Husqvarna F2303R0 Repair Manual Download Page 145

Page: 145 / 333

WIRING HARNESS, BATTERY 15

Connect cables

to the starter relay.

Plug in connector

Mount the starter relay onto the holder and route the cables.

Finishing work

Connect the negative cable of the 12 V battery. (

p. 136)

Mount the seat. (

p. 101)

Install the air filter box cover. (

p. 96)

143

Summary of Contents for F2303R0

Page 1: ...PIONEERING SINCE 1903 REPAIR MANUAL2018 FS 450 Art no 3403060en 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 40 Installing the lower triple clamp 41 6 23 Checking steering head bearing play 43 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: ...lling the locking lever 231 Installing the shift drum locating unit 231 17 5 11 Installing the shift shaft 231 TABLE OF CONTENTS 17 5 12 Installing the force pump 231 17 5 13 Installing the starter idler gear 232 17 5 14 Installing the torque limiter 233 17 5 15 Installing the clutch basket 233 17 5 16 Installing the clutch discs 234 17 5 17 Installing the clutch cover 235 17 5 18 Installing the w...

Page 8: ... 280 25 1 Engine 280 25 2 Tolerance engine wear limits 281 25 3 Engine tightening torques 281 25 4 Capacities 283 25 4 1 Engine oil 283 25 4 2 Coolant 283 25 4 3 Fuel 283 25 5 Chassis 283 25 6 Electrical system 284 25 7 Tires 284 25 8 Fork 285 25 9 Shock absorber 285 25 10 Chassis tightening torques 286 26 CLEANING PROTECTIVE TREATMENT 288 26 1 Cleaning the motorcycle 288 27 STORAGE 290 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 314 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 connectin...

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 303 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 320 Release cartridge O using special tool 8 I Ring wrench T14017 8 p 320 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 320 Remove the screw Remove adjuster 8 on compression damping Loosen cartridge C Ring wrench T14017 0 p 320 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: ...emove piston D Remove end stop Remove spring pack 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 321 Loosen screw cap 8 1 Special socket T14084 0 p 321 Remove the screw cap with sh...

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 320 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 302 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 321 Lubricate friction ring on the shock absorber cartridge I Fork oil SAE 4 48601166S1 0 p 301 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 301 Lubricate O ring 41 on the screw cover I Lubricant T158 8 p 302 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 321 Assembling the air cartridge 803556 10 Slot special tool O over thread on p...

Page 34: ...rtridge Grease capacity left cartridge Clamp the air cartridge 11 ml 0 37 fl oz I Clamping stand T14072 a p 321 Multi purpose grease 00062010051 a p 303 Position the special tool in the cartridge I Mounting sleeve T14092 a p 322 Push the piston rod into the air cartridge Info The air cartridge must be absolutely clean on the inside Do not damage the gasket when inserting the piston Remove the spec...

Page 35: ...i I Fork airpump 79412966000 ra l p 314 Mount protection cap Info Only mount the protection cap by hand Preparatory work Check the fork legs ra l p 28 Left fork leg Clamp the inside fork tube using the axle clamp Guideline I Use soft jaws Mount the special tool I Protecting sleeve T1401 ra l p 320 Grease and push on dust boot O I Lubricant T14034 ra l p 302 The sealing lip is mounted with the spri...

Page 36: ...tack slightly apart by hand Warm up the outside fork tube in area 6 of the lower slide bearings Guideline I so 0 c 122 F Hold the lower slide bearing with the longer side of the special tool I Mounting tool T14040S 8 p 321 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 t...

Page 37: ... and outside fork tube with warning label 0 screw cartridge Slide the air cartridge into the inside fork tube Lubricate O ring I Lubricant T158 0 p 302 Mount and tighten the screw Guideline Screw cartridge on M20x1 45 Nm 33 2 lbf ft axle clamp Clamp the left fork leg vertically Guideline I Use soft jaws Fill with fork oil Oil capacity exter nal mechanism left 200 ig ml 6 76 g fl oz Fork oil SAE 4 ...

Page 38: ...h T14017 0 p 320 Right fork leg 50 Nm 36 9 lbf ft Clamp the inside fork tube using the axle clamp Guideline I Use soft jaws Mount the special tool I Protecting sleeve T1401 0 p 320 Grease and push on dust boot O I Lubricant T14034 0 p 302 The 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 ...

Page 39: ...k tube in area G of the lower slide bearings Guideline I so 0 c 122 F Hold the lower slide bearing with the longer side of the special tool I Mounting tool T14040S 8 p 321 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 321 Press the seal ...

Page 40: ...und adjuster I Lubricant T158 0 p 302 Mount and tighten the rebound adjuster Guideline Rebound adjuster on the axle clamp M20x1 Clamp the left fork leg vertically Guideline I Use soft jaws Fill with fork oil Oil capacity exter nal mechanism right 200 18 ml 6 76 Jg fl oz 45 Nm 33 2 lbf ft Fork oil SAE 4 48601166S1 0 p 301 Lubricate O ring fD on the shock absorber cartridge I Lubricant T158 0 p 302 ...

Page 41: ...rre sponding to the fork type Guideline Compression damping Comfort Standard Sport Rebound damping Comfort Standard Sport Mount protection cap 48 Condition Value determined on removal 15 clicks 12 clicks 9 clicks 15 clicks 12 clicks 9 clicks Turn compression adjusting screw Gi and rebound adjusting screw 48 clockwise all the way Turn the adjusting screws to the position they were in before removin...

Page 42: ...ve front fender 8 p 114 Main work Remove indicator lamp holder Open cable holder O on the left and detach the wiring har ness Remove screw 8 Remove screw fD Take off the upper triple clamp with the handlebar and place to one side Info Cover the components to protect them against dam age Do not kink the cables and lines Remove 0 ring 8 Remove protective ring 0 Remove the lower triple clamp with the...

Page 43: ... ring 8 Position the upper triple clamp with the handlebar Mount screw 8 but do not tighten yet Guideline Screw top steering head Position the fork legs M20x1 5 12 Nm 8 9 lbf ft Air bleeder screw 0 of the right fork leg is positioned to the front Valve f of the left fork leg faces the front Info Grooves are milled into the side of the upper end of the fork legs The second milled groove from the to...

Page 44: ...9 lbf ft 12 Nm 8 9 lbf ft 20 Nm 14 8 lbf ft Loctite 243 Using a plastic hammer tap lightly on the upper triple clamp to avoid stresses Tighten screws Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Secure the wiring harness with cable holder on the left Mount indicator lamp holder Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake line and the clamp Mount and tighten s...

Page 45: ...eriod with play in the steering head bearing the bearings and the bearing seats in the frame can become damaged over time Preparatory work Raise the motorcycle with a lift stand 0 p 12 Main work Move the handlebar to the straight ahead position Move the fork legs to and fro in the direction of travel Play should not be detectable on the steering head bear ing If there is detectable play Adjust ste...

Page 46: ...amp 8 p 40 Main work Remove lower bearing ring O with special tool 8 Tool bracket 58429089000 8 p 307 Pressing tool 58429092000 8 p 308 Press the new bearing ring up to the stop with special tool CD Tool bracket 58429089000 8 p 307 Pressing tool 58429091000 8 p 308 Remove upper bearing ring C with special tool Tool bracket 58429089000 8 p 307 Pressing tool 58429092000 0 p 308 Press the new bearing...

Page 47: ... head bearing play a p 43 Remove the motorcycle from the lift stand a p 12 Ad usting steering head bearing la Preparatory work Raise the motorcycle with a lift stand a p 12 Remove the handlebar cushion Main work Loosen screws O Remove screw 8 Loosen and retighten screw Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid s...

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 314 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 314 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 319 ...

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 322 69 ...

Page 72: ...rt seal ring retainer 8 with sleeve 9 of the special tool I Mounting tool T150S 0 p 322 Press the special tool through the new pilot bushing I Calibrating unit T1205 8 p 318 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 318 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 319 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 318 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 302 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 322 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 302 Lubricate the thread I Lubricant T159 8 p 303 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 317 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: ...mper 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 switc...

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 323 Filling adapter T1296 8 p 319 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 317 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: ...Remove 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 Nut fork pivot M16x1 5 100 Nm 73 8 lbf ft ...

Page 87: ...itting 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 cylinder M6 10 Nm 7 4 lbf ft Mount and tighten screw with the ...

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 302 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 302 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 318 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 319 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 317 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 317 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: ...uideline 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 hi...

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: ...ing pin fj is secured with 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 ...

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

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: ...nse 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 disconn...

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 302 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 302 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 302 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 Info WHEELS 14 Cover the com...

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 302 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 284 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: ...attery 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 t...

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 300 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 300 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 300 Mount bleeder cover 8 I Bleeder cover 00029013002 0 p 304 Connect the bleeding device I Bleeding device 00029013100 0 p 304 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 300 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 F01125 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 304 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 317 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 317 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 300 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 262 Check the coolant level a p 259 Mount the special tool on the engine assembly stand Holder and fitting for work stand 79429002000 a p 315 Engine assembly stand 80329001000 a p 316 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 307 ...

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 313 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 305 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: ...ver Info If work is to be performed on the water pump unscrew the nut of the water pump impeller Remove dowels 8 Take off clutch cover gasket fs ENGINE 17 Loosen screws O in a crisscross pattern and remove them Take off clutch pressure cap Remove clutch throw out fs Take out clutch disc pack C entirely 181 ...

Page 184: ...et and primary gear wheel using special tool O I Gear segment 80029004000 0 p 316 Remove nut Info LH thread Hold the inner clutch hub with the special tool I Holding wrench 51129003000 0 p 307 Remove nut 8 with the lock ring Take off inner clutch hub C and washer Info The washer usually sticks to the inner clutch hub Take off clutch basket 0 ...

Page 185: ...gs and collar bushing ti 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 312 Mount special tool I Puller 75029021000 8 p 311 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 315 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 310 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 309 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 311 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 315 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 313 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 309 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 0 08 mm 0 0031 in Oil scraper ring I 0 08 mm 0 0031 in I Feeler gauge 59029041100 0 p 309 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 309 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 308 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 312 Remove the large camshaft bearing using special tool O I Pressing tool 75029051000 0 p 312 Remove small camshaft bearing 8 using the special tool Bearing puller 15112017000 0 p 306 Internal bearing puller 15112018100 0 p 306 Remove shaft seal ring fD using a suitable tool Press the ...

Page 209: ...pecial tool 0 Pressing tool 75029044010 IUI p 311 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: ...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 1 9 2 1 mm 0 075 0 083 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 8 p 309 If the special tool is easy to in...

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: ...tighten screw plugs with the O ring Guideline Screw plug rocker arm shaft M10x1 25 10 Nm 7 4 lbf ft 17 4 36 Disassembling the antihopping clutch D04579 10 D04580 10 D04581 10 D04582 10 Remove outer lock ring O Remove outer pretension ring Remove outer spring washer Remove inner pretension ring 8 41 211 ...

Page 214: ...0 D04584 10 D04585 10 D04586 10 D04587 10 212 Remove inner lock ring 0 Remove spacer ring D Remove inner spring washer Remove release ring Loosen screws in a crisscross pattern and remove them Take off the clutch center ...

Page 215: ... the clutch 0 p 216 17 4 37 Preassembling the antihopping clutch D04590 10 D04589 11 D04588 11 Position ball bearing basket O The cut outs for the ball bearings face upward Grease and position the ball bearings I Long life grease 0 p 302 Position inner clutch hub holder The gearing faces upward ENGINE 17 213 ...

Page 216: ...ws C and tighten in a crisscross pattern Guideline Screw inner M6 10 Nm 7 4 lbf ft clutch hub Loctite 243 holder Position release ring 0 The rounded side faces downward Position inner spring washer D The curved side faces upward Position spacer ring The sharp edge faces upward Mount inner lock ring CD ...

Page 217: ...04579 11 Position inner pretension ring with the collar facing upward Position outer spring washer The curved side faces downward Position outer pretension ring 41 with the collar facing upward Mount outer lock ring 48 ENGINE 17 215 ...

Page 218: ... ring C for damage and wear If there is damage or wear Change outer pretension ring Check outer spring washer 0 for damage and wear If there is damage or wear Change outer spring washer Check inner pretension ring D for damage and wear If there is damage or wear Change inner pretension ring Check inner spring washer for damage and wear If there is damage or wear Change inner spring washer Check re...

Page 219: ...iscs in clutch basket for wear Thrust surface clutch facing discs in outer clutch hub If the thrust surface exhibits excessive wear 0 5 mm 0 02 in Change the clutch facing discs and the clutch basket Check needle bearings 48 and collar bushing Cli for damage and wear If there is damage or wear Change the needle bearings and collar bushing Check clutch facing discs G for discoloration and scoring I...

Page 220: ...lers C for surface damage and cracking If the shift roller exhibits surface damage or cracking Change the shift roller Check springs 0 of the shift rails for damage and wear If the spring is broken or worn Change the spring of the shift rail Check shift rails D on a flat surface for run out If there is run out Change the shift rail Check the shift rails for scoring seizure marks and stiffness in t...

Page 221: ...Shift shaft play in sliding plate shift quadrant 0 40 0 80 mm 0 0157 0 0315 in If the measured value does not meet specifications Change the sliding plate Secure the short end of the shift shaft in the bench vise Guideline I Use soft jaws Mount sliding plate O with the guide pin facing downward and put the guide pin on the shift quadrant Mount pressure spring Slide on spring guide D push return sp...

Page 222: ...the vise with the gear teeth facing downward Guideline I Use soft jaws Remove stop disk O and second gear fixed gear f Remove lockring D Remove distance sleeve C Remove third fourth gear sliding gear C Remove lockring Cs and stop disk Remove fifth gear idler gear Remove needle bearing 220 ...

Page 223: ...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 224: ...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 225: ... assembling Check the transmission 0 p 221 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 226: ... 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 227: ...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 228: ... 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 229: ...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 300 Slide crankshaft O into the bearing seat Info Ensure that washer 8 is not damaged 227 ...

Page 230: ... 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 231: ...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 229 ...

Page 232: ... 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 233: ...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 234: ...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 232 Slide on starter idler gear O with the collar facing the engine case ...

Page 235: ...im 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 Slide on washer 0 and inner clutch hub D Mount nut with the lock ring Tighten the nut holding the inner clutch hub with a special tool Guideline I Nut inner clutch hub I M18x1 5 I 80 Nm 59 lbf ft I Holding ...

Page 236: ... with special tool I Locking screw 113080802 IUI p 305 Mount sleeves O Thoroughly oil the clutch facing discs Mount intermediate clutch disc f with marking S Guideline Thickness of intermediate clutch disc f 1 0 mm 0 039 in Alternately place the clutch facing and 7 intermediate discs into the clutch basket Guideline Thickness of intermediate clutch discs 1 4 mm 0 055 in Place intermediate clutch d...

Page 237: ... pressure cap may cause the clutch to slip Align the holes of the clutch pressure cap with the spring washer and the pretension ring Mount screws 8 and tighten in a crisscross pattern Guideline Screw clutch pres sure cap M5 8 Nm 5 9 lbf ft Position the balancer shaft with special tool O I Locking screw 78129032000 p 313 Marking f and the special tool are aligned Mount dowels 8 and position the clu...

Page 238: ...t tern Guideline I Screw clutch cover I M6x30 110 Nm 7 4 lbf ft Remove the special tool I Locking screw 78129032000 8 p 313 17 5 18 Installing the water pump cover 236 Put the water pump cover seal in place Mount the water pump cover Mount screw O with the sealing washer but do not tighten yet Guideline Screw water pump cover M6x25 Mount screw f but do not tighten yet Guideline 10 Nm 7 4 lbf ft Sc...

Page 239: ...5 Nm 3 7 lbf ft Loctite 243 Oil the internal rotor and external rotor before mounting Insert 0 ring O Position pin fj into the oil pump shaft from above Position pin D Mount internal rotor 8 and external rotor t The rounded sides of the external rotor face the engine case Position oil pump cover 3 Mount and tighten screws Guideline Screw suction pump cover M5 6 Nm 4 4 lbf ft Loctite 243 237 ...

Page 240: ...ing 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 8 from above Mount and tighten screw CD Guideline Screw timing M6 chain tension ing rail Mount the woodruff key Mount the rotor 10 Nm 7 4 lbf ft Loctite 243 Mount and tighten nut O with the spring washer Guideline Nut rotor M12x1 60 N...

Page 241: ...ssor 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 piston into the cylinder by striking it carefully with the hammer handle The piston rings should not catch or they will be dam aged Mount timing chain guide rail O from above The holding lug G engages in the recess ...

Page 242: ...perly Ensure that piston marking C faces the exhaust side Cover the engine case opening with a cloth Feed the timing chain through the timing chain shaft and mount the piston pin Info For purposes of illustration the following operations are shown on the removed piston Position the piston ring lock ...

Page 243: ...hat 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 Put the cylinder head in place Mount screws D with the washers and tighten them in a crisscross pattern Guideline Screw cylinder head M10x1 25 1st stage 10 Nm 7 4 lbf ft 2nd stage 3...

Page 244: ...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 bracket 17 5 26 Installing the timing chain tensioner 306359 10 242 Activate release 6 and push the timing chain tensioner all the way back Position the timing chain tensioner with the gasket Mo...

Page 245: ... 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 ra l p 309 If the valve clearance does not meet specifications Adjust the valve clearance ra l p 243 Remove the special tool I Locking screw 113080802 ra l p 305 Mount and tighten screw with washer 17 5 28 Adjusting the ...

Page 246: ...clearance 8 p 243 17 5 29 Installing the alternator cover 17 5 30 Installing the valve cover 244 Position alternator cover gasket O Position the alternator cover Mount screws 8 with the washers but do not tighten yet Guideline Screw alternator cover M6x25 10 Nm 7 4 lbf ft Mount screws 8 and tighten all screws in a crisscross pat tern Guideline Screw alternator cover M6x25 Position the valve cover ...

Page 247: ...0 0 p 313 Grease the O ring Insert the starter motor I Long life grease 0 p 302 Mount and tighten screws O Guideline I Screw starter motor I M6 10 Nm 7 4 lbf ft Tilt the motorcycle to one side and fill the oil filter housing to about full with engine oil Insert oil filter O into the oil filter housing Lubricate the O ring of the oil filter cover Mount oil filter cover 8 Mount and tighten screws Gu...

Page 248: ...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 ring Guideline Screw plug oil screen M20x1 5 15 Nm 11 1 lbf ft Mount and tighten oil drain plug 8 with the magnet and a new seal ring Guideline ...

Page 249: ...the engine assembly stand Remove the fitting from the special tool ENGINE 17 I Holder and fitting for work stand 79429002000 p 315 Remove the engine from the engine assembly stand Info I Work with an assistant or a motorized hoist 247 ...

Page 250: ...e 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 L 2 Move the clutch fluid reservoir mounted on t...

Page 251: ...ispose 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 Move...

Page 252: ...lames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhal...

Page 253: ...g O Remove screws 8 Take off the clutch cover with the gasket Loosen screws 8 in a crisscross pattern and remove them Take off clutch pressure cap 8 Take off clutch throw out 0 with clutch push rod Q Remove sleeves 251 18 ...

Page 254: ...00 p 307 Remove nut with the lock ring Take off inner clutch hub Gi and washer 48 Info The washer usually sticks to the inner clutch hub Take off clutch basket 48 Take off both needle bearings 48 and collar bushing e Info The needle bearing and collar bushing may be in the clutch basket Disassemble the antihopping clutch p 211 ...

Page 255: ...hange outer pretension ring Check outer spring washer Ci for damage and wear If there is damage or wear Change outer spring washer Check inner pretension ring 4D for damage and wear If there is damage or wear Change inner pretension ring Check inner spring washer Qi for damage and wear If there is damage or wear Change inner spring washer Check release ring G for damage and wear If there is damage...

Page 256: ...n outer clutch hub If the thrust surface exhibits excessive wear 5 0 5 mm 5 0 02 in Change the clutch facing discs and the clutch basket Check needle bearings 41 and collar bushing 4D for damage and wear If there is damage or wear Change the needle bearings and collar bushing Check clutch facing discs for discoloration and scoring If there is discoloration or scoring Change all clutch facing discs...

Page 257: ... 5 I 80 Nm 59 lbf ft I Holding wrench 51129003000 p 307 Mount sleeves Thoroughly oil the clutch facing discs Mount intermediate clutch disc G with marking S Guideline Thickness of intermediate clutch disc G 1 0 mm 0 039 in Alternately place the clutch facing and 7 intermediate discs into the clutch basket Guideline Thickness of intermediate clutch discs 1 4 mm 0 055 in Place intermediate clutch di...

Page 258: ...itioning of the clutch pressure cap may cause the clutch to slip Align the holes of the clutch pressure cap with the spring washer and the pretension ring Mount screws and tighten in a crisscross pattern Guideline Screw clutch pres sure cap M5 Position the clutch cover with the gasket Mount and tighten screws 8 Guideline I Screw clutch cover M6 Attach spring O 8 Nm 5 9 lbf ft 10 Nm 7 4 lbf ft ...

Page 259: ...D04678 10 Place vehicle in upright position and rest on the plug in stand Finishing work Check the engine oil level p 262 CLUTCH 18 257 ...

Page 260: ...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 261: ...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 262: ...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 263: ...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 300 Mount the radiator cap Take a short test ride Check the coolant level 0 p 259 261 ...

Page 264: ...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 262 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 265: ...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 266: ...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 267: ...hten the screws Guideline I Screw oil filter cover I M6 Stand the motorcycle upright 110 Nm 7 4 lbf ft Remove filler plug D with the O ring and fill up with engine oil Engine oil Info 1 20 I Engine oil 1 27 qt SAE 10W 50 a p 300 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 Danger Danger of ...

Page 268: ... 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 269: ...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 270: ...20 LUBRICATION SYSTEM Finishing work Check the engine oil level 0 p 262 268 ...

Page 271: ...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 272: ...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 273: ...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 274: ...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 313 Push back hose clamp fD Pull off the air release hose Remove screws C Remove the valve cover with the gasket ...

Page 275: ...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 309 If the valve clearance does not meet specifications Adjust the valve clearance a p 243 Remove locking screw 0 Crank the engine several times Check the valve cleara...

Page 276: ...29172000 0 p 313 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 274 Preparatory work Raise the motorcycle with a lift stand 0 p 12 Remove the right side cover 0 p 100 Rem...

Page 277: ...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 in the rocker arm shafts with drill holes in the cylinder head Install and tighten screws 8 and 8 of the rocker arm shafts Guideline Screw roc...

Page 278: ...nishing work Check the valve clearance 8 p 272 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 279: ...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 277 ...

Page 280: ...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 306 Performing the initialization run Condition Info Turning counterclockwise lowers the idle speed Turning clockwise raises the idle speed The diagnosti...

Page 281: ...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 282: ...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 283: ...0 mm 0 00472 in Piston ring end gap Compression ring s 0 08 mm S 0 0031 in Oil scraper ring s 0 08 mm s 0 0031 in Piston ring groove clearance s 0 08 mm S 0 0031 in Connecting rod end play of lower conrod bearing 0 20 0 45 mm 0 0079 0 0177 in Crankshaft axial play 0 50 0 60 mm 0 0197 0 0236 in Crankshaft run out on bearing pin s 0 16 mm s 0 0063 in Clutch disc pack thickness Wear limit 26 4 mm 1 0...

Page 284: ...h cover M6 10 Nm 7 4 lbfft Screw cylinder head M6 10 Nm 7 4 lbfft Screw engine case M6 10 Nm 7 4 lbfft Screw exhaustflange M6 10 Nm 7 4 lbfft Loctite 243 Screw inner clutch hub holder M6 10 Nm 7 4 lbfft Loctite 243 Screw oilfilter cover M6 10 Nm 7 4 lbfft Screw pressure pump cover M6 10 Nm 7 4 lbfft Loctite 243 Screw shi ft drum locating M6 10 Nm 7 4 lbfft Loctite 243 Screw shi ft lever M6 14 Nm 1...

Page 285: ...UI p 301 25 5 Chassis Frame Fork Suspension travel front rear Fork offset Shock absorber TECHNICAL DATA 25 8 Nm 5 9 lbf ft 10 Nm 7 4 lbf ft 15 Nm 11 1 lbf ft 60 Nm 44 3 lbf ft Loctite 243 Loctite 2701 TM 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 ...

Page 286: ...eering head angle 63 9 Wheelbase 1 475 10 mm 58 07 0 39 in Ground clearance unloaded 290 mm 11 42 in Seat height unloaded 890 mm 35 04 in Weight without fuel approx 104 8 kg 231 lb Maximum permissible front axle load 145 kg 320 lb Maximum permissible rear axle load 190 kg 419 lb Maximum permissible overall weight 335 kg 739 lb 25 6 Electrical s stem 12 V battery HJTZ5S FP Lithium ion battery Batte...

Page 287: ... Fork oil SAE 4 48601166S1 a p 301 Grease capacity left cartridge 11 ml 0 37 fl oz Multi purpose grease 00052010051 a p 303 25 9 Shock absorber Shock absorber article number 18 15 7R 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 ...

Page 288: ...ew 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 Screw bottom triple clamp M8 Screw chain sliding piece M8 286 Shock absorber fluid SAE 2 5 50180751S1 0 p 301 3 5 Nm 2 58 lbf ft 0 7 Nm 0 52 l...

Page 289: ...t wheel spindle Nut rear wheel spindle 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 25 Nm 18 4 lbf ft 15 Nm 11 1 lbf ft 20 Nm 14 8 lbf ft 30 Nm 22 1 lbf ft 20 Nm 14 8 lbf ft 17 Nm 12 5 lbf ft 60 Nm 44 3 lbf ft 45 Nm 33 2 lbf ft 45 Nm 33 2 lbf ft 60 Nm 44 3 lbf ft 40 Nm 29 5 lbf ft 60 Nm 44 3 lbf ft 45 Nm 33...

Page 290: ...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 303 I Info Use warm water containin...

Page 291: ...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 303 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 303 41 289 26 ...

Page 292: ...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 302 Refuel Clean the motorcycle p 288 Change the engine oil and oil filter and clean the oil screens p...

Page 293: ...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 41 291 ...

Page 294: ...aring for play 8 p 82 I I I I I Check the heim joint for play 0 p 89 I I I I I Check the shock absorber linkage 8 p 62 I I I Check the tire condition 8 p 116 0 I I I Check tire pressure 0 p 116 0 I I I I I Check the wheel bearing for play 0 p 117 I I I I I Check the wheel hubs I I I Check the rim run out l l p 119 0 I I I Check the spoke tension 8 p 118 0 I I I Check the chain rear sprocket engine...

Page 295: ...terval 28 3 Recommended work Annually Every 100 operating hours Every 50 operating hours Once after 20 operating hours Once after 10 operating hours Change the front brake fluid ral p 148 Change the rear brake fluid ral p 155 Change the hydraulic clutch fluid ral p 249 Lubricate the steering head bearing ral p 39 Service the fork 0 p 20 Service the shock absorber 0 p 64 Change the fuel filter ral ...

Page 296: ...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 297: ...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 29 295 ...

Page 298: ... 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 299: ...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 29 297 ...

Page 300: ...X16 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 II ...

Page 301: ...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 29 299 ...

Page 302: ...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 303: ...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 304: ...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 302 ...

Page 305: ... 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 306: ...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 304 ...

Page 307: ...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 308: ...17000 Internal bearing uller p 15112018100 Tachometer M 45129075000 s ringe 50329050000 306 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 309: ...012011000 51012011000 H00572 01 Holding wrench Art no 51129003000 r 51129003000 H00575 01 Puller Art no 58429037043 Feature I Inside diameter I 43 9 mm 1 728 in 58429037043 H00598 01 Tool bracket Art no 58429089000 2x 58429089000 H00603 01 307 ...

Page 310: ...0606 01 Valve s ring mounter 59029019000 H00610 01 308 Art no 58429091000 Art no 58429092000 Art no 58429094000 Feature Torque Open ended bit Open ended bit Open ended bit Open ended bit Bit diameter Art no 59029019000 3 15 Nm 2 2 11 1 lbf ft 3 9 mm 0 154 in 4 9 mm 0 193 in 5 5 mm 0 217 in 6 8 mm 0 268 in 5 9 mm 0 232 in ...

Page 311: ...r 60029015000 H00628 01 Puller 2x 60029033000 H00633 01 Art no 59029026006 Feature I Diameter Art no 59029041100 Feature 15 piece Art no 60029015000 Feature Height Diameter Art no 60029033000 SPECIAL TOOLS 32 I 6 05 mm 0 2382 in I 0 10 0 25 mm 0 0039 0 0098 in 80 mm 3 15 in 57 125 mm 2 24 4 92 in 309 ...

Page 312: ...tool Art no 60029043040 60029043040 H00639 01 Hose clamQ Qlier Art no 60029057000 60029057000 H00650 01 Testing hose Art no 61029093000 61029093000 H00659 01 Pressure testin tool Art no 61029094000 4x D 61029094000 H00660 01 310 ...

Page 313: ...OOLS 32 Puller Art no 75029021000 75029021000 H00707 01 Pressing tool Art no 75029044010 75029044010 H00712 01 Pressing tool Art no 75029044020 75029044020 H00713 01 Art no 75029047000 75029047000 H00714 01 311 ...

Page 314: ...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 01 312 ...

Page 315: ...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 313 ...

Page 316: ...08 01 Puller 79229048000 H00809 01 79412966000 H01687 01 314 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 317: ...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 01 315 ...

Page 318: ...segment 80029004000 Engine assembl stand 80329001000 Lift stand 80329955100 316 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 319: ...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 01 317 ...

Page 320: ... Pressing tool T1206 318 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 321: ...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 319 ...

Page 322: ...lam ing stand 2x T1403S 320 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 323: ... 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 321 ...

Page 324: ...ool T1504 Mounting tool T150S Mounting sleeve T1515 322 H02261 01 H00899 01 H00852 01 H00900 01 Art no T14092 Feature I Diameter Art no T1504 Feature I Diameter Art no T150S Art no T1515 Feature I Diameter I 34 mm 1 34 in 118 mm 0 71 in 118 mm 0 71 in ...

Page 325: ...SPECIAL TOOLS 32 Filling tool 2x 3x Art no T170S1 T170S1 H00855 01 323 ...

Page 326: ...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 327: ...LIST OF ABBREVIATIONS 34 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly 325 ...

Page 328: ...ake changing rear brake checking 326 122 126 118 147 148 155 154 147 153 144 144 150 150 Capacitor checking 141 Capacity coolant 261 283 engine oil 172 265 283 Chain checking cleaning Chain guide checking Chain tension adjusting checking 127 130 127 127 126 Characteristic map of the throttle response adjusting 50 Charging voltage checking 140 Clutch fluid level checking correcting 248 fluid changi...

Page 329: ...g 221 valves removing 205 water pump installing 193 Engine assembly alternator cover installing 244 camshaft installing 242 clutch basket installing 233 clutch cover installing 235 clutch discs installing 234 clutch push rod installing 246 crankshaft installing cylinder head installing engine removing from the engine assembly 227 241 stand 247 force pump installing 231 freewheel gear installing 23...

Page 330: ...tridge 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 16 328 removing 18 shock absorber cartridge assembling 29 shock absorber cartridge disassembling 26 Fork part number 1 0 Fork p...

Page 331: ...ging 262 263 Oil pressure checking 266 Oil pressure control valve installing 192 removing 191 spring length checking 192 Oil screens cleaning 263 Open circuit current checking 141 p Preparing for use after storage 291 mounting 101 removing 100 Service schedule 292 293 Servicing the fork 20 Servicing the shock absorber 64 Shock absorber damper assembling 75 damper bleeding and filling 77 damper che...

Page 332: ...ng 44 lubricating 39 Steering head bearing play adjusting 45 checking 43 Storage 290 iT Technical data capac es 283 chassis 283 chassis tightening torques 286 electrical system 284 engine 280 engine tolerance wear limits 281 engine tightening torques 281 fork 285 shock absorber 285 tires 284 Throttle cable play adjusting 49 330 checking 48 Throttle cable routing checking 48 Tire condition checking...

Page 333: ...111111111111111111111111111IIIIIIIIIIII 3403060en 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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Husqvarna F2303R0, Repair Manual

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