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Husqvarna F2303V4, Owner'S Manual

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Husqvarna F2303V4 Owner'S Manual Download Page 88

12 SERVICE WORK ON THE CHASSIS

86

Finishing work

–

Install the fuel tank.

(

p. 78)

–

Install the right side cover. (

p. 72)

–

Mount the seat. (

p. 68)

–

Install the air filter box cover. (

p. 69)

12.41

Checking the rubber grip

401197-01

–

Check the rubber grips on the handlebar for damage, wear,
and looseness.

Info

The rubber grips are vulcanized onto a sleeve on the
left and onto the handle tube of the throttle grip on the
right. The left sleeve is clamped onto the handlebar.
The rubber grip can only be replaced with the sleeve
or the throttle tube.

» If a rubber grip is damaged, worn, or loose:

–

Change the rubber grip.

F03502-10

(All EU models)

–

Check that screw

1

is firmly seated.

Guideline

Screw, fixed
grip

M4

5 Nm (3.7 lbf ft)

Loctite

®

243™

Diamond

A

must be positioned visibly as shown in

the figure.

F03522-10

(US)

–

Check that screw

1

is firmly seated.

Guideline

Screw, fixed
grip

M4

5 Nm (3.7 lbf ft)

Loctite

®

243™

Diamond

A

must be positioned visibly as shown in

the figure.

12.42

Adjusting the basic position of the clutch lever

F03503-10

–

Adjust the basic position of the clutch lever to your hand size
by turning adjusting screw

1

.

Summary of Contents for F2303V4

Page 1: ...OWNER S MANUAL 2022 FE 450 FE 501 Art no 3402542en ...

Page 2: ......

Page 3: ...rms 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 Motorcycles accepts no liability for delivery options deviations from illustrations and descriptions as well as misprints and other errors The models por trayed partly contain special e...

Page 4: ...13 Overview of indicator lights US 21 6 14 Opening fuel tank filler cap 21 6 15 Closing the fuel tank filler cap 22 6 16 Cold start button 22 6 17 Idle speed adjusting screw 23 6 18 Shift lever 23 6 19 Foot brake lever 24 6 20 Side stand 24 6 21 Steering lock All EU models 24 6 22 Locking the steering All EU models 25 6 23 Unlocking the steering All EU models 25 7 COMBINATION INSTRUMENT 26 7 1 Com...

Page 5: ...tector 56 12 6 Installing the fork protector 57 12 7 Removing the fork legs 57 12 8 Installing the fork legs 58 12 9 Removing the lower triple clamp 58 12 10 Installing the lower triple clamp 59 12 11 Checking the steering head bearing play 61 12 12 Adjusting the steering head bearing play 62 12 13 Lubricating the steering head bearing 63 12 14 Removing front fender 63 12 15 Installing front fende...

Page 6: ...ng the turn signal bulb All EU models 116 15 10 Checking the headlight setting 117 15 11 Adjusting the headlight range 118 15 12 Changing the combination instrument battery 118 15 13 Diagnostics connector 119 16 COOLING SYSTEM 120 16 1 Cooling system 120 16 2 Checking the antifreeze and coolant level 120 16 3 Checking the coolant level 121 16 4 Draining the coolant 121 16 5 Refilling with coolant ...

Page 7: ...hassis tightening torques 151 24 SUBSTANCES 154 25 AUXILIARY SUBSTANCES 156 26 STANDARDS 158 27 INDEX OF SPECIAL TERMS 159 28 LIST OF ABBREVIATIONS 160 29 LIST OF SYMBOLS 161 29 1 Yellow and orange symbols 161 29 2 Green and blue symbols 161 INDEX 162 ...

Page 8: ...cially trained experts using the specialist tools required Indicates a page reference more information is provided on the specified page Indicates information with more details or tips Indicates the result of a testing step Indicates a voltage measurement Indicates a current measurement Indicates the end of an activity including potential rework 1 2 Formats used The typographical formats used in t...

Page 9: ...nian and EPA emission requirements for offroad motorcycles This vehicle is not designed for use in racing on closed circuits or for Motocross use 2 2 Misuse The vehicle must only be used as intended Dangers can arise for people property and the environment through use not as intended Any use of the vehicle beyond the intended and defined use constitutes misuse Misuse also includes the use of opera...

Page 10: ...orated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below 1 Removal or puncturing of the main silencers baffles manifolds...

Page 11: ... safety risk Wear appropriate protective clothing such as helmet boots gloves as well as trousers and a jacket with protectors on all rides Always wear protective clothing that is in good condition and meets the legal regulations In the interest of your own safety Husqvarna Motorcycles recommends that you only operate the vehicle while wearing protective clothing 2 8 Work rules Unless specified ot...

Page 12: ...ual contains useful information and many tips on how to operate handle and service your motor cycle This is the only way to find out how best to customize the vehicle for your own use and how you can protect yourself from injury Tip Store the Owner s Manual on your terminal device for example so that you can read it whenever you need to If you would like to know more about the vehicle or have ques...

Page 13: ...rent Husqvarna Motorcycles accessories for your vehicle are available from your authorized Husq varna Motorcycles dealer and on the Husqvarna Motorcycles website International Husqvarna Motorcycles website www husqvarna motorcycles com 3 4 Service A prerequisite for perfect operation and prevention of premature wear is that the service care and tuning work on the engine and chassis is properly car...

Page 14: ...dealer will be happy to answer any questions you may have regarding your vehicle and Husqvarna Motorcycles A list of authorized Husqvarna Motorcycles dealers can be found on the Husqvarna Motorcycles website International Husqvarna Motorcycles website www husqvarna motorcycles com ...

Page 15: ...VEHICLE 4 13 4 1 View of vehicle front left example F03542 10 1 Hand brake lever p 17 2 Clutch lever p 17 3 Fuel tank filler cap 4 Air filter box cover 5 Side stand p 24 6 Engine number p 15 7 Shift lever p 23 ...

Page 16: ...dels 2 Light switch p 18 All EU models 2 Turn signal switch p 19 All EU models 3 Start button p 19 4 Emergency OFF switch p 19 All EU models 5 Throttle grip p 17 6 Fork rebound adjustment 7 Foot brake lever p 24 8 Level viewer engine oil 9 Shock absorber compression adjuster bk Shock absorber rebound adjuster bl Level viewer for brake fluid rear ...

Page 17: ...EU models V01808 10 The Europe type label 1 is fixed to the front of the steering head The Canada type label 2 is fixed to the front of the chest tube 5 3 Key number All EU models H02475 10 Key number 1 for the steering lock is stamped on a tag on the key ring 5 4 Engine number H00940 01 Engine number 1 is embossed on the left side of the engine behind the shift lever ...

Page 18: ...1947 10 The fork part number 1 is stamped on the inner side of the fork stub 5 6 Shock absorber article number H02222 10 Shock absorber article number 1 is stamped on the top of the shock absorber above the adjusting ring towards the engine side ...

Page 19: ...ti cally 6 2 Hand brake lever F03492 10 The hand brake lever 1 is fitted on the right side of the handle bar The hand brake lever is used to activate the front brake 6 3 Throttle grip F03493 10 The throttle grip 1 is fitted on the right side of the handlebar 6 4 Stop button F03494 10 All EU models The stop button 1 is fitted on the left side of the handlebar ...

Page 20: ...n button is pressed The horn is operated in this position 6 6 Light switch All EU models F03494 12 Light switch 1 is fitted on the left side of the handlebar Possible states Low beam on Light switch is in the central posi tion In this position the low beam and tail light are switched on High beam on Light switch is turned to the left In this position the high beam and the tail light are switched o...

Page 21: ...cy OFF switch 1 is fitted on the right side of the handlebar Possible states Ignition off In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start Ignition on In this position the ignition circuit is closed and the engine can be started 6 10 Start button F03497 10 All EU models Start button 1 is fitted on the right side of the handlebar F0...

Page 22: ...ad permit if any expires Only operate the vehicle in closed off areas remote from public road traffic if the combination switch is installed The engine characteristic can be changed using button MAP on the combination switch The traction control can also be activated via the combination switch 6 12 Overview of indicator lights All EU models F03498 01 Possible states The high beam indicator lamp li...

Page 23: ...larly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes tho...

Page 24: ...he ambient temperature is low To help the engine burn the increased fuel quantity it must be supplied with additional oxygen by pushing the cold start button After briefly opening up the throttle and then releasing the throttle grip again or turning the throttle grip towards the front the cold start button returns to its original position Info Check whether the cold start button has returned to it...

Page 25: ... idle setting of the throttle valve body substantially influences the vehicle s starting behavior a stable idle speed and the vehi cle s response when the throttle is opened An engine with a correctly set idle speed is easier to start than an engine with the idle speed set incorrectly 6 18 Shift lever 401950 10 Shift lever 1 is mounted on the left of the engine 401950 11 The gear positions can be ...

Page 26: ... 1 is attached to the left side of the vehicle 401944 10 The side stand is used for parking the motorcycle Info When you are riding side stand 1 must be folded up and secured with rubber strap 2 6 21 Steering lock All EU models S03571 10 Steering lock 1 is fitted on the left side of the steering head The steering lock is used to lock the steering Steering and therefore riding is no longer possible...

Page 27: ... into the steering lock p 24 turn it to the left push it in and turn it to the right Pull out the key for the steering lock Steering is no longer possible Info Never leave the key for the steering lock in the steer ing lock 6 23 Unlocking the steering All EU models 400731 01 Insert the key for the steering lock into the steering lock p 24 turn it to the left pull it out and turn it to the right Pu...

Page 28: ...speed sensor 7 3 Message on the combination instrument 401901 01 Possible states Battery voltage of the combination instrument Bat tery voltage of the combination instrument is too low Change combination instrument battery Service A service is due Contact an authorized Husqvarna Motorcycles workshop 7 4 Setting the combination instrument Condition The motorcycle is stationary 401909 01 Press and h...

Page 29: ...vancing the time Press the right button The value increases 401913 01 Wait for 5 seconds Combination instrument changes to the next menu item The symbol flashes Shortening the service interval Press the left button The value decreases Extending the service interval Press the right button The value increases 401914 01 Switching off the service interval display Press and hold the left button off app...

Page 30: ...to select the 24 h display or 12 h display for the clock 401912 01 Wait for 5 seconds Combination instrument changes to the next menu item The symbol flashes Resetting the time Press the left button The value decreases Advancing the time Press the right button The value increases 7 7 Setting the service display Condition The motorcycle is stationary 401913 01 Press and hold both buttons for 3 5 se...

Page 31: ... to 0 0 Press the left button briefly Next display mode Press the left button for 3 5 seconds DST can be preset to a value between 0 0 and 39999 9 by pressing the buttons Press the right button briefly Next display mode Press the right button for 3 5 sec onds DST is reset to 0 0 7 9 Speed time and DST2 distance 2 401902 01 Press one of the buttons until DST2 appears on the combina tion instrument ...

Page 32: ...istance covered 401903 01 Press one of the buttons until AVG ART and ODO appear on the combination instrument AVG shows the average speed since the last reset ART shows the operating hours ODO shows the total distance covered Press the left button briefly Next display mode Press the left button for 3 5 seconds The OPEN END WRENCH SYMBOL shows the remaining operating hours until the next service is...

Page 33: ...haracteristic Adapt your riding speed to the road conditions and your riding ability Warning Danger of accidents The vehicle is not designed to carry passengers Do not ride with a passenger Warning Danger of accidents The brake system fails in the event of overheating If the foot brake lever is not released the brake linings drag continuously Take your foot off the foot brake lever if you do not w...

Page 34: ... riding If you carry any luggage make sure you fix it firmly as close as possible to the center of the vehicle and ensure even weight distribution between the front and rear wheels Info Motorcycles react sensitively to any changes of weight distribution The maximum permissible overall weight and the maximum permissible axle loads must not be exceeded Guideline Maximum permissible overall weight 33...

Page 35: ... as the battery warms up 8 4 Preparing the vehicle for difficult operating conditions Info Use of the vehicle under difficult conditions such as on sand or on wet and muddy surfaces can result in significantly increased wear of components such as the drive train brake system or suspension components For this reason it may be necessary to inspect or replace parts before the next scheduled service C...

Page 36: ...or fins Straighten the bent radiator fins carefully M01459 01 450 EU Change the clutch spring Clutch spring hard 78932005000 8 6 Preparing the vehicle for riding on wet sand 102137 01 Mount the air filter rain cover Air filter rain cover 79006921000 Info Read the fitting instructions for Husqvarna Motorcy cles accessories 600868 01 Clean the chain Mount the steel sprocket Grease the chain Universa...

Page 37: ...cles accessories 600868 01 Mount the steel sprocket Clean the motorcycle p 136 Straighten the bent radiator fins carefully M01459 01 450 EU Change the clutch spring Clutch spring hard 78932005000 8 8 Preparing vehicle for high temperatures or slow riding 600868 01 Adjust the secondary drive to the road conditions Info The engine oil heats up quickly when the clutch is operated frequently due to an...

Page 38: ...fins carefully Check the coolant level p 121 8 9 Preparing the vehicle for low temperatures or snow 102137 01 Mount the air filter rain cover Air filter rain cover 79006921000 Info Read the fitting instructions for Husqvarna Motorcy cles accessories ...

Page 39: ... Check the tire condition p 105 Check tire pressure p 105 Check the spoke tension p 106 Info The spoke tension must be checked regularly as incorrect spoke tension will strongly impair riding safety Clean the dust boots of the fork legs p 56 Bleed the fork legs p 55 Check the air filter Check the settings of all controls and ensure that they can be operated smoothly Check all screws nuts and hose ...

Page 40: ...up 9 3 Activating traction control Warning Voiding of the government approval for road use and the insurance coverage If the combination switch is mounted the vehicle s road permit if any expires Only operate the vehicle in closed off areas remote from public road traffic if the combination switch is installed Info The traction control reduces excessive slip on the rear wheel in favor of more cont...

Page 41: ...it is open This will barely reduce the speed but fuel consumption will be considerably lower Always open the throttle only as much as the engine can handle abrupt throttle opening increases fuel consumption To shift down apply the brakes and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and either open the throttle or shift ag...

Page 42: ...ns Some vehicle components become very hot when the vehicle is operated Do not touch any parts such as the exhaust system radiator engine shock absorber or brake sys tem before the vehicle parts have cooled down Let the vehicle parts cool down before you perform any work on the vehicle Note Material damage The vehicle may be damaged by incorrect procedure when parking Significant damage may be cau...

Page 43: ...g 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 rinse the affected a...

Page 44: ...sewage system Switch off engine Open fuel tank filler cap p 21 401226 10 Fill the fuel tank with fuel up to measurement A Guideline Measurement of A 35 mm 1 38 in Total fuel tank capacity approx All EU models Super unleaded ROZ 95 p 155 9 l 2 4 US gal Total fuel tank capacity approx US Super unleaded ROZ 95 p 155 8 2 l 2 17 US gal Close the fuel tank filler cap p 22 ...

Page 45: ...arge the 12 V battery Check the front brake linings p 92 Check the rear brake linings p 98 Check the brake discs p 90 Check the brake lines for damage and leakage Check the rear brake fluid level p 96 Check the free travel of the foot brake lever p 95 Check the frame p 85 Check the link fork p 85 Check the fork bearing for play Check the shock absorber heim joint for play Check the shock absorber ...

Page 46: ...rews and nuts Check the headlight setting p 117 Change the fuel screen p 130 Check the fuel pressure Check the idle speed Check that the radiator fan is functioning properly Check the inlet membrane Final check Check the vehicle is roadworthy and take a test ride Read out the fault memory after the test ride using the Husqvarna Motorcycles diag nostics tool Make a service entry in Husqvarna Motorc...

Page 47: ... cylinder Check the cylinder head Change the valves valve springs and valve spring seats Check the camshaft rocker arm and rocker arm shafts Change the connecting rod conrod bearing and crank pin Change the radial shaft seal ring of the water pump Check the transmission and the shift mechanism Check the oil pressure control valve Change the suction pump Check the force pump and lubrication system ...

Page 48: ...into two ranges high speed and low speed High speed and low speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed The high speed compression adjuster has an effect for example when landing after a jump the rear wheel suspension compresses quickly The low speed compression adjuster has an effect for example when riding over long ground swells the rear wheel ...

Page 49: ...ock 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 Your authorized Husqvarna Motorcycles workshop will be glad to help Info The effect of the high speed compression adjuster can be seen in the fast compression of the shock absorber S03551 10 Using an open end wrench turn ad...

Page 50: ...last perceptible click Turn counterclockwise by the number of clicks correspond ing to the shock absorber type Guideline Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Info Turn clockwise to increase the damping turn counterclockwise to reduce damping when the shock absorber rebounds 11 6 Measuring the dimension of the rear wheel unloaded Preparatory work Raise the motorcycle...

Page 51: ...ed value Adjust the spring preload of the shock absorber p 50 11 8 Checking the riding sag of the shock absorber 402417 10 Measure dimension A of rear wheel unloaded p 48 With another person holding the motorcycle the rider wear ing full protective clothing sits on the seat in a normal sitting position feet on footrests and bounces up and down a few times The rear wheel suspension levels out Anoth...

Page 52: ...4 After removing the shock absorber clean it thoroughly 402659 10 Main work Loosen screw 1 Turn adjusting ring 2 until the spring is no longer under ten sion Hook wrench 90129051000 Info If the spring cannot be fully released the spring must be removed to accurately measure the spring length Measure the total spring length while the spring is not under tension Tension the spring by turning adjusti...

Page 53: ...changing the spring preload Finishing work Install the shock absorber p 66 Remove the motorcycle from the lift stand p 55 Check the static sag of the shock absorber p 49 Check the riding sag of the shock absorber p 49 Adjust the rebound damping of the shock absorber p 48 11 11 Checking the basic setting of the fork Info For various reasons no exact riding sag can be determined for the fork 401000 ...

Page 54: ...pression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase damping turn counter clockwise to reduce damping during compression 11 13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior H03676 10 Turn red adjuster 1 clockwise as far as it will go Info Adjuster 1 is located at the upper end of...

Page 55: ... the numerical values Info Adjust the spring preload to the numerical values only as the preload will not engage between the numerical values Turn clockwise to increase the spring preload turn counterclockwise to reduce the spring preload Adjusting the spring preload has no influence on the absorption setting of the rebound Basically however you should set the rebound damp ing higher with a higher...

Page 56: ...ne side Info Cover the components to protect them against dam age Do not bend the cables and lines Remove screws 2 Take off the handlebar supports Place the handlebar supports in the required position Mount and tighten screws 2 Guideline Screw handle bar holder M10 40 Nm 29 5 lbf ft Loctite 243 Info Position the left and right handlebar holders evenly Position the handlebar Info Make sure the cabl...

Page 57: ...age The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 401943 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle press side stand 1 to the ground with your foot and lean the motorcycle on it Info When you are riding the side stand must be folded up and secured with rubber strap 12 3 Bleeding the fork legs Preparatory wo...

Page 58: ...nts 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 Clean and oil the dust boots and inner fork tubes of both fork legs Universal oil spray p 157 Press the dust boots back into their installation position Remove excess oil Finishing work Install the fork protector p 57 Remove the ...

Page 59: ...Mount and tighten screws 3 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 12 7 Removing the fork legs Preparatory work Remove the headlight mask with the headlight p 114 Raise the motorcycle with a lift stand p 55 Remove the front wheel p 101 S04825 10 Main work Remove screws 1 and take off the clamp Remove the cable tie Remove screws 2 and take off the brake caliper Allow the brake calipe...

Page 60: ...p triple clamp M8 17 Nm 12 5 lbf ft Tighten screws 3 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft S04826 10 Position the brake caliper and mount and tighten screws 4 Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Mount the cable ties Position the brake line the wiring harness and the clamp Mount and tighten screws 5 Finishing work Install the front wheel p 102 Ins...

Page 61: ...cables and lines H03683 10 Remove O ring 4 and protective ring 5 Remove the lower triple clamp with the steering stem Remove the upper steering head bearing 12 10 Installing the lower triple clamp B01632 10 Main work Clean the bearing and sealing elements check for damage and grease High viscosity grease p 156 Position the lower triple clamp with the steering stem Mount upper steering head bearing...

Page 62: ... adjuster The compression damping is located in left fork leg COMP white adjuster Grooves are milled into the side of the upper end of the fork legs The second milled groove from the top must be flush with the upper edge of the upper triple clamp S03575 11 Tighten screws 7 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft S03553 11 Tighten screw 4 Guideline Screw top steering head M20x1 5 1...

Page 63: ...bles and brake and clutch lines can move freely and are routed correctly Check the steering head bearing for play p 61 Remove the motorcycle from the lift stand p 55 Check the headlight setting p 117 12 11 Checking the steering head bearing play Warning Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components Correct incorrect steering hea...

Page 64: ...eering head bearing and replace if neces sary Check the steering stop bolts for correct adjustment and locking Finishing work Remove the motorcycle from the lift stand p 55 12 12 Adjusting the steering head bearing play Preparatory work Raise the motorcycle with a lift stand p 55 S03554 10 Main work Loosen screws 1 Remove screw 2 Loosen and retighten screw 3 Guideline Screw top steering head M20x1...

Page 65: ...ll the lower triple clamp p 59 Info The steering head bearing is cleaned and lubricated in the course of removal and installation of the lower triple clamp 12 14 Removing front fender Preparatory work Remove the headlight mask with the headlight p 114 H03690 10 Main work Remove screws 1 Remove screws 2 Take off the front fender ...

Page 66: ...Nm 7 4 lbf ft Finishing work Install the headlight mask with the headlight p 114 Check the headlight setting p 117 12 16 Removing the shock absorber Preparatory work Raise the motorcycle with a lift stand p 55 F03545 10 Main work Remove the cable ties Remove screws 1 with the washers Detach the frame protector in area A and take it off H03693 10 Remove screw 2 Remove fitting 3 Info Raise the link ...

Page 67: ...g in connector of the brake light switch F03547 10 Remove screws 6 Pull off foot brake cylinder from the push rod F03467 01 Remove the connecting link of the chain Info Cover the components to protect them against dam age Take off the chain F03548 10 Remove nut 7 and pull out the swingarm pivot Push the link fork back and secure it against falling over ...

Page 68: ...en screw 1 Guideline Screw top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 F03549 10 Position the link fork and mount the swingarm pivot Info Pay attention to flat area A Mount and tighten nut 2 Guideline Nut fork pivot M16x1 5 100 Nm 73 8 lbf ft F03467 02 Mount the chain Connect the chain with the connecting link Guideline The closed side of the chain joint lock must face in the direction o...

Page 69: ...le lever M14x1 5 60 Nm 44 3 lbf ft Info Pay attention to flat area B Mount and tighten screw 6 Guideline Screw bottom shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 Info Raise the link fork slightly to be able to mount the screw more easily F03545 11 Attach frame protector in area C and position Mount and tighten screws 7 with the washers Guideline Screw frame pro tector M5 3 Nm 2 2 lbf ft Moun...

Page 70: ...eat S03559 11 Main work Mount the front of the seat on the collar bushing of the fuel tank and the rear in the bracket Push the seat forward Make sure the seat is latched in place correctly Mount and tighten screw 1 and the bushing Guideline Screw rear seat fix ing M6 10 Nm 7 4 lbf ft Finishing work Install the air filter box cover p 69 ...

Page 71: ...r in areas B C and D 12 22 Removing the air filter Note 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 Only operate the vehicle if it is equipped with an air filter Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake ...

Page 72: ...ining tab 3 Retaining pin 2 is secured with retaining tab 3 Info If the air filter is not mounted correctly dust and dirt may enter the engine and result in damage Finishing work Install the air filter box cover p 69 12 24 Cleaning the air filter and air filter box Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fl...

Page 73: ...r filter with a high grade air filter oil Oil for foam air filter p 156 Clean the air filter box Check the intake flange for damage and looseness Finishing work Install the air filter p 70 Install the air filter box cover p 69 12 25 Removing the right side cover Preparatory work Remove the air filter box cover p 69 Remove the seat p 67 F02343 10 Main work Detach side cover in area A pull off sidew...

Page 74: ...he main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down before performing any work on the vehicle Preparatory work Remove the air filter box cover p 69 Remove the seat p 67 Remove the right side cover p 71 F03475 10 Main work Detach spring 1 Spring hook 50305017000C1 All EU models Remove screws 2 and take off the ma...

Page 75: ...g work Install the right side cover p 72 Mount the seat p 68 Install the air filter box cover p 69 12 29 Cleaning the spark arrestor US Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down before performing any work on the vehicle Info Soot particles accumulate on the screen of the spark arrestor over time This changes the perfor...

Page 76: ...ear suitable breathing and eye protection when cleaning the main silencer and carbon screen Clean main silencer sleeve 3 and screen 4 of the spark arrestor with compressed air Position silencer cap 1 with O ring 2 Mount and tighten all of the screws Guideline Screws on main silencer M5 7 Nm 5 2 lbf ft Finishing work Install the main silencer p 73 Install the right side cover p 72 Mount the seat p ...

Page 77: ...acteristics change Preparatory work Remove the air filter box cover p 69 Remove the seat p 67 Remove the right side cover p 71 Remove main silencer p 72 S03541 11 Main work All EU models Remove all the screws on the main silencer Take off silencer cap 1 with O ring 2 Remove glass fiber yarn filling 3 from main silencer 4 Clean the parts that need to be reinstalled and check for damage Mount the ne...

Page 78: ...s highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not fuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel...

Page 79: ... line Dirt in the fuel line clogs the injection valve F03552 10 Disconnect the quick release coupling Info Remaining fuel may flow out of the fuel hose Mount wash cap set 3 Wash cap set 81212016100 Pull the fuel tank breather hose off the fuel tank lid H03705 10 Remove screws 4 All EU models Hang the horn and horn bracket to one side H03704 10 Remove screw 5 with the rubber bushing H03706 10 Pull ...

Page 80: ...d clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Main work Check the throttle cable routing p 85 H03706 11 Position the fuel tan...

Page 81: ...the fuel line clogs the injection valve Spray silicone spray onto a lint free cleaning cloth and lightly lubricate the O ring of the quick release coupling Silicone spray p 156 Join quick release coupling 4 Info Route the cable and fuel line at a safe distance from the exhaust system Finishing work Install the right side cover p 72 Mount the seat p 68 Install the air filter box cover p 69 12 33 Ch...

Page 82: ...e motorcycle with a lift stand p 55 400725 01 Main work Rinse off loose dirt with a soft jet of water Remove old grease residue with chain cleaner Chain cleaner p 156 After drying apply chain spray Off road chain spray p 156 Finishing work Remove the motorcycle from the lift stand p 55 12 35 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages components and resul...

Page 83: ... chain tension p 81 Finishing work Remove the motorcycle from the lift stand p 55 12 36 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents If the chain 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 to...

Page 84: ... 1 Guideline Nut rear wheel spin dle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm 1 26 in enables different secondary ratios with the same chain length Chain adjusters 4 can be turned by 180 Finishing work Remove the motorcycle from the lift stand p 55 12 37 Checking the chain rear sprocket engine sprocket and chain guide Preparatory work Raise the motorcycle...

Page 85: ...n 272 mm 10 71 in If distance B is greater than the specified measurement Change the drivetrain kit Info When a new chain is mounted the rear sprocket and engine sprocket should also be changed New chains wear out faster on old worn sprockets F02349 10 Check the chain sliding guard for wear If the lower edge of the chain pins is in line with or below the chain sliding guard Change the chain slidin...

Page 86: ...n sliding piece Guideline Screw chain slid ing piece M8 15 Nm 11 1 lbf ft 400985 01 Check the chain guide for wear Info Wear can be seen on the front of the chain guide If the light part of the chain guide is worn Change the chain guide F00322 01 Check that the chain guide is firmly seated If the chain guide is loose Tighten the fitting on the chain guide Guideline Remaining screws chassis M6 10 N...

Page 87: ... replace a damaged link fork Repair of the link fork is not authorized by Husqvarna Motorcycles 12 40 Checking the throttle cable routing Preparatory work Remove the air filter box cover p 69 Remove the seat p 67 Remove the right side cover p 71 Remove the fuel tank p 76 F03561 01 Main work Check the throttle cable routing Both throttle cables must be routed side by side on the back of the handleb...

Page 88: ...bar The rubber grip can only be replaced with the sleeve or the throttle tube If a rubber grip is damaged worn or loose Change the rubber grip F03502 10 All EU models Check that screw 1 is firmly seated Guideline Screw fixed grip M4 5 Nm 3 7 lbf ft Loctite 243 Diamond A must be positioned visibly as shown in the figure F03522 10 US Check that screw 1 is firmly seated Guideline Screw fixed grip M4 ...

Page 89: ...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 The fluid level rises with increasing wear of the clutch facin...

Page 90: ...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 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 br...

Page 91: ... Correct the fluid level of the hydraulic clutch Guideline Fluid level below container rim 4 mm 0 16 in Position the cover with the membrane Mount and tighten the screws Info Use water to immediately clean up any brake fluid that has overflowed or spilled 12 45 Removing the engine guard H01655 01 Remove screws 1 and engine guard 12 46 Installing the engine guard H01655 01 Attach the engine guard o...

Page 92: ... discs Warning Danger of accidents Worn out brake discs reduce the braking effect Make sure that worn out brake discs are replaced immediately Your authorized Husqvarna Motor cycles workshop will be glad to help 400257 10 Check the front and rear brake disc thickness at multiple points for the dimension A Info Wear reduces the thickness of the brake disc around the contact surface of the brake lin...

Page 93: ...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 Your authorized Husqvarna Motorcycles workshop will be glad to help Warning Skin irritation Brake fluid ca...

Page 94: ...ff cover 2 with membrane 3 Add brake fluid to level A Guideline Level A brake fluid level below reservoir rim 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 154 Position the cover with the membrane Mount and tighten the screws Info Immediately clean up any brake fluid that has over flowed or spilled with water 13 5 Checking the front brake linings Warning Danger of accidents Worn out brake linings reduce...

Page 95: ...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 Warning Danger of accidents Brake linings which have not been approved alter the braking efficiency Not all brake linings are tested and approved for Husqvarna motorcycles The structure and friction coeffi...

Page 96: ...per against the spokes when pushing back the brake pis tons Remove cotter pin 4 Pull out pin 5 Remove the brake linings Clean the brake caliper and the brake caliper bracket S04465 10 Check that spring plate 6 in the brake caliper and brake pad sliding plate 7 in the brake caliper bracket are seated correctly S04463 01 Insert the new brake linings Mount pin 5 Spring plate 6 engages in the groove o...

Page 97: ...e brake system fails in the event of overheating If there is no free travel on the foot brake lever pressure builds up in the brake system on the rear brake Set the free travel on the foot brake lever in accordance with the specification 402026 10 Disconnect spring 1 Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free trave...

Page 98: ... foot brake lever Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in Hold screw 3 and tighten nut 2 Guideline Nut foot brake lever stop M8 20 Nm 14 8 lbf ft Hold push rod 5 and tighten nut 4 Guideline Remaining nuts chassis M6 10 Nm 7 4 lbf ft Attach spring 1 13 9 Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system...

Page 99: ...r 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 sure that brake f...

Page 100: ...heck the brake linings for damage and cracking If damage or cracking is visible Change the rear brake linings p 98 13 12 Changing the rear brake linings Warning Danger of accidents Incorrect servicing will cause the brake system to fail Ensure that service work and repairs are performed professionally Your authorized Husqvarna Motorcycles workshop will be glad to help Warning Skin irritation Brake...

Page 101: ...guaranteed In this case the vehicle no longer corresponds to its condition at delivery and the manufacturer warranty shall be void Only use brake linings approved and recommended by Husqvarna motorcycles 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 regula...

Page 102: ...t pin 4 The spring plate engages in the groove on the pin Info Always change the brake linings in pairs Mount cotter pins 3 Operate the foot brake lever repeatedly until the brake lin ings are in contact with the brake disc and there is a pressure point F03485 10 Correct brake fluid level to marking A Brake fluid DOT 4 DOT 5 1 p 154 Mount and tighten screw cap 1 with membrane 2 Info Use water to i...

Page 103: ...ng back the brake pis tons S04841 10 Loosen screw 1 by several rotations Loosen screws 2 Press on screw 1 to push the wheel spindle out of the axle clamp Remove screw 1 S04842 10 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 front wheel and remove wheel spindle Take front wheel out of the fo...

Page 104: ...ert the spacers S04841 11 Clean and grease the wheel spindle Long life grease p 156 Position the front wheel and insert the wheel spindle The brake linings are correctly positioned Mount and tighten screw 2 Guideline Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Operate the hand brake lever several times until the brake linings are seated correctly against the brake disc Remove the motorcycl...

Page 105: ...r 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 the rear wheel and remove the wheel spindle Take the rear wheel out of the link fork Info Do not operate the foot brake lever when the rear wheel is removed H03002 10 Remove spa...

Page 106: ...ectly positioned S04835 11 Position chain adjuster 3 Mount nut 4 but do not tighten it yet Make sure that chain adjusters 3 are fitted correctly on adjusting screws 5 Check the chain tension p 80 Tighten nut 4 Guideline Nut rear wheel spin dle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm 1 26 in enables different secondary ratios with the same chain length Ch...

Page 107: ...the tires Check the tread depth Info Adhere to the legally required minimum tread depth Minimum tread depth 2 mm 0 08 in If the tread depth is less than the minimum tread depth Change the tires H01144 01 Check the tire age Info The tire date of manufacture is usually contained in the tire label and is indicated by the last four digits of the DOT number The first two digits indicate the week of man...

Page 108: ...n the spokes is too low then lateral and radial run out will form in the wheel Other spokes will become looser as a result Check spoke tension regularly and in particular on a new vehicle Your authorized Husqvarna Motorcycles workshop will be glad to help 400694 01 Strike each spoke briefly using a screwdriver blade Info The frequency of the sound depends on the spoke length and spoke diameter If ...

Page 109: ... injury 12 V batteries contain harmful sub stances Keep 12 V batteries out of the reach of children Keep sparks and open flames away from 12 V batteries Only charge 12 V batteries in well ventilated rooms Maintain a minimum clearance from inflammable materials when charging 12 V batteries Minimum clearance 1 m 3 ft Do not charge deeply discharged 12 V batteries if the charge is already below the m...

Page 110: ...ok the holding bracket Lift out the 12 V battery 15 2 Installing the 12 V battery S03583 10 Main work Insert the 12 V battery into the battery compartment with the terminals facing forward and secure with holding bracket 1 12 V battery HJTZ5S FP C p 149 Mount and tighten screw 2 Guideline Screw battery sup port bracket M6 6 Nm 4 4 lbf ft ...

Page 111: ...5 Nm 1 84 lbf ft Info Contact disk A must be mounted under screw 8 and cable lug 9 with the claws toward the battery terminal Slide the positive terminal cover over the positive terminal Connect negative cable bk to the 12 V battery Guideline Screw battery termi nal M5 2 5 Nm 1 84 lbf ft Info Contact disk A must be mounted under screw 8 and cable lug 9 with the claws toward the battery terminal Fi...

Page 112: ...nts brake fluid etc correctly and in compliance with the applicable regulations Info Even if there is no load on the 12 V battery it discharges each day 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 or charging voltage are exceed...

Page 113: ...y charger The charg ing time may be longer at low temperatures This battery charger is only suitable for lithium iron phosphate batteries Read the accompanying instruc tions for Husqvarna Motorcycles accessories Info Never remove cover 1 Switch off the battery charger after charging and disconnect it from the 12 V battery Finishing work Install the 12 V battery p 108 Mount the seat p 68 Install th...

Page 114: ...properly Tip Insert a spare fuse so that it is available if needed Mount the protection caps Mount the starter relay onto the holder and route the cable Finishing work Mount the seat p 68 Install the air filter box cover p 69 15 5 Changing the fuses of individual electrical power consumers Info The fuse box containing the fuses of individual electrical power consumers is located under the seat Pre...

Page 115: ...ic fuel injection diagnostics connector fuel vapor retention system fuse 4 Fuse 2 10 A low beam position light tail light Fuse 3 10 A radiator fan Fuse 4 5 A fuel pump Fuses res 10 A spare fuse Info A faulty fuse has a burned out fuse wire A Warning Fire hazard Incorrect fuses overload the electrical system Only use fuses with the required ampere value Do not bypass or repair fuses Insert the spar...

Page 116: ...g harness from the headlight mask Pivot the headlight mask forwards and place it on the fender H03750 10 All EU models Detach plug in connectors 3 and take off the headlight mask with the headlight H03751 10 US Disconnect plug in connector 3 and take off the head light mask together with the headlight 15 7 Installing the headlight mask with the headlight H03750 11 Main work All EU models Join plug...

Page 117: ...52 10 Position the brake line and the wiring harness in the cable guide Mount and tighten screw 2 Position the headlight mask The holding lugs engage in the fender H03749 11 Secure the headlight mask with rubber straps 3 Finishing work Check the headlight setting p 117 ...

Page 118: ...ion light out of the reflector H03754 10 Pull out headlight bulb 3 Insert the new headlight bulb Headlight HS1 Sockel PX43t p 149 Insert the protection cap with the bulb socket into the reflec tor and turn it clockwise all the way Ensure that O ring 4 is seated properly Insert the bulb socket of the position light into the reflector Finishing work Install the headlight mask with the headlight p 11...

Page 119: ...rclockwise until it engages in the thread with a small jerk Tighten the screw lightly Finishing work Check that the turn signal system is functioning properly 15 10 Checking the headlight setting 400726 10 Position the vehicle upright on a horizontal surface in front of a light wall and make a marking at the height of the center of the low beam headlight Make another mark at a distance B under the...

Page 120: ...atory work Remove the headlight mask with the headlight p 114 H03756 10 Main work Remove screws 1 with the washers Pull the combination instrument upward out of the holder H03757 10 Using a coin turn protection cap 2 all the way counter clockwise and take it off Remove combination instrument battery 3 Insert the combination instrument battery with the label fac ing outward Combination instrument b...

Page 121: ... Finishing work Install the headlight mask with the headlight p 114 Check the headlight setting p 117 Set the combination instrument p 26 15 13 Diagnostics connector H00933 12 Diagnostics connector 1 is located under the seat ...

Page 122: ... engine to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immedi...

Page 123: ...y with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing Condition The engine is cold 400243 10 Stand the motorcycle upright on a horizontal surface Remove the radiator cap Check the coolant level in the radiator Coolant level A above the radiator...

Page 124: ...letely drain the coolant Mount and tighten screw 1 with a new seal ring Guideline Screw water pump cover M6 10 Nm 7 4 lbf ft 16 5 Refilling with coolant 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 immediately if coolant is swallowed Rinse the...

Page 125: ...e eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing Condition The engine is cold Preparatory work Remove the engine guard p 89 F02355 1...

Page 126: ...he throttle cable p 124 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 Start the engine and let it run at idle speed Move the handle bar to and fro over the entire steering ra...

Page 127: ...there is play in the throttle cable at the throttle grip Guideline Play in throttle cable 3 5 mm 0 12 0 2 in Tighten nut 2 Slide on sleeve 1 Check the throttle grip for smooth operation Finishing work Check the play in the throttle cable p 124 17 3 Adjusting the characteristic map of the throttle response Info On the throttle grip the characteristic map of the throttle response is changed by chang...

Page 128: ...e valve more slowly The black guide plate opens the throttle valve more quickly The gray guide plate is mounted upon delivery F03512 10 Clean the outside of the handlebar and the inside of the grip tube Mount the grip tube on the handlebar Attach the throttle cables to the guide plate and route cor rectly Position half shells 3 mount and tighten screws 2 Guideline Screw throttle grip M6 5 Nm 3 7 l...

Page 129: ... activated again when restarting The traction control can also be activated in each mapping using the TC button The mapping can also be changed during the ride H02889 01 Activating STANDARD mapping Press button MAP until LED 1 lights up Guideline Engine speed 4 000 rpm STANDARD balanced response H02886 01 Activating ADVANCED mapping Press button MAP until LED 2 lights up Guideline Engine speed 4 0...

Page 130: ...raises the idle speed 17 6 Programming the throttle valve position Info If the control unit detects that the throttle valve position at idle speed needs to be reprogrammed then the malfunction indicator lamp flashes 2x per second H02263 10 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation wh...

Page 131: ...of the boot 10 20 mm 0 39 0 79 in If the distance does not meet specifications Adjust the basic position of the shift lever p 129 17 8 Adjusting the basic position of the shift lever 401950 12 Remove screw 1 with the washers and take off shift lever 2 401951 10 Clean gear teeth A of the shift lever and shift shaft Mount the shift lever on the shift shaft in the required position and engage gearing...

Page 132: ...ed 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 Note Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system F03564 10 Clean quick release coupling 1 thoroughly with compressed...

Page 133: ... oil p 134 Condition The engine is at operating temperature Check the engine oil level Info After switching off the engine wait one minute before checking the level The engine oil is at a level between lower edge A and middle B of the level viewer If the engine oil is not at a level between lower edge A and middle B of the level viewer Add engine oil p 134 18 3 Changing the engine oil and oil filt...

Page 134: ...e Remove oil drain plug 1 with the magnet and seal ring F00442 10 Remove screw plug 2 with the short oil screen and the O rings Info Do not remove screw A F00443 10 Remove screw plug 3 with long oil screen 4 and the O rings Allow the engine oil to drain completely Thoroughly clean the parts and the sealing surfaces F00442 11 Mount and tighten screw plug 2 with the short oil screen and the O rings ...

Page 135: ...line Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft F00440 10 Remove screws 5 Remove the oil filter cover with the O ring F00446 10 Pull oil filter 6 out of the oil filter housing Lock ring plier 51012011000 Allow the engine oil to drain completely Thoroughly clean the parts and the sealing surface F00440 11 Lay the motorcycle on its side and fill the oil filter housing to about full with en...

Page 136: ... engine Use effective exhaust extraction when starting or running the engine in an enclosed space Start the engine and check it for leaks Finishing work Install the engine guard p 89 Check the engine oil level p 131 18 4 Adding engine oil Info Too little engine oil or poor quality engine oil will result in premature wear of the engine F02360 10 Main work Remove filler plug 1 with the O ring Fill e...

Page 137: ...ing 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 Start the engine and check for leaks Finishing work Check the engine oil level p 131 ...

Page 138: ...n it regularly Avoid direct sunshine when cleaning the motorcycle 401061 01 Close off the exhaust system to keep water from entering Remove the coarse dirt particles with a gentle water jet Spray the heavily soiled parts with a normal commercial motorcycle cleaner and clean using a brush Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to a ...

Page 139: ... tions against aggressive road salt If the vehicle was operated in road salt clean it with cold water after riding Warm water would enhance the corrosive effects of salt 401060 01 Clean the motorcycle p 136 Clean brake system Info After EVERY trip on salted roads thoroughly clean the brake calipers and brake linings after they have cooled down and without removing them with cold water and dry them...

Page 140: ...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 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Refuel p 41 Clean the motorcycle p 136 Change the engine oil and the oil filter clean the oil screens p 131 Check the antifreeze and coolant level p 120 Che...

Page 141: ...he water vapor produced during combustion condenses and causes valves and the exhaust system to rust 20 2 Preparing for use after storage 401059 01 Remove the motorcycle from the lift stand p 55 Install the 12 V battery p 108 Perform checks and maintenance measures when preparing for use p 37 Take a test ride ...

Page 142: ...lug connector or change if necessary Plug gap of spark plug too wide Adjust plug gap Guideline Spark plug electrode gap 1 0 mm 0 039 in Ignition system defective Check the ignition system Short circuit cable in wiring harness frayed stop button or emergency OFF switch faulty Check the wiring harness visual check Check the electrical system Error in the electronic fuel injection Read out the fault ...

Page 143: ...th coolant p 122 Bent radiator hose Change the radiator hose Thermostat defective Check the thermostat Guideline Opening temperature 70 C 158 F Defect in radiator fan system Check fuse 3 Check the radiator fan Malfunction indicator lamp lights up or flashes Error in the electronic fuel injection Check wiring for damage and electri cal plug in connectors for corrosion and damage Read out the fault ...

Page 144: ...light position light and license plate lamp are not working Fuse 2 blown Change the fuses of individual electri cal power consumers p 112 The horn brake light turn sig nal and radiator fan are not working Fuse 3 blown Change the fuses of individual electri cal power consumers p 112 ...

Page 145: ...fold pressure sensor cylinder 1 input signal too high Blink code for malfunc tion indicator lamp 12 Malfunction indicator lamp flashes 1x long 2x short Error level condition Coolant temperature sensor input signal too low Coolant temperature sensor input signal too high Blink code for malfunc tion indicator lamp 13 Malfunction indicator lamp flashes 1x long 3x short Error level condition Intake ai...

Page 146: ...Blink code for malfunc tion indicator lamp 37 Malfunction indicator lamp flashes 3x long 7x short Error level condition Ignition coil 1 cylinder 1 circuit fault Blink code for malfunc tion indicator lamp 41 Malfunction indicator lamp flashes 4x long 1x short Error level condition Fuel pump relay short circuit to ground or open circuit Fuel pump relay input signal too low ...

Page 147: ...bearing 2 cylinder roller bearing Conrod bearing Slide bearing 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 2 trochoidal pumps Primary transmission 31 76 Clutch Multidisc clutch in oil bath hydraulically activated Transmission ratio first gear 14 36 sec...

Page 148: ...4 lbf ft Loctite 243 Nut water pump impeller M6 6 Nm 4 4 lbf ft Loctite 243 Screw alternator cover M6 10 Nm 7 4 lbf ft Screw clutch cover M6 10 Nm 7 4 lbf ft Screw clutch slave cylinder M6 10 Nm 7 4 lbf ft Screw cylinder head M6 10 Nm 7 4 lbf ft Screw engine case M6 10 Nm 7 4 lbf ft Screw exhaust flange M6 10 Nm 7 4 lbf ft Loctite 243 Screw fuel vapor retention sys tem connection M6 5 Nm 3 7 lbf f...

Page 149: ...rew engine sprocket M10 60 Nm 44 3 lbf ft Loctite 2701 Spark plug M10x1 10 12 Nm 7 4 8 9 lbf ft Engine coolant temperature sen sor M10x1 25 12 Nm 8 9 lbf ft Screw cylinder head M10x1 25 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 Nut rotor M12x1 60 Nm 44 3 lbf ft Thread oiled with engine oil cone degreased Oil drain plug with magnet M1...

Page 150: ...rear 220 mm 8 66 in Brake discs wear limit front 2 5 mm 0 098 in rear 3 5 mm 0 138 in Offroad tire pressure front 1 0 bar 15 psi rear 1 0 bar 15 psi Street tire pressure front 1 5 bar 22 psi rear 1 8 bar 26 psi Final drive 450 EU 14 52 13 52 Final drive 501 EU 14 50 13 50 Final drive US 14 48 Chain 5 8 x 1 4 Rear sprockets available 45 48 49 50 51 52 Steering head angle 63 5 Wheelbase 1 487 10 mm ...

Page 151: ... EU models LED License plate lamp All EU mod els LED 23 6 Tires Validity Front tire Rear tire All EU models 90 90 21 M C 54R M S TT Michelin Enduro Medium 140 80 18 M C 70R M S TT Michelin Enduro Medium US 80 100 21 51M TT Dunlop Geomax AT81F 110 100 18 64M TT Dunlop Geomax AT81 The tires specified represent one of the possible series production tires Additional information is available in the Ser...

Page 152: ... WPXACT 5750 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 damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload 12 mm 0 47 in Spring rate Weight of rider 65 75 kg 143 165 lb 39 N mm 223 lb in Weight of rider 75 85 kg 165 187 lb 42 N mm 240 lb in Weight...

Page 153: ...rew emergency OFF switch All EU models M4 0 4 Nm 0 3 lbf ft Screw fixed grip M4 5 Nm 3 7 lbf ft Loctite 243 Screw stop button US M4 0 4 Nm 0 3 lbf ft Spoke nipple front wheel M4 5 6 Nm 4 4 lbf ft Spoke nipple rear wheel M4 5 6 Nm 4 4 lbf ft Remaining nuts chassis M5 5 Nm 3 7 lbf ft Remaining screws chassis M5 5 Nm 3 7 lbf ft Screw battery terminal M5 2 5 Nm 1 84 lbf ft Screw brake line guide on li...

Page 154: ...8 25 Nm 18 4 lbf ft Screw bottom triple clamp M8 15 Nm 11 1 lbf ft Screw chain sliding piece M8 15 Nm 11 1 lbf ft Screw engine brace M8x15 25 Nm 18 4 lbf ft Loctite 2701 Screw engine brace M8x20 25 Nm 18 4 lbf ft Loctite 243 Screw engine sprocket cover M8 20 Nm 14 8 lbf ft Screw fork stub M8 15 Nm 11 1 lbf ft Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Screw handlebar clamp M8 20 Nm...

Page 155: ...1 1 lbf ft Nut angle lever to link fork M14x1 5 60 Nm 44 3 lbf ft Nut frame on linkage lever M14x1 5 60 Nm 44 3 lbf ft Nut linkage lever on angle lever M14x1 5 60 Nm 44 3 lbf ft Nut fork pivot M16x1 5 100 Nm 73 8 lbf ft Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Screw in fitting cooling system ...

Page 156: ...s Only use coolant that complies with the requirements stated see specifications on the container and that has the relevant properties Antifreeze protection to at least 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 f...

Page 157: ...on SAE p 158 SAE 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding properties Super unleaded ROZ 95 Standard classification DIN EN 228 ROZ 95 Guideline Only use super unleaded fuel that matches or is equivalent to the specified standard Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do ...

Page 158: ...ier MOTOREX Bike Grease 2000 Off road chain spray Recommended supplier MOTOREX Chainlube Offroad Oil for foam air filter Recommended supplier MOTOREX Racing Bio Liquid Power Preserving materials for paints metal and rubber Recommended supplier MOTOREX Moto Protect Silicone spray Recommended supplier MOTOREX Silicone Spray Special cleaner for glossy and matte paint finishes metal and plastic surfac...

Page 159: ...AUXILIARY SUBSTANCES 25 157 Universal oil spray Recommended supplier MOTOREX Joker 440 Synthetic ...

Page 160: ...ice 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 accordin...

Page 161: ...INDEX OF SPECIAL TERMS 27 159 OBD On board diagnosis Vehicle system which monitors the specified param eters of the vehicle electronics ...

Page 162: ...28 LIST OF ABBREVIATIONS 160 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 163: ...shes yellow The OBD has detected an error in the vehicle electronics Come safely to a halt and contact an authorized Husqvarna Motorcy cles workshop The fuel level warning lamp lights up yellow The fuel level has reached the reserve mark 29 2 Green and blue symbols Green and blue symbols reflect information The high beam indicator lamp lights up blue The high beam is switched on Turn signal indica...

Page 164: ... fuel 42 148 Chain checking 82 cleaning 80 Chain guide checking 82 Chain tension adjusting 81 checking 80 Characteristic map of the throttle response adjusting 125 Clutch fluid level checking correcting 87 fluid changing 88 Clutch lever 17 basic position adjusting 86 Cold start button 22 Combination instrument adjusting 26 adjusting the kilometers or miles 27 clock setting 28 combination instrumen...

Page 165: ...ller cap closing 22 opening 21 Fuel oils etc 11 Fuse main fuse changing 111 of individual electrical power consumers changing 112 H Hand brake lever 17 basic position adjusting 90 Handlebar position 53 adjusting 54 Headlight range adjusting 118 Headlight bulb changing 116 Headlight mask with headlight installing 114 removing 114 Headlight setting checking 117 High speed compression damping shock a...

Page 166: ...g 86 S Safe operation 8 Seat mounting 68 removing 67 Service 11 Service schedule 43 45 Shift lever 23 basic position adjusting 129 basic position checking 129 Shock absorber installing 66 removing 64 riding sag checking 49 spring preload adjusting 50 static sag checking 49 Side stand 24 Spare parts 11 Spoke tension checking 106 Start button 19 Starting 37 Starting power of lithium ion batteries at...

Page 167: ...vating 38 Transporting 41 Troubleshooting 140 142 Turn signal bulb changing 116 Turn signal switch 19 Type label 15 V Vehicle identification number 15 View of vehicle front left 13 rear right 14 W Winter operation checks and maintenance steps 137 Work rules 9 ...

Page 168: ... 3402542en 3402542en 05 2021 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria www husqvarna motorcycles com Photo Mitterbauer KISKA Husqvarna Motorcycles GmbH ...

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