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Husqvarna F2303Q0, Repair Manual

The Husqvarna F2303Q0 Repair Manual is a comprehensive guide designed to help users troubleshoot and fix issues with their Husqvarna F2303Q0 model. Available for free download at manualshive.com, this manual ensures easy access to step-by-step instructions, enabling users to efficiently repair their equipment and enhance its longevity.

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17  ENGINE 

17.3.13  Removing the piston 

17.3.14  Removing the rotor 

178 

-

Push the cylinder upward.

Info 

Only push the cylinder as far up as necessary to take 
the piston pin out. 

Remove piston ring lock 

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. 

-

Remove cylinder base gasket  (D.

Info 

Ensure locating pins 

8 

remain in place. 

-

Remove timing chain guide rail 

C, 

from the top.

-

Remove nut 

O 

with the spring washer.

Summary of Contents for F2303Q0

Page 1: ...PIONEERING SINCE 1903 REPAIR MANUAL2017 FS 450 Art no 3403050en Husqvarna MOTORCYCLES ...

Page 2: ......

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

Page 4: ...ling the air cartridge 25 6 15 6 16 6 17 6 18 6 19 6 20 6 21 6 22 Disassembling the shock absorber cartridge 26 Checking the fork legs 28 Assembling the shock absorber cartridge 29 Assembling the air cartridge 31 Assembling the fork legs 33 Lubricating the steering head bearing 39 Removing the lower triple clamp 39 Installing the lower triple clamp 40 6 23 Checking steering head bearing play 42 6 ...

Page 5: ...ight side cover 100 12 5 Removing the seat 100 12 6 Mounting the seat 101 12 7 Removing the fuel tank 102 TABLE OF CONTENTS 12 8 Installing the fuel tank 103 12 9 Checking the fuel pressure 105 12 10 Changing the fuel pump 106 12 11 Changing the fuel filter 109 12 12 Changing the fuel screen 112 13 MASK FENDER 114 13 1 Removing front fender 114 13 2 Installing front fender 114 13 3 Removing the st...

Page 6: ...ump cover 180 17 3 19 Removing the clutch cover 181 17 3 20 Removing the clutch discs 181 17 3 21 Removing the clutch basket 182 17 3 22 Removing the torque limiter 183 17 3 23 Removing the starter idler gear 183 17 3 24 Removing the force pump 183 17 3 25 Removing the shift shaft 184 17 3 26 Removing the shift drum locating unit 185 17 3 27 Removing the locking lever 185 17 3 28 primary gear whee...

Page 7: ...17 5 10 Installing the shift drum locating unit 227 17 5 11 Installing the shift shaft 227 TABLE OF CONTENTS 17 5 12 Installing the force pump 227 17 5 13 Installing the starter idler gear 228 17 5 14 Installing the torque limiter 229 17 5 15 Installing the clutch basket 229 17 5 16 Installing the clutch discs 230 17 5 17 Installing the clutch cover 231 17 5 18 Installing the water pump cover 232 ...

Page 8: ... 270 25 1 Engine 270 25 2 Tolerance engine wear limits 271 25 3 Engine tightening torques 271 25 4 Capacities 273 25 4 1 Engine oil 273 25 4 2 Coolant 273 25 4 3 Fuel 273 25 5 Chassis 273 25 6 Electrical system 274 25 7 Tires 274 25 8 Fork 275 25 9 Shock absorber 275 25 10 Chassis tightening torques 276 26 CLEANING PROTECTIVE TREATMENT 278 26 1 Cleaning the motorcycle 278 27 STORAGE 280 27 1 Stora...

Page 9: ...tips Indicates the result of a testing step V Indicates a voltage measurement A Indicates a current measurement 0 Indicates a resistance measurement Indicates the end of an activity including potential rework 1 2 Formats used The typographical formats used in this document are explained below Proprietary name Name Brand Underlined terms Indicates a proprietary name Indicates a protected name Indic...

Page 10: ...s permanent injury if the appropriate measures are not taken Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken Caution Identifies a danger that may lead to minor injuries if the appropriate measures are not taken Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not ta...

Page 11: ...r to the environment Do not allow fuel to enter the groundwater the soil or the sewage system Use the operating and auxiliary substances such as fuel and lubricants specified in the manual 3 3 S are arts accessories Only use spare parts and accessories approved and or recommended by Husqvarna Motorcycles Husqvarna Motorcycles accepts no liability for other products and any resulting damage or loss...

Page 12: ...10 4 4 Fork Rart number 401947 10 10 The vehicle identification number O is stamped on the right side of the steering head The type label O is fixed to the front of the steering head The engine number O is stamped on the left side of the engine The fork part number O is stamped on the inside of the axle clamp ...

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

Page 14: ...gned only for the weight of the vehicle Park the vehicle on a firm and level surface Ensure that nobody sits on the vehicle when the vehicle is parked on a stand 5 3 Note 402001 10 Starting the vehicle Danger Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle insert plug in stand O into the left side of the wheel spindle Info Remove the plug in stand before ridi...

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

Page 16: ...led The time con suming mounting of harder or softer fork springs is not required If the air chamber loses air due to a damaged seal the fork will still not sag In this case the air is retained in the fork The sus pension travel is maintained as far as possible The damping becomes harder and the riding comfort reduces As with a conventional fork the damping can be adjusted in rebound and compressi...

Page 17: ...Preparatory work Raise the motorcycle with a lift stand 0 p 12 Main work Remove protection cap O Push together fork airpump 8 fully I Fork airpump 79412966000 0 p 304 Info I The fork airpump is included as part of the motorcy cle s accessory pack Connect the fork airpump to the left fork leg The fork airpump indicator switches on automatically A little air escapes from the fork leg when connecting...

Page 18: ...O clockwise all the way Info Adjusting screw O is located at the upper end of the right fork leg Turn counterclockwise by the number of clicks correspond ing to the fork type Guideline Compression damping Comfort Standard Sport Info 15 clicks 12 clicks 9 clicks I Turn clockwise to increase damping turn counter clockwise to reduce damping Adjusting the rebound damping of the fork Info The hydraulic...

Page 19: ...excess pressure escapes from the interior of the fork Tighten the bleeder screws Finishing work Remove the motorcycle from the lift stand a p 12 Cleaning the dust boots of the fork legs Preparatory work Raise the motorcycle with a lift stand a p 12 Remove the fork protector a p 19 Main work Push dust boots O of both fork legs downward Info I The dust boots remove dust and coarse dirt parti cles fr...

Page 20: ...rk legs I Universal oil spray 8 p 293 Press the dust boots back into their installation position Remove excess oil Finishing work Install the fork protector al p 20 Remove the motorcycle from the lift stand 8 p 12 Preparatory work Raise the motorcycle with a lift stand 0 p 12 Remove the front wheel 0 p 120 Main work Remove screws O and take off the clamp Allow the brake caliper and brake line to h...

Page 21: ... edge of the upper triple clamp The air suspension is located in the left fork leg The pressure and rebound damping is located in the right fork leg Tighten screws 8 Guideline Screw top triple clamp Tighten screws Guideline M8 Screw bottom triple M8 clamp 17 Nm 12 5 lbf ft 12 Nm 8 9 lbf ft Position the brake line and clamp Mount and tighten screws e Finishing work Install the front wheel 8 p 121 R...

Page 22: ...rews Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Danger of accidents Disassembling pressurized parts can cause injuries The fork is filled with compressed air Please follow the description provided 0 Q 311645 01 Condition The fork legs have been removed Disassemble the fork legs 0 p 21 Disassemble the air cartridge 0 p 25 Disassemble the shock absorber cartridge 0 p 26 Check the fork le...

Page 23: ...4 10 Condition The fork legs have been removed Left fork leg Clamp the fork leg in the area of the lower triple clamp I Clamping stand T1403S al p 310 Release cartridge O using special tool 8 I Ring wrench T14017 8 p 310 Info The cartridge cannot be taken off yet Unclamp the fork leg Drain the fork oil Clamp the fork leg with the axle clamp Guideline I Use soft jaws Remove protection cap f Remove ...

Page 24: ...slide bearing Guideline 1 so 0 c 122 F Pull the outside fork tube off the inside fork tube with a jerk Info The lower slide bearing D must be drawn out of its bearing seat Remove upper slide bearing Info Without using a tool pull the stack slightly apart by hand Take off lower slide bearing D Take off support ring fD Take off seal ring Take off lock ring 0 Take off dust boot C Unclamp the fork leg...

Page 25: ...sion damping Open the adjusters of the rebound and compression damping completely Clamp the fork leg in the area of the lower triple clamp I Clamping stand T1403S ll I p 310 Remove the screw Remove adjuster 8 on compression damping Loosen cartridge C Ring wrench T14017 0 p 310 Info The cartridge cannot be taken off yet Unclamp the fork leg Drain the fork oil 23 ...

Page 26: ...he cartridge Remove dust boot D Remove lock ring Info The lock ring has a beveled end where a screw driver can be applied Warm up the outside fork tube in area 9 of the lower slide bearing Guideline I so 0 c 122 F Pull the outside fork tube off the inside fork tube with a jerk Info The lower slide bearing must be drawn out of its bearing seat ...

Page 27: ...illed with compressed air Please follow the description provided 0 e B03552 10 Preparatory work Disassemble the fork legs a p 21 Main work Remove protection cap O Slowly release the pressure from the air cartridge Info I Hold the piston rod in extended position to allow the air pressure to balance between the positive air cham ber and the negative air chamber Remove valve core 8 Clamp the air cart...

Page 28: ... Remove end stop Remove spring 0 with spring support and spring sup port Ci Remove seal ring retainer 0 6 15 Disassembling the shock absorber cartridge 26 Preparatory work Disassemble the fork legs 8 p 21 Main work Allow oil to drain from breathing hole O Degrease and clamp the top of the shock absorber cartridge I Clamping stand T14072 8 p 311 Loosen screw cap 8 1 Special socket T14084 0 p 311 Re...

Page 29: ...er cartridge f Guideline I so 0 c 122 F Loosen seal ring retainer 0 Remove piston rod with seal ring retainer and shock absorber unit Degrease piston rod and clamp underneath spring I Clamping stand T14016S 0 p 310 Heat up the thread area of piston retainer 6 Guideline I so 0 c 122 F Remove piston retainer 6 with the shock absorber unit Remove adjustment valve Qi with the spring from the piston ro...

Page 30: ...amage is found Change the inside fork tube Measure the outside diameter of the inside fork tube at sev eral places Outside diameter of the inside fork tube 47 975 48 005 mm 1 88878 1 88996 in If the measured value is less than the specified value Change the inside fork tube Measure the run out of the inside fork tube Run out of the inside fork tube 0 20 mm 0 0079 in If the measured value is greate...

Page 31: ...he surface is rough Change the slide bearing Check the piston rod for damage If damage is found Replace the piston rod Measure the outside diameter of the piston rod at several locations Outside diameter of the pis 11 965 mm 0 47106 in ton rod If the measured value is less than the specified value Replace the piston rod Measure the run out of the piston rod I Run out of the piston rod I s 0 40 mm ...

Page 32: ...f adjustment valve I Lubricant T158 0 p 292 Mount and tighten piston retainer 0 with shock absorber unit Guideline Piston retainer on piston rod M9x1 20 Nm 14 8 lbf ft Loctite 2701 TM Clamp the shock absorber cartridge at the bottom I Clamping stand T14072 0 p 311 Lubricate friction ring on the shock absorber cartridge I Fork oil SAE 4 48601166S1 0 p 291 Push the piston rod into the shock absorber...

Page 33: ...bricate seals G and friction rings 4D I Fork oil SAE 4 48601166S1 8 p 291 Lubricate O ring 41 on the screw cover I Lubricant T158 8 p 292 Mount the screw cover with pressure stage unit tighten with special tool Guideline Pressure stage unit M44x1 40 Nm 29 5 lbf ft on shock absorber cartridge I Special socket T14084 8 p 311 Assembling the air cartridge 803556 10 Slot special tool O over thread on p...

Page 34: ... Piston on piston M12x1 rod 20 Nm 14 8 lbf ft Loctite 2701 TM Lubricate piston in area of f and inside of the cartridge Grease capacity left cartridge Clamp the air cartridge 11 ml 0 37 fl oz I Clamping stand T14072 a p 311 Push the piston rod into the air cartridge Multi purpose grease 00062010051 a p 293 Lubricate O ring 0 of seal ring retainer 8 I Lubricant T158 a p 292 Mount and tighten the se...

Page 35: ...axle clamp Guideline I Use soft jaws Mount the special tool I Protecting sleeve T1401 IUI p 310 Grease and push on dust boot O I Lubricant T14034 IUI p 292 The sealing lip is mounted with the spring expander facing down Info I Always change the dust boot seal ring lock ring and support ring Push on lock ring 8 Grease and push on seal ring fD I Lubricant T14034 IUI p 292 The sealing lip points down...

Page 36: ...ith the longer side of the special tool I Mounting tool T14040S 0 p 311 Slide on the outside fork tube Press the slide bearing all the way into the outside fork tube Position the support ring Hold the seal ring with the shorter side of the special tool I Mounting tool T14040S 8 p 311 Press the seal ring and support ring all the way into the outside fork tube Mount lock ring 8 The lock ring engages...

Page 37: ...be Lubricate O ring I Lubricant T158 8 p 292 Mount and tighten the screw Guideline Screw air cartridge M20x1 on axle clamp 45 Nm 33 2 lbf ft Clamp the left fork leg vertically Guideline I Use soft jaws Fill with fork oil Oil capacity exter nal mechanism left 200 8 ml 6 76 l g fl oz Fork oil SAE 4 48601166S1 8 p 291 Lubricate O ring fD on the air cartridge I Lubricant T158 8 p 292 Push the outside ...

Page 38: ...e sealing lip is mounted with the spring expander facing down Info Always change the dust boot seal ring lock ring and support ring Push on lock ring 8 Grease and push on seal ring 8 I Lubricant T14034 ral p 292 The sealing lip points downward the open side upward Remove the special tool Push on support ring C Sand the edges of the slide bearings with 600 grit sand paper then clean and grease the ...

Page 39: ...he outside fork tube Position the support ring Hold the seal ring with the shorter side of the special tool I Mounting tool T14040S alp 311 Press the seal ring and support ring all the way into the outside fork tube Mount lock ring 8 The lock ring engages audibly Mount dust boot O Assemble the individual components that belong together Info Shock absorber cartridge right fork leg cartridge with si...

Page 40: ... ml 6 76 il fl oz 45 Nm 33 2 lbf ft Fork oil SAE 4 48601166S1 a p 291 Lubricate O ring on the shock absorber cartridge I Lubricant T158 a p 292 Push the outside fork tube upwards and screw in the shock absorber cartridge Clamp the outside fork tube in the area of the lower triple clamp I Clamping stand T1403S a p 310 Tighten the shock absorber cartridge Guideline Damper cartridge on outer tube M51...

Page 41: ...ew and rebound adjusting screw 48 clockwise all the way Turn the adjusting screws to the position they were in before removing Mount protection cap 8 6 20 Lubricating the steering head bearing 9 H02387 01 6 21 Removin the lower tri Remove the lower triple clamp ra l p 39 Install the lower triple clamp ra l p 40 Info The steering head bearing is cleaned and lubricated in the course of removal and i...

Page 42: ...bles and lines Remove 0 ring 8 Remove protective ring 0 Remove the lower triple clamp with the steering stem Remove the upper steering head bearing 6 22 Installing the lower tri le clam 800221 10 40 Main work Clean the bearing and sealing elements check for damage and grease I High viscosity grease 8 p 292 Insert the lower triple clamp with the steering stem Mount the upper steering head bearing C...

Page 43: ...rooves are milled into the side of the upper end of the fork legs The second milled groove from the top must be flush with the upper edge of the upper triple clamp The air suspension is located in the left fork leg The pressure and rebound damping is located in the right fork leg Tighten screws Q Guideline Screw bottom triple MS clamp Tighten screw C Guideline Screw top steering head M20x1 5 Mount...

Page 44: ...15 Install the front wheel 8 p 121 Check that the wiring harness throttle cables and brake and clutch lines can move freely and are routed correctly Check steering head bearing play 8 p 42 Remove the motorcycle from the lift stand 8 p 12 Checking steering head bearing play Warning Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components Co...

Page 45: ...just steering head bearing play a p 44 Check the steering head bearing and adjust if neces sary Finishing work Remove the motorcycle from the lift stand a p 12 Changing the steering head bearing Preparatory work Raise the motorcycle with a lift stand a p 12 Remove the handlebar cushion Remove the front wheel a p 120 Remove the fork legs a p 18 Remove the start number plate a p 115 Remove front fen...

Page 46: ... new seal ring Press on the new bearing with a suitable tube as far as it will go Finishing work Install the lower triple clamp i ll p 40 Mount the handlebar cushion Install front fender 0 p 114 Install the start number plate 0 p 115 Install the front wheel 0 p 121 Check that the wiring harness throttle cables and brake and clutch lines can move freely and are routed correctly Check steering head ...

Page 47: ...tic hammer tap lightly on the upper triple clamp to avoid stresses Mount and tighten screw Guideline Screw top M8 steering stem 20 Nm 14 8 lbf ft Loctite 243 Tighten screws O Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Check steering head bearing play 8 p 42 Finishing work Mount the handlebar cushion Remove the motorcycle from the lift stand 8 p 12 45 ...

Page 48: ...mps Remove the handlebar and lay it to one side Info Cover the components to protect them against dam age Do not kink the cables and lines Remove screws Take off the handlebar supports Place the handlebar supports in the required position Info The handlebar supports are longer and higher on one side Position the left and right handlebar supports evenly Mount and tighten screws 8 Guideline Screw ha...

Page 49: ...moves closer to the handlebar The range of adjustment is limited Only turn the adjusting screw by hand and do not use force Do not make any adjustments while riding Check the rubber grips on the handlebar for damage wear and looseness Info The rubber grips are vulcanized onto a sleeve on the left and onto the handle tube of the throttle grip on the right The left sleeve is clamped onto the handleb...

Page 50: ...outing Finishing work Install the fuel tank 0 p 103 Mount the seat 0 p 101 Install the air filter box cover a p 96 Install the right side cover a p 100 7 6 Checkin throttle cable play Check the throttle grip for smooth operation Move the handlebar to the straight ahead position Turn the throttle grip back and forth slightly and determine the play in throttle cable f I Throttle cable play I 3 5 mm ...

Page 51: ... secured the fuel tank does not need to be removed Preparatory work Remove the right side cover a p 100 Remove the air filter box cover a p 96 Remove the seat 0 p 100 Remove the fuel tank 0 p 102 Check throttle cable routing 0 p 48 Main work Move the handlebar to the straight ahead position Push back sleeve O Loosen nut Turn adjusting screw D in as far as possible Loosen nut 8 Push cold start butt...

Page 52: ...ables and take off the grip tube Remove guide plate 8 from handle tube 0 Position the required guide plate on the grip tube Guideline The label OUTSIDE must be visible Marking f must be positioned at marking G I Grey guide plate 79002014000 Alternative 1 I Black guide plate 79002014100 Info I The gray guide plate opens the throttle valve more slowly The black guide plate opens the throttle valve m...

Page 53: ...Position half shells 6 mount and tighten screws 4i Guideline I Screw throttle grip I M6 I 5 Nm 3 7 lbf ft Slide on sleeve O and check the throttle grip for ease of movement Finishing work Check throttle cable play 8 p 48 51 ...

Page 54: ...Repair of the frame is not authorized by Husqvarna Motorcycles The procedures are the same on both footrests D02603 10 Condition The frame protectors have been removed on the left and right Remove pin O and take off the washer Press the spring with special tool 8 1 Footrest spring plier 79029083000 0 p 304 The special tool is applied to area f on the footrest Remove pin Position the new footrest a...

Page 55: ...g as shown Spring G engages in area Press the spring with special tool 8 I Footrest spring plier 79029083000 ll I p 304 The special tool is applied to area f on the footrest Mount pin 8 Mount the washer and splint O FRAME 8 53 ...

Page 56: ...nfo I Do not loosen fitting 81 Turn counterclockwise by the number of turns corresponding to the shock absorber type Guideline Highspeed compression damping Comfort Standard Sport Info 2 5 turns 2 turns 1 5 turns I Turn clockwise to increase damping turn counter clockwise to reduce damping 9 2 Adjusting the low speed compression damping of the shock absorber A 54 Caution Risk of injury rectly Part...

Page 57: ...damping Adjusting the rebound dam ing of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incor rectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Turn adjusting screw O clockwise up to the last perceptible click F00376 10 Turn counterclockwise by the number of clicks cor...

Page 58: ...torcycle from the lift stand 8 p 12 Checking the static sag of the shock absorber Measure dimension 6 of rear wheel unloaded 8 p 56 Hold the motorcycle upright with the aid of an assistant Measure the distance again between the rear axle and mark ing SAG on the rear fender using the sag gage Note down the value as dimension Cs Info The static sag is the difference between measure ments 6 and Cs Ch...

Page 59: ...e as dimension 9 Info The riding sag is the difference between measure ments G and 9 Check the riding sag Guideline I Riding sag I Bomm 3 15in If the riding sag differs from the specified measurement Adjust the riding sag 8 p 58 reload of the shock absorber Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incor rectly The shock absorber is filled with h...

Page 60: ...rew shock M5 absorber adjusting ring Finishing work Install the shock absorber 0 p 60 5 Nm 3 7 lbf ft Remove the motorcycle from the lift stand 0 p 12 Check the free travel of the foot brake lever 0 p 152 Preparatory work Raise the motorcycle with a lift stand 0 p 12 Remove the shock absorber 0 p 59 After removing the shock absorber clean it thoroughly Main work Choose and mount a suitable spring ...

Page 61: ...hock absorber Preparatory work Raise the motorcycle with a lift stand 8 p 12 Main work Remove the cable ties Remove screws O Remove screws 8 with the washers Remove the frame protectors on the left and right Remove screw fD Remove fitting C Info I Raise the wheel slightly to be able to remove the screws more easily Press angle lever 0 toward the rear Press linkage lever D downward Remove screws Pu...

Page 62: ...t the fork pivot Push the link fork back and secure it against falling over Hold the shock absorber and remove screw Remove the shock absorber carefully at the bottom Installing the shock absorber Main work Carefully position the shock absorber into the vehicle from the bottom Mount and tighten screw O Guideline Screw top M10 shock absorber 60 Nm 44 3 lbf ft Loctite 2701 TM ...

Page 63: ...brake cylinder Push rod 8 engages in the foot brake cylinder Info I Ensure that the dust boot is correctly seated Mount and tighten screws 0 Guideline Remaining screws chassis M6 Position the angle lever and linkage lever Mount and tighten fitting D Guideline Nut linkage lever to M14x1 5 angle lever Info I Pay attention to flat area 0 Mount and tighten screw Guideline 10 Nm 7 4 lbf ft 80 Nm 59 lbf...

Page 64: ...e pro tector M5 Mount the new cable ties Finishing work 3 Nm 2 2 lbf ft Remove the motorcycle from the lift stand 8 p 12 Check the free travel of the foot brake lever 8 p 152 Checking the shock absorber linkage Preparatory work Raise the motorcycle with a lift stand 0 p 12 Main work Remove screw O Remove fitting 8 Info Raise the wheel slightly to be able to remove the screws more easily Remove fit...

Page 65: ...wear Change the spacers Check the shaft seal rings for damage and wear If there is damage or wear Change the shaft seal rings Check dimension f 303096 10 I 54 91 55 00 mm 2 1618 2 1654 in If dimension f is below the specified value Add the necessary spacing washers Position the angle lever Mount fitting 8 but do not tighten yet Guideline Nut angle lever to link fork M14x1 5 80 Nm 59 lbf ft 63 ...

Page 66: ...to be able to mount the screw more easily Tighten screws O Guideline Screw bottom M10 shock absorber Tighten fitting Ci Guideline Nut angle lever to link fork Finishing work M14x1 5 60 Nm 44 3 lbf ft Loctite 2701 TM 80 Nm 59 lbf ft Remove the motorcycle from the lift stand 8 p 12 Servicing the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber ...

Page 67: ...im joint 0 p 72 Assemble the seal ring retainer 0 p 72 Assemble the piston rod 0 p 73 Assemble the damper IUI p 75 Install the spring IUI p 81 Condition The shock absorber has been removed Clamp the shock absorber into the vise Guideline I Use soft jaws Measure and note the spring length while the spring is under tension Loosen screw O Turn the adjusting ring until the spring is completely without...

Page 68: ...Main work Make a note of the present state of rebound O and com pression damping Open the adjusters of the rebound and compression damp ing completely Slowly open screw The nitrogen pressure dissipates Remove the screw with the 0 ring Remove locking cap 8 Press in seal ring retainer 0 using the special tool Pressing tool T1216 alp 309 ...

Page 69: ...Check inner surface do not scratch Remove any burrs with sandpaper if necessary Remove the piston rod Remove adjusting ring with the clamping ring Drain the oil Remove compression adjuster Remove the spring and piston 41 Preparatory work Remove the spring 0 p 65 Disassemble the damper 0 p 66 67 ...

Page 70: ...k onto a screwdriver and put them aside together Remove piston C Remove compression shim stack 0 Info Guide the compression shim stack onto a screwdriver and put them aside together Remove rebound washer D Remove seal ring retainer Remove locking cap and rubber buffer Disassembling the seal ring retainer Preparatory work Remove the spring 8 p 65 Disassemble the damper 8 p 66 Disassemble the piston...

Page 71: ...move washer 3 from seal ring 0 Remove washer Remove dust boot 9 17 Changing the pilot bushing 200796 10 Preparatory work Remove the spring a p 65 Disassemble the damper a p 66 Disassemble the piston rod a p 67 Disassemble the seal ring retainer a p 68 Main work Press pilot bushing O out of seal ring retainer 8 with the special tool I Pressing tool T1504 a p 312 69 ...

Page 72: ...rt seal ring retainer 8 with sleeve 9 of the special tool I Mounting tool T150S 0 p 312 Press the special tool through the new pilot bushing I Calibrating unit T1205 8 p 308 The pilot bushing is calibrated Finishing work Assemble the seal ring retainer 8 p 72 Condition The damper has been disassembled Measure the inside diameter on both ends and in the middle of the damper cartridge Damper cartrid...

Page 73: ...fied value Change the piston rod Check the piston rod for damage and wear If there is damage or wear Change the piston rod Check the piston rings for damage and wear If damage or a bronze colored surface is visible Change the piston Condition The shock absorber has been removed Clamp the shock absorber into the vise Guideline I Use soft jaws Remove both collar bushings O of the heim joint with a s...

Page 74: ...e bench vise Guideline I Use soft jaws I Pressing tool T1206 IOI p 308 Press the heim joint all the way in Press the heim joint against the lock ring using the special tool I Pressing tool T1207S IOI p 309 Mount second lock ring 8 Position both collar bushings D and press in Mount dust boot O with the special tool I Mounting sleeve T1204 0 p 308 Grease the sealing lip of the dust boot I Lubricant ...

Page 75: ...ng D Mount rebound rubber Grease the 0 ring groove I Lubricant T158 8 p 292 Mount 0 ring Preparatory work Assemble the seal ring retainer 8 p 72 Main work Clamp the piston rod with the fork in a bench vise Guideline I Use soft jaws Mount rubber buffer O and locking cap Position special tool on the piston rod I Mounting sleeve T1515 8 p 312 Grease the dust boot and slide the seal ring retainer onto...

Page 76: ... with the smaller washers facing downward Sand down piston D on both sides on a surface plate using 1200 grit sandpaper Clean the piston Mount the piston Guideline ViewO ViewG of piston from above of piston from below Mount rebound shim stack with the smaller washers fac ing upward Mount washer fD with the groove facing downward ...

Page 77: ...158 0 p 292 Lubricate the thread I Lubricant T159 8 p 293 Mount the piston with the spring Mount and tighten compression adjuster O Guideline Compression damp M31x1 ing adjuster Clamp the damper in a bench vise Guideline I Use soft jaws 35 Nm 25 8 lbf ft Mount adjusting ring 8 with the clamping ring Info The adjusting ring cannot be mounted after the piston rod has been mounted Fill the damper car...

Page 78: ... counterclockwise by the number of clicks corre sponding to the shock absorber type Guideline Lowspeed compression damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Turn adjusting screw fD all the way clockwise with a socket wrench Turn counterclockwise by the number of turns corre sponding to the shock absorber type Guideline Highspeed compression damping Comfort 2 5 turns Standard 2 t...

Page 79: ...nd in the location determined during disassembly Bleeding and filling the dam er Info Before working with the vacuum pump carefully read the operating manual included with the vacuum pump Open the adjusters of the rebound and compression damping completely Clamp the damper as shown Guideline I Use soft jaws Info I The filling port must be located at the highest position The piston rod moves in and...

Page 80: ...tool I Depth micrometer T107S al p 307 The floating piston is located in the lowermost position When the vacuum gauge reaches the required value turn control lever Oil reservoir 0 to Equalize pressure Guideline 14 mbar The pressure gauge increases to the required value 0 bar When the pressure gauge reaches the specified value turn control lever Damper C to Pressure Guideline 0 bar Oil is pumped in...

Page 81: ...per 8 to Pressure Guideline 0 bar Oil is pumped into the damper The pressure gauge increases to the required value 3 bar When the pressure gauge reaches the specified value turn control lever Damper 8 to Vacuum Guideline 3 bar The pressure gauge drops to the required value 0 bar When the pressure gauge reaches the required value acti vate the On Off switch Guideline 0 bar The vacuum pump is switch...

Page 82: ...damper with nitrogen B04383 10 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 Filling tool T170S1 IUI p 312 Filling adapter T1296 8 p 309 Connect the special tool to the pressure regulator of the filling cylinder I Filling gas nitrogen Adjust the pressure regulator Guideline I ...

Page 83: ...O is mounted with the clamping ring Mount washer 8 Measure the total spring length while the spring is not under tension Position the spring Guideline Spring rate Weight of rider 65 75 kg 143 165 lb Weight of rider 75 85 kg 165 187 lb Weight of rider 85 95 kg 187 209 lb Mount washer 8 Mount spring retainer C Mount lock ring 0 Alternative 1 45 N mm 257 lb in 48 N mm 274 lb in 51 N mm 291 lb in Tens...

Page 84: ...handling characteristic Tension the spring to the length measured during disas sembly by turning the adjusting ring I Hook wrench 90129051000 8 p 307 Tighten screw D Guideline Screw shock MS 5 Nm 3 7 lbf ft absorber adjusting ring Check the link fork for damage cracking and deformation If the link fork exhibits damage cracking or deformation Change the link fork Info I Always replace a damaged lin...

Page 85: ... p 86 Finishing work Remove the motorcycle from the lift stand 0 p 12 Preparatory work Raise the motorcycle with a lift stand 0 p 12 Remove the rear wheel 0 p 124 Remove the air filter box cover 0 p 96 Main work Take the brake line out of the guide Push the brake caliper forward slip it out and hang it to the side Info Cover the components to protect them against dam age Remove screw O with the wa...

Page 86: ...ve fitting C Lower the link fork Remove the cable ties Remove screws 0 Remove screws D with the washers Remove the frame protectors on the left and right Remove nut Remove the swingarm pivot Take off the link fork Main work Position the link fork Mount the fork pivot Mount and tighten nut O Guideline I Nut fork pivot I M16x1 5 1100 Nm 73 8 lbf ft I ...

Page 87: ...ighten fitting C Guideline Nut angle lever to link fork Mount the chain M14x1 5 3 Nm 2 2 lbf ft 80 Nm 59 lbf ft Connect the chain with connecting link 0 Guideline The closed side of the chain joint lock must face in the direction of travel Position the engine sprocket cover Mount and tighten screw D with the washer Guideline Screw clutch slave M6 cylinder Mount and tighten screw Guideline Remainin...

Page 88: ...tall the air filter box cover a p 96 Install the rear wheel a p 125 Remove the motorcycle from the lift stand a p 12 Preparatory work Raise the motorcycle with a lift stand a p 12 Remove the rear wheel a p 124 Remove the air filter box cover a p 96 Remove the link fork a p 83 Left fork bearing Remove collar bushings O Remove bushing fj ...

Page 89: ...s C Press out bearing 0 using a suitable tool Using a suitable tool press in new bearing 0 Position the stop disks C Press in shaft seal rings D Mount bushing Grease the shaft seal rings I Long life grease 8 p 292 Position the collar bushings O with the shoulder facing inward Right fork bearing Remove collar bushings D 87 ...

Page 90: ...Using a suitable tool press in new bearing 0 Press in shaft seal rings Mount bushing Grease the shaft seal rings I Long life grease a p 292 Position the collar bushings D with the shoulder facing inward Finishing work Install the link fork 8 p 84 Install the air filter box cover 8 p 96 Install the rear wheel 8 p 125 Remove the motorcycle from the lift stand a p 12 ...

Page 91: ...hange the heim joint 0 p 89 Finishing work Remove the load from the front of the vehicle Remove the motorcycle from the lift stand ra l p 12 Preparatory work Raise the motorcycle with a lift stand 0 p 12 Remove the shock absorber 0 p 59 Main work Clamp the shock absorber into the vise Guideline I Use soft jaws Remove both collar bushings O of the heim joint with a spe cial tool I Drift T120 ra l p...

Page 92: ... Guideline I Use soft jaws I Pressing tool T1206 0 p 308 Press the heim joint all the way in Press the heim joint against the lock ring using the special tool I Pressing tool T1207S IOI p 309 Mount second lock ring 8 Position both collar bushings O and press in Finishing work Install the shock absorber 0 p 60 Check the free travel of the foot brake lever 0 p 152 Remove the motorcycle from the lift...

Page 93: ...r 0 p 100 Remove the main silencer 0 p 93 Main work Remove screw O Remove fitting 8 Info Raise the link fork slightly to be able to remove the screws more easily Press angle lever 8 toward the rear Press linkage lever C downward Detach springs 0 I Spring hook 5030501700004 0 p 307 Remove screw D Remove screws Take off the engine brace 91 ...

Page 94: ...er and mount and tighten screw O Guideline Screw top M10 shock absorber 60 Nm 44 3 lbf ft Loctite 2701 TM Position the engine brace Mount and tighten screws 8 Guideline Screw engine brace MB 25 Nm 18 4 lbf ft Loctite 2701 TM Mount screw D but do not tighten yet Guideline Remaining screws chassis Attach springs C MB 25 Nm 18 4 lbf ft I Spring hook 5030501700004 0 p 307 Tighten screw D ...

Page 95: ...crew more easily Mount and tighten screw D Guideline Screw bottom M10 shock absorber 60 Nm 44 3 lbf ft Loctite 2701 Finishing work Install the main silencer 0 p 94 Install the right side cover 0 p 100 Remove the motorcycle from the lift stand 0 p 12 Removin the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down be...

Page 96: ... Guideline Remaining screws chassis Finishing work M6 Install the right side cover 0 p 100 of the main silencer 10 Nm 7 4 lbf ft 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 Info I Over time the fibers of the glass fiber yarn escape and the damper burns out 94 Not only is the noise level ...

Page 97: ...be reinstalled and check for damage Mount the new glass fiber yarn filling with connecting cap onto the inner tube Position the inner tube with the connecting cap and glass fiber yarn filling in the outer tube Position the silencer cap in the outer tube Mount and tighten all of the screws Guideline Screws on main M5 silencer Finishing work Install the main silencer 0 p 94 Install the right side co...

Page 98: ...air filter box cover in areas f C and D Engine damage Unfiltered intake air has a negative effect on the service life of the engine Dust and dirt will enter the engine without an air filter Never start to use the vehicle without an air filter 96 Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly an...

Page 99: ...pin fj is secured by retaining tab D Info If the air filter is not mounted correctly dust and dirt may enter the engine and result in damage Finishing work Install the air filter box cover a p 96 Cleanin the air filter and air filter box Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in com...

Page 100: ...ver wring it out Oil the dry air filter with a high grade air filter oil I Oil for foam air filter a p 293 Clean the air filter box Clean the intake flange and check it for damage and tight ness Finishing work Install the air filter a p 97 Install the air filter box cover 0 p 96 Preparatory work Remove the air filter box cover a p 96 Main work Seal the air filter box in marked area f Finishing wor...

Page 101: ...h fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Note Environmental hazar...

Page 102: ...d and remove toward the front Installing the right side cover Removin the seat Position the side cover on collar bushings O and 8 and push toward the rear Engage the side cover in areas f and Mount and tighten screw Guideline Remaining screws chassis Preparatory work M5 Remove the air filter box cover 0 p 96 5 Nm 3 7 lbf ft ...

Page 103: ... work Mount the front of the seat on the collar bushing of the fuel tank and the rear in the bracket Push the seat forward Make sure that the seat is locked in correctly Mount and tighten screw O Guideline Remaining screws chassis Finishing work M6 Install the air filter box cover p 96 10 Nm 7 4 lbf ft 101 ...

Page 104: ...ntact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Preparatory work Remove the right side cover 0 p 100 Remove the air filter box cover 0 p 96 Remove the seat 0 p 100 Main wor...

Page 105: ...e engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact...

Page 106: ...eline Remaining screws chassis M6 Plug in connector D for the fuel pump 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft Remove the wash cap set and thoroughly clean the plug in connection of the fuel line using compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Lubricate the 0 ring and connect plug in connection 8 for the fuel line Inf...

Page 107: ...inse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Condition The fuel tank is completely full Ensure that the battery voltage does not drop below 12 5 V The diagnostic tool is discon...

Page 108: ...tion of the fuel line 12 10 Changing the fuel pump A 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 vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off i...

Page 109: ...l or the sewage system Preparatory work Drain the fuel from the fuel tank into a suitable container Remove the right side cover 0 p 100 Remove the air filter box cover 0 p 96 Remove the seat 0 p 100 Remove the fuel tank 0 p 102 Main work Remove nut O with the gasket Remove fuel connection 8 with the gasket Remove screws 8 Remove the fuel pump R00450 10 107 ...

Page 110: ...kwise and position The hoses in the tank are located in the left half of the tank The connector points downwards Mount and tighten screws Guideline I Screw fuel pump I EJOT 1 2 3 Nm 1 7 lbf ft Mount fuel connection 8 with the gasket but do not tighten yet Tighten nut O Guideline Nut fuel pump fas tener M12x1 75 Tighten fuel connection 8 Guideline Fuel connection on fuel tank Finishing work M8x1 25...

Page 111: ...tact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Note Environment...

Page 112: ...RIM R00449 10 R00450 11 305317 10 110 Remove screws 8 Remove the fuel pump Remove hose clamps C Remove fuel filter Ci Press locking mechanism Q Pull back fuel pump housing Change fuel screen CD Mount the fuel pump housing ...

Page 113: ...th gasket but do not tighten yet Pull out the fuel pump The fuel filter remains in the fuel tank Info I Make sure that the fuel filter is not pulled out too far Keep the fuel pump with hose tensioned turn clockwise and position The hoses in the tank are located in the left half of the tank The connector points downwards Mount and tighten screws Guideline I Screw fuel pump I EJOT 1 2 3 Nm 1 7 lbf f...

Page 114: ...y of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel D...

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

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

Page 117: ...f the brake line guide and start number plate Installing the start number late Position the brake line and brake line guide on the start num ber plate Mount and tighten screw O Position the start number plate The holding lugs engage in the fender Mount and tighten screw 8 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 115 ...

Page 118: ... does not meet specifications Correct the tire pressure Mount the protection cap Checkin the tire condition Info Only mount tires approved and or recommended by Husqvarna Motorcycles Other tires could have a negative effect on handling characteristics The type condition and pressure of the tires all have a major impact on the handling characteristic of the motorcycle The tires mounted on the front...

Page 119: ...the tires Checking the wheel bearing for la Preparatory work Raise the motorcycle with a lift stand 0 p 12 Place a load on the rear of the vehicle The front wheel is not in contact with the ground Main work Move the front wheel from side to side Info Hold the fork leg to check it If there is detectable play Change front wheel bearing 0 p 122 Place a load on the front of the vehicle The rear wheel ...

Page 120: ...ormation_ If the brake disc exhibits damage cracking or deforma tion Change the front brake disc ra l p 122 Change the rear brake disc 0 p 126 Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary damage The spokes break due to being overloaded if they are too tightly tensioned If the tension in the spokes is too low then lateral and radial run...

Page 121: ...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 Check for lateral and radial run out of the rims Lateral runout Outside the rim joint 1 8 ...

Page 122: ...y back from the brake disc and hang to the side loosely Info I Do not operate the hand brake lever if the brake caliper has been removed Loosen screw by several rotations Loosen screws C Press on screw 8 to push the wheel spindle out of the axle clamp Remove screw 8 Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc...

Page 123: ...disc side Insert the narrow spacer on the opposite side Clean and grease the wheel spindle I Long life grease IUI p 292 Position the front wheel and insert the wheel spindle Mount and tighten screw Guideline Screw front wheel spindle M24x1 5 45 Nm 33 2 lbf ft Position the brake caliper Mount screws with wash ers 8 but do not tighten yet The brake linings are correctly positioned Operate the hand b...

Page 124: ...atory work Raise the motorcycle with a lift stand 0 p 12 Remove the front wheel 0 p 120 Main work Remove screws O Remove the brake disc Clean the contact surface of the brake disc Position the new brake disc with the label facing outward Mount and tighten screws O Guideline Screw front brake disc Finishing work M6 Install the front wheel 8 p 121 Changing the front wheel bearing Preparatory work 14...

Page 125: ... via the outer bearing race otherwise the bearing will be damaged when it is pressed in Clean grease and mount spacing tube C I Long life grease a p 292 Press in new bearing D all the way using a suitable tool Info Only press the bearing in via the outer bearing race otherwise the bearing will be damaged when it is pressed in Grease new shaft seal rings 8 and O and press in until they are flush Fi...

Page 126: ...ve chain adjuster 8 Pull out wheel spindle 8 far enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Remove the chain from the rear sprocket Info Cover the components to protect them against dam age Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Hold ...

Page 127: ...rease IOJ p 292 Position the rear wheel and insert wheel spindle 8 The brake linings are correctly positioned Mount the chain Position chain adjuster 4D 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 IOJ p 126 Tighten nut C Guideline Nut rear wheel spin M25x1 5 die Info 80 Nm 59 lbf ft I The wide adjustment ...

Page 128: ...hain is tensioned too much the chain engine sprocket rear sprocket transmission and rear wheel bearings wear 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 specif...

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

Page 130: ...ied weight O Guideline Weight chain wear mea surement 10 15 kg 22 33 lb Measure distance G of 18 chain rollers in the lower chain section Info Chain wear is not always even so you should repeat this measurement at different chain positions Maximum distance G from 18 chain rollers at the longest chain section 272 mm 10 71 in If distance G is greater than the specified measurement Change the drivetr...

Page 131: ... ft Loctite 243 Check the chain sliding piece for wear If the lower edge of the chain pins is in line with or below the chain sliding piece Change the chain sliding piece Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten the screw on the chain sliding piece Guideline Screw chain slid MS ing piece 15 Nm 11 1 lbf ft Check the chain guide with a slide gau...

Page 132: ...ents Lubricants on the tires reduces the road grip Remove lubricants from the tires using a suitable cleaning agent Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils...

Page 133: ...otorcycle from the lift stand el p 12 Preparatory work Remove the air filter box cover el p 96 Raise the motorcycle with a lift stand el p 12 Main work Remove screw O with the washer Remove screw 8 Take off the engine sprocket cover Have an assistant operate the rear brake Remove screw with the washer Remove the rear wheel el p 124 Remove connecting link C of the chain Take off the chain Info WHEE...

Page 134: ...ft Loctite 2701 TM Slide new engine sprocket 0 onto the countershaft Mount the new chain Connect the chain with connecting link C Guideline The closed side of the chain joint lock must face in the direction of travel Install the rear wheel I p 125 Have an assistant operate the rear brake Mount and tighten screw CD with the washer Guideline Screw engine sprocket M10 60 Nm 44 3 lbf ft Loctite 2701 T...

Page 135: ...18 4 lbf ft Finishing work Remove the motorcycle from the lift stand p 12 Install the air filter box cover p 96 14 8 10 Changing the rear wheel bearing Preparatory work Raise the motorcycle with a lift stand p 12 Remove the rear wheel p 124 Main work Remove shaft seal ring O Remove lock ring Remove shaft seal ring D Using a suitable tool press bearing 8 out from the inside to the outside Remove sp...

Page 136: ...ing will be damaged when it is pressed in Clean grease and mount spacing tube 0 I Long life grease 8 p 292 Press new bearing C all the way in from the outside to the inside Info Only press the bearing in via the outer bearing race otherwise the bearing will be damaged when it is pressed in Grease new shaft seal ring CD and press it in until it is flush Mount lock ring 8 The lock ring engages audib...

Page 137: ...gine stops Remove the air filter box cover 0 p 96 Remove the seat 0 p 100 Main work Pull starter relay O from the holder Take off protection caps Remove faulty main fuse 8 Info A faulty fuse has a burned out fuse wire 6 A spare fuse C is located in the starter relay Insert a new main fuse I Fuse 58011109110 0 p 274 Check that the electrical system is functioning properly Tip I Insert a spare fuse ...

Page 138: ...l back the negative terminal cover Disconnect negative cable O from the 12 V battery ative cable of the 12 V batte T02638 10 Main work Connect negative cable O of the 12 V battery Guideline Screw battery termi M5 nal 2 5 Nm 1 84 lbf ft Contact disk 6 must be mounted under screw and cable lug fD with the claws toward the battery terminal Slide negative terminal cover over the negative terminal Fini...

Page 139: ... if the charge is already below the minimum voltage Minimum voltage before the start of the charge 9 V Dispose of 12 V batteries with less than the minimum voltage correctly H01190 10 Preparatory work Press and hold the kill switch while the engine is idling until the engine stops Remove the air filter box cover 0 p 96 Remove the seat 0 p 100 Main work Pull back negative terminal cover O and disco...

Page 140: ...ery Guideline Screw battery termi M5 nal Info 2 5 Nm 1 84 lbf ft I Contact disk G must be mounted under screw CD and cable lug 8 with the claws toward the battery terminal Slide positive terminal cover Cs over the positive terminal Connect negative cable to the 12 V battery Guideline M5 2 5 Nm 1 84 lbf ft Info Contact disk G must be mounted under screw CD and cable lug 8 with the claws toward the ...

Page 141: ... with the applicable regulations Info Even when there is no load on the 12 V battery it discharges steadily The charging level and the method of charging are very important for the service life of the 12 V battery Rapid recharging with a high charging current shortens the service life of the battery If the charging current charging voltage and charging time are exceeded the 12 V battery will be de...

Page 142: ...96 Checking the charging voltage Condition The 12 V battery must be fully functional and completely charged Preparatory work Remove the air filter box cover 0 p 96 Remove the seat l p 100 Main work Pull back the positive terminal cover Start the motorcycle to check the function 0 p 13 V Measure the voltage between the specified points Measuring point plus Measuring point Ground I Charging voltage ...

Page 143: ...n circuit cur I 1 0 mA If the measured value is greater than the specified value Disconnect the voltage regulator from the wiring har ness and perform the measurement again Check the capacitor 0 p 141 Finishing work Connect the negative cable of the 12 V battery 0 p 136 Mount the seat 0 p 101 Install the air filter box cover 0 p 96 Condition The 12 V battery is disconnected Remove the capacitor Di...

Page 144: ...apacitor Preparatory work Press and hold the kill switch while the engine is idling until the engine stops Remove the air filter box cover 8 p 96 Remove the seat ra l p 100 Disconnect the negative cable of the 12 V battery ra l p 136 Main work Pull starter relay O from the holder Unplug connector 8 Pull back the cover Detach cables from the starter relay Connect the starter relay to a 12 V power s...

Page 145: ... D to the starter relay Plug in connector 8 Mount the starter relay onto the holder and route the cables Finishing work Connect the negative cable of the 12 V battery 8 p 136 Mount the seat 8 p 101 Install the air filter box cover 8 p 96 143 ...

Page 146: ...brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Da...

Page 147: ... 8 with membrane 0 Press the brake piston back into the basic position and ensure that brake fluid does not flow out of the brake fluid reservoir extract some if necessary Press together brake linings D and remove them from the brake caliper Clean the brake caliper and spring plate Ensure that the spring plate is correctly positioned Info The arrow on the spring plate points in the direction of ro...

Page 148: ...ke fluid DOT 4 DOT 5 1 ra l p 290 Position cover C with membrane 0 Mount and tighten screws Info Clean up overflowed or spilled brake fluid immediately with water Adjusting the basic position of the hand brake lever 146 Adjust the basic position of the hand brake lever to your hand size by turning adjusting wheel O Info Push the hand brake lever forward and turn the adjusting wheel Turn the adjust...

Page 149: ...I p 147 Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the brake system is leaking or the brake linings are worn down Check the brake system and do not continue riding until the problem is eliminated Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid...

Page 150: ...T 5 1 g p 290 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilled brake fluid immediately with water Changing the front brake fluid Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with the skin ...

Page 151: ... DOT 5 1 0 p 290 Mount bleeder cover 8 I Bleeder cover 00029013002 0 p 294 Connect the bleeding device I Bleeding device 00029013100 0 p 294 Open shut off valve 8 Info I Follow the instructions in the Owner s Manual of the bleeding device Ensure that the inflation pressure is set on pressure gauge 6 Correct the inflation pressure on pressure regulator 0 if necessary Guideline I Inflation pressure ...

Page 152: ...ressure point Checkin the brake linin s of the rear brake Warning Danger of accidents Worn out brake linings reduce the braking effect Ensure that worn out brake linings are replaced immediately Check the brake linings for minimum thickness f I Minimum thickness f I 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings ll I p 150 Check the brake linings for dam...

Page 153: ... Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake ...

Page 154: ...p 290 Mount and tighten screw cap O with membrane 8 and the O ring Info Clean up overflowed or spilled brake fluid immediately with water Checking the free travel of foot brake lever Warning Danger of accidents The brake system fails in the event of overheating If there is no free travel on the foot brake lever pressure builds up in the brake system on the rear brake Set the free travel on the foo...

Page 155: ...ecessary adjust the basic position of the foot brake lever Guideline F00416 10 Free travel at foot brake lever 3 5 mm 0 12 0 2 in Hold push rod 0 and tighten nut C Guideline Remaining nuts chassis M6 Hold screw 8 and tighten nut Guideline 10 Nm 7 4 lbf ft Nut foot brake lever M8 stop 20 Nm 14 8 lbf ft Attach spring O Checking the rear brake fluid level Warning Danger of accidents An insufficient b...

Page 156: ...Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make su...

Page 157: ...with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Nev...

Page 158: ... Bleeding device 00029013100 0 p 294 Open bleeder screw 0 by approx one half turn Info I Drain until fresh brake fluid emerges in the bleeder bottle hose without bubbles Tighten the bleeder screw Close shut off valve Open the bleeder screw again until brake fluid stops emerg ing Info I Overfilling the brake fluid reservoir is prevented Tighten the bleeder screw Remove the bleeder bottle hose Attac...

Page 159: ...BRAKE SYSTEM 16 Check the foot brake lever for a firm pressure point 157 ...

Page 160: ...move the air filter box cover 0 p 96 Remove the seat 0 p 100 Remove the fuel tank 0 p 102 Remove the main silencer 0 p 93 Main work Remove the cable ties Remove screw O Remove screws 8 with the washers Remove the frame protectors on the left and right Disconnect the negative cable of the 12 V battery Loosen hose clip s Push back protection cap C Unplug the connector ...

Page 161: ...one side Push back hose clamp D and pull off the vent hose Remove screw Loosen screw C Repeat these steps on the opposite side Pivot the subframe up and secure it Remove screw 0 ENGINE 17 Pivot the shock absorber toward the rear and twist it slightly 159 ...

Page 162: ...Remove springs 41 I Spring hook 5030501700004 8 p 307 Remove screw 4D with the washer Remove screws 48 Take off the engine braces Take off the manifold Disconnect plug in connector 41 Disconnect plug in connectors 4D ...

Page 163: ...or 48 Remove the cable tie Remove the cable clamps and expose the cable Push back protection cap 0 Unplug the connector Loosen hose clip 4D Pull off the radiator hose Loosen hose clips G Pull off the radiator hoses ENGINE 17 161 ...

Page 164: ...9 Take off the engine sprocket cover Remove screws Take off the slave cylinder of the clutch and hang it to one side Info Do not kink the clutch line Do not activate the clutch lever while the slave cylin der of the clutch is removed Actuate the foot brake lever Loosen screw e Info The help of an assistant is useful in this step ...

Page 165: ...gainst dam age Remove screw Take off the engine sprocket Remove screw Ci with the washers Take off the shift lever Loosen hose clip Pull the throttle valve body off of the cylinder head toward the rear and hang it to one side Push back protection cap and remove the nut Hang the positive cable to the side 163 ...

Page 166: ...move fitting G Remove screws D Remove the foot brake cylinder and allow it to hang tension free to the side Take the brake line out of the guide Remove nut G Remove the swingarm pivot Carefully pull the link fork back and secure it ...

Page 167: ...work Position the engine in the frame Info The help of an assistant is useful in this step Make sure that the engine is sufficiently secured against falling over Cover the components to protect them against dam age Mount screws O but do not tighten yet Guideline Engine carrying screw Position the link fork Mount the fork pivot M10 Mount and tighten nut 8 Guideline 60 Nm 44 3 lbf ft I Nut fork pivo...

Page 168: ...maining screws chassis M6 Position the linkage lever Mount and tighten fitting 0 Guideline Nut linkage lever to angle lever Info M14x1 5 10 Nm 7 4 lbf ft 80 Nm 59 lbf ft Raise the wheel slightly to be able to mount the screw more easily Mount spring Cs Position the positive cable on the starter motor Mount and tighten the nut Guideline Remaining nuts chassis M6 Position protection cap 10 Nm 7 4 lb...

Page 169: ...gine Mount screw Ci with the washer but do not tighten yet Guideline Screw engine sprocket Mount the chain M10 60 Nm 44 3 lbf ft Loctite 2701TM Connect the chain with connecting link a Guideline The closed side of the chain joint lock must face in the direction of travel Actuate the foot brake lever Tighten screw Ci Guideline Screw engine sprocket M10 60 Nm 44 3 lbf ft Loctite 2701TM Info I The he...

Page 170: ... M6 Position the engine sprocket cover Mount and tighten screw I Guideline Screw clutch slave cylinder M6 Mount and tighten screw 41 Guideline Remaining screws chassis M8 Mount spark plug connector 48 Mount capacitor Gs Mount the radiator hoses Position and tighten hose clips 48 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 25 Nm 18 4 lbf ft ...

Page 171: ...otection cap Ci ENGINE 17 Route the cable without tension and secure with cable clips and cable ties Join plug in connector of the gear position sensor Join plug in connector D of the crankshaft speed sensor Join plug in connectors of the alternator Route the cables without tension 169 ...

Page 172: ... ft Loctite 2701TM 60 Nm 44 3 lbf ft Mount screw ewith the washer but do not tighten yet Guideline Remaining screws chassis Mount springs M8 25 Nm 18 4 lbf ft I Spring hook 5030501700004 0 p 307 Tighten screw e Guideline Remaining screws chassis M8 Position the shock absorber Mount and tighten screw Guideline Screw top M10 shock absorber 25 Nm 18 4 lbf ft 60 Nm 44 3 lbf ft Loctite 2701 ...

Page 173: ...uideline Screw sub frame Remove screw MB Mount and tighten screw Guideline Screw sub frame MB 30 Nm 22 1 lbf ft Loctite 2701 TM 30 Nm 22 1 lbf ft Loctite 2701 TM Repeat the operation on the opposite side Mount the vent hose and position hose clamp Ci Mount rollover sensor Ci Plug in the connector Mount protection cap G 171 ...

Page 174: ...e left and right Mount and tighten screw Guideline Screw frame pro tector M5 3 Nm 2 2 lbf ft Mount and tighten screws G with the washers Guideline Screw frame pro tector Mount the cable ties M5 3 Nm 2 2 lbf ft Remove filler plug s with the O ring and fill up with engine oil Engine oil 1 20 I Engine oil 1 27 qt SAE 10W 50 l ll p 290 Mount and tighten oil filler plug s with the O ring Finishing work...

Page 175: ...Read out the fault memory using the Husqvarna Motorcycles diagnostics tool Check the engine for leak tightness Check the engine oil level p 252 Check the coolant level a p 249 Mount the special tool on the engine assembly stand Holder and fitting for work stand 79429002000 a p 305 Engine assembly stand 80329001000 a p 306 Mount the engine on the special tool Info Work with an assistant or a motori...

Page 176: ... screw plug C with the short oil screen Removing the clutch push rod Removing the oil filter Remove clutch push rod O Remove screws O Remove the oil filter cover 8 with the O ring Pull oil filter out of the oil filter housing I Lock ring plier 51012011000 8 p 297 ...

Page 177: ... Remove screws O and take off the starter motor Remove the spark plug using the special tool I Spark plug wrench with link 77229172000 0 p 303 Remove screws O Take off the valve cover with the valve cover seal Removing the alternator cover Remove screws O Take off the alternator cover ENGINE 17 41 41 175 ...

Page 178: ...t ignition top dead center Align camshaft marking 6 with the center of screw 4D on the cylinder head Remove screw O with the washer Screw in special tool 8 Locking screw 113080802 8 p 295 17 3 10 Removing the timing chain tensioner Remove screw O with the washer and spring 176 ...

Page 179: ... with the gasket Remove screws O Take off camshaft retaining bracket Pull the camshaft out of the bearing seats Take the timing chain from the camshaft gear Remove the camshaft Remove screw O Unscrew screws 8 in a crisscross pattern and remove Remove the cylinder head Take off dowels D Remove cylinder head gasket C 177 ...

Page 180: ...piston ring lock 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 Remove cylinder base gasket D Info Ensure locating pins 8 remain in place Remove timing chain guide rail C from the top Remove nut O with the spring washer ...

Page 181: ... special tool and pull off the rotor by turning the screw in Remove the woodruff key Remove screw O Remove timing chain tensioning rail 8 toward the top Remove screw 8 Remove the timing chain securing guide Take off the timing chain Info If the timing chain is to be reused mark the direction of travel Remove screws O Take off oil pump cover 8 of the suction pump 179 ...

Page 182: ...e off pin 0 Remove pin D upward Remove O ring 17 3 17 Removing the gear position sensor Remove screws O Take off the gear position sensor 17 3 18 Removing the water pump cover 180 Remove screws O Take off the water pump cover Take off the water pump cover seal ...

Page 183: ...ve dowels 8 Take off clutch cover gasket fs Clamp the antihopping clutch with special tool O I Assembly screws 75029033000 8 p 301 Info I Apply the special tool by hand only do not use another tool Remove screws 8 with the spring retainers and clutch springs Remove clutch pressure cap fs Remove clutch throw out C Bend up lock washer 0 Remove special tool D I Locking screw 113080802 il I p 295 ENGI...

Page 184: ...the lock washer I Gear segment 80029004000 0 p 306 Remove clutch disc pack 0 entirely Take off washer O Info The washer usually sticks to the inner clutch hub Lock the clutch basket and primary gear wheel using special tool 8 I Gear segment 80029004000 0 p 306 Remove nut 8 Info LH thread Take off clutch basket e ...

Page 185: ...s 0 and collar bushing 0 Remove screw O with the washer Take off the torque limiter 17 3 23 Removing the starter idler gear 17 3 24 Removing the force pump Take off starter idler gear O Remove lock ring O Take off washer 8 Remove oil pump idler gear 5 ENGINE 17 183 ...

Page 186: ...gear wheel D Remove pin Remove screws Take off oil pump cover Remove internal rotor QD and external rotor 48 Remove the pin Push oil pump shaft 48 inward and take it out of the engine from the ignition side Push sliding plate O away from the shift drum locating unit Remove shift shaft 8 with the washer ...

Page 187: ...screw O and remove together with locking lever washer sleeve and spring 17 3 28 primary gear wheel removing Insert special tool O into the crankshaft I Protection cap 75029090000 g p 302 Mount special tool I Puller 75029021000 8 p 300 Hold the special tool firm and pull off the primary gear wheel by turning the screw in Remove the special tools 17 3 29 Removing the freewheel gear Remove woodruff k...

Page 188: ...nfo I Use the 794 drill hole Tilt the left section of the engine case upward and remove the fitting of the engine fixing arm Pull off the section of the engine case Info Ensure that washer f is not damaged Do not tension the section of the engine case Remove the special tool Take off the left section of the engine case Remove spacer 8 Remove dowel C ...

Page 189: ...rks Remove shift rails O together with upper springs 8 and lower springs Swing shift forks O to one side Info I Do not misplace the shift rollers Remove shift drum Take shift forks O out of the shift grooves Info Do not misplace shift rollers 8 17 3 34 Removing the transmission shafts Remove O ring O 187 ...

Page 190: ...ke sure not to misplace the washers 17 3 35 Removing the crankshaft 17 4 17 4 1 188 Remove crankshaft O Info I Ensure that washer 8 is not damaged Take off the right section of the engine case Working on individual arts Working on the right section of the engine case Preparatory work Remove the oil pressure control valve 0 p 191 ...

Page 191: ... 1150 C 302 F Position washer CD Insert the new cold bearings into the bearing seats of the hot section of the engine case and if necessary use a suitable press drift to push the bearings from the inside to the out side all the way to the stop or until flush Info When pressing in ensure that the section of the engine case lies flat in order prevent damage Only press the bearings in using the outer...

Page 192: ...al ring 0 of the shift shaft Remove any remnants of sealing compound and clean the engine case section thoroughly Warm the engine case section in an oven Guideline 1150 C 302 F Knock the engine case section against a level wooden board This will cause the bearings to drop out of the bearing seats Info Any bearings that remain in the engine case section must be removed using a suitable tool Remove ...

Page 193: ...ase the engine case must be renewed Press in shaft seal ring 8 of the countershaft and shaft seal ring C of the shift shaft with the open side facing inward until it is flush Position the bearing retainers Mount and tighten screws Guideline Screw bearing retainer MS Position oil spray tube 8 Mount and tighten screw O Guideline Screw oil spray M4 tube Mount the dowels 6 Nm 4 4 lbf ft Loctite 243 5 ...

Page 194: ...rol valve installing Insert ball O and pressure spring 8 Mount and tighten screw plug D with sealing washer C Guideline Screw plug oil pres M12x1 5 sure control valve 20 Nm 14 8 lbf ft e 8 17 4 6 17 4 7 192 310047 11 crankshaft seal ring in the clutch cover changing B03798 10 Removing the water pump Remove lock ring O Remove crankshaft seal ring 8 Press the new crankshaft seal ring into the clutch...

Page 195: ...l Info Suitably support the clutch cover while pressing it out Press bearing O of the water pump shaft up to the stop with a suitable tool I Pressing tool 79429006000 a p 305 Info I Provide suitable support for the clutch cover while pressing in Press shaft seal ring 8 all the way in I Pressing tool 60029043040 al p 299 The narrower chamfer faces the balancer shaft 193 ...

Page 196: ...e 243 17 4 9 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 a p 299 Info I The timing chain sprocket is usually damaged by the disassembly and must be replaced 17 4 10 Installing the timing chain sprocket 194 Info Never clamp the crankshaft with a crankshaft journal in the bench ...

Page 197: ...ensating disk Repeat these steps on the opposite side 17 4 12 Installing the crankshaft bearing inner race 310069 11 Main work Fix the crankshaft in the vise Guideline I Use soft jaws Slide on compensating disk O Info The compensating disks have a larger diameter than the crankshaft stub Ensure that the compensating disks are centered and fixed with a small amount of grease Only add the compensati...

Page 198: ...ecial tool I Crankshaft pressing tool 75029047000 l p 301 Info I Hold the lower crankweb Remove the connecting rod and bearing Press crank pin fD out of the lower crankweb Place the crankweb onto special tool C Insert for crankshaft pressing tool 79429008000 l p 305 Info The special tool must be positioned with the flat sur face facing downward Press in new crank pin 0 all the way Oil channel 6 is...

Page 199: ...8929008000 8 p 303 Press in the upper crankweb as far as possible Info I The press mandrel must be positioned over the crank pin Take the crankshaft out of the special tool and check that the connecting rod can move freely Measure axial play O between the connecting rod and the crankwebs using the special tool I Feeler gauge 59029041100 8 p 299 Connecting rod end play of lower conrod bearing 0 20 ...

Page 200: ...nt the left section of the engine case Mount and tighten the screws Guideline I Screw engine case I M6 110 Nm 7 4 lbf ft Mount the dial gauge support on the engine case and mea sure and note down the crankshaft axial play Guideline Crankshaft axial play 0 50 0 60 mm 0 0197 0 0236 in If the measured value does not meet specifications Remove the crankshaft Remove the crankshaft bearing inner race 0 ...

Page 201: ...eck the cylinder bearing surface for damage If the cylinder bearing surface is damaged Change the cylinder and piston Measure the bore diameter at several locations on the 0 axis and 0 axis using a micrometer to identify oval wear Guideline Cylinder drill hole 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 The cylinder size O is marked on the side o...

Page 202: ... 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 Change the piston ring Info I Mount the piston ring with the marking facing upward Check the piston pins for discoloration or signs of wear If the piston pin shows severe discoloration signs ...

Page 203: ...ideline Piston ring end gap Compression ring I 1 00 mm 0 0394 in Oil scraper ring I 1 20 mm 0 0472 in I Feeler gauge 59029041100 0 p 299 If the end gap is greater than the specified value Check measure the cylinder 0 p 199 If cylinder wear lies within the specified tolerance Change the piston ring Mount the piston ring with the marking facing upward 41 17 4 20 Measuring the piston cylinder mountin...

Page 204: ...9 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 ra l p 299 Oil pump External rotor internal rotor clearance I s 0 20 mm s 0 0079 in If the measured value d...

Page 205: ...1 304674 11 304673 11 Insert long flange O of the autodecompression spring in the hole push the autodecompression spring over bearing bolt 4 and hook it into autodecompression weight fi 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 206: ...he camshaft 17 4 25 Checking the timing assembly 0 v e 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 chain tensioning rail 8 for damage and wear If there is damage or wear Replace the timing chain tensioning rail Check the timing chain guide rail D for damage and wea...

Page 207: ...th the O rings Screw in appropriate screw C into the rocker arm shafts Pull out rocker arm shafts 0 Guideline I Screw Take off the rocker arm D Take the shims out of the valve spring retainers and lay them to one side according to their normal built in position Pretension the valve springs using the special tool Valve spring mounter 59029019000 8 p 298 Insert for valve spring lever 77029041200 8 p...

Page 208: ...he valves are removed and the exhaust flange is removed Mount the cylinder head I Clamping plate 75029050000 a p 302 Remove the large camshaft bearing using special tool O I Pressing tool 75029051000 0 p 302 Remove small camshaft bearing 8 using the special tool Bearing puller 15112017000 0 p 296 Internal bearing puller 15112018100 0 p 296 Remove shaft seal ring fD using a suitable tool Press the ...

Page 209: ...pecial tool 0 Pressing tool 75029044010 IUI p 301 The valve stem is hard chrome plated wear generally appears at the valve guide 302808 10 Check the valve plate for run out Valve Run out at valve plate 0 05 mm 0 002 in If the measured value does not meet specifications Change the valve Check sealing seat f on valve for damage and wear If the sealing surface is damaged or worn Machine the valve sea...

Page 210: ...e and wear visual check If the valve spring seat is broken or worn Change the valve spring seat Measure the thickness of the valve spring seat Valve spring Valve spring seat 1 8 mm 0 071 in If the measured value does not meet specifications Change the valve spring seat Check exhaust valve guides O using the special tool I Limit plug gauge 59029026006 p 298 If the special tool is easy to insert int...

Page 211: ...nder head Check sealing seat width f of the valves 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 measured value does not meet specifications Machine the valve seat Blow compressed air through all oil channels and check that they are clear Check the rocker arm shafts for damage and wear If there is damage or wear Change the rocker arm ...

Page 212: ...ocker arm shaft with marking 6 is installed on the intake side Marking 6 faces 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 8 in the cylinder head Remove appropriate screw M6 Use special tool 0 to adjust the distance of the intake rocker arm Guideline I Rocker arm axial play I 0 10 mm 0 0039 in I ...

Page 213: ... 306629 10 Clamp clutch O into a vise Info I Use soft jaws Carefully loosen special tool 8 in steps and remove it Take the clutch out of the vise and place it on a clean work bench with the outside inner clutch hub D facing down ward Take the inside inner clutch hub C and release springs 0 out of the outer inner clutch hub Remove clutch facing discs D from the outer inner clutch hub Remove sleeves...

Page 214: ...prings 8 in the inside inner clutch hub Slide on the outside inner clutch hub watching out for the markings Align markings 9 and Tightly press both inner clutch hubs together and have an assistant screw in the special tool I Assembly screws 75029033000 l ll p 301 Info I Apply the special tool by hand only do not use another tool Only tighten the special tool to the point where the clutch facing di...

Page 215: ...springs Check the contact surface of clutch pressure cap 8 for damage and wear If there is damage or wear Change the clutch pressure cap Check inside inner clutch hub 0 for damage and wear If there is damage or wear Change the inside inner clutch hub Check sleeves 3 for damage and wear If there is damage or wear Change the sleeves Check outside inner clutch hub for damage and wear If there is dama...

Page 216: ...iscs Check the thickness of the clutch disc pack Clutch disc pack thickness Wear limit 26 4 mm 1 039 in If the clutch disc pack does not meet specifications Change the clutch disc pack Check intermediate clutch discs G for damage and wear If the intermediate clutch discs are not level and are pitted Change all intermediate clutch discs 17 4 39 Checking the shift mechanism Check shift forks O on pl...

Page 217: ... areas 9 for wear If the sliding plate is worn Change the sliding plate Check return surface on the sliding plate for wear If deep notches are present Change the sliding plate Check guide pin for looseness and wear If the guide pin is loose and or worn Change the sliding plate Preassemble the shift shaft IUI p 215 304682 10 17 4 40 Preassembling the shift shaft 304683 10 Check clearance O between ...

Page 218: ...se with the gear teeth facing downward Guideline I Use soft jaws Remove stop disk O and second gear fixed gear 8 Remove lock ring Remove distance sleeve C Remove third fourth gear sliding gear 0 Remove lock ring 3 and stop disk Remove fifth gear idler gear D Remove needle bearing CD 216 310083 10 ...

Page 219: ...k C Remove the fifth gear sliding gear 0 and lock ring D Remove stop disk and third gear idler gear fD Remove needle bearing and fourth gear idler gear Gi Remove needle bearing G and stop disk 48 Remove lockring G and second fourth gear shift collar 4D Remove lockring and stop disk 41 Remove second gear idler gear 48 and needle bearing Qi 17 4 43 Checking the transmission Condition The transmissio...

Page 220: ...s 0 for damage and wear If there is damage or wear Change the gear wheel pair Check the tooth faces of idler gears C sliding gears 0 and fixed gear D for damage and wear If there is damage or wear Change the gear wheel pair Check the tooth profiles of sliding gears 0 for damage and wear If there is damage or wear Change the gear wheel pair Check sliding gear 0 for smooth operation in the profile o...

Page 221: ... assembling Check the transmission 0 p 217 Main work Secure the main shaft in the vise with the gear teeth facing downward Guideline I Use soft jaws 310084 10 Mount needle bearing O and mount fifth gear idler gear 8 with the shift dogs facing up Mount stop disk D and lock ring C Mount third fourth gear sliding gear 0 with the small gear wheel facing downward Mount distance sleeve D Mount lock ring...

Page 222: ... collar facing downward Mount stop disk C and lock ring C Mount second fourth gear shift collar 0 with the shift groove facing up Mount lock ring 3 and stop disk Mount needle bearing and the fourth gear idler gear with the collar facing up Mount needle bearing 4D and the third gear idler gear 48 with the collar facing down Mount stop disk 48 and lock ring 41 Mount the fifth gear sliding gear e wit...

Page 223: ...mage or wear Change the freewheel gear or bearing Check freewheel C for damage and wear when it is disassembled If there is damage or wear Change the freewheel Check the gear mesh of starter motor 0 for damage and wear If there is damage or wear Change the starter motor Change the O ring 3 of the starter motor ENGINE 17 Connect the negative cable of a 12 volt power supply to the housing of the sta...

Page 224: ... primary gear wheel clockwise do not wedge Check the locking action of freewheel gear O The primary gear wheel cannot be turned clockwise or does not lock counterclockwise Change the freewheel Press expansion ring O together with suitable pliers and take off Take freewheel 8 out of the primary gear wheel Thoroughly oil all parts Slide freewheel O into the primary gear wheel Info Note the direction...

Page 225: ...lugs of the expansion ring pass through slots 8 of the freewheel and engage in groove G of the primary gear wheel Position the right section of the engine case in the engine assembly stand Oil the bearing I Engine oil SAE 1 0W 50 0 p 290 Slide crankshaft O into the bearing seat Info Ensure that washer 8 is not damaged 223 ...

Page 226: ... Info Make sure not to misplace the washers Mount lock ring O Lubricate all parts thoroughly Mount shift fork O in the upper shift groove of the main shaft Mount shift fork 8 in the lower shift groove of the counter shaft Mount shift fork D in the upper shift groove of the counter shaft Mount shift rollers C Info Fix the shift rollers in the shift forks with grease ...

Page 227: ...Install shift rails O together with upper springs 8 and lower springs Info Fix the springs in the shift rails with grease ENGINE 17 Installing the left engine case Install dowel O Degrease the sealing surfaces Apply sealing compound to the left section of the engine case I Loctite 591 O Info I To prevent sealing compound from entering into the oil channel dowel O must be mounted first 225 ...

Page 228: ... 7 4 lbf ft Mount screws but do not tighten yet Guideline I Screw engine case I M6x70 110 Nm 7 4 lbf ft Mount screws C and tighten all screws in a crisscross pat tern Guideline I Screw engine case I M6x80 Mount the O ring on the countershaft Lightly grease and mount spacer Ci Mount freewheel gear O 110 Nm 7 4 lbf ft primary gear wheel installing Mount woodruff key O Degrease the cone and thinly ap...

Page 229: ...hift drum locating unit are not symmetric Relieve tension from the locking lever Mount and tighten screw i Guideline Screw shift drum locating M6 10 Nm 7 4 lbf ft Loctite 243 Slide shift shaft O with the washer into the bearing seat Push sliding plate 8 away from the shift drum locating unit and insert the shift shaft all the way Let the sliding plate engage in the shift drum locating unit i Shift...

Page 230: ...in D Position oil pump gear wheel Position washer fD Mount lock ring Mount oil pump idler gear Gi Mount washer 4D and lock ring 48 10 Nm 7 4 lbf ft Loctite 243 Crank the oil pump gear wheels and ensure that they can move easily 17 5 13 Installing the starter idler gear 228 Slide on starter idler gear O with the collar facing the engine case ...

Page 231: ...lt torque lim Loctite 243 iter Mount collar bushing O and both needle bearings Slide clutch basket D onto the gearbox main shaft Turn oil pump gear wheel 8 until the gear teeth of the clutch basket engage Lock the clutch basket and primary gear wheel using special tool 0 I Gear segment 80029004000 p 306 Mount and tighten nut D Guideline Nut primary gear wheel Mount washer M20LHx1 5 100 Nm 73 8 lbf...

Page 232: ...ut inner clutch hub I M18x1 5 I 80 Nm 59 lbf ft I Gear segment 80029004000 il I p 306 Info I Make sure that the crankshaft is not locked Secure the nut with the lock washer Insert clutch throw out 8 Position crankshaft to TDC and lock with special tool 0 I Locking screw 113080802 il I p 295 Mount clutch pressure cap D Install and tighten screws with the spring retainers and clutch springs Guidelin...

Page 233: ...unt screws C but do not tighten yet Guideline I Screw clutch cover I M6x25 10 Nm 7 4 lbf ft Mount screw 0 but do not tighten yet Guideline I Screw clutch cover I M6x45 10 Nm 7 4 lbf ft Mount screw D but do not tighten yet Guideline I Screw clutch cover I M6x50 10 Nm 7 4 lbf ft Mount screw and tighten all screws in a crisscross pat tern Guideline I Screw clutch cover I M6x30 I10 Nm 7 4 lbf ft Remov...

Page 234: ...x25 10 Nm 7 4 lbf ft Loctite 243 Mount screw CD and tighten all screws in a crisscross pat tern Guideline Screw water pump cover M6x55 10 Nm 7 4 lbf ft 17 5 19 Installing the gear position sensor 17 5 20 Installing the suction pump 232 Position the gear position sensor Mount and tighten screws O Guideline Screw gear M5 position sensor 5 Nm 3 7 lbf ft Loctite 243 Oil the internal rotor and external...

Page 235: ...243 Thread in the timing chain and place it over the timing chain sprocket Info I If the timing chain was used before ensure it is run ning in the correct direction Position the timing chain securing guide Mount and tighten screw O Guideline Screw timing M6 10 Nm 7 4 lbf ft chain securing Loctite 243 guide Thread in timing chain tensioning rail from above Mount and tighten screw 8 Guideline Screw ...

Page 236: ...raper ring so they are offset by 180 Place the oiled piston on the cylinder Clamp the piston rings together using the special tool I Piston ring compressor 60029015000 8 p 299 Tap lightly on the piston ring compressor from the top with a plastic hammer so that it lies flush with the cylinder The special tool must press the piston rings together properly and lie flush with the cylinder Drive the pi...

Page 237: ...h the rotor removed for a clearer view Mount cylinder base gasket 8 Info Ensure that locating pins 8 are seated properly Ensure that piston marking C faces the exhaust side Cover the engine case opening with a cloth Feed the timing chain through the timing chain shaft and mount the piston pin Info For purposes of illustration the following operations are shown on the removed piston 235 ...

Page 238: ...e special tool clockwise thereby pushing the piston ring lock into the groove I Insertion for piston ring lock 773290301 00 0 p 303 Ensure that the piston ring lock is in the correct position on both sides Remove the cloth Keep the timing chain taut Carefully push the cylinder downward letting the dowels engage Mount dowels O and fit cylinder head gasket 8 ...

Page 239: ...cylinder head I M6 10 Nm 7 4 lbf ft Place the timing chain over the camshaft gear Push the camshaft into the bearing seat Marking C on the camshaft and hole G on the cylinder head are lined up with each other Info Make sure that the crankshaft is at top dead center Position the camshaft retaining bracket Mount and tighten screw O Guideline Screw M6 10 Nm 7 4 lbf ft camshaft Loctite 243 retaining b...

Page 240: ...alve clearance 238 Remove special tool O I Locking screw 113080802 8 p 295 Crank the engine several times Position the engine at ignition top dead center 8 p 176 Check the valve clearance at all valves between the valve and rocker arm Guideline Valve clearance Intake at 20 C 68 F 0 10 0 15 mm 0 0039 0 0059 in Exhaust at 20 c 68 F 0 12 0 17 mm 0 0047 0 0067 in I Feeler gauge 59029041100 l p 299 If ...

Page 241: ...llation position 41 Correct the shims based on the results of the valve clearance check Insert suitable shims Install the camshaft 0 p 237 Install the timing chain tensioner 0 p 237 Finishing work Check the valve clearance 0 p 238 17 5 29 Installing the alternator cover Position alternator cover gasket O Position the alternator cover Mount screws with the washers but do not tighten yet Guideline S...

Page 242: ...110Nm 7 4 lbf ft Mount and tighten the spark plug using the special tool Guideline I Spark plug IM10x1 I10 12Nm 7 4 8 9 lbf ft I Spark plug wrench with link 77229172000 il I p 303 Grease the O ring Insert the starter motor I Long life grease 0 p 292 Mount and tighten screws O Guideline I Screw starter motor I M6 110Nm 7 4 lbf ft Tilt the motorcycle to one side and fill the oil filter housing to ab...

Page 243: ...t Mount and tighten screw plug O with the short oil screen and the O ring Guideline Screw plug oil screen M20x1 5 15 Nm 11 1 lbf ft Position the long oil screen with the O rings on a pin wrench Position the pin wrench through the drilled hole of the screw plug in the opposite section of the engine case Push the oil screen all the way into the engine case Mount and tighten screw plug with the O rin...

Page 244: ...n plug with magnet M12x1 5 20 Nm 14 8 lbf ft 17 5 36 Removing the engine from the engine assembly stand 242 Remove the fitting from the special tool I Holder and fitting for work stand 79429002000 p 305 Remove the engine from the engine assembly stand Info Work with an assistant or a motorized hoist ...

Page 245: ... the clothing Info I The fluid level rises with increasing wear of the clutch facing discs Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and clutch lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container Move the clutch fluid reservoir mounted on th...

Page 246: ...ge Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and clutch lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container ...

Page 247: ...ollability Ride stability is enhanced as the engine braking effect causes less slip on the rear wheel thanks to the antihopping system The antihopping system uses a two part inner clutch hub The individual parts are connected via helical gears The clutch spring preload can be adjusted if necessary Low preload with out washer 6 Moderate preload with washer G condition at deliv ery Washer 5903200010...

Page 248: ...ffect The clutch also engages differently when starting the differences are considerably less pro nounced than when braking The clutch then behaves somewhat more aggressively M01377 10 Preparatory work Place the motorcycle on its left side with the aid of an assis tant Main work Detach spring O Remove screws fj D and C Take off the clutch cover Remove screw 0 Info I Never remove more than one scre...

Page 249: ...rew 8 but do not tighten yet Tighten all screws in a crisscross pattern Guideline I Screw clutch cover I M6 Attach spring O Finishing work Stand the motorcycle upright Danger 10 Nm 7 4 lbf ft Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction ...

Page 250: ...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 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 haz...

Page 251: ...gine to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediate...

Page 252: ...tely with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing Condition The engine is cold Position the motorcycle upright Place an appropriate container under the water pump cover Remove screw O Take off radiator cap Completely drain the coolant Mo...

Page 253: ...ition the motorcycle upright Pour coolant in up to measurement f above the radiator fins Guideline Dimension f over the radi 10 mm 0 39 in ator fins Coolant 1 20 I 1 27 qt Coolant 8 p 290 Mount the radiator cap Take a short test ride Check the coolant level 0 p 249 251 ...

Page 254: ...tion fD Suction pump Ci Oil channel transmission lubrication Checkin Info 401628 60 The engine oil level can be checked when the engine is cold or warm 252 Preparatory work Stand the motorcycle upright on a horizontal surface Condition The engine is cold Check the engine oil level The engine oil reaches the middle of level viewer 6 If the engine oil does not reach the middle of the level viewer Ad...

Page 255: ...il get very hot when the motorcycle is ridden Wear suitable protective clothing and safety gloves In the event of scalding rinse the area affected immediately with lukewarm water Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Check the O ri...

Page 256: ...ings Guideline Screw plug oil screen M20x1 5 15 Nm 11 1 lbf ft Position long oil screen C with the O rings on a pin wrench Position the pin wrench through the drill hole of the screw plug in the opposite section of the engine case Push the oil screen all the way into the engine case Mount and tighten screw plug 8 with the O ring Guideline Screw plug oil screen M20x1 5 15 Nm 11 1 lbf ft Mount and t...

Page 257: ...Guideline I Screw oil filter cover I M6 Stand the motorcycle upright 110 Nm 7 4 lbf ft Remove filler plug D from the clutch cover together with the O ring and fill up with engine oil Engine oil Info 1 20 I 1 27 qt Engine oil SAE 10W 50 a p 290 I Too little engine oil or poor quality engine oil will result in premature wear of the engine Mount and tighten the filler plug together with the O ring Da...

Page 258: ... types of engine oil We recommended changing the engine oil when nec essary Mount and tighten the filler plug together with the 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 effective exhaust extraction when starting or running the engine in an enclosed...

Page 259: ...unning the engine in an enclosed space Start the engine and let it warm up Check the oil pressure Oil pressure Engine oil temperature 80 C 176 F Engine speed Idle speed Engine oil temperature 80 C 176 F Engine speed 6 000 rpm 0 6 bar 9 psi 1 7 bar 25 psi 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 Warn...

Page 260: ...20 LUBRICATION SYSTEM Finishing work Check the engine oil level 0 p 252 258 ...

Page 261: ...ng 11 075 15 525 kn resistance at 20 C 68 F If the displayed value does not correspond to specifica tions Change the ignition coil connector Condition Spark plug connector cylinder 1 has been removed 0 Measure the resistance between the specified points Measuring point 1 Measuring point 2 Spark plug connector Resistance at 20 C 68 F 1 3 75 6 25 kn If the specification is not reached Change the spa...

Page 262: ...ctor O Finishing work Install the fuel tank 0 p 103 Mount the seat 0 p 101 Install the air filter box cover 0 p 96 Install the right side cover 0 p 100 Alternator checkin stator windin Condition The alternator is disconnected Stator winding checking the resistance n Measure the resistance between the specified points Alternator connector CR pin 1 Alternator connec tor CR pin 1 Alternator Resistanc...

Page 263: ...ndition The alternator cover has been removed Remove screws O Remove the retaining bracket Remove screws 8 Remove rubber grommet from the alternator cover Remove the stator from the alternator cover Position the stator in the alternator cover Mount and tighten screws O Guideline Screw stator 0 M5 6 Nm 4 4 lbf ft Loctite 243 D00343 11 Position the retaining bracket Mount and tighten screws 8 Guidel...

Page 264: ...r box cover 0 p 96 Remove the seat 0 p 100 Remove the fuel tank 0 p 102 Main work Pull capacitor O off of the holder and hang to one side Disconnect spark plug connector 8 Remove the spark plug using the special tool I Spark plug wrench with link 77229172000 8 p 303 Push back hose clamp fD Pull off the air release hose Remove screws C Remove the valve cover with the gasket ...

Page 265: ...her Check the valve clearance at all valves between the valve and rocker arm Guideline Valve clearance Intake at 20 C 68 F 0 10 0 15 mm 0 0039 0 0059 in Exhaust at 20 C 68 F 0 12 0 17 mm 0 0047 0 0067 in Feeler gauge 59029041100 a p 299 If the valve clearance does not meet specifications Adjust the valve clearance a p 239 Remove locking screw 0 Crank the engine several times Check the valve cleara...

Page 266: ...29172000 0 p 303 Plug in spark plug connector 8 Mount capacitor O Finishing work Install the fuel tank 0 p 103 Mount the seat 0 p 101 Install the air filter box cover 0 p 96 Install the right side cover 0 p 100 Remove the motorcycle from the lift stand 0 p 12 22 2 Ad ustin the valve clearance 264 Preparatory work Raise the motorcycle with a lift stand 0 p 12 Remove the right side cover 0 p 100 Rem...

Page 267: ...nsert suitable shims Position rocker arm D Mount rocker arm shafts 0 The rocker arm shaft with marking f is installed on the intake side Marking f faces upward Info Make sure that the tapped hole of the rocker arm shaft is facing outward Align drill holes D of the rocker arm shafts with drill holes of the cylinder head Install and tighten screws 8 and 8 of the rocker arm shafts Guideline Screw roc...

Page 268: ...nishing work Check the valve clearance 8 p 262 Install the fuel tank 0 p 103 Mount the seat 0 p 101 Install the air filter box cover 8 p 96 Install the right side cover 8 p 100 Remove the motorcycle from the lift stand 8 p 12 ...

Page 269: ...otor has been removed Connect the negative cable of a 12 volt power supply to the housing of the starter motor Connect the positive cable of the power supply briefly with connector O of the starter motor If the starter motor does not turn when the circuit is closed Change the starter motor 267 ...

Page 270: ...en running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Set the idle speed by turning the idle speed adjusting screw O Guideline I Idle speed I 2 250 2 350 rpm I Tachometer 45129075000 IUI p 296 Performing the initialization run Condition Info Turning counterclockwise lowers the idle speed Turning clockwise raises the idle speed The diagnosti...

Page 271: ...ace Start the engine without operating the throttle grip Guideline I Coolant temperature I 25 C 77 F Let the engine warm up to the specified temperature at idle speed Guideline I Coolant temperature I ao 90 c 176 194 F Info Do not operate the throttle grip during the initialization process Switch off the ignition when the specified temperature is reached Info If initialization is not completed or ...

Page 272: ...g Piston pin bearing No bearing bush DLC coated piston pin Pistons Forged light alloy Piston rings 1 compression ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with two Eaton pumps Primary transmission 31 76 Clutch Multidisc clutch in oil bath hydraulically activated Gearbox 5 gear transmission claw shifted Transmission ratio First gear 16 32 Second gear 18 30 Third ge...

Page 273: ... 0 00472 in Piston ring end gap Compression ring s 1 00 mm 5 0 0394 in Oil scraper ring s 1 20 mm 5 0 0472 in Connecting rod end play of lower conrod bearing 0 20 0 45 mm 0 0079 0 0177 in Crankshaft run out on bearing pin s 0 03 mm 5 0 0012 in Clutch disc pack thickness Wear limit 26 4 mm 1 039 in Clutch spring length 45 60 46 80 mm 1 7953 1 8425 in Oil pressure control valve Minimum length of pre...

Page 274: ...ug timing chain tensioner Screw plug locking screw Plug oil channel Screw engine sprocket 272 M5 6 Nm 4 4 lbfft M5 8 Nm 5 9 lbfft M5 5 Nm 3 7 lbfft M5 6 Nm 4 4 lbfft M5 6 Nm 4 4 lbfft M5 6 Nm 4 4 lbfft M6 6 Nm 4 4 lbfft M6 10 Nm 7 4 lbfft M6 10 Nm 7 4 lbfft M6 10 Nm 7 4 lbfft M6 10 Nm 7 4 lbfft M6 10 Nm 7 4 lbfft M6 10 Nm 7 4 lbfft M6 10 Nm 7 4 lbfft M6 10 Nm 7 4 lbfft M6 10 Nm 7 4 lbfft M6 10 Nm ...

Page 275: ...rear Brake discs diameter TECHNICAL DATA 25 10 12 Nm 7 4 8 9 lbf ft 12 Nm 8 9 lbf ft 10 Nm 7 4 lbf ft 1st stage 10 Nm 7 4 lbf ft 2nd stage 30 Nm 22 1 lbf ft 3rd stage 50 Nm 36 9 lbf ft Collar and thread oiled 60 Nm 44 3 lbf ft Thread oiled with engine oil cone degreased 20 Nm 14 8 lbf ft 20 Nm 14 8 lbf ft 80 Nm 59 lbf ft 100 Nm 73 8 lbf ft Loctite 243 15 Nm 11 1 lbf ft I Engine oil SAE 10W 50 IUI ...

Page 276: ...ndicator lamp 25 7 Tires Front tire 125 600 R 16 5 TL C22S 58011109110 Bridgestone Battlax Supermoto BM01Z 310 mm 12 2 in 220 mm 8 66 in 4 5 mm 0 177 in 3 5 mm 0 138 in 1 9 bar 28 psi 1 7 bar 25 psi 2 1 bar 30 psi 1 9 bar 28 psi 14 45 5 8 X 1 4 40 42 45 48 49 50 51 52 63 9 1 475 10 mm 58 07 0 39 in 290 mm 11 42 in 890 mm 35 04 in 104 8 kg 231 lb 145 kg 320 lb 190 kg 419 lb 335 kg 739 lb Lithium io...

Page 277: ...ork oil SAE 4 48601166S1 a p 291 Grease capacity left cartridge 11 ml 0 37 fl oz Multi purpose grease 00052010051 a p 293 25 9 Shock absorber Shock absorber article number 18 15 7Q 08 Shock absorber WP Suspension 5018 DCC Link Lowspeed compression damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Highspeed compression damping Comfort 2 5 turns Standard 2 turns Sport 1 5 turns Rebound da...

Page 278: ...crews chassis M6 Screw ball joint of push rod on M6 foot brake cylinder Screw battery support bracket M6 Screw chain sliding guard M6 Screw front brake disc M6 Screw rear brake disc M6 Screw throttle grip M6 Fuel connection on fuel tank M8 Nut foot brake lever stop M8 Nut rear sprocket screw M8 Nut rim lock M8 Remaining nuts chassis M8 Remaining screws chassis M8 276 Shock absorber fluid SAE 2 5 5...

Page 279: ... front wheel spindle Nut rear wheel spindle M8 M8 M8 M8 M8 M8 M8 M8 M10 M10 M10 M10 M10 M10 M10x1 25 M12 M14x1 5 M14x1 5 M14x1 5 M16x1 5 M20x1 5 M20x1 5 M24x1 5 M25x1 5 TECHNICAL DATA 25 12 Nm 8 9 lbf ft 15 Nm 11 1 lbf ft 25 Nm 18 4 lbf ft 15 Nm 11 1 lbf ft 20 Nm 14 8 lbf ft 30 Nm 22 1 lbf ft 20 Nm 14 8 lbf ft 17 Nm 12 5 lbf ft 60 Nm 44 3 lbf ft 45 Nm 33 2 lbf ft 45 Nm 33 2 lbf ft 60 Nm 44 3 lbf f...

Page 280: ...motorcycle over a long period clean it regularly Avoid direct sunshine when cleaning the motorcycle 7 11111111111111 401061 01 Close off the exhaust system to keep water from entering Remove loose dirt first with a soft jet of water Spray heavily soiled parts with a normal commercial motorcy cle cleaner and then brush off with a soft brush Motorcycle cleaner 0 p 293 I Info Use warm water containin...

Page 281: ...130 Treat bare metal except for brake discs and the exhaust sys tem with a corrosion inhibitor Preserving materials for paints metal and rubber ll I p 293 Treat all plastic parts and powder coated parts with a mild cleaning and care product Special cleaner for glossy and matte paint finishes metal and plastic surfaces p 293 41 279 26 ...

Page 282: ...replacements are necessary you should do this during the storage period less workshop overload In this way you can avoid long workshop waiting times at the start of the new season 1111 When refueling for the last time before taking the motorcycle out of service add fuel additive I Fuel additive p 292 Refuel Clean the motorcycle p 278 Change the engine oil and oil filter and clean the oil screens p...

Page 283: ...me only Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust Preparin for use after stora e 401059 01 Install the 12 V battery 8 p 138 Remove the motorcycle from the lift stand 8 p 12 Perform checks and maintenance measures when preparing for use Make a test ride 41 41 281 ...

Page 284: ...re pressure 8 p 116 0 I I Check the wheel bearing for play 8 p 117 I I I I Check the wheel hubs I I Check the rim run out 8 p 119 0 I I Check the spoke tension 8 p 118 0 I I Check the chain rear sprocket engine sprocket and chain guide 8 p 127 I I Check the chain tension 8 p 126 0 I I Grease all moving parts e g hand lever chain and check for smooth operation I I I I Check correct the fluid level ...

Page 285: ... front brake fluid 8 p 148 Change the rear brake fluid 8 p 155 Change the hydraulic clutch fluid 8 p 244 Lubricate the steering head bearing 8 p 39 Service the fork 8 p 20 Service the shock absorber 8 p 64 Change the fuel filter 8 p 109 Perform minor engine service engine has been installed Change spark plug and spark plug connector Change piston check and measure cylinder check cylin der head Che...

Page 286: ...1 NfC 2 C10 S 2 1 FC 2 X7 tel HUSQ l ma 1 1 X295 1r oi i I 11 2 II 1 X 1 9 NBR 4 l 521 M10 r K 4 t R 4 X19 i l FS 450 HQV 2017 2018 3 4 I I E E 1 1 rn NAF 4 X17 11 5 j I II G10 X302 J 5 E E 1 1 1 N EB 4 u 3 1 N lB o 1 EZ 3 X1 X18 r nw 1 I I I 6 7 b 2 E1 a 2 F1 I I II ...

Page 287: ...ontrol unit C10 Capacitor G10 12 V battery G20 Alternator K10 Starter relay with main fuse K30 Power relay M10 Electric starter system T20 Voltage regulator S21 E tip switch X295 Diagnostics connector WIRING DIAGRAM 29 285 ...

Page 288: ... 33 t t HY 33 HY 33 520 1 X16 1 X16 I 1 X16 1 X16 1 X16 I 1 X16 1 X16 t i is I I t X S BF 1 dA 1 E I X295 l11AP 6 1 t4 i fr12 a P25 l x2 iCX 2 W 2 W 2 CX 2 1 X2 1 xJ f1 2 Hl 2 1 x 3 0 0 1515 I 1 xs l GA 3 GA 3 1 x 5 l 1 ES b b 3 E1 1 FB a a 3 F1 HUSQ l ma FS 450 HQV 2017 2018 I l I I I I I ...

Page 289: ...Components A11 EFI control unit M13 Fuel pump M51 Injection valve P25 Malfunction indicator lamp R30 CAN bus terminating resistor S20 Kill switch X295 Diagnostics connector WIRING DIAGRAM 29 287 ...

Page 290: ... 16 1 X16 I 1 X16 l f I f 1 t 7 f 2 B i 1 x5 tT 3 M S S f T 3 I _il s I I n HU 555 1NIMl IC8 MAP TC n 1 X15 NDX 3 X 3 I 5 _il s I I f f HV 2 lCR 1 X12 X11 B21 EE 1 r R51 I HV 2 1 x12 1i 1 f X1 4 tg Hf f AP 6 cM 2 I 1 X1 4 _il I I B34 r l x20 iJM 3 3 JM 3 I 1 X20 _il s I I I I I IE I IF I a 1 1 M tel FS 450 HQV 2017 2018 oi HUSQ l ma I 6 I 7 I I 4 5 I I 2 I 3 Cl Cl II ...

Page 291: ...or B34 Gear position sensor B37 Crankshaft speed sensor B41 Induction manifold pressure sensor B43 Throttle valve position sensor R51 Ignition coil S55 Map select switch Cable colors bl Black br Brown bu Blue gn Green gr Gray lbu Light blue or Orange pk Pink pu Violet rd Red wh White ye Yellow WIRING DIAGRAM 29 289 ...

Page 292: ...use coolant that complies with the requirements stated see specifications on the container and that has the relevant properties I Antifreeze protection to at least I 25 C 13 F The mixture ratio must be adjusted to the necessary antifreeze protection Use distilled water if the coolant needs to be diluted The use of premixed coolant is recommended Observe the coolant manufacturer specifications for ...

Page 293: ...5 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding properties Su er unleaded ROZ 95 RON 95 PON 91 Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to u...

Page 294: ...uel Stabilizer High viscosi grease Recommended supplier SKF LGHB 2 Long life grease Recommended supplier MOTOREX Bike Grease 2000 Lubricant 14034 Recommended supplier WP Performance Systems WP Racing Grease IPR 2 Lubricant T158 Recommended supplier Lubcon Turmogrease PP 300 Lubricant T625 Recommended supplier Molykote 33 Medium Lubricant T152 Recommended supplier Bel Ray Molylube Anti Seize 292 ...

Page 295: ... road chain SRra Recommended supplier MOTOREX Chainlube Offroad Oil for foam air filter Recommended supplier MOTOREX Racing Bio Liquid Power Preservin materials for aints metal and rubber Recommended supplier MOTOREX Moto Protect Special cleaner for lossy and matte paint finishes metal and plastic surfaces Recommended supplier MOTOREX Quick Cleaner Universal oil spray Recommended supplier MOTOREX ...

Page 296: ...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 294 ...

Page 297: ...essional Art no 00029095052 Feature UK safety plug Nominal voltage 230V Mains fuse 16 A Power cable length 5 m 16 ft approx Charger cable 5 m 16 ft H01065 01 length approx CH batte charger XChar e rofessional Art no 00029095053 Feature CH plug Nominal voltage 230V Mains fuse 16 A Power cable length 5 m 16 ft approx Charger cable 5 m 16 ft H01065 01 length approx Locking screw Art no 113080802 1130...

Page 298: ...17000 Internal bearing uller p 15112018100 Tachometer M 45129075000 s ringe 50329050000 296 H00520 01 H00522 01 H00525 01 H00565 01 Art no 15112017000 Art no 15112018100 Feature 118 23 mm 0 71 0 91 in Art no 45129075000 Art no 50329050000 ...

Page 299: ...37043 Tool bracket 2x 58429089000 Pressing tool 58429091000 H00572 01 H00598 01 H00603 01 H00604 01 Art no 51012011000 Art no 58429037043 Feature I Inside diameter Art no 58429089000 Art no 58429091000 SPECIAL TOOLS 32 I 43 9 mm 1 728 in 297 ...

Page 300: ...05 01 H00606 01 H00610 01 H00612 01 Art no 58429092000 Art no 58429094000 Feature Torque Open ended bit Open ended bit Open ended bit Open ended bit Bit diameter Art no 59029019000 Art no 59029026006 Feature I Diameter 3 15 Nm 2 2 11 1 lbf ft 3 9 mm 0 154 in 4 9 mm 0 193 in 5 5 mm 0 217 in 6 8 mm 0 268 in 5 9 mm 0 232 in I 6 05 mm 0 2382 in ...

Page 301: ...9033000 Pressing tool 60029043040 H00616 01 H00628 01 H00633 01 H00639 01 Art no 59029041100 Feature 15 piece Art no 60029015000 Feature Height Diameter Art no 60029033000 Art no 60029043040 SPECIAL TOOLS 32 I 0 10 0 25 mm 0 0039 0 0098 in 80 mm 3 15 in 57 125 mm 2 24 4 92 in 299 ...

Page 302: ...lamQ Qlier 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 01 300 ...

Page 303: ...2 Assembly screws 4x Art no 75029033000 75029033000 H00708 01 Pressing tool Art no 75029044010 75029044010 H00712 01 Pressing tool Art no 75029044020 75029044020 H00713 01 Art no 75029047000 75029047000 H00714 01 301 ...

Page 304: ...ate Art no 75029050000 75029050000 H00719 01 Pressing tool Art no 75029051000 75029051000 H00721 01 Protection ca Art no 75029090000 75029090000 H00726 01 Insert for valve s ring lever Art no 77029041200 77029041200 H00746 01 302 ...

Page 305: ...7329030100 H00768 01 Locking screw 78129032000 H00796 01 Insert for crankshaft ressing tool 78929008000 H01016 01 Art no 77229172000 Feature Drive Hexagonal part Length Art no 77329030100 Art no 78129032000 Art no 78929008000 SPECIAL TOOLS 32 3 8 in 14 mm 0 55 in 130 mm 5 12 in 303 ...

Page 306: ...08 01 Puller 79229048000 H00809 01 79412966000 H01687 01 304 Art no 79029083000 Art no 79229032044 Art no 79229048000 Art no 79412966000 Feature Maximum pressure Display Valve connection Units Material 20 bar 290 psi Digital pressure gauge Schrader valve bar psi and kg cm2 Aluminum tube ...

Page 307: ...for work stand 2x Art no 79429002000 79429002000 H01081 01 Pressing tool Art no 79429006000 79429006000 H01018 01 Insert for crankshaft ressing tool Art no 79429008000 79428008000 H01169 01 Se Art no 79429009000 79429009000 H00812 01 305 ...

Page 308: ...segment 80029004000 Engine assembl stand 80329001000 Lift stand 80329955100 306 H01045 01 H00813 01 H01047 01 H02016 01 Art no 79429094000 Art no 80029004000 Art no 80329001000 Art no 80329955100 Feature Height Load 260 370 mm 10 24 14 57 in 150 kg 331 lb ...

Page 309: ...2 Protection ca Art no 90129005000 90129005000 H00816 01 Hook wrench Art no 90129051000 90129051000 H00831 01 S ring hook Art no 5030501700004 5030501700004 H00973 01 De th micrometer Art no T107S T107S H00842 01 307 ...

Page 310: ... Pressing tool T1206 308 H00844 01 H00878 01 H00879 01 H00880 01 Art no T120 Feature I Diameter Art no T1204 Feature I Diameter Art no T1205 Feature I Diameter Art no T1206 Feature I Diameter I 8 mm 0 31 in I25 5 30 5 mm 1 004 1 201 in 118 mm 0 71 in 115 30 mm 0 59 1 18 in ...

Page 311: ...7S Pressing tool l T1216 Vacuum um T1240S Filling ada ter T1296 Art no T1207S H00881 01 Art no T1216 Feature I Diameter H00887 01 Art no T1240S H00890 01 Art no T1296 H01573 01 SPECIAL TOOLS 32 138 49 mm 1 5 1 93 in 309 ...

Page 312: ...lam ing stand 2x T1403S 310 H00894 01 H01036 01 H00904 01 H00896 01 Art no T1401 Feature I Diameter Art no T14016S Feature I Diameter Art no T14017 Feature I Hexagonal part Art no T1403S Feature Diameter Diameter I 48 mm 1 89 in I 12 mm 0 47in I 50 mm 1 97in 48 mm 1 89 in 60 mm 2 36 in ...

Page 313: ... 6 T14073 H00929 01 s ecial socket T14084 H01518 01 Art no T14040S Feature I Diameter Art no T14072 Feature I Diameter Art no T14073 Feature I Diameter Art no T14084 Feature I Drive Diameter SPECIAL TOOLS 32 I 48 mm 1 89 in I 37 mm 1 46 in 111 5 mm 0 453 in 4 mm 0 94 in 1 1 2 in 311 ...

Page 314: ...04 Mounting tool T150S Mounting sleeve T1515 Filling tool 2x 3x T170S1 312 H00899 01 H00852 01 H00900 01 H00855 01 Art no T1504 Feature I Diameter Art no T150S Art no T1515 Feature I Diameter Art no T170S1 118 mm 0 71 in 118 mm 0 71 in ...

Page 315: ...intervals are demanded for automobile engines the focus for motorcycle engines is on high performance at high engine speeds In most motorcycle engines the transmission and clutch are lubricated with the same oil The JASO T903 MA2 standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to...

Page 316: ...34 LIST OF ABBREVIATIONS Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly 314 ...

Page 317: ...ng 147 rear brake checking 153 Brake linings front brake changing 144 C front brake checking 144 of rear brake changing 150 rear brake checking 150 Capacitor checking 141 Capacity coolant 251 273 engine oil 172 255 273 Chain checking cleaning 127 130 Chain guide checking 127 Chain tension adjusting 127 checking 126 Characteristic map of the throttle response adjusting 50 Charging voltage checking ...

Page 318: ...g 214 spring length of the oil pressure control valve checking 192 timing chain sprocket installing 194 transmission checking 217 valves removing 205 316 water pump installing 193 Engine assembly alternator cover installing 239 camshaft installing 237 clutch basket installing 229 clutch cover installing 231 clutch discs installing 230 clutch push rod installing 241 crankshaft installing 223 cylind...

Page 319: ...djusting 153 free travel checking 152 Fork bearing changing 86 checking 82 Fork legs air cartridge assembling 31 air cartridge disassembling 25 air pressure adjusting 15 assembling 33 basic setting checking 14 bleeding 17 checking 28 compression damping adjusting 16 disassembling 21 dust boots cleaning 17 fork servicing 20 installing 19 rebound damping adjusting 16 removing 18 shock absorber cartr...

Page 320: ...53 318 Open circuit current checking 141 p Preparing for use after storage 281 R Rear sprocket checking 127 Rear wheel installing removing 125 124 Rebound damping fork adjusting 16 shock absorber adjusting 55 Riding sag adjusting 58 Right side cover installing removing 100 100 Rim run out checking 119 Rubber grips checking 47 s Seat mounting 101 removing 100 Service schedule 282 283 Servicing the ...

Page 321: ... function 13 Stator installing 261 removing 261 Steering head bearing changing 43 lubricating 39 Steering head bearing play adjusting 44 checking 42 Storage 280 iT Technical data capacities 273 chassis 273 chassis tightening torques 276 electrical system 274 engine 270 engine tolerance wear limits 271 engine tightening torques 271 fork 275 shock absorber 275 tires 274 Throttle cable play adjusting...

Page 322: ...111111111111111111111111111IIIIIIIIIIII 3403050en 07 2018 Husqvarna MOTORCYCLES Husqvarna Motorcycles GmbH _ _ StallhofnerstraBe 3 5230 Mattighofen Austria LZZa JUV Photo Mitterbauer www husqvarna motorcycles com Husqvarna Motorcycles GmbH ...

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