Husqvarna FC 250 2017 Page 50 Owner'S Manual Download

Page: 50 / 114

11 SERVICE WORK ON THE CHASSIS

Preparatory work

–

Remove the air filter box cover. (

p. 46)

–

Remove the air filter.

(

p. 47)

H01407-10

Main work

–

Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.

Air filter cleaning agent (

p. 104)

Info

Only press the air filter to dry it, never wring it out.

–

Oil the dry air filter with a high quality filter oil.

Oil for foam air filter (

p. 104)

–

Clean the air filter box.

–

Check the intake flange for damage and looseness.

Finishing work

–

Install the air filter.

(

p. 47)

–

Install the air filter box cover. (

p. 46)

11.27

Removing the main silencer

Warning

Danger of burns

The exhaust system gets very hot when the vehicle is driven.

–

Allow the exhaust system to cool down before performing any work on the vehicle.

Preparatory work

–

Remove the right side cover. (

p. 49)

H01408-10

Main work

–

Disconnect spring



Spring hook (50305017000)

–

Remove screws



and take off the main silencer.

11.28

Installing the main silencer

H01408-11

Main work

–

Mount the main silencer. Mount screws



, but do not tighten yet.

–

Attach spring



Spring hook (50305017000)

–

Tighten screws



Guideline

Remaining screws, chassis

10 Nm (7.4 lbf ft)

Finishing work

–

Install the right side cover. (

p. 50)

Summary of Contents for FC 250 2017

Page 1: ...OWNER S MANUAL 2017 FC 250 Art no 3402095en ...

Page 2: ......

Page 3: ... 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 Motorcy cles accepts no liability for delivery options deviations from illustrations and descriptions as well as misprints and other errors The models portrayed partly contain special equipment that...

Page 4: ... 8 3 Activating Launch Control 21 8 4 Activating traction control 21 8 5 Starting off 22 8 6 Shifting riding 22 8 7 Applying the brakes 22 8 8 Stopping parking 23 8 9 Transport 23 8 10 Refueling 24 9 SERVICE SCHEDULE 25 9 1 Additional information 25 9 2 Required work 25 9 3 Recommended work 26 10 TUNING THE CHASSIS 27 10 1 Checking the basic chassis setting with the rider s weight 27 10 2 Air susp...

Page 5: ... 12 Checking the rear brake linings 67 12 13 Changing the rear brake linings 67 13 WHEELS TIRES 69 13 1 Removing the front wheel 69 13 2 Installing the front wheel 69 13 3 Removing the rear wheel 70 13 4 Installing the rear wheel 71 13 5 Checking the tire condition 72 13 6 Checking the tire air pressure 72 13 7 Checking spoke tension 72 14 ELECTRICAL SYSTEM 74 14 1 Removing the battery 74 14 2 Ins...

Page 6: ...shop There your motorcycle will be optimally cared for by specially 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 1 2 Formats used The typographical formats used in this document are explained below Proprietary name Indicates a p...

Page 7: ...onmental damage if the appropriate measures are not taken 2 4 Tampering warning Tampering with the noise control system is prohibited Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of ...

Page 8: ...ces a thread locker e g Loctite is required The manufacturer instructions for use must be followed After disassembly clean the parts that are to be reused and check them for damage and wear Change damaged or worn parts After you complete the repair or service work check the operating safety of the vehicle 2 8 Environment If you use your motorcycle responsibly you can ensure that problems and confl...

Page 9: ...s accessories for your vehicle can be found 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 carried out as described in the Owner s Manual Incorrect adjustment and tuning of th...

Page 10: ...f vehicle front left example E00258 10 1 Hand brake lever p 11 2 Fork air pressure setting 3 Clutch lever p 11 4 Filler cap 5 Plug in stand p 15 6 Air filter box cover 7 Cold start button p 13 8 Engine number p 10 9 Shift lever p 14 ...

Page 11: ...E00259 10 1 Kill switch p 11 2 Electric starter button p 11 3 Throttle grip p 11 4 Fork compression adjustment 5 Fork part number p 10 6 Foot brake lever p 14 7 Engine oil level viewer 8 Shock absorber compression adjustment 9 Shock absorber rebound adjustment ...

Page 12: ...ng head 5 3 Engine number H01047 10 Engine number is stamped onto the engine case at the top near the engine sprocket 5 4 Fork part number 401947 10 The fork part number is stamped on the inner side of the axle clamp 5 5 Shock absorber article number 0 0 1 1 401948 10 The shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side ...

Page 13: ...6 4 Kill switch F00042 10 Kill switch is fitted on the left side of the handlebar Possible states Kill switch in the basic position In this position the ignition circuit is closed and the engine can be started Kill switch pressed In this position the ignition circuit is interrupted a run ning engine stops and a non running engine will not start 6 5 Electric starter button F00043 10 The electric st...

Page 14: ...ated 6 8 Opening the filler cap Danger Fire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the sp...

Page 15: ...d and the outside temperature is low To help the engine burn the increased amount of fuel 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 turn ing the throttle grip towards the front the cold start button returns to its original posi tion Info Check whether the cold start button has retu...

Page 16: ...is adjusted using idle speed adjusting screw red Increase the idle speed by turning the idle speed adjusting screw clockwise Decrease the idle speed by turning the idle speed adjusting screw counterclockwise 6 12 Shift lever 401950 10 Shift lever is mounted on the left of the engine 401950 13 The gear positions can be seen in the figure The neutral or idle position is between the first and second ...

Page 17: ...e plug in stand before starting on a trip 6 15 Service hour counter K00483 10 The service hour counter is fitted in front of the handlebar It shows the total number of service hours of the engine The service hour counter begins counting when the engine is started and stops when the engine is switched off Info It is not possible to delete or adjust anything on the service hour counter ...

Page 18: ...s 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 when you are not braking Warning Danger of accidents Total weight and axle loads influence the handling characteristic Do not exceed the maximum permissible overall weight or the axle loads Warning Risk of misappropriation People who act without authoriz...

Page 19: ...Multiple starting attempts may be needed Press the electric starter button for 5 sec onds and wait 30 seconds between attempts The pauses are necessary so that the created heat can distribute through the lithium ion battery and the battery is not dam aged If the charged lithium ion battery does not or only weakly turns over the electric starter when temperatures are below 15 C 60 F then the batter...

Page 20: ...eel sprocket Tip Do not grease the chain Clean the radiator fins Straighten bent radiator fins carefully Condition Regular use in sand Change the piston every 20 operating hours 7 6 Preparing for rides on wet sand 102137 01 Fit a waterproofing device on the air filter Waterproofing device for air filter 79006921000 Info See the Husqvarna Motorcycles accessories fitting instructions 600868 01 Clean...

Page 21: ...for rides at high temperatures and low speeds 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 excessively high secondary drive Clean the chain Clean the radiator fins Straighten bent radiator fins carefully Check the coolant level p 79 7 9 Preparing for rides at low temperature and in snow 102137 01 F...

Page 22: ...ke tension p 72 Clean the dust boots of the fork legs p 36 Bleed the fork legs p 35 Check the air filter Check the settings of all controls and ensure that they can be operated smoothly Check all screws nuts and hose clamps regularly for tightness Check the fuel reserves 8 2 Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always...

Page 23: ... MAP and TC buttons simultaneously FI warning lamp flashes orange rapidly Info Several seconds after the vehicle starts Launch Control is deactivated automatically The Launch Control is deactivated in the following cases FI warning lamp no longer flashes After full throttle the throttle valve was closed by more than 1 3 of the way and or there is no start within 3 minutes To reactivate Launch Cont...

Page 24: ...hrottle at the same time to shift down Pull the clutch lever and shift into a lower gear release the clutch lever slowly and either open the throttle or shift again Switch off the engine if you expect to be standing for a long time Guideline 1 min Avoid frequent and longer slipping of the clutch As a result the engine oil engine and cooling system heat up Ride at a low engine speed instead of at a...

Page 25: ... and level surface Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk Do not park the vehicle near to materials which are highly flammable or explosive Allow the vehicle to cool down before covering it Brake the motorcycle Shift the transmission to idle Press and hold the kill switch while the engine is idling until the engine stops Park the motorcycle on firm ground 8 9...

Page 26: ...ly 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 Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged In some countries and regions the available fuel quality and cleanliness may not be sufficient This will result in problems with the fuel system Refuel only with clean fuel that mee...

Page 27: ...heel bearing for play Check the wheel hubs Check the rim run out Check the spoke tension Check the chain rear sprocket engine sprocket and chain guide p 54 Check the chain tension p 53 Grease all moving parts e g hand lever chain and check for smooth operation Check correct the fluid level of the hydraulic clutch p 58 Check the front brake fluid level p 61 Check the free travel of the hand brake l...

Page 28: ... brake fluid Change the hydraulic clutch fluid p 58 Grease the steering head bearing p 41 Service the fork Service the shock absorber Change the fuel filter Perform minor engine service including removing and installing the engine Change the spark plug and spark plug connector Change the piston check and measure the cylinder check the cylinder head Check the camshaft and cam lever Check the timing...

Page 29: ...uently overloaded then the air pressure in the fork must be increased to avoid damage to the fork and frame The air pressure in the fork can be quickly adjusted for the rider s weight surface conditions and the rider s preference using a fork pump The fork does not have to be detached The time consuming mounting of harder or softer fork springs is not required If the air chamber loses air due to a...

Page 30: ... 17 clicks Standard 15 clicks Sport 13 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 10 5 Adjusting the high speed compression damping of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the descripti...

Page 31: ...tible click Turn counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 10 7 Measuring the rear wheel sag unloaded Preparatory work Raise the motorcycle with a lift stand p 35 402415 10 Main work Position the sag g...

Page 32: ...feet on footrests and bounces up and down a few times The rear wheel suspension levels out Another person again measures the distance between the rear axle and mark ing SAG on the rear fender using the sag gauge Note down the value as dimension Info The riding sag is the difference between measurements and Check the riding sag Riding sag 105 mm 4 13 in If the riding sag differs from the specified ...

Page 33: ...foot brake lever p 64 Remove the motorcycle from the lift stand p 35 10 11 Adjusting the riding sag Preparatory work Raise the motorcycle with a lift stand p 35 Remove the shock absorber p 42 After removing the shock absorber clean it thoroughly B00292 10 Main work Choose and mount a suitable spring Guideline Spring rate Weight of rider 65 75 kg 143 165 lb 39 N mm 223 lb in Weight of rider 75 85 k...

Page 34: ...to get the feel of the new handling characteristic Info Check or adjust the air pressure under the same conditions at the earliest 5 minutes after switching off the engine The air suspension is located in the left fork leg The pressure and rebound damping is located in the right fork leg Preparatory work Raise the motorcycle with a lift stand p 35 K00475 10 Main work Remove protection cap Push for...

Page 35: ...fork leg Turn counterclockwise by the number of clicks corresponding to the fork type Guideline Compression damping Comfort 20 clicks Standard 17 clicks Sport 12 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 10 15 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior M01100 10 Remove protection ...

Page 36: ...k the cables and lines Remove screws Take off handlebar supports Position rubber bushings and push through nuts from below 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 Guideline Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Position the h...

Page 37: ...nd Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 0 0 1 1 402001 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle insert plug in stand into the left side of the wheel spindle Info Remove the plug in stand before starting on a trip 11 3 Bleeding the fork legs Preparatory work Raise the motorcy...

Page 38: ...oil the dust boots and inner fork tubes of both fork legs Universal oil spray p 104 Press the dust boots back into their normal position Remove excess oil Finishing work Install the fork protector p 36 Remove the motorcycle from the lift stand p 35 11 5 Removing the fork protector F00047 10 Remove screws on the left fork leg Take off the clamp Remove screws on the left fork leg Take off the left f...

Page 39: ...r screw of the right fork leg is positioned to the front Valve of the left fork leg faces the front Info Grooves are milled into the side of the upper end of the fork legs The sec ond milled groove from the top must be flush with the top 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 F00078 11 Tigh...

Page 40: ...the upper triple clamp with the handlebar and set it aside Info Cover the components to protect them against damage Do not kink the cables and lines B01865 10 Remove O ring Remove protective ring Take off the lower triple clamp with the steering stem Remove the upper steering head bearing 11 10 Installing the lower triple clamp 102146 10 Main work Clean the bearing and sealing elements check for d...

Page 41: ...cated in the left fork leg The pressure and rebound damping is located in the right fork leg F00080 10 Tighten screws Guideline Screw bottom triple clamp M8 12 Nm 8 9 lbf ft F00081 10 Tighten screw Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft F00082 10 Mount and tighten screw Guideline Screw top steering stem M8 20 Nm 14 8 lbf ft Loctite 243 F00080 11 Using a plastic hammer tap light...

Page 42: ...eering head bearing play immediately Your authorized Husqvarna Motorcycles workshop will be glad to help Info If the bike is ridden with play in the steering head bearing the bearing and the bearing seats in the frame can become dam aged over time Preparatory work Raise the motorcycle with a lift stand p 35 400738 11 Main work Move the handlebar to the straight ahead position Move the fork legs to...

Page 43: ...ft Loctite 243 Finishing work Check the steering head bearing play p 40 Remove the motorcycle from the lift stand p 35 Mount the handlebar cushion 11 13 Greasing the steering head bearing 800010 10 Remove the lower triple clamp p 38 Install the lower triple clamp p 38 11 14 Removing the start number plate F00049 10 Remove screw Swivel the start number plate to one side Remove screw and take off th...

Page 44: ... screws and Remove the front fender 11 17 Installing the front fender H00271 10 Main work Position the front fender Mount and tighten screws and Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the start number plate p 41 11 18 Removing the shock absorber Preparatory work Raise the motorcycle with a lift stand p 35 ...

Page 45: ...lightly to be able to remove the screws more easily F00075 10 Press angle lever toward the rear Press linkage lever downward K00285 10 Remove screws Pull off foot brake cylinder from the push rod 120320 01 Remove the connecting link of the chain Take off the chain Info Cover the components to protect them against damage K00286 10 Remove nut and pull out the swingarm pivot Push the swingarm back an...

Page 46: ... Loctite 2701 120324 10 Position the swingarm and mount the swingarm pivot Info Pay attention to flat area Mount and tighten nut Guideline Nut swingarm pivot M16x1 5 100 Nm 73 8 lbf ft 120325 10 Mount the chain Connect the chain with connecting link Guideline The closed side of the chain joint lock must face in the direction of travel F00077 10 Position the foot brake cylinder Push rod engages in ...

Page 47: ... able to mount the screw more easily F00074 11 Position the frame protector on the left and right Mount and tighten screws Guideline Screw frame protector M5 3 Nm 2 2 lbf ft Mount and tighten screws with the washers Guideline Screw frame protector M5 3 Nm 2 2 lbf ft Mount the new cable ties Finishing work Check the free travel of the foot brake lever p 64 Remove the motorcycle from the lift stand ...

Page 48: ...nd tighten screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the air filter box cover p 46 11 22 Removing the air filter box cover E00261 10 Pull off the air filter box cover sideways in areas and and remove toward the front 11 23 Installing the air filter box cover E00262 10 Position air filter box cover on collar bushings and and push toward the rear Engage the ...

Page 49: ...ilter support 11 25 Installing the air filter 102178 10 Main work Mount the clean air filter on the air filter support Grease the air filter in area Long life grease p 104 H01406 10 Insert air filter and position retaining pin in bushing The air filter is correctly positioned Insert retaining tab Retaining pin is secured by retaining tab Info If the air filter is not mounted correctly dust and dir...

Page 50: ...nstall the air filter p 47 Install the air filter box cover p 46 11 27 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down before performing any work on the vehicle Preparatory work Remove the right side cover p 49 H01408 10 Main work Disconnect spring Spring hook 50305017000 Remove screws and take off...

Page 51: ...in silencer p 48 402618 10 Main work Remove all screws on the main silencer Take off silencer cap Take off outer tube Pull glass fiber yarn filling off of inner tube Clean the parts that need to be reinstalled and check for damage Mount the new glass fiber yarn filling on the inner tube Slide outer tube over the glass fiber yarn filling Insert silencer cap into the outer tube Mount and tighten all...

Page 52: ...the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clo...

Page 53: ...hen warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and...

Page 54: ... M6 10 Nm 7 4 lbf ft H01411 11 Plug in connector for the fuel pump Remove the wash cap set and thoroughly clean the plug in connection of the fuel line using compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Lubricate the O ring and connect plug in connection for the fuel line Info Route the cable and fuel line at a safe...

Page 55: ... with chain spray Offroad chain spray p 104 Finishing work Remove the motorcycle from the lift stand p 35 11 36 Checking 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 overlo...

Page 56: ...n tension by turning adjusting screws left and right Guideline Chain tension 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 The rear wheel is then correctly aligned Tighten nuts Make sure that chain adjusters are fitted correctly on adjusting screws Tighten nut Guideli...

Page 57: ... New chains wear out faster on an old worn rear sprocket or engine sprocket H01416 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 sliding guard Check that the chain sliding guard is firmly seated If the chain sliding guard is loose Tighten the screws on the chain sliding guard Guideline Screw chain sli...

Page 58: ...e for cracks and deformation If the frame exhibits cracks or deformation due to a mechanical impact Change the frame Info Always replace a frame that has been damaged due to a mechan ical impact Repair of the frame is not authorized by Husqvarna Motorcycles 11 40 Checking the swingarm 401520 01 Check the swingarm for damage cracking and deformation If the swingarm shows signs of damage cracking or...

Page 59: ...eft and onto the han dle tube of the throttle grip on the right The left sleeve is clamped onto the handlebar The rubber grip can only be replaced with the sleeve or the throttle tube If a rubber grip is damaged or worn Change the rubber grip E00265 10 Check that screw is firmly seated Guideline Screw fixed grip M4 5 Nm 3 7 lbf ft Loctite 243 The diamond must be located at the top 11 43 Adjusting ...

Page 60: ... reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane Check the fluid level Fluid level below container rim 4 mm 0 16 in If the fluid level does not meet specifications Correct the fluid level of the hydraulic clutch Brake fluid DOT 4 p 102 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilled brake flu...

Page 61: ...sible Info Clean up overflowed or spilled brake fluid immediately with water Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container F00058 10 Inject the liquid into the system only until it emerges from drill hole of the master cylinder without bubbles Now and then extract fluid from the master cylinder reservoir to prevent ...

Page 62: ...lebar Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 12 3 Checking the brake discs Warning Danger of accidents Worn out brake discs reduce the braking effect Make sure that worn out brake disc...

Page 63: ...he 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 Motorcy cles workshop will be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wea...

Page 64: ...s Info Clean up overflowed or spilled brake fluid immediately with water 12 6 Checking the front brake linings Warning Danger of accidents Worn out brake linings reduce the braking effect Ensure that worn out brake linings are replaced immediately Your authorized Husqvarna Motorcycles workshop will be glad to help F00062 10 Check the brake linings for minimum thickness Minimum thickness 1 mm 0 04 ...

Page 65: ...ironmental 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 fluid attacks paint Only use clean brake fluid from a sea...

Page 66: ...here 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 Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Guideline Free travel at foot brake lever 3 5 mm 0 12...

Page 67: ...e fluid level Warning 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 Your authorized Husqvarna Motorcy cles workshop will be glad ...

Page 68: ...tact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Your autho rized Husqvarna Motorcycles workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental da...

Page 69: ...ng and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clot...

Page 70: ...rt H00326 10 Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly Info The arrow on the leaf spring points in the rotation direction of the brake disc H00327 10 Insert the new brake linings insert pin and mount cotter pins Info Always change the brake linings in pairs Make sure that decoupling plate is mounted on the piston side brake lini...

Page 71: ...uce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork Info Do not pull the hand brake lever when the front wheel is removed H00934 10 Remove spacers 13 2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect...

Page 72: ...d p 35 E00268 10 Main work Press the brake caliper onto the brake disc by hand in order to push back the brake piston Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove nut Remove chain adjuster Withdraw wheel spindle only enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Remove the ch...

Page 73: ...sition the rear wheel and insert wheel spindle The brake linings are correctly positioned Mount the chain E00271 10 Position chain adjuster Mount nut but do not tighten it yet Make sure that chain adjusters are fitted correctly on adjusting screws Check the chain tension p 53 Tighten nut Guideline Nut rear wheel spindle M25x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters ...

Page 74: ...k of manufacture and the last two digits the year of manu facture Husqvarna Motorcycles recommends that the tires be changed after 5 years at the latest regardless of the actual state of wear If the tires are more than 5 years old Change the tires 13 6 Checking the tire air pressure Info Low tire air pressure leads to abnormal wear and overheating of the tire Correct tire air pressure ensures opti...

Page 75: ... tone frequencies from different spokes of equal length and diameter this is an indication of different spoke tensions You should hear a high note If the spoke tension differs Correct the spoke tension Check the spoke torque Guideline Spoke nipple front wheel M4 5 6 Nm 4 4 lbf ft Spoke nipple rear wheel M4 5 6 Nm 4 4 lbf ft Torque wrench with various accessories in set 58429094000 ...

Page 76: ... switch off the engine Remove the air filter box cover p 46 Remove the seat p 45 H01190 10 Main work Pull back the negative terminal cover and disconnect negative cable from the battery Pull back the positive terminal cover and disconnect positive cable from the battery Remove screw Pull holding bracket forward and take out the battery toward the top 14 2 Installing the battery H00388 10 Main work...

Page 77: ...dispose of batteries as household waste Return batteries to your authorized Husqvarna Motorcycles dealer or dispose of them at a collection point for used bat teries Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Even when there is no lo...

Page 78: ... the open circuit voltage and start potential of the battery and to test the alternator With this device you cannot overcharge the battery The charging time may be longer at low temperatures Switch off the battery charger after charging and disconnect from the battery Finishing work Install the battery p 74 Mount the seat p 46 Install the air filter box cover p 46 14 4 Changing the main fuse Warni...

Page 79: ...use is located in the starter relay Install a new main fuse Fuse 58011109110 p 99 Check that the electrical equipment is functioning 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 lay the cable Finishing work Mount the seat p 46 Install the air filter box cover p 46 ...

Page 80: ...r other compo nents 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 immediately if coolant is swallowed Rinse the affected area immediately wit...

Page 81: ...orcycle upright on a horizontal surface Remove the radiator cap Check the coolant level in the radiator Coolant level above the radiator fins 10 mm 0 39 in If the coolant level does not match the specified value Correct the coolant level Coolant p 102 Mount the radiator cap 15 4 Draining the coolant Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under press...

Page 82: ... to come into contact with the skin the 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 120353 10 Make sure that screw is tightened P...

Page 83: ...ngine in an enclosed space Start the engine and let it run idle Move the handlebar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust the play in the throttle cable p 81 16 2 Adjusting the play in the throttle cable Info If the correct routing of the throttle cables has already been secured the fuel tank does not need to be removed Preparatory...

Page 84: ...ells Detach the throttle cables and take off the grip tube 102246 10 Remove guide plate from handle tube Position the required guide plate on the grip tube Guideline The label OUTSIDE must be visible Marking must be positioned at mark ing Alternative 1 Grey guide plate 79002014000 Alternative 2 Black guide plate 79002014100 Info The gray guide plate opens the throttle valve more slowly The black g...

Page 85: ... 10 Activating STANDARD mapping Press button MAP until LED1 lights up Guideline Engine speed 4 000 rpm STANDARD balanced response H01180 11 Activating ADVANCED mapping Press button MAP until LED2 lights up Guideline Engine speed 4 000 rpm ADVANCED direct response 16 5 Adjusting the idle speed Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and dea...

Page 86: ... engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Allow the vehicle to idle The MIL stops flashing once teaching is completed Info If the engine becomes too hot perform a cool down ride at medium revs Then do not switch off the engine after this but leave it running at idle speed until teaching is completed 16 7 Checking the basic position ...

Page 87: ...of the shift lever and shift shaft Mount the shift lever on the shift shaft in the required position and engage the gearing Info The range of adjustment is limited The shift lever must not come into contact with any other vehicle compo nents during the shift procedure Locate and tighten screw with washers Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 ...

Page 88: ...er handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system F00073 10 Clean plug in connection of the fuel line thoroughly with compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Disconnect the plug in connection of the fuel line Info Remaining fuel may flow ...

Page 89: ...oil and oil filter cleaning the oil screen Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden Wear suitable protective clothing and safety gloves In the event of scalding rinse the area affected immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake...

Page 90: ...l drain plug with the magnet and a new seal ring Guideline Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft 120303 10 Remove screws Remove the oil filter cover with the O ring F00092 10 Pull oil filter out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing surfaces 120303 11 Lay the motorcycle on its side and fill...

Page 91: ...dding engine oil Info Too little engine oil or poor quality engine oil results in premature wear of the engine S00931 10 Main work Remove oil filler plug with the O ring from the clutch cover Fill engine oil to the middle of the level viewer Add the same engine oil that was used when the last oil change was carried out Engine oil SAE 10W 50 p 102 Info For optimal performance of the engine oil do n...

Page 92: ...les with a gentle spray of water Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to a dry vehicle always rinse the vehicle with water first After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the closure of the ex...

Page 93: ... taking the motorcycle out of service add fuel additive Refuel p 24 Clean the motorcycle p 90 Change the engine oil and oil filter clean the oil screen p 87 Check the antifreeze and coolant level p 78 Check the tire air pressure p 72 Remove the battery p 74 Recharge the battery p 75 Guideline Storage temperature of battery with out direct sunshine 0 35 C 32 95 F Store the vehicle in a dry location...

Page 94: ...es diagnostics tool Engine has too little power Air filter is very dirty Clean the air filter and air filter box p 47 Fuel filter is very dirty Change the fuel filter Defect in fuel injection system Read out the fault memory using the Husq varna Motorcycles diagnostics tool Exhaust system leaky deformed or too little glass fiber yarn filling in main silencer Check exhaust system for damage Change ...

Page 95: ... oil consumption Piston or cylinder worn Measure the piston cylinder mounting clear ance Battery discharged Battery is not charging Check the charging voltage Check the stator winding of the alternator Unwanted power consumer Check the open circuit current ...

Page 96: ...nal too low Engine coolant temperature sensor input signal too high Blink code of FI warning lamp MIL 13 FI warning lamp MIL flashes 1x long 3x short Error level condition Intake air temperature sensor input signal too low Intake air temperature sensor input signal too high Blink code of FI warning lamp MIL 15 FI warning lamp MIL flashes 1x long 5x short Error level condition Rollover sensor A D t...

Page 97: ... CODE 95 Blink code of FI warning lamp MIL 41 FI warning lamp MIL flashes 4x long 1x short Error level condition Fuel pump control short circuit to ground or open circuit Fuel pump control input signal too low ...

Page 98: ...n ratio 1st gear 13 32 2nd gear 16 32 3rd gear 17 28 4th gear 19 26 5th gear 21 25 Alternator 12 V 66 W Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment Spark plug NGK LMAR9AI 8 Spark plug electrode gap 0 8 mm 0 031 in Cooling Water cooling permanent circulation of coolant by water pump Starting aid Electric starter 22 2 Engine tightening torques Nozzle c...

Page 99: ...bf ft Screw autodecompression M7x1 15 Nm 11 1 lbf ft Loctite 243 Screw camshaft bearing bridge M7x1 14 Nm 10 3 lbf ft Lubricated with engine oil Screw plug crankshaft location M8 10 Nm 7 4 lbf ft Screw timing chain tensioning rail M8 15 Nm 11 1 lbf ft Loctite 243 Screw engine sprocket M10 60 Nm 44 3 lbf ft Loctite 2701 Plug oil channel M10x1 15 Nm 11 1 lbf ft Loctite 243 Rotor screw M10x1 70 Nm 51...

Page 100: ...rmance Systems 5018 DCC Link Brake system Disc brakes brake calipers on floating bearings Brake discs diameter Front 260 mm 10 24 in Rear 220 mm 8 66 in Brake discs wear limit Front 2 5 mm 0 098 in Rear 3 5 mm 0 138 in Tire air pressure offroad Front 1 0 bar 15 psi Rear 1 0 bar 15 psi Secondary ratio 13 50 Chain 5 8 x 1 4 Available rear sprockets 48 50 51 52 Steering head angle 63 9 Wheelbase 1 48...

Page 101: ...s Air pressure 10 6 bar 154 psi Fork length 950 mm 37 4 in Oil capacity external mecha nism right 200 40 20 ml 6 76 1 35 0 68 fl oz Fork oil SAE 4 48601166S1 p 102 Oil capacity external mecha nism left 200 40 20 ml 6 76 1 35 0 68 fl oz Fork oil SAE 4 48601166S1 p 102 Oil capacity right cartridge 380 ml 12 85 fl oz Fork oil SAE 4 48601166S1 p 102 Grease capacity left cartridge 11 ml 0 37 fl oz Mult...

Page 102: ... 7 Nm 5 2 lbf ft Remaining nuts chassis M6 10 Nm 7 4 lbf ft Remaining screws chassis M6 10 Nm 7 4 lbf ft Screw ball joint of push rod on foot brake cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw battery support bracket M6 10 Nm 7 4 lbf ft Screw chain sliding guard M6 6 Nm 4 4 lbf ft Loctite 243 Screw electric starter cable connec tion M6 4 Nm 3 lbf ft Screw front brake disc M6 14 Nm 10 3 lbf ft Lo...

Page 103: ...f ft Loctite 2701 Nut fuel pump M12 15 Nm 11 1 lbf ft Nut frame to linkage lever M14x1 5 80 Nm 59 lbf ft Nut linkage lever on swingarm M14x1 5 80 Nm 59 lbf ft Nut linkage lever to angle lever M14x1 5 80 Nm 59 lbf ft Nut swingarm pivot M16x1 5 100 Nm 73 8 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 nozzles cooling system M20x1...

Page 104: ...50 Standard classification JASO T903 MA p 105 SAE p 105 SAE 10W 50 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corre sponding properties Synthetic engine oil Recommended supplier Bel Ray Works Thumper Racing Synthetic Ester 4T Fork oil SAE 4 48601166S1 Standard classification SAE p 105 SAE 4 Guideline Use only oil...

Page 105: ...28 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100 ...

Page 106: ...ife grease Recommended supplier Bel Ray Waterproof Grease Offroad chain spray Guideline Recommended supplier Bel Ray Blue Tac Chain Lube Oil for foam air filter Recommended supplier Bel Ray Foam Filter Oil Preserving materials for paints metal and rubber Recommended supplier Bel Ray Silicone Detailer Protectant Spray Universal oil spray Recommended supplier Bel Ray 6 in 1 ...

Page 107: ...rvice intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils ...

Page 108: ... OF SPECIAL TERMS 106 MIL Malfunction indicator lamp Indicator lamp that supports vehicle diagnostics through flash codes OBD On board diagnosis Vehicle system that monitors emission and safety related val ues ...

Page 109: ...27 LIST OF ABBREVIATIONS 107 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 110: ...llow and orange symbols indicate an error condition that requires prompt intervention Active driving aids are also represented by yellow or orange symbols FI warning lamp MIL lights up flashes orange The OBD has detected an emission or safety critical fault ...

Page 111: ...2 Chassis number 10 Clutch fluid level checking correcting 58 fluid changing 58 Clutch lever 11 basic position adjusting 57 Cold start button 13 Compression damping fork adjusting 33 Compression damping high speed shock absorber adjusting 28 Compression damping low speed shock absorber adjusting 28 Coolant antifreeze and coolant level checking 78 draining 79 level checking 79 refilling 80 Cooling ...

Page 112: ...ising with 35 removing from lift stand 35 O Oil filter changing 87 Oil screen cleaning 87 Operating substances 7 Overview of indicator lamps 12 Owner s Manual 6 P Plug in stand 15 Preparing for use advice on first use 16 Protective clothing 6 Putting into operation after storage 91 checks and maintenance before putting into operation 20 R Rear sprocket checking 54 Rear wheel installing 71 removing...

Page 113: ... 40 Storage 91 Swingarm checking 56 T Technical data capacities 98 chassis 98 chassis tightening torques 100 electrical system 99 engine 96 engine tightening torques 96 fork 99 shock absorber 99 tires 99 Throttle cable play adjusting 81 checking 81 Throttle cable routing checking 56 Throttle grip 11 Throttle valve position teaching 84 Tire air pressure checking 72 Tire condition checking 72 Tracti...

Page 114: ... 3402095en 3402095en 03 2016 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria www husqvarna motorcycles com Photo Mitterbauer Husqvarna Motorcycles GmbH ...

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