light S22 Light switch horn button kill switch 30 WIRING DIAGRAM 293 ...

Page 296: ...C 1X18 1X19 l 1 i X 1 3 C AH 2 AH 2 BY 4 D1 2 r X11 B76 B77 P36 CV 4 f 7 f r l X17 AK 2 K 2 X11 V 4 I D f H 2 f H 2 ii Y 4 X14 D X18 X19 X13 l sl 1 I I I I I f w w 3 ES et ye OO E C0 a v C nr E 3 EB b C t E f F F C c I 1 z FE 450 501 EU 2016 hm HUSQl l ma 1 2 I 3 I 4 5 I 6 I 7 I 8 a ...

Page 297: ...Components B76 Front brake light switch B77 Rear brake light switch E60 License plate lamp P36 Brake tail light 30 WIRING DIAGRAM 295 ...

Page 298: ... X 42 j X23 j X25 j X41 X28 C J N AJ 3 H CX 2 CX 2 CX 2 CX 2 AH 2 NF0 2 525 P42 P46 P41 P45 R f 13 W 2 W 2 W 2 W 2 i D X45 fJ 3 i CX 2 l X 2 l X 2 l X 2 D X42 X23 X25 X41 X28 w i i I I I I f w E C0 a It C nr E E f F F c I IU z FE 450 501 EU 2016 I hm HUSQl l ma 1 2 I 3 I 4 5 I 6 I 7 I 8 a ...

Page 299: ...nts K20 Turn signal relay P21 Turn signal indicator lamp P41 Turn signal front left P42 Turn signal front right P45 Turn signal rear left P46 Turn signal rear right S25 Turn signal switch 30 WIRING DIAGRAM 297 ...

Page 300: ...a co C nr E F c I I FE 450 501 EU 2016 HUSQl l ma 1 2 I 3 I 4 5 a 1 Jl X15 X15 I B51 j 20 CU 4 M Y 4 M l i CU 4 X20 6 I I P13 3 A6 7 A2 1 X15 i 6 I 7 I S 1lY 3 lY 3 l cm M l cv J X51 X51 p i GA 3 Jm Tl T 07 R rr D7 I 7 I 8 A f B C f D f O t g 7 E1 E f bl t h 8 F1 F hm 8 ...

Page 301: ...Components A11 EFI control unit B32 Fuel level sensor B51 Lambda sensor cylinder 1 F1 Fuse P13 Speedometer 30 WIRING DIAGRAM 299 ...

Page 302: ...J X15 X15 X15 X15 X15 f X52 B70 5 l5 l5 e r j i f 1515 il 8 B I I i HHr 1 f il C U C 1 NDQ 2 NAT 2 GA 3 f f X295 X 3 01 r 7 6 D7 M f AP 6 n 16 Dl 1 0 0 t D X26 X29 D 5 l5 l5 1515 f w w E C0 a C nr E 6 EB g C er E f 2 FS b C t F F c I Ir FE 450 501 EU 2016 I hm HUSQl l ma 1 2 I 3 I 4 5 6 I 7 I 8 a ...

Page 303: ...mponents A11 EFI control unit B70 Front wheel speed sensor M13 Fuel pump M51 Injection valve cylinder 1 P13 Speedometer R30 CAN bus terminating resistor 1 X295 Diagnostics connector 30 WIRING DIAGRAM 301 ...

Page 304: ...15 X15 X15 X15 I t 1 B f t B B f 9 t 9 C x34 I I X37 C DV 2 NAL 2 S51 u2 AX 2 FL 1 EX 3 AP 6 NDX 3 CM 2 B37 M f n El f fv e 0 F r n n w n m t D X35 X30 X33 X32 X38 D X34 B B f w w E 00 a 00 C nr E E f 6 FB h I bl F F c I 1 FE 450 501 EU 2016 I hm HUSQl l ma 1 2 I 3 I 4 5 I 6 I 7 I 8 a ...

Page 305: ...ensor B41 Induction manifold 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 for basic position optional Cable colors bl Black br Brown bu Blue gn Green gr Gray lbu Light blue or Orange pk Pink pu Violet rd Red wh White ye Yellow 30 WIRING DIAGRAM 303 ...

Page 306: ...2 l 1 a w E E C0 F a C nr HUSQl l ma 1 2 c I IO z a I 3 I 4 II G10 1 X300 l 1 FE 450 501 AU 2016 I 3 I 4 523 3 C2 n 5 l x4 BR 4 I BK 4 1 E 1 fv j 1 D2 I BK 4 I i i R 4 X4 1 s 5 I 6 I 7 I 8 A f B C f D f w rd a 2 E1 E f lW t b 2 F1 F I ha I 6 I 7 I 8 g ...

Page 307: ...Components G10 Battery K10 Starter relay with main fuse M10 Electric starter system S23 Emergency OFF switch tip switch 30 WIRING DIAGRAM 305 ...

Page 308: ...ij f EB 4 I 1 X10 1 1 rrDY 4 I 1 X9 1 5 t6 1 t3 J 2 i iEB 4 X295 F2 K 3 0a AP 6 e FJ 2 f EB 4 1 X6 I 1 X 3 1 1 1 1 EB aC wlHdl e 1 t L j __ B33 C Lf l M14 J 2 F4 2 M BV 26 J i BS 2 u co t X285 FJ 2 XS 0 i t7 t J 2 m 1 L_J I 1 IfI l b 3 E1 1 FB bC tr 0 tr t b 7 F1 HUSQl l ma FE 450 501 AU 2016 2 8 ...

Page 309: ...11 EFI control unit B33 Radiator fan temperature switch F2 Fuse F3 Fuse F4 Fuse G20 Alternator K12 Light relay K30 Power relay M14 Radiator fan T20 Voltage regulator X295 Diagnostics connector 30 WIRING DIAGRAM 307 ...

Page 310: ... S P13 I I n Ji CX 2 X50 B I l wh c f 4 B1 1 f u i w I P15 8 cru _ _ _ ttlBP 4 M j DG 4 1 X44 l DG 4 I BP 4 X46 X22 1 1 1 1 l l l J c 2 EB dC I I 11LJ 1 1 I I eo H I e E 2 EB bC 0 l b 4 E1 IE C0 0 I I C I ll ll HUSQl l ma FE 450 501 AU 2016 I l I 1 I I I g ...

Page 311: ...Components A11 EFI control unit E13 Low beam high beam P13 Speedometer P15 Horn P35 Parking light S22 Light switch horn button kill switch S23 Emergency OFF switch tip switch 30 WIRING DIAGRAM 309 ...

Page 312: ...t C 1 X18 1 X19 l 1 i X 1 3 C AH 2 AH 2 BY 4 D1 2 r X11 B76 B77 P36 CV 4 f f r l X17 AK 2 K 2 X11 V 4 I D f H 2 f H 2 ii Y 4 X14 D X18 X19 X13 l sl i_ 1 I I I I I f w 3 EB et ye 00 E C0 a v C nr E 3 EB bC 0 E f F F I I z FE 450 501 AU 2016 hm HUSQl l ma 1 2 I 3 I 4 5 I 6 I 7 I 8 0 a ...

Page 313: ...Components B76 Front brake light switch B77 Rear brake light switch E60 License plate lamp P36 Brake tail light 30 WIRING DIAGRAM 311 ...

Page 314: ... P42 R 13 i D X45 fJ 3 X42 i i w E C0 a It C nr E F I I z FE 450 501 AU 2016 HUSQl l ma 1 2 I 3 I a 4 5 I l I I j X23 j X25 j X41 CX 2 CX 2 CX 2 P46 P41 W 2 W 2 W 2 i C X 2 l X 2 l X 2 X23 X25 X41 I I 4 5 I 6 I I X28 CX 2 P45 W 2 i CX 2 X28 I 6 I 7 I 8 I I 7 I 8 A f B C f D f E f F hm C II ...

Page 315: ...nts K20 Turn signal relay P21 Turn signal indicator lamp P41 Turn signal front left P42 Turn signal front right P45 Turn signal rear left P46 Turn signal rear right S25 Turn signal switch 30 WIRING DIAGRAM 313 ...

Page 316: ... XS w E C0 a co C nr E F I I FE 450 501 AU 2016 HUSQl l ma 1 2 I 3 I 4 5 a TI X15 X15 ca l 7 1 1 rrrn CU 4 6 I I P13 3 A6 7 A2 1 X15 i 6 I 7 I S 1lY 3 lY 3 l cm 1cv3 X51 X51 p i GN3 Jm Tl T 07 R rr D7 I 7 I 8 A f B C f D f O t g 7 E1 E f bl t h 8 F1 F hm 8 ...

Page 317: ...Components A11 EFI control unit B32 Fuel level sensor F1 Fuse P13 Speedometer 30 WIRING DIAGRAM 315 ...

Page 318: ...ifY J X15 X15 X15 X15 X15 f X52 B70 5 l5 l5 e r j i f 1515 il 8 B I I i HHr 1 f il C U C 1 NDQ 2 NAT 2 GA 3 f f X295 X 3 01 r 7 6 D7 M f AP 6 n 16 Dl 1 0 0 t D X26 X29 D 5 l5 l5 1515 f w E C0 a C nr E 6 EB g C er E f 2 FS b C t F F I I FE 450 501 AU 2016 I hm HUSQl l ma 1 2 I 3 I 4 5 6 I 7 I 8 a ...

Page 319: ...mponents A11 EFI control unit B70 Front wheel speed sensor M13 Fuel pump M51 Injection valve cylinder 1 P13 Speedometer R30 CAN bus terminating resistor 1 X295 Diagnostics connector 30 WIRING DIAGRAM 317 ...

Page 320: ...2 1 x35 3 4 l X15 11 X15 t 1 I I I 9 1 l X37 X36 N AU2 1 HT 2 R51 lJJ B37 5 6 7 1 1 1 1 1 X15 X15 X15 X15 X15 il f t I I I I to i_X33 i_X32 t38 iEX 3 fP 6 rX 3 cM 2 M f EX 3 AP 6 oX 3 cM 2 I 0 I 1 X33 I 1 X32 1 X38 il E E E 6 FB 01 bl L I L HUSQl l ma FE 450 501 AU 2016 1 I l I I I 8 I IA f Is I I C0 ...

Page 321: ...ensor B41 Induction manifold 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 for basic position optional Cable colors bl Black br Brown bu Blue gn Green gr Gray lbu Light blue or Orange pk Pink pu Violet rd Red wh White ye Yellow 30 WIRING DIAGRAM 319 ...

Page 322: ...IAGRAM 30 17 Page 1 of 6 FE 450 501 US I m ii Tl m 0 0 0 0 I 0 I m 320 I 0 I 0 I l l p J oo ro 4 h ro I Jd 1 w d 20A f wh rd 3 9 1 i i i 1 f ip J wh rd wh rd I i oo d c 2 b bl A A _i A 0 I 0 I ro I ro I T00165 10 ...

Page 323: ...Components G10 Battery K10 Starter relay with main fuse M10 Electric starter system S21 E tip switch 30 WIRING DIAGRAM 321 ...

Page 324: ... I 1 X 10 1 1 rrDY 4 I 1 X9 1 5 t6 1 t3 J 2 i iEB 4 X295 F2 K30 a AP 6 e FJ 2 f EB 4 1 X6 I 1 X 3 1 1 1 1 EB aC wlHdl e 1 t L j __ B33 Lf l M14 4 2 N BV 2o J C l BS 2 1 X285 l I i xs t7 j j J 2 J 2 F4 F3 X19 111 FJ 2 1FJ 2 X23 1 xs X7 t 1 L_JI 1 t l l b 3 E1 1 FB bC tr 0 tr t b 5 F1 HlJSCl l ma FE 450 501 US 2016 2 6 ...

Page 325: ...ntrol unit B33 Radiator fan temperature switch optional F2 Fuse F3 Fuse F4 Fuse G20 Alternator K12 Light relay K30 Power relay M14 Radiator fan optional T20 Voltage regulator X295 Diagnostics connector 30 WIRING DIAGRAM 323 ...

Page 326: ...1 x 15 t B B I l 11 1 1 l C 1 X18 is 1 1 X17 is 1 C BF 1 X12 M BY 4 X1 X31 FF 1 FP 1 Dl 2 BA 1 V 4 i BP 4 M DG 4 J v 1 0814 I BP 4 V 4 X16 X22 l l c ii l l 1 CNOH l j jr 1 j E 2 EB bC 0 E Ft iF tel FE 450 501 us 2016 I l_ HUSQ llma I 3 6 1 2 I J I 4 s I 6 I 1 I a ...

Page 327: ...Components A11 EFI control unit E11 Low beam P35 Parking light P37 Tail light S20 Kill switch S30 Light switch 30 WIRING DIAGRAM 325 ...

Page 328: ...f i m D XS w E 0 a v C nr E F I I tel FE 450 501 US 2016 HUSQ l ma 1 2 I 3 I 4 5 a TI X15 X15 ca l l l CU 4 6 6 I I P13 5 A2 1 X15 i I 7 I S 1lY 3 lY 3 l cm 1c v3 X14 X14 p 1 GN3 Jm Tl 15 07 R r i D7 I 7 I 8 A f B C f D f O t e 5 E1 E f bl f 6 F1 F 8 ...

Page 329: ...Components A11 EFI control unit B32 Fuel level sensor F1 Fuse P13 Speedometer 30 WIRING DIAGRAM 327 ...

Page 330: ...fY J X15 X15 X15 X15 X15 f X13 B70 5 l5 l5 e r j i f 1515 E B B I I i HHr 1 f E C U C 1 NDQ 2 NAT 2 GA 3 f f X295 X301 r 7 4 D7 M f AP 6 n 14 D7 1 0 0 t D X26 X29 D 5 l5 l5 1515 f w E 0 a It C nr E 4 EB eC cr E f 2 FS b C t F F I 1 tel FE 450 501 US 2016 I HUSQ l ma 1 2 I 3 I 4 5 6 I 7 I 8 a ...

Page 331: ...mponents A11 EFI control unit B70 Front wheel speed sensor M13 Fuel pump M51 Injection valve cylinder 1 P13 Speedometer R30 CAN bus terminating resistor 1 X295 Diagnostics connector 30 WIRING DIAGRAM 329 ...

Page 332: ... 2 1 x35 3 4 l X15 11 X15 t 1 I I I 9 1 l X28 X36 N AU2 1 HT 2 R51 lJJ B37 5 6 7 1 1 1 1 1 X15 X15 X15 X15 X15 il f t I I I I to i_X33 i_X32 t25 iEX 3 fP 6 rX 3 cM 2 M f EX 3 AP 6 oX 3 cM 2 I 0 I 1 X33 I 1 X32 1 X25 il E E E 4 FB 11 bl L I L HUSQ l ma FE 450 501 US 2016 1 I l I I I 8 I IA f Is I I ...

Page 333: ...ensor B41 Induction manifold 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 for basic position optional Cable colors bl Black br Brown bu Blue gn Green gr Gray lbu Light blue or Orange pk Pink pu Violet rd Red wh White ye Yellow 30 WIRING DIAGRAM 331 ...

Page 334: ...A B B II 11 II I l l 11 l I M10 K10 G10 523 510 F3 X56 1i f _ V 8 v GT 6 e o ii 1d 4 i is f s r o X4 X55 11 2 l a 1 1 X300 I i I 1 I rf7 rd a 2 E1 t 1 w rd b 2 E1 E E t ye tlr t c 2 E1 1 l d 2 F1 Ft F Hu ma FE 501 SUS 2016 I hm 1 2 I J I 4 s I 6 I 1 I a ...

Page 335: ...Components F3 Fuse G10 Battery K10 Starter relay with main fuse M10 Electric starter system S10 Ignition lock S23 Emergency OFF switch tip switch 30 WIRING DIAGRAM 333 ...

Page 336: ... I f X20 EB 4 X10 J l 1 ES aC rd I W DY 4 I 1 X9 11 1 t6 1 t3 fJ12 1 ies14 F2 w K3 0 a X295 AP 6 e FJ 2 iEB 4 1 X 6 I 1 X 3 1 l 1 1 EB bC WIHd J f 1 L 1 EB cC ye br 1 X285 iBS 2 BV 2 M14 1 J th BV 28 18S 2 1 X285 t8 i J 2 Ill w m m 00 _ 1 FB dC tr tr t d 7 F1 HUSQl l ma FE 501 SUS 2016 2 8 ...

Page 337: ...ts A11 EFI control unit B33 Radiator fan temperature switch F2 Fuse F4 Fuse G20 Alternator K12 Light relay K30 Power relay M14 Radiator fan T20 Voltage regulator X295 Diagnostics connector 30 WIRING DIAGRAM 335 ...

Page 338: ...X43 BP 4 I l I LAI MjDG 4 1CW 2 IAI JCXJ2 X46 t f X22 X50 X53 1 x i 1 0814 II 11 IYI 1 sp14 1 cXJ2 IYI 1 cw12 cR l i FF 1 i FF 1 i Dl 2 i F0 2 D 1 x12 X24 X21 X31 X54 ti I t Z Z i il il i E E 0 0 LJ 1 1 I 11 LJ 2 EB IC I E 2 EB dC 0 c d 4 E1 IE C0 0 I l g g HUSQl l ma FE 501 SUS 2016 I l I 1 I I I ...

Page 339: ...Components A11 EFI control unit E13 Low beam high beam P15 Horn P23 High beam indicator lamp P35 Parking light S29 Light switch horn button turn signal switch 30 WIRING DIAGRAM 337 ...

Page 340: ... E ct C 1 X18 1 X19 l 1 i X 1 3 C AH 2 AH 2 BY 4 D1 2 r X11 B76 B77 P36 CV 4 f f r l X17 AK 2 K 2 X11 V 4 I D f H 2 f H 2 ii Y 4 X14 D X18 X19 X13 l sl i_ 1 I I I I I f w 3 EB It ye 00 E C0 a v C nr E 3 EB dC 0 E f F F I I z FE 501 SUS 2016 hm HUSQl l ma 1 2 I 3 I 4 5 I 6 I 7 I 8 a ...

Page 341: ...Components B76 Front brake light switch B77 Rear brake light switch E60 License plate lamp P36 Brake tail light 30 WIRING DIAGRAM 339 ...

Page 342: ...U X 42 j X23 j X25 j X41 X28 C J N AJ 3 H CX 2 CX 2 CX 2 CX 2 AH 2 NF0 2 529 P42 P46 P41 P45 f 3 C3 f 13 W 2 W 2 W 2 W 2 i D X45 fJ 3 i CX 2 l X 2 l X 2 l X 2 D X42 X23 X25 X41 X28 u i i I I I I f w E C0 a It nr E E f F F I I z FE 501 SUS 2016 I hm HUSQl l ma 1 2 I 3 I 4 5 I 6 I 7 I 8 g a ...

Page 343: ...urn signal relay P21 Turn signal switch P41 Turn signal front left P42 Turn signal front right P45 Turn signal rear left P46 Turn signal rear right S29 Light switch horn button turn signal switch 30 WIRING DIAGRAM 341 ...

Page 344: ... J FJ 2 W f i m D X5 u w E F E C0 a co C nr FE 501 SUS 2016 HUSQl l ma 1 2 I 3 I I I a 4 5 I 6 I I P13 7 A2 X15 i 4 5 I 6 I 7 l NI i I S CY 3 1CY 3 CZ 3 1 CZ 3 X60 X60 X29 GN3 Tl 17 07 R rr D7 I 7 I 8 A f B C f D f O t h 7 E1 E f F hm 8 ...

Page 345: ...Components A11 EFI control unit B32 Fuel level sensor F1 Fuse P13 Speedometer 30 WIRING DIAGRAM 343 ...

Page 346: ... l5 5 u w E C0 a C nr 6 EB h C er E 2 FS d C t F I I FE 501 SUS 2016 HUSQl l ma 1 2 I 3 I 4 a 5 m ITT X15 j i I 9 9 9 9 r l1 o a AT 2 X295 AP 6 5 5 6 II DF 2 I X57 5 6 I 7 I 8 I A 1 ITT l oo TI ITT OO X15 X15 X15 f 1515 il B I f f il C GA 3 X 3 01 r 7 6 D7 M f 16 Dl t X29 D 1515 f E f F I hm I 7 I 8 g ...

Page 347: ...ontrol unit B70 Front wheel speed sensor M13 Fuel pump M20 Evaporate emission control valve M51 Injection valve cylinder 1 P13 Speedometer R30 CAN bus terminating resistor 1 X295 Diagnostics connector 30 WIRING DIAGRAM 345 ...

Page 348: ...5 X15 X15 X15 X15 X15 X15 I t 1 _a f t B B f 9 t 9 C x34 I I X37 C DV 2 NAU2 ss1 u2 AX 2 FU1 EX 3 AP 6 NDX 3 CM 2 B37 M f n El f fv e 0 F r n n n m t D X35 X30 X33 X32 X38 D X34 _a _a u f w E C0 a C0 C nr E E f F F I I FE 501 SUS 2016 I hm HUSQl l ma 1 2 I 3 I 4 5 I 6 I 7 I 8 g a ...

Page 349: ...ensor B41 Induction manifold 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 for basic position optional Cable colors bl Black br Brown bu Blue gn Green gr Gray lbu Light blue or Orange pk Pink pu Violet rd Red wh White ye Yellow 30 WIRING DIAGRAM 347 ...

Page 350: ...otection to at least I 25 C 13 F The mixture ratio must be adjusted to the necessary antifreeze protection Use distilled water if the coolant needs to be diluted The use of premixed coolant is recommended Observe the coolant manufacturer specifications for antifreeze protection dilution and miscibility compatibility with other coolants Recommended supplier Bel Ray Moto Chill Racing Coolant En ine ...

Page 351: ...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 352: ...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 353: ...nded supplier Bel Ray Foam Filter Oil Preserving materials for aints metal and rubber Recommended supplier Bel Ray Silicone Detailer Protectant Spray Universal oil s ra Recommended supplier Bel Ray 6 in 1 32 AUXILIARY SUBSTANCES 351 ...

Page 354: ...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 352 ...

Page 355: ...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 33 SPECIAL TOOLS 120V 32 A 5 m 16 ft 5 m 16 ft 230V 16 A 5 m 16 ft 5 m 16 ft 230V 16 A 5 m 16 ft 5 ...

Page 356: ...2017000 Internal bearing uller 15112018100 S ring hook 50305017000 s ringe 50329050000 354 H00520 01 H00522 01 H00973 01 H00565 01 Art no 15112017000 Art no 15112018100 Feature 118 23 mm 0 71 0 91 in Art no 50305017000 Art no 50329050000 ...

Page 357: ... Lock ring lier Art no 51012011000 51012011000 H00572 01 Holding wrench Art no 51129003000 51129003000 H00575 01 Puller Art no 58012009000 58012009000 H00592 01 Tool bracket Art no 58429089000 58429089000 H00603 01 355 ...

Page 358: ...0606 01 Valve s ring mounter 59029019000 H00610 01 356 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 359: ... r 60029015000 H00628 01 Puller 2x 60029033000 H00633 01 Art no 59029026006 Feature I Diameter Art no 59029041100 Feature 15 piece Art no 60029015000 Feature Height Diameter Art no 60029033000 33 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 357 ...

Page 360: ...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 01 358 ...

Page 361: ...ssing tool Art no 75029044010 75029044010 H00712 01 Pressing tool Art no 75029044020 75029044020 H00713 01 Crankshaft ressing tool Art no 75029047000 75029047000 H00714 01 Clam Art no 75029050000 75029050000 H00719 01 359 ...

Page 362: ...5029051000 75029051000 H00721 01 Protection caR Art no 75029090000 75029090000 H00726 01 Oil Rressure ada ter Art no 75029094000 75029094000 H00728 01 Limit Art no 77029026000 Feature I Diameter I 5 05 mm 0 1988 in 77029026000 H00741 01 360 ...

Page 363: ...00 H00761 01 Insertion for iston ring lock 77329030100 H00768 01 Holder and fitting for work stand 78029002000 H00783 01 Art no 77029041200 Art no 77229172000 Feature Drive Hexagonal part Length Art no 77329030100 Art no 78029002000 33 SPECIAL TOOLS 3 8 in 14 mm 0 55 in 130 mm 5 12 in 361 ...

Page 364: ...a Art no 78029005000 78029005000 H00784 01 Crankshaft ressing tool insert Art no 78029008000 78029008000 H00786 01 Se arator late Art no 78029009100 78029009100 H01174 01 Marking mandrel Art no 78129032000 78129032000 H00796 01 362 ...

Page 365: ...d 80329001000 H01047 01 Lift stand 81329955100 H00985 01 Protection ca 90129005000 H00816 01 Art no 80029004000 Art no 80329001000 Art no 81329955100 Feature Height Load Art no 90129005000 33 SPECIAL TOOLS 315 425 mm 12 4 16 73 in s 150 kg 5 331 lb 363 ...

Page 366: ...100 Hook wrench T106S De th micrometer T107S Drift T120 364 H00828 01 H00841 01 H00842 01 H00844 01 Art no 90129048100 Art no T106S Feature I Diameter Art no T107S Art no T120 Feature I Diameter I 68 75 mm 2 68 2 95 in I 8 mm 0 31 in ...

Page 367: ...0879 01 Pressing tool T1206 H00880 01 Art no T1202S Feature Diameter Diameter Art no T1204 Feature I Diameter Art no T1205 Feature I Diameter Art no T1206 Feature I Diameter 33 SPECIAL TOOLS 10 mm 0 39 in 18 mm 0 71 in I 25 5 30 5 mm 1 004 1 201 in I m mm 0 71 in 1 15 30 mm 0 59 1 18 in 365 ...

Page 368: ...207S Mounting sleeve T1215 Pressing tool T1216 Vacuum T1240S 366 H00881 01 H00886 01 H00887 01 H00890 01 Art no T1207S Art no T1215 Feature I Diameter Art no T1216 Feature I Diameter Art no T1240S 118 mm 0 71 in I 38 49 mm 1 5 1 93 in ...

Page 369: ...0896 01 H00922 01 H00923 01 Art no T1401 Feature I Diameter Art no T1403S Feature Diameter Diameter Art no T14040S Feature I Diameter Art no T14047 Feature Drive Narrow diameter Wide diameter 33 SPECIAL TOOLS I 48 mm 1 89 in 48 mm 1 89 in 60 mm 2 36 in I 48 mm 1 89 in 1 2 in 34 mm 1 34 in 42 7 mm 1 681 in 367 ...

Page 370: ... Pressing tool T1504 Mounting tool T150S 368 H00924 01 H00926 01 H00899 01 H00852 01 Art no T14049S Feature Diameter Diameter Art no T14051 Feature I Diameter Art no T1504 Feature I Diameter Art no T150S 8 mm 0 31 in 24 8 mm 0 976 in I 50 mm 1 97 in 118 mm 0 71 in ...

Page 371: ...33 SPECIAL TOOLS Filling tool 2x 3x Art no T170S1 T170S1 H00855 01 369 ...

Page 372: ... 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 373: ...35 LIST OF ABBREVIATIONS Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly 371 ...

Page 374: ...changing 158 rear brake checking 157 372 Capacity coolant 256 277 engine oil 180 260 277 fuel 277 Cartridge of fork legs disassembling 24 of the fork legs assembling 31 Chain checking cleaning 131 134 Chain guide checking 131 Chain tension adjusting 130 checking 129 Charging voltage checking 147 Chassis number 11 Clutch fluid level checking correcting 250 fluid changing 251 Clutch lever basic posi...

Page 375: ...nstalling 217 valves removing 213 Engine working on the individual parts camshaft bearing changing clutch checking 214 219 countershaft assembling 224 countershaft disassembling 224 engine case section left 199 main shaft assembling 222 rocker arm installing 218 water pump removing 202 Engine assembly alternator cover installing 246 camshaft installing 244 clutch cover installing 238 clutch discs ...

Page 376: ...ioner removing 185 timing chain tensioning rail removing 187 timing chain removing 188 valve cover removing 183 water pump cover removing 189 Engine guard installing 50 removing 50 Engine number 12 Engine oil adding 260 changing 258 Engine oil level checking 257 Engine oil pressure checking 261 Engine sprocket checking 131 374 F Figures 10 Filler cap closing 97 opening 96 Foot brake lever basic po...

Page 377: ...ng the glass fiber yarn filling 89 installing 88 removing 88 spark arrestor cleaning 91 Manifold installing 86 removing 84 Motorcycle cleaning 282 lift stand raising with 14 removing from lift stand 14 0 Oil circuit Oil filter changing Oil pressure regulator valve 257 258 installing 202 removing 201 spring length checking 201 Oil screens cleaning 258 Open circuit current checking 147 Operating sub...

Page 378: ...20 Spring fork legs removing 23 Starter motor checking 270 Starter relay checking 144 Starting 14 15 Stator installing 265 removing 264 Steering head bearing changing 42 lubricating 37 376 Steering head bearing play adjusting 43 checking 41 Storage 284 Swingarm checking installing removing 77 79 78 Swingarm bearing T changing 81 checking 77 Technical data capacities 277 chassis 277 chassis tighten...

Page 379: ...ge 3 of 6 324 Page 3 of 8 292 308 336 Page 4 of 6 326 Page 4 of 8 294 310 338 Page 5 of 6 328 Page 5 of 8 296 312 340 Page 6 of 6 330 Page 6 of 8 Page 7 of 8 Page 8 of 8 298 314 342 300 316 344 302 318 346 Work rules 9 INDEX 377 ...

Page 380: ...11111111111111111111IIIIIIIIIIII 3403030en 07 2017 Husqvarna MOTORCYCLES Husqvarna Motorcycles GmbH fiiiHiAvl StallhofnerstraBe 3 5230 Mattighofen Austria llmi LZZa O www husqvarna motorcycles com __ __ Photo Mitterbauer Husqvarna Motorcycles GmbH ...

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