Husqvarna FC 350 2014 Repair Manual Download Page 41

Page: 41 / 242

FORK, TRIPLE CLAMP

Mount and tighten screw@.

Guideline

Screw, top steering stem

17 Nm

(12.5 lbf ft)

Loctite

243

™

Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.

Tighten screws

fD.

Guideline

Screw, top triple clamp

17 Nm (12.5 lbf ft)

B01872-10

Secure the wiring harness with cable holder@).

Position the brake caliper. Mount and tighten screws Ci).

Guideline

Screw, front brake caliper MS

25 Nm

(18.4 lbf ft)

Loctite

243

™

Position the brake line and clamp. Mount and tighten screws

48.

Finishing work

Install the front fender. (or p. 89)

Install the start number plate. (or p. 90)

Install the front wheel. (or p. 93)

Check that the wiring harness, throttle cables and brake and clutch lines can

move freely and are routed correctly.

Check the steering head bearing play. (or p. 39)

Remove the motorcycle from the lift stand. (or p. 10)

Checking the steering head bearing play

Warning

Danger of accidents

Unstable vehicle handling from incorrect steering head bearing play.

- Adjust the steering head bearing play without delay.

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 the lift stand. (or p. 10)

Main work

Move the handlebar to the straight-ahead position. Move the fork legs to and fro

in the direction of travel.

No play should be noticeable in the steering head bearing.

If there is noticeable play present:

- Adjust the steering head bearing play. (or p. 41)

Summary of Contents for FC 350 2014

Page 1: ...PIONEERING SINCE 1903 REPAIR MANUAL2014 FC 350 EU Art no 3403006en Husqvarna MOTORCYCLES ...

Page 2: ......

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

Page 4: ...le clamp 38 6 31 Checking the steering head bearing play 39 7 8 9 2 6 32 Changing the steering head bearing 40 6 33 Adjusting the steering head bearing play 41 HANDLEBAR CONTROLS 42 7 1 Handlebar position 42 7 2 Adjusting the handlebar position 42 7 3 Adjusting the basic position of the clutch lever 42 7 4 Checking the throttle cable routing 43 7 5 Checking the play in the throttle cable 43 7 6 Ad...

Page 5: ...avel of the hand brake lever 105 106 106 107 107 108 109 109 109 110 17 3 16 4 Adjusting the basic position of the hand brake lever 111 16 5 Checking the brake fluid level of the front brake 111 16 6 Adding front brake fluid 112 16 7 Changing the front brake fluid 113 16 8 Checking the rear brake linings 114 16 9 Changing the rear brake linings 114 16 10 Checking the free travel of foot brake leve...

Page 6: ... Installing the primary gear 172 Installing the force pump 173 Installing the suction pump 173 Installing the locking lever 174 Installing the shift drum locating unit 174 Installing the shift shaft 175 17 5 15 Installing the outer clutch hub 17 5 16 Installing the clutch discs 17 5 17 Installing the clutch cover 17 5 18 Installing the water pump cover 17 5 19 Installing the starter drive 17 5 20 ...

Page 7: ...ING 208 24 1 Cleaning themotorcycle 208 25 STORAGE 209 25 1 Storage 209 25 2 Preparing for use after storage 209 26 SERVICE SCHEDULE 210 26 1 Service schedule 210 26 2 Servicework as additional order 211 27 WIRING DIAGRAM 212 27 1 Page1 of3 212 27 2 Page2 of3 214 27 3 Page3 of3 216 28 SUBSTANCES 218 29 AUXILIARY SUBSTANCES 219 30 SPECIAL TOOLS 221 31 STANDARDS 235 INDEX 236 5 ...

Page 8: ...e Indicates information with more details or tips Indicates the result of a testing step V Denotes a voltage measurement A Denotes a current measurement Denotes a resistance measurement 1 2 Formats used The typographical formats used in this document are explained below Proprietary name Name Brand Underlined terms Identifies a proprietary name Identifies a protected name Identifies a trademark Ref...

Page 9: ...riate measures are not taken Warning Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken Caution Indicates a danger that may lead to minor injuries if the appropriate measures are not taken Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken Warning Indicates a danger that...

Page 10: ...ng of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Use the operating and auxiliary substances such as fuel and lubricants as specified in the manual 3 3 Spare parts accessories Only use spare parts and accessories approved and or recommended by Husqvarna Husqvarna accepts no liability for other prod ucts and any resulting damage...

Page 11: ...he steering head The type label O is fixed to the front of the steering head The engine number O is stamped on the left side of the engine under the engine sprocket The fork part number O is stamped on the inner side of the axle clamp The shock absorber part number O is stamped on the top of the shock absorber above the adjusting ring on the engine side 9 ...

Page 12: ... poisoning 402001 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle insert plug in stand O into the left side of the wheel spindle Info Remove the plug in stand before riding Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the...

Page 13: ...ger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Info Press the starter for a maximum of 5 seconds Wait for at least 5 seconds before trying again 400733 01 Shift t...

Page 14: ...ounterclockwise to reduce damping Ad usting the rebound dam ing of the fork Info The hydraulic rebound damping determines the fork suspension behavior Bleeding the fork legs Remove protection caps O Turn adjusting screws 8 clockwise all the way Info I Adjusting screws 8 are located at the bottom end of the fork legs Make the same adjustment on both fork legs Turn back counterclockwise by the numbe...

Page 15: ...the dust boots If this dirt is not removed the oil seals behind can start to leak Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Clean and oil the dust boots and inner fork tube of both fork legs I Universal oil spray p 220 Press the dust boots back in...

Page 16: ... O and take off the clamp Remove screws 8 and take off the brake caliper 10 Nm 7 4 lbf ft Allow the brake caliper and brake line to hang tension free to the side Info Do not pull the hand brake lever if the front wheel has been removed Loosen screws Take out the left fork leg Unscrew screws C Take out the right fork leg Main work Position the fork legs Bleeder screws O face forward Info I Grooves ...

Page 17: ...fork leg Remove the fork protector from above 15 Remove the screws on the right fork leg Remove the fork protector from above B00306 10 Installing the fork rotector B00306 10 Main work Position the fork protection on the left fork leg Mount and tighten screws 0 Guideline I Remaining screws chassis I 10Nm 7 4Ibf ft Position the fork protection on the right fork leg Mount and tighten the screws Guid...

Page 18: ... Assemble the screw cap with the membrane holder or p 28 Assemble the piston rod or p 29 Assemble the cartridge or p 30 Assemble the fork legs or p 32 Conducting minor fork service Info The steps are identical for both fork legs 0 200978 01 Condition The fork legs are disassembled Disassemble the fork legs or p 16 Check the fork legs during a minor fork service or p 25 Assemble the fork legs or p ...

Page 19: ...stand T1403S p 233 Remove the screw Remove adjuster of the compression damping Loosen cartridge 8 Ring wrench T14017 p 231 Info I The cartridge cannot be taken off yet Unclamp the fork leg Push the outer tube down Drain the fork oil Clamp the fork leg with the axle clamp Guideline I Use soft jaws Loosen rebound adjustment Info I Do not use an impact wrench Place a fluid collector beneath it as usu...

Page 20: ...e fork leg Remove the preload spacers and spring Remove dust boot C Remove fork protection ring C5 Info I The fork protection ring does not necessarily need to be removed for repair work Remove lock ring Info I The lock ring has a ground end against which a screwdriver can be posi tioned Warm the outer tube in area Ci of the lower sliding bushing Guideline I so 0 c 122 F Pull the outer tube forcef...

Page 21: ...ff support ring 48 Take off seal ring Cl Take off lock ring Take off dust boot Unclamp the fork leg Disassemblin the cartrid e Info The steps are identical for both fork legs 200835 10 200836 10 Preparatory work Disassemble the fork legs p 16 Main work Remove adjusting tube O and nut 8 Clamp the cartridge into a vise Info Use soft jaws Remove filling screw s 19 ...

Page 22: ...nitrogen is bled off Loosen and remove screw cap C with the membrane holder I Pin wrench T103 p 228 Unclamp the cartridge Empty the cartridge Reclamp the cartridge upside down Guideline I Use soft jaws Heat the cartridge in area f of pilot bushing t Guideline 1100 C 212 F Loosen the screw sleeve and remove the piston rod Remove spring guide 0 and ring Remove guide ring 20 ...

Page 23: ...e identical for both fork legs 200856 10 Preparatory work Disassemble the fork legs p 16 Disassemble the cartridge p 19 Main work Remove screw sleeve O and washer 8 from the piston rod Degrease the piston rod Clamp the piston rod with the special tool as far up as possible I Clamping stand T14016S p 231 Remove nut Remove rebound shim stack C Remove rebound piston 0 21 ...

Page 24: ...ap rebound fD Remove the 0 rings Disassembling the screw ca with the membrane holder Info The steps are identical for both fork legs Preparatory work Disassemble the fork legs p 16 Disassemble the cartridge p 19 Main work 22 Clamp the screw cap with the membrane holder and the special tool into a vise Guideline I Use soft jaws I Pin wrench T103 p 228 Info Only tighten the vise lightly Remove compr...

Page 25: ...Remove rebound washer D Remove compression piston Remove O ring Remove compression shim stack Remove O ring 41 Disassembling the screw sleeve Info The steps are identical for both forklegs 8 1 f 200866 10 Preparatory work Disassemble the forklegs p 16 Disassemble the cartridge p 19 Disassemble the piston rod p 21 Main work Remove O ring O Remove lockring 8 Remove ring D 23 ...

Page 26: ...asure the outside diameter of the inner tube at several locations Outside diameter of the inner tube 47 975 48 005 mm 1 88878 1 88996 in If the measured value is less than the specified value Change the inner tube Measure the run out of the inner tube I Inner tube run out I 5 0 20 mm 5 0 0079 in If the measured value is greater than the specified value Change the inner tube Measure the inside diam...

Page 27: ...heck valve spring length Guideline I Spring length of the check valve I 5 8 mm 0 228 in If the measured value is less than the specified value Change the spring Check the piston rod for damage If there is damage Replace the piston rod Measure the outside diameter of the piston rod at several locations I Outside diameter of the piston rod I 11 965 mm 0 47106 in If the measured value is less than th...

Page 28: ... 937 in If the measured value is greater than the specified value Change the outer tube Check the outer tube for damage If there is damage Change the outer tube Check the surface of the sliding bushing If the bronze colored layer G under the sliding layer Ce is visible or the sur face is rough Replace the sliding bushing Check the spring length Guideline I Spring length with preload spacer s I 490...

Page 29: ...ing in the screw sleeve with the special tool and press it in all the way I Mounting tool T14022 p 232 Lubricate the special tool Fork oil SAE 4 48601166S1 p 218 Calibrating unit T14021 p 232 Press the special tool through the new pilot bushing a number of times I Calibrating unit T14021 p 232 The pilot bushing is calibrated Finishing work Assemble the screw sleeve p 27 Assembling the screw sleeve...

Page 30: ...ton Guideline View6 Compression piston from above View Compression piston from below Mount rebound damping washer 0 Mount spring 3 with the tighter coil at the bottom Mount and tighten new nut with the collar facing downward Guideline INut compression piston I M6x0 5 I 3 Nm 2 2 lbf ft The collar centers the rebound washer and the spring Check the freedom of movement of the rebound washer against t...

Page 31: ...pring 8 with the sleeve Mount and tighten tap rebound O Guideline Tap rebound M9x1 Mount spring 5 18 Nm 13 3 lbf ft Loctite 2701 TM Mount compression shim stack C with the smaller washer facing downward Grind the rebound piston on both sides on a surface plate with 1200 grit sandpa per Clean the rebound piston Wrap the piston ring around the shaft of a screwdriver before mounting Mount the piston ...

Page 32: ...10 200884 10 200882 10 Preparatory work Check the fork legs p 24 Assemble the screw cap with the membrane holder p 28 Assemble the piston rod p 29 Main work Lubricate and mount 0 ring O I Lubricant T158 p 219 Mount the spring and 0 ring on check valve fj I Lubricant T158 p 219 Mount the check valve with the special tool I Tweezers T14033 p 233 Mount guide ring Mount spring guide C and ring 0 Clamp...

Page 33: ...idge M24x1 Mount filling screw with the O ring 40 Nm 29 5 lbf ft Loctite 241 Clamp the cartridge vertically and fill with fork oil to the lower edge 6 of the upper part of the cartridge I Fork oil SAE 4 48601166S1 r p 218 The piston rod is fully extended Mount the screw cap with the membrane holder and tighten with the special tool Guideline I Screw cap on the cartridge I Pin wrench T103 r p 228 B...

Page 34: ...e and slide on dust boot O I Lubricant T511 p 219 Info I Always change the dust boot seal ring lock ring and support ring Mount the sealing lip with the spring expander facing downward Slide on lock ring 8 Lubricate and slide on seal ring I Lubricant T511 p 219 Mount with the sealing lip facing downward the open side facing upward Slide on support ring 8 Remove the special tool Roughen clean and l...

Page 35: ...rk protector ring Cs Mount the preload spacers and spring Guideline Spring rate Weight of rider 65 75 kg 143 165 lb Weight of rider 75 85 kg 165 187 lb Weight of rider 85 95 kg 187 209 lb Push the cartridge into the fork leg 4 6 N mm 26 3 lb in 4 8 N mm 27 4 lb in 5 0 N mm 28 6 lb in Press the cartridge against the spring and mount special tool I Support tool T14020 p 231 Grease the O ring of the ...

Page 36: ...cant T158 p 219 Push the outer tube upward p 218 Clamp the outer tube in the area of the lower triple clamp I Clamping stand T1403S p 233 Tighten the cartridge Guideline I Cartridge on the outer tube I M51x1 5 I Ring wrench T14017 p 231 I 50 Nm 36 9 lbf ft I Mount adjuster of the compression damping Mount and tighten the screw Guideline Screw compression adjuster M4x0 5 1 5 Nm 1 11 lbf ft Alternat...

Page 37: ...figure Guideline I Use soft jaws Info I Clamp the cartridge only lightly The filling port must be located at the highest point During the filling procedure the cartridge must be lower than the oil tank of the vacuum pump The piston rod moves in and out during filling do not immobilize it by holding it with your hand Remove the screw of the filling port Mount special tool O on the cartridge I Filli...

Page 38: ...en the pressure gauge reaches the required value activate the On Off switch Guideline 0 bar The vacuum pump is switched off Disconnect the vacuum pump Remove the special tool Info I The filling port must be positioned at the highest point Mount and tighten the filling screw with the O ring Guideline I Cartridge filling screw M4x0 5 I 2 Nm 1 5 lbf ft e with nitro en 200890 10 Clamp the cartridge in...

Page 39: ...e lower triple clamp p 37 Install the lower triple clamp p 38 Removing the lower triple clamp Preparatory work Raise the motorcycle with the lift stand p 10 Remove the front wheel p 92 Remove the fork legs p 14 Remove the start number plate p 89 Remove the front fender p 89 Main work Take off cable holder O in front of the left radiator Remove screw 8 Remove screw Take off the top triple clamp wit...

Page 40: ... positioned Slide on protective ring 8 and O ring Position the upper triple clamp with the handlebar Mount screw C but do not tighten yet Position the fork legs Bleeder screws 0 face forward Info I 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 Tighten screws D Guideline I Screw bot...

Page 41: ...g harness throttle cables and brake and clutch lines can move freely and are routed correctly Check the steering head bearing play or p 39 Remove the motorcycle from the lift stand or p 10 Checking the steering head bearing play Warning Danger of accidents Unstable vehicle handling from incorrect steering head bearing play Adjust the steering head bearing play without delay Info If the bike is rid...

Page 42: ...rk Remove the motorcycle from the lift stand p 10 Changing the steering head bearing ff Preparatory work Raise the motorcycle with the lift stand p 10 Remove the front wheel p 92 Remove the fork legs p 14 Remove the start number plate p 89 Remove the front fender p 89 Remove the lower triple clamp p 37 Main work Remove the lower bearing race O using a suitable tool Press in the new bearing race al...

Page 43: ...aring play p 39 Remove the motorcycle from the lift stand p 10 Adjusting the steering head bearing la Preparatory work Raise the motorcycle with the lift stand p 10 Remove the handlebar cushion Main work Loosen screws O Remove screw 8 Loosen and retighten screw D Guideline I Screw top steering head I M20x1 5 12 Nm 8 9 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid str...

Page 44: ... the handlebar supports Place the handlebar supports in the required position Mount and tighten screws 8 Guideline Screw handlebar support M10 Info 40 Nm 29 5 lbf ft Position the left and right handlebar supports evenly Position the handlebar Info Loctite 243 I Make sure the cables and wiring are positioned correctly Position the handlebar clamps Mount and tighten screws O evenly Guideline I Screw...

Page 45: ...ad position Turn the throttle grip back and forth slightly and determine the play in throttle cable G I Play in throttle cable 13 5 mm 0 12 0 2 in If the throttle cable play does not meet specifications Adjust the play in the throttle cable p 44 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure t...

Page 46: ...le 44 Loosen nut 8 Turn adjusting screw 0 so that there is play in the throttle cable at the throttle grip Guideline I Play in throttle cable 13 5 mm 0 12 0 2 in Tighten nut 8 Press and hold the throttle grip in the closed setting Turn adjusting screw out until there is no play in the throttle cable 0 Tighten nut Push sleeves O on Check the throttle grip for smooth operation Finishing work Check t...

Page 47: ...deformation If the frame exhibits cracks or deformation due to a mechanical impact Change the frame Info 45 I Always replace a frame that has been damaged due to a mechan ical impact Repair of the frame is not authorized by Husqvarna Motorcycles ...

Page 48: ...s 2 turns 1 5 turns I Turn clockwise to increase damping turn counterclockwise to reduce damping ression dam in of the shock absorber Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Info The low speed setting can be seen during the slow to normal compression of the shock absorber 46 T...

Page 49: ...ag unloaded Preparatory work Raise the motorcycle with the lift stand or p 10 Main work Measure the vertical distance between the rear axle and a fixed point such as a marking on the side cover Note down the value as dimension f Finishing work Remove the motorcycle from the lift stand or p 10 Checking the static sag of the shock absorber Measure distance f of rear wheel unloaded or p 47 Hold the m...

Page 50: ...d parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Info Before changing the spring preload make a note of the present setting e g by measuring the length of the spring Preparatory work Raise the motorcycle with the lift stand p 10 Remove the seat p 80 Remove the right side cover p 79 Remove the main silencer p 75 Remove the shock a...

Page 51: ...ider 65 75 kg 143 165 lb Weight of rider 75 85 kg 165 187 lb Weight of rider 85 95 kg 187 209 lb Info 54 N mm 308 lb in 57 N mm 325 lb in 60 N mm 343 lb in I The spring rate is shown on the outside of the spring Finishing work Install the shock absorber p 50 Install the main silencer p 75 Install the right side cover p 80 Mount the seat p 80 Check the static sag of the shock absorber p 47 Check th...

Page 52: ...ff the manifold Remove screws on both sides Loosen screws on both sides Remove screw Raise the rear frame slightly and remove the shock absorber toward the top Main work Raise the rear frame slightly and insert the shock absorber from above Position the shock absorber Mount and tighten screw O Guideline Screw top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 50 ...

Page 53: ...line 30 Nm 22 1 lbf ft 30 Nm 22 1 lbf ft I Nut linkage lever to angle lever I M14x1 5 Mount and tighten screw Guideline Screw bottom shock absorber Finishing work M10 Install the main silencer p 75 Install the right side cover p 80 Mount the seat p 80 60 Nm 44 3 lbf ft Remove the motorcycle from the lift stand p 10 9 11 Checkin the shock absorber linkage Preparatory work Raise the motorcycle with ...

Page 54: ...s damage or wear Change the spacers Check the shaft seal rings for damage and wear If there is damage or wear Change the shaft seal rings Check dimension 6 303096 10 I 54 91 55 00 mm 2 1618 2 1654 in If dimension 6 is less than the specified value Add the corresponding spacing washers D Position the angle lever Mount screw connection CD but do not tighten yet Guideline I Nut linkage lever on swing...

Page 55: ... I Nut linkage lever on swingarm I M14x1 5 Finishing work Remove the motorcycle from the lift stand p 10 Loctite 2701 TM I 80 Nm 59 lbf ft Servicing the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided 201457 01 Condition The shock absorber has been removed Remov...

Page 56: ...no longer under tension I Hook wrench T106S p 229 Remove ring 8 Remove spring retainer and intermediate washer C Remove the spring Disassembling the dam er 0 Preparatory work Remove the spring p 54 Main work Note down the current state of rebound damping O and compression damp ing 8 Completely open the adjusters of the rebound and compression damping Remove rubber cap of the reservoir Open screw C...

Page 57: ...ssembly tool T1216 p 230 Remove lock ring Info Do not scratch the inner surface Remove the piston rod Remove adjusting ring with the intermediate washer Drain the oil Remove compression adjuster Remove the spring and piston iston rod Preparatory work Remove the spring p 54 Disassemble the damper p 54 55 ...

Page 58: ...n as a unit Remove piston 8 Remove compression shim stack 0 Info I Place the compression shim stack onto a screwdriver and set it down as a unit Remove rebound washer D Remove seal ring retainer Remove locking cap and rubber buffer Disassembling the seal ring retainer 201405 10 Preparatory work Remove the spring p 54 Disassemble the damper p 54 Disassemble the piston rod p 55 Main work Remove spri...

Page 59: ...shing O onto the special tool I Press drift T1504 r p 233 Position the pilot bushing in the seal ring retainer using the special tool I Press drift T1504 r p 233 Support seal ring retainer 8 with sleeve f of the special tool Press the pilot bushing all the way in I Assembly tool T150S r p 233 Lubricate the special tool Shock absorber fluid SAE 2 5 50180751S1 r p 218 Calibration pin T1205 r p 229 S...

Page 60: ...iameter of the piston rod Piston rod Diameter 17 95 mm 0 7067 in If the measured value is less than the specified value Change the piston rod Measure the run out of the piston rod I Piston rod Run out I s 0 02 mm s 0 0008 in If the measured value is greater than the specified value Change the piston rod Check the piston rod for damage and wear If there is damage or wear Change the piston rod Check...

Page 61: ...ecial tool f underneath and press out heim joint D with special tool I Pressing tool T1207S p 230 Position the new heim joint O and the special tool into a vise as shown Guideline I Use soft jaws I Pressing tool T1206 p 230 Press the heim joint all the way in Press the heim joint against the lock ring using the special tool I Pressing tool T1207S p 230 Mount the second lock ring 8 Mount seal rings...

Page 62: ...I Mounting sleeve T1204 p 229 Lubricate the sealing lip of the dust boot I Lubricant T625 p 219 Mount washer Position washer Don seal ring e Grease seal ring 8 and mount with the washer facing downward I Lubricant T511 p 219 Mount centering disk Mount rebound rubber 0 Lubricate the groove of the O ring I Lubricant T158 p 219 Mount O ring Mount spring 60 ...

Page 63: ...nting sleeve T1215 p 230 Grease the dust boot and push seal ring retainer onto the piston rod I Lubricant T625 p 219 Remove the special tool Mount rebound washer 8 with the cut out facing downward Mount the compression shim stack 0 with the smaller shims facing downward Sand both sides of piston D on a surface plate using 1200 grit sandpaper Clean the piston Assemble the piston Guideline ViewO Pis...

Page 64: ...cate the threads I Lubricant T159 p 219 Mount the piston with the spring Mount and tighten the compression adjuster 0 Guideline I Compression adjuster Clamp the damper in a bench vise Guideline I Use soft jaws I M31x1 Mount adjusting ring with the intermediate washer Info 62 I 45 Nm 33 2 lbf ft I I 45 Nm 33 2 lbf ft I The adjusting ring cannot be mounted after the piston rod is mounted Fill the da...

Page 65: ...pti ble click Turn counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Compression damping low speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Turn adjusting screw all the way clockwise with a socket wrench Turn counterclockwise by the number of turns corresponding to the shock absorber type Guideline Compression damping high speed Comfort 2 5 tur...

Page 66: ...99 10 Remove the screw of the filling port Install adapter O on the damper Info I Tighten only hand tight without the use of tools Connect the adapter O to connector of the vacuum pump I Vacuum pump T1240S p 230 Clamp the damper with soft jaws or hold it as shown in the figure Info I Clamp the damper only lightly The filling port must be at the highest point The piston rod slides in and out during...

Page 67: ...fied value turn the Damper C con trol lever to Vacuum Guideline 3 bar The pressure gauge drops to the specified value 0 bar When the pressure gauge reaches the specified value turn the Oil reservoir 0 control lever to Vacuum Guideline 0 bar The vacuum gauge falls to the specified value 8 mbar When the vacuum pressure gauge reaches the specified value turn the Oil reser voir control lever 0 to Equa...

Page 68: ...ly extended otherwise damage will occur during compression of the shock absorber Remove the special tool Remove adapter O from connection of the vacuum pump Info I Hold the damper so that the filling port is at the highest point Remove the adapter Mount and tighten screw Guideline I Screw filling port I M10x1 1 14 Nm 10 3 lbf ft I Filling the dam er with nitrogen 201396 10 201397 10 Screw in screw...

Page 69: ...eight of rider 75 85 kg 165 57 N mm 325 lb in 187 lb Weight of rider 85 95 kg 187 60 N mm 343 lb in 209 lb Mount intermediate washer 8 and spring retainer C Mount ring C Alternative 1 Tension the spring to the prescribed amount by turning the adjusting ring Guideline I Spring preload I Hook wrench T106S p 229 Alternative 2 Warning 112 mm 0 47 in Danger of accident Modifications to the suspension s...

Page 70: ...f damage cracking or deformation Change the swingarm Info I Always change a damaged swingarm Repair of the swingarm is not authorized by Husqvarna Motorcycles Preparatory work Raise the motorcycle with the lift stand p 10 Remove the rear wheel p 95 Main work Take the brake line out of the guide Push the brake caliper forward remove it and hang it to the side Info Cover the components to protect th...

Page 71: ...ingarm Remove nut 0 Remove the swingarm pivot Remove the swingarm Main work Position the swingarm Mount the swingarm pivot Mount and tighten nut O Guideline Nut swingarm pivot Lift the swingarm Mount and tighten fitting Guideline Nut linkage lever on swingarm Mount the chain M16x1 5 M14x1 5 Connect the chain with connecting link CD 100 Nm 73 8 lbf ft I 80 Nm 59 lbf ft 69 ...

Page 72: ... and pull it back Position the brake line in the guide Finishing work Install the rear wheel or p 96 M6 M8 Remove the motorcycle from the lift stand or p 10 Changing the swingarm bearing Info These operations are the same on both swingarm bearings Preparatory work Raise the motorcycle with the lift stand or p 10 Remove the rear wheel or p 95 Remove the swingarm or p 68 70 10 Nm 7 4 lbf ft 25 Nm 18...

Page 73: ...in work Remove the outer collar bushings O Remove bushing 8 Remove shaft seal rings D using a suitable tool Using a suitable tool press the bearing out from the inside to the outside Press in the new bearing until it is flush using a suitable tool 71 ...

Page 74: ...ft seal rings CD Mount bushing Grease the shaft seal rings I Long life grease p 219 Position collar bushings O with the shoulder facing inward Finishing work Install the swingarm p 69 Install the rear wheel p 96 Remove the motorcycle from the lift stand p 10 72 ...

Page 75: ...with the lift stand p 10 Remove the right side cover p 79 Remove the main silencer p 75 Main work Remove screw O Remove fitting Press angle lever toward the rear Press linkage lever C downward Detach springs 0 I Spring hook 50305017000 p 221 Remove screw D Lift the swingarm 73 ...

Page 76: ...yet Guideline I Screw manifold I M8 Attach springs 8 I Spring hook 50305017000 or p 221 Tighten screw Guideline I Screw manifold Lower the swingarm Position the angle lever and linkage lever Mount and tighten fitting 8 Guideline 60 Nm 44 3 lbf ft I Nut linkage lever to angle lever I M14x1 5 Mount and tighten screw 3 Guideline Screw bottom shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 TM 15 Nm ...

Page 77: ...e main silencer Mount screws O but do not tighten yet Guideline I Remaining screws chassis Reconnect spring 8 Tighten screws O Guideline I Remaining screws chassis Finishing work Install the right side cover p 80 Changing the glass fiber arn filling of 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 Do not ...

Page 78: ... filling 0 off of inner tube D Clean the parts that are to be reinstalled Mount the new glass fiber yarn filling 0 on the inner tube Slide O ring C and outer tube CD over the glass fiber yarn filling Insert O ring and silencer cap O into the outer tube Mount and tighten all screws Finishing work Install the main silencer p 75 Install the right side cover p 80 76 ...

Page 79: ...ncreased wear 11 4 Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations lnstallin the air filter Preparatory work Remove the air filter box lid or p 77 Main work Push air filter holder O toward the air filter at position f and detach it at end G Swing the air filte...

Page 80: ... fuel or petroleum since these substances attack the foam Sealing the air filter box 401559 01 Preparatory work Remove the air filter box lid p 77 Remove the air filter p 77 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly I Air filter cleaning agent p 219 Info I Only press the air filter to dry it never wring it out Oil the dry air filter with a hig...

Page 81: ...apors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that has been contaminated with fuel Store fuel properly in a suitable canister and keep away from children Warning Environmental hazard Improper handling of fuel is a dan...

Page 82: ...le Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately The fuel in the fuel tank expands when warm and may emerge if overfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not co...

Page 83: ...uel line Mount wash cap set f I Wash cap set 81212016100 Remove the tube from the fuel tank breather Remove screws D with the collar bushing Remove screw C with the rubber bushing Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spi...

Page 84: ...into the fuel line Dirt in the fuel line clogs the injection valve Lubricate the O ring and connect plug in connection 8 of the fuel line Info I Route the cable and fuel line at a safe distance from the exhaust system Finishing work Mount the seat r p 80 Checking the fuel ressure Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always ...

Page 85: ...clear Change the fuel filter p 85 Change the fuel pump p 83 3 3 3 7 bar 48 54 psi Stop the Function test of fuel pump control actuator test by pressing the Quit button Remove the special tools Join the fuel hose connection 83 12 10 Changing the fuel pump m A Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine ...

Page 86: ...ble container Remove the seat p 80 Remove the fuel tank p 80 Main work Remove nut O with the gasket Remove fuel connection i with the gasket Remove screws CD Pull out the fuel pump Position the fuel pump Mount fuel connection i with the gasket but do not tighten yet Mount and tighten nut O with the gasket Guideline 84 I Nut fuel pump fastener I M12x1 75 15 Nm 11 1 lbf ft Tighten fuel connection i ...

Page 87: ... hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that has been contaminated with fuel Store fuel properly in a suitable c...

Page 88: ...ump Remove hose clamps C Remove fuel filter 0 Press lock D Pull back fuel pump housing Change fuel screen Mount the fuel pump housing Mount fuel filter 0 Arrow 6 points away from the fuel pump Mount hose clamps C I Hose clamp pliers 60029057000 p 224 86 ...

Page 89: ... or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow ...

Page 90: ...12 FUEL TANK SEAT TRIM Start the motor and check the response 88 ...

Page 91: ...d Remove the front fender Main work Position the front fender Mount and tighten screws O and Guideline I Remaining screws chassis 110Nm 7 41bf ft Finishing work Install the start number plate p 90 13 3 Removing the start number plate Take brake line O out of the brake line guide Remove screw Take off the start number plate 89 ...

Page 92: ...R Installing the start number late Position the start number plate Mount and tighten screw O Guideline I Remaining screws chassis 110 Nm 7 4 lbf ft The holding lugs engage Position brake line 8 in the brake line guide 90 ...

Page 93: ...Worn tires have a negative effect on handling characteristics especially on wet surfaces Check the front and rear tires for cuts run in objects and other damage If the tires have cuts run in objects or other damage Change the tires Check the tread depth Info I Adhere to the legally required minimum tread depth I Minimum tread depth I 2 mm 0 08 in If the tread depth is less than the minimum tread d...

Page 94: ...t Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes If the spokes are too tight they can break due to local overload Check the spoke tension regularly especially on a new motorcycle Briefly strike each spoke with the tip of a screwdriver Info I The tone frequency depends on the length of the spoke and the spoke diameter Front wheel If you hear different tone frequenc...

Page 95: ...the front wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged Remove spacers fD 14 5 2 Installing the front wheel Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Check the wheel bearing for damage and wear If the...

Page 96: ...g the brake disc of the front brake Preparatory work Raise the motorcycle with the lift stand p 10 Remove the front wheel p 92 Main work Remove screws 0 Take off the brake disc Installing the brake disc of the front brake Main work Clean the contact surface of the brake disc Position the brake disc with the label facing outward Mount and tighten screws O Guideline Screw front brake disc Finishing ...

Page 97: ...ly press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in Position spacing tube C Press in the new bearing D all the way using a suitable tool Info I Only press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in Grease the new shaft seal rings 8 and O and press in until they are flush Finishing work Install the...

Page 98: ...the swing arm Info I Do not operate the foot brake when the rear wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged Remove spacers C 14 6 2 Installing the rear wheel Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessa...

Page 99: ...atedly until the brake linings are in contact with the brake disc and there is a pressure point Finishing work Remove the motorcycle from the lift stand p 10 Removing the brake disc of the rear brake Preparatory work Raise the motorcycle with the lift stand p 10 Remove the rear wheel p 95 Main work Remove screws 0 Take off the brake disc Installing the brake disc of the rear brake Main work Clean ...

Page 100: ... chain tension p 98 Finishing work Remove the motorcycle from the lift stand p 10 Warning Danger of accidents Danger caused by incorrect chain tension If the chain is too taut the components of the secondary power transmission chain engine sprocket rear sprocket bearings in the transmission and in the rear wheel will be under additional load In addition to premature wear this can cause the chain o...

Page 101: ... measurement 110 15 kg 22 33 lb Measure distance CD of 18 chain rollers on the lower chain section Info I Chains do not always wear evenly which is why the measurement should be repeated at several locations on the chain Maximum distance CD on the longest 272 mm 10 71 in part of the chain If the distance CD is larger than the specified length Change the drivetrain kit p 101 o l o o 0 o o Info I Wh...

Page 102: ...hain guide If the light part of the chain guide is worn Change the chain guide Check that the chain guide is firmly seated If the chain guide is loose Tighten the chain guide Guideline Remaining screws chassis Finishing work M6 Remove the motorcycle from the lift stand p 10 14 6 8 Checking for chain dirt accumulation 400678 01 14 6 9 Cleaning the chain Warning Check the chain for coarse dirt accum...

Page 103: ...ends largely on its maintenance Preparatory work Raise the motorcycle with the lift stand p 10 Main work Clean the chain regularly and then treat with chain spray I Offroad chain spray p 219 400725 01 Finishing work Remove the motorcycle from the lift stand p 10 14 6 10 Changing the drivetrain kit Preparatory work Raise the motorcycle with the lift stand p 10 Remove the rear wheel p 95 Main work R...

Page 104: ...with connecting link C Have an assistant operate the rear brake Mount and tighten screw CD with the washer Guideline Screw engine sprocket M10 Position the engine sprocket cover Mount and tighten screw O Guideline I Screw clutch slave cylinder Mount and tighten screw 8 Guideline I Remaining screws chassis Finishing work Install the rear wheel p 96 M6 MB 60 Nm 44 3 lbf ft Remove the motorcycle from...

Page 105: ...ove lock ring 8 Remove shaft seal ring Using a suitable tool press bearing C out from the inside to the outside Remove spacing tube 0 Using a suitable tool press bearing 0 out from the inside to the outside Press the new bearing 0 all the way in from the outside to the inside Info I Only press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in ...

Page 106: ... the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in Grease the new shaft seal ring D and press it in until it is flush Mount lock ring i The lock ring engages audibly Grease the new shaft seal ring O and press it in until it is flush Finishing work Install the rear wheel p 96 Remove the motorcycle from the lift stand p 10 ...

Page 107: ...the 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 Install the air filter box lid p 77 Risk of injury Battery acid and battery gases cause serious chemical burns Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases K...

Page 108: ... 5 Nm 1 84 lbf ft 2 5 Nm 1 84 lbf ft 15 4 Checking the charging voltage r _ I ti __ QIt i V v c A 0 7 I I I Condition The battery must be fully functional and completely charged Preparatory work Remove the seat p 80 Main work Pull back the positive terminal cover Start the motorcycle for a check p 11 Measure the voltage between the specified points Measuring point Plus Measuring point Ground I Cha...

Page 109: ...apacitor p 107 Finishing work Mount the seat p 80 Condition The battery is disconnected Remove the capacitor Discharge the capacitor by bridging the two contacts Connect the capacitor with a 12 V test lamp on one connector and connect it to the battery as shown in the figure Info I As the charge of the capacitor increases the test lamp becomes dimmer The lamp lights up for 0 5 2 0 s The capacitor ...

Page 110: ... starter relay Pull the starter relay off of the holder Connect the starter relay to a 12 V power supply as shown Measure the resistance between the specified points I Resistance of open circuit I on If the value displayed does not meet specifications Change the starter relay Mount the starter relay onto the holder and lay the cable Clamp cable 8 on the starter relay Plug in connector O Connect th...

Page 111: ... reach of children Wear suitable protective clothing and goggles 109 If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Warning Environmental hazard Hazardous substanc...

Page 112: ...ings insert pin 0 and mount cotter pins 8 Info I Always change the brake linings in pairs Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Add brake fluid to level 6 Guideline Dimension O brake fluid level below 5 mm 0 2 in top edge of container I Brake fluid DOT 4 p 218 Position cover with membrane D Mount and tighten...

Page 113: ...nge of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding Checkin the brake fluid level of the front brake Warning Danger of accidents Brake system failure If the brake fluid level drops below the specified marking or the specified value this is an indication that the brake sys tem is leaking or that the brake linings are...

Page 114: ...and rear brake according to the service schedule Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in 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 br...

Page 115: ...al position Cover the painted parts Remove screws O Remove cover 8 with membrane Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid Bleed syringe 50329050000 p 222 Brake fluid DOT 4 p 218 Mount bleeder cover D I Bleeder cover 00029013005 p 221 Connect the bleeding device I Bleeding device 00029013100 p 221 Open shut off valve 8 Info I Follow t...

Page 116: ...ckness 6 I 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings or p 114 Check the brake linings for damage and cracking If damage or cracking is visible Change the rear brake linings or p 114 Changing the rear brake linings Warning Danger of accident Brake system failure Maintenance work and repairs must be carried out professionally Warning Skin irritation B...

Page 117: ...gainst the spokes Remove cotter pin D pull out pin C and remove the brake linings Clean the brake caliper and brake caliper support Check that leaf spring 0 in the brake caliper and sliding plate D in the brake caliper support are seated correctly Info I The arrow on the leaf spring points in the rotation direction of the brake disc Insert the new brake linings insert pin C and mount cotter pins D...

Page 118: ...ever according to specifications r _ f I I I Disconnect spring O Loosen nut C and with push rod 0 turn it back until you have maximum free travel To adjust the basic position of the foot brake lever individually loosen nut and turn screw 8 accordingly Info I The range of adjustment is limited Turn push rod 0 accordingly until you have free travel 6 If necessary adjust the basic position of the foo...

Page 119: ... thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable re...

Page 120: ...ove screw cap O with the membrane and O ring Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid Bleed syringe 50329050000 or p 222 Brake fluid DOT 4 or p 218 Mount bleeder cover 8 I Bleeder cover 00029013006 or p 221 Connect the bleeding device I Bleeding device 00029013100 or p 221 Open shut off valve fD Info I Follow the operating instructio...

Page 121: ...ve the hose of the bleeder bottle Mount the pro tection cap Disconnect the bleeding device Remove the bleeder cover Stand the vehicle upright Add brake fluid to level I Brake fluid DOT 4 p 218 Fit and tighten the screw cap with the membrane and O ring Info I Clean up overflowed or spilt brake fluid immediately with water Check the foot brake lever for a firm pressure point ...

Page 122: ...0 Remove the fuel tank p 80 Remove the right side cover p 79 Remove the main silencer p 75 Main work Connect the negative cable of the battery Pull the EFI control unit O from the holder and hang it to one side Remove the cable binder and expose the cable Disconnect plug in connector 8 Disconnect plug in connectors 8 Loosen hose clip 8 120 ...

Page 123: ...s and expose the cable Remove screw D Loosen screw Repeat the operation on the opposite side Swing up the subframe and secure it Remove screw Swing the shock absorber to the rear and twist it slightly Remove springs I Spring hook 50305017000 r p 221 121 ...

Page 124: ...ew C Take off the manifold Loosen hose clip 49 Pull off the radiator hose Loosen hose clip Pull off the radiator hose Push back protection cap G Unplug connector 4D Pull off the spark plug connector 48 Remove screw 4D 122 ...

Page 125: ...side Info I Do not kink the clutch line Do not activate the clutch lever if the clutch slave cylinder has been removed Activate the foot brake lever Loosen screw G Info You should have an assistant for this step Remove the connecting link of the chain Take off the chain Remove screw G Take off the engine sprocket Remove screw D Take off the shift lever 123 ...

Page 126: ...ng it to one side Push back hose clamp and remove the vent hose Push back protection cap and remove the nut Remove the positive cable and hang it to one side Remove fittings Take off the engine braces Remove spring Remove nut Remove the swingarm pivot Pull the swingarm slightly toward the rear Remove screws fl ...

Page 127: ...engine is sufficiently secured against falling over Protect the frame and attachments from damage Mount screws O but do not tighten yet Guideline I Engine carrying screw Position the swingarm Insert the swingarm pivot Mount and tighten nut 8 Guideline Nut swingarm pivot Tighten screws O Guideline I Engine carrying screw Mount spring CD Position the engine braces Mount and tighten screws C Guidelin...

Page 128: ...rew Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Slide on the engine sprocket with the collar facing the engine Mount screw Q with the washer but to not tighten yet Guideline Screw engine sprocket M10 Mount the chain Connect the chain with connecting link CD Activate the foot brake lever Tighten screw Q Guideline Screw engine sprocket Info M10 60 Nm 44 3 lbf ft 60 Nm 44 3 lbf ft I You should h...

Page 129: ...ion the engine sprocket cover Mount and tighten screw CB Guideline I Screw clutch slave cylinder Mount and tighten screw 48 Guideline Remaining screws chassis Connect spark plug connector C Plug in connector 48 Mount protection cap Mount the radiator hose Position and tighten hose clip G s M6 M6 M8 127 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft I 25 Nm 18 4 lbf ft I ...

Page 130: ... the shock absorber Mount and tighten screw Guideline Screw top shock absorber M10 60 Nm 44 3 lbf ft Remove the fixation and position the subframe Info I Watch out for the intake flange Mount and tighten screw a Guideline Screw subframe Remove screw fl Mount and tighten screw fl Guideline Screw subframe MS MS Repeat the operation on the opposite side 30 Nm 22 1 lbf ft 30 Nm 22 1 lbf ft 128 15 Nm 1...

Page 131: ...cure with cable clamps Plug in connector Position and tighten hose clip Plug in connector of the ignition pulse generator Plug in connector of the alternator Route the cable without tension and secure it with cable binders Mount EFI control unit 129 ...

Page 132: ...n silencer p 75 Install the right side cover p 80 Install the fuel tank p 81 Mount the seat p 80 Remove the motorcycle from the lift stand p 10 Refill the coolant p 193 Execute the initialization run p 201 Take a short test ride Read out the fault memory using the Husqvarna diagnostics tool Check the engine for leakage Check the engine oil level p 194 Check the coolant level p 192 Mount the specia...

Page 133: ...er Draining the engine oil Remove clutch push rod O Remove spacer O of the countershaft Remove O ring Remove plug O with oil screen and the O rings Remove the oil drain plug with the magnet and seal ring Remove oil drain plug 8 with the O ring Completely drain the engine oil 131 ...

Page 134: ... Remove the oil filter cover with the O ring Pull oil filter D out of the oil filter housing I Circlip pliers reverse 51012011000 p 222 Remove the spark plug using special tool O I Spark plug wrench 77229172000 p 228 Remove screws O Remove the valve cover with the valve cover seal Remove the spark plug shaft insert 132 ...

Page 135: ...t Remove torque limiter D Remove screws 8 Remove the alternator cover Remove screws 0 and take off the starter motor 133 Positioning the engine at ignition top dead center Turn the crankshaft counterclockwise until markings O on the cylinder head are located flush above the flat areas Ce of the camshafts ...

Page 136: ...ng chain tensioner 17 3 11 Removing the camshaft 8 I Loosen screw O Remove screw with the seal ring Pull out timing chain tensioner CD Remove O ring e Loosen screws O from the outside to the inside and remove Take off guide rail Take off the camshaft bearing bridge Info Ensure that the dowel pins remain in place Take the timing chain off the camshaft gear Remove the camshafts 134 ...

Page 137: ...Remove cylinder head gasket Push the cylinder upward Info 135 I Only push the cylinder as far up as necessary to take the piston pin out Remove the piston pin retainer 0 Remove the piston pin Take off the cylinder and piston Push the piston upward out of the cylinder Info I If no further work is to be performed on the cylinder and piston the piston can remain in the cylinder Take off cylinder base...

Page 138: ...otection cap 75029090000 p 225 136 Attach special tool CD to the rotor Hold it tight using the special tool and pull off the rotor by turning the screw in I Extractor 58012009000 p 222 Info I Ensure that the woodruff key remains in place Remove lock ring O Take off the starter idler gear 8 with the washer Take off freewheel gear Remove screws O Take off oil pump cover ...

Page 139: ...E Remove O ring CD Take off suction pump C Remove needle roller 17 3 17 Removing the water pump wheel Remove screws O Take off the water pump cover Remove nut 8 Take off the two part water pump impeller CD 137 ...

Page 140: ...rs and springs Take off the pressure cap Completely remove clutch discs 8 Remove pressure piece 8 17 3 20 Removing the outer clutch hub Bend up the lock washer Hold the inner clutch hub with the special tool Loosen nut O I Clutch holder 59029003100 p 223 Remove the nut with the lock washer Take off inner clutch hub 8 and washer Info I The washer usually sticks to the inner clutch hub Take off C 13...

Page 141: ...ing the shift drum locating unit 17 3 23 Removing the locking lever 17 3 24 Removing the force pump Remove screw O Push away locking lever from shift drum locating unit 8 and remove the shift drum locating unit Relieve tension from the locking lever Unscrew O and remove together with locking lever washer sleeve and spring Remove lock ring O Take off washer Take off oil pump idler gear 8 with the w...

Page 142: ...ump cover Remove pin Remove oil pump shaft G from below Remove force pump 48 Remove nut Q Info I Left handed thread Position the special tool in the crankshaft I Protection cap 75029090000 p 225 Pull off primary gear 8 using the special tool I Extractor 46129021000 p 221 Remove screw 8 Remove screws O Remove the timing chain tensioning rail Remove the timing chain guide rail 140 ...

Page 143: ... left section of the engine case upward and remove the screw connections of the engine fixing arm Insert the special tool into the crankshaft I Protection cap 75029090000 p 225 Mount special tool 8 with the appropriate screws I Puller 77229048000 p 227 Info I Use the drill hole marked with 772 Take off the section of the engine case Info I Do not subject the section of the engine case to any stres...

Page 144: ...ft rail O together with upper spring 8 Remove shift rail together with upper spring C and the lower spring Tilt shift forks O to the side Info I Do not misplace the shift rollers Remove shift drum 8 Remove shift forks O Info Do not misplace shift rollers 8 17 3 32 Removing the transmission shafts Remove lock ring O 142 ...

Page 145: ...section in an oven Guideline 1150 C 302 F Knock the engine case section against a level wooden plate This will cause the bearings to drop out of the bearing seats Info I Any bearings that remain in the engine case section must be removed using a suitable tool Blow out oil nozzle D with compressed air and check that it is clear Guideline Oil nozzle for balancer shaft lubrication M4 2Nm 1 5 lbf ft L...

Page 146: ... channel with compressed air and check that it is clear Work on the left section of the engine case Remove all dowels Remove shaft seal ring O of the crankshaft shift shaft and s countershaft Remove oil nozzle C for clutch lubrication Remove oil nozzle 0 for piston cooling Remove screws D Remove the bearing retainers Remove any sealing mass remnants and clean the engine case section thoroughly War...

Page 147: ...eal ring of the shift shaft so it is flush with the open side facing in Press in shaft seal ring of the countershaft so it is flush with the open side facing in Mount and tighten oil nozzle C Guideline Oil nozzle for clutch lubri M5 cation Mount and tighten oil nozzle 0 Guideline Oil nozzle piston cooling Position all bearing locks M5 Mount and tighten screws D Guideline Locking screw for bearing ...

Page 148: ...pen side facing outward Remove lock ring 0 Remove shaft seal ring D of the crankshaft Press the new shaft seal ring in with the open side facing inward Info I Press the shaft seal ring inward to the point where the lock ring can be mounted Provide suitable support for the clutch cover while pressing in Mount lock ring 0 Blow out the oil channel with compressed air and check that it is clear Checki...

Page 149: ...g seat Install ball e and pressure spring CD Mount and tighten screw plug O with sealing washer 8 Guideline I Plug oil pressure regulator valve I M12x1 5 17 4 5 Checking the lubrication system 01 305003 10 Check the internal rotor and external rotor of oil pumps O for damage and wear If there is damage or wear Change the oil pumps Check oil pump shaft 8 for damage and wear If there is damage or we...

Page 150: ... crank pin Main work Position crankshaft O in the press using special tool I Extrude plate base 77229009000 p 226 Press the crank pin with the special tool out of the upper crank web I Pressing tool for crankshaft complete 75029047000 p 225 Info I Hold the lower crank web Remove the connecting rod Press the crank pin out of the lower crank web Press in the new crank pin as far as possible Oil hole...

Page 151: ...od bearing 0 20 0 45 mm 0 0079 0 0177 in If the measured value is less than the specification Correct it so the dimension is equal to the specified value Finishing work Check the crankshaft run out at the bearing pin p 149 17 4 8 Checking the crankshaft run out at the bearing pin 17 4 9 Position the crankshaft on a roller block Turn the crankshaft slowly Check the crankshaft run out on both bearin...

Page 152: ...ine case I M6 10 Nm 7 4 lbf ft Mount the dial gauge support on the engine case and measure and note down the crankshaft end play Guideline I Crankshaft axial play I 0 50 0 60 mm 0 0197 0 0236 in If the measured value does not meet specifications Remove the crankshaft Remove the crankshaft bearing inner race p 148 Calculate the thickness of the compensating disks Add or remove compensating disks eq...

Page 153: ...mproved performance low wear and a lightweight cylinder 17 4 14 Checking measuring the cylinder 305004 10 Check the cylinder bearing surface for damage If the cylinder bearing surface is damaged Change the cylinder and piston Measure the cylinder diameter at several locations on the 0 and 0 axes using a micrometer to identify oval wear Guideline Cylinder drill hole diameter Size I Size II Info 88 ...

Page 154: ...ston ring with the marking facing upward Check the piston pins for discoloration or signs of wear If the piston pin shows severe discoloration signs of wear Change the piston pin Place the piston pin in the connecting rod and check the seating for play If the piston pin seating has excessive play Change the connecting rod and piston pin Measure the piston at the piston skirt at right angles to the...

Page 155: ...ure the cylinder r p 151 If cylinder wear lies within the specified tolerance Replace the piston ring Mount the piston ring with the marking facing toward the piston head 17 4 18 Changing the camshaft bearing e I 306550 10 306552 10 Clamp special tool O into a vise I Adjustment bush bridge 77229050044 r p 228 Mount the camshaft on the special tool Remove screw 8 Pull camshaft gear D off of the cam...

Page 156: ...e camshaft bearing to the camshaft gear Pull lever O away from camshaft and release it If the lever does not return to its original position Change the exhaust camshaft 17 4 20 Checking the pivot points of the camshafts 306563 10 Check the pivot points of the camshafts If there is damage or wear Change the cylinder head with the camshaft bearing bridge Position the camshafts The valves are not act...

Page 157: ...r shaft Hold cam levers fD and remove the cam lever shaft Info I If the cam levers will continue to be used note down their installation posi tion Take the shims from the valve spring retainers and put them aside corresponding to their installation position Pre tension the valve spring using the special tool Valve spring mounter 59029019000 p 223 Insert for valve spring lever 77229060000 p 228 Rem...

Page 158: ... speci fication Rework the valve seat Check the valve springs for breakage and wear visual check Info I Intake valves are marked with a green color coding Exhaust valves are marked with a brown color coding If the valve spring is broken or worn Change the valve spring Measure the length of the valve springs Valve spring Minimum length of intake valve Minimum length of exhaust valve I 41 20 mm 1 62...

Page 159: ...ol check the sealing area of the cylinder for distortion I Feeler gauge 59029041100 p 223 Cylinder cylinder head distortion of sealing area 5 0 10 mm 5 0 0039 in If the measured value does not meet specifications Change the cylinder head Check sealing seat t of the valves Valve sealing seat width Intake Valve sealing seat width Exhaust 1 40 mm 0 0551 in 1 40 mm 0 0551 in If the measured value does...

Page 160: ...ll amount of grease Position cam levers C in the positions they had before they were removed Mount the cam lever shafts Remove screw 0 Mount and tighten screw plugs D Guideline I Screw plug cam lever axis M10x1 10 Nm 7 4 lbf ft Place the shims in the valve spring retainers corresponding to their installation position Insert freewheel gear O into the freewheel hub turning the freewheel gear clock w...

Page 161: ...g the freewheel 308684 11 308685 10 Remove lock ring O Press expansion ring fj together with suitable pliers and take off Take freewheel 8 out of the primary gear Thoroughly oil all parts Slide freewheel O into the primary gear Info Note the direction of rotation Mount spreader ring 159 ...

Page 162: ...s damage or wear Change the starter idler gear Check the gear mesh and bearing of torque limiter 8 for damage and wear If there is damage or wear Change the torque limiter Check the gear mesh and bearing of freewheel gear 6 for damage and wear If there is damage or wear Change the freewheel gear or bearing Check freewheel C for damage and wear If there is damage or wear Change the free wheel Check...

Page 163: ...il 8 for damage and wear If there is damage or wear Replace the timing chain tensioning rail Check the timing chain guide rail D for damage and wear If there is damage or wear Replace the timing chain guide rail Check the timing chain securing guide 8 for damage and wear If there is damage or wear Replace the timing chain securing guide Check camshaft gears 0 for damage and wear If there is damage...

Page 164: ...in tensioner The detent mechanism engages and the piston remains in place Final position of the piston after engagement Info 3 mm 0 12 in This position is necessary for installation If the timing chain tensioner is now pressed again and is only extended a maximum of half way it is prevented from extending completely This locks the detent mechanism and the timing chain tensioner can no longer be sq...

Page 165: ... CD for damage and wear If there is damage or wear Change the needle bearing and collar sleeve Check intermediate clutch discs and G for damage and wear If the intermediate clutch discs are not even or are pitted Change all intermediate clutch discs Check clutch facing discs Qi for discoloration and scoring If there is discoloration or scoring Change all clutch facing discs Check the thickness of ...

Page 166: ...rollers for damage and wear If there is damage or wear Change the shift rollers Check the springs of shift rails 8 for damage and wear If the spring is damaged or worn Change the spring of the shift rail Check the shift rails 8 for run out on a flat surface If there is run out Change the shift rail 306554 10 Check the shift rails for scoring wear and smooth operation in the shift forks If scoring ...

Page 167: ...g plate O with the guide pin facing downward and put the guide pin on the shift quadrant Mount pressure spring Slide on spring guide push return spring C with the offset end facing upward over the spring guide and lift the offset end over abutment bolt Mount washer D 17 4 37 Disassembling the main shaft Secure the main shaft with the toothed end facing downward in the vise Guideline Use soft jaws ...

Page 168: ... needle bearing fs and stop disk C Remove fifth gear sliding gear 0 Remove lock ring D Remove stop disk Remove third gear idler gear fD and needle bearing Remove stop disk Gi Remove lock ring G Remove fourth gear sliding gear 48 Remove lock ring 48 Remove stop disk 4D Remove second gear idler gear e and needle bearing 4D 17 4 39 Checking the transmission Condition The transmission has been disasse...

Page 169: ...ere is damage or wear Change the gear wheel pair Check the tooth faces of idler gears 8 sliding gears and fixed gear 3 for damage and wear If there is damage or wear Change the gear wheel pair Check the tooth profiles of sliding gears 0 for damage and wear If there is damage or wear Change the gear wheel pair Check sliding gears 0 for smooth operation in the profile of main shaft 8 If the sliding ...

Page 170: ... idler gear Mount stop disk D and lock ring 8 Mount third gear sliding gear 0 Mount lock ring D and stop disk Mount needle bearing Mount fourth gear idler gear 0 Mount second gear fixed gear Gi and stop disk 48 Finally check all gear wheels for smooth operation 17 4 41 Assembling the countershaft Info I Use new lock rings with every repair Preparatory work Check the transmission p 166 Carefully lu...

Page 171: ...ing D and stop disk Mount needle bearing G and third gear idler gear with the shift dogs facing upward Mount stop disk GD and lock ring 41 Mount fifth gear sliding gear with the shift groove facing downward Mount stop disk G Mount needle bearing and first gear idler gear 48 Mount stop disk 41 Finally check all gear wheels for smooth operation 17 5 Engine assembl 17 5 1 Installing the crankshaft Po...

Page 172: ...ing Shift fork O has a smaller inside diameter mount this in the shift groove of the main shaft Mount shift fork in the lower shift groove of the countershaft Mount shift fork fD in the upper shift groove of the countershaft Slide on shift rollers 8 Tip Fix the shift rollers in the shift forks with grease Push shift drum O into the bearing seat Put shift forks in the shift drum Info Do not misplac...

Page 173: ...ection of the engine case If necessary strike it lightly with a rub ber mallet and turn the transmission shafts Info I Do not use the screws to pull the two sections of the engine case together Mount screws O but do not tighten yet Guideline I Screw engine case I M6x55 Mount screws 8 but do not tighten yet Guideline 10 Nm 7 4 lbf ft I Screw engine case I M6x65 I 10 Nm 7 4 lbf ft Mount screws D and...

Page 174: ...ne Screw timing chain securing guide M6 Position timing chain guide rail 8 Mount and tighten screw C Guideline Screw timing chain guide M6 rail Position timing chain tensioning rail 0 Mount and tighten screw D Guideline Screw timing chain ten sioning rail Position primary gear 0 M8 Markings f and G are aligned 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 15 Nm 11 1 lbf ft Loctite 243 Loctite 243 Loctite 243 ...

Page 175: ... the engine case Mount the oil pump shaft 8 from the ignition side Mount pin Position the oil pump cover Marking 6 faces upward Mount and tighten screws C Guideline Screw oil pump cover Insert pin 0 Position oil pump gear D Mount washer Mount lock ring C MS 6Nm 4 4 lbf ft Crank the oil pump gear and ensure that it can move easily Mount oil pump idler gear 0 with the washer Mount washers i Mount lo...

Page 176: ...e washer sleeve and spring Mount and tighten screw Guideline Screw locking lever M5 6Nm 4 4 lbf ft Loctite 243 Loctite 243 17 5 13 Installing the shift drum locating unit Push away locking lever O from the shift drum locating unit and position the shift drum locating unit Info I The flat areas of the shift drum locating unit are not symmetric Relieve tension from the locking lever Mount and tighte...

Page 177: ...7 5 15 Installing the outer clutch hub Mount collar sleeve O and needle bearing 8 Slide the outer clutch hub 8 onto the gearbox main shaft Turn the oil pump gear until the gear of the outer clutch hub meshes Slide on washer 8 and inner clutch hub 0 Position the new lock washer and mount nut Q Tighten the nut holding the inner clutch hub with a special tool Guideline Nut inner clutch hub M18x1 5 I ...

Page 178: ... 04 in Position the pressure cap Mount screws 8 with the washers and springs Tighten the screws in a crisscross pattern Guideline 176 I Screw clutch spring 10 Nm 7 4 lbf ft Prepare the tool special screw A conventional screw is required Cut screw Q to length f Guideline I Screw I Length e I M6x70 I 60 mm 2 36 in Cut a slot into the top end of the screw Mount and hand tighten screw 0 Put on the clu...

Page 179: ...water pump wheel M6 5Nm 3 7 lbfft Mount the water pump cover with the seal ring Info I Ensure that the dowel pins are seated properly Mount screw D with the seal ring b ut to not tighten yet Guideline I Screw water pump cover I M6x25 Mount screw 8 b ut do not tighten yet Guideline I Screw water pump cover Mount and tighten screws 0 Guideline I Screw water pump cover Tighten screws D and 8 Guidelin...

Page 180: ... 17 5 21 Installing the piston 302642 10 303078 10 302641 10 Shift the joint of the piston rings by 120 51 6 lbf ft engine oil cone degreased Place the special tool on the oiled piston Compress the piston rings using the special tool I Piston ring mounting tool 60029015000 or p 224 The piston rings are pushed together all the way Position the piston on the cylinder using the special tool Push the ...

Page 181: ...r to present them more clearly the following steps are shown with a removed piston Position the piston pin retainer Insert the special tool and press it forcefully to the piston Turn the special tool clockwise thereby pushing the piston pin retainer into the groove I Insertion for piston ring lock 77229030000 p 227 Ensure that the piston pin retainer is seated properly on both sides Remove the clo...

Page 182: ... tighten in a crisscross pattern Guideline 180 Nut cylinder head M10x1 25 Tightening Thread oiled with I Graduated disc 60029010000 p 223 Mount and tighten nut 8 Guideline Nut cylinder head M6 sequence Tighten diag onally 1st tightening stage 10 Nm 7 4 lbf ft 2nd tighten ing stage 30 Nm 22 1 lbf ft 3rd tightening stage 50 Nm 36 9 lbf ft 10 Nm 7 4 lbf ft engine oil cone greased Lubricated with engi...

Page 183: ...haft bearing bridge Info I Ensure that the dowel pins are seated properly Position guide rail C Mount screws 0 and tighten from the inside to the outside Guideline Screw camshaft bearing bridge Condition M7x1 Camshaft gears were not loosened 14 Nm 10 3 lbf ft Mount the special tool and tension the timing chain I Insert timing chain tensioner 77229035000 p 227 Position special tool O I Adjustment b...

Page 184: ...m shafts Mount and tighten screws D Guideline Screw special tool adjustment bush bridge Info M7x1 10 Nm 7 4 lbf ft I Tighten the screws of the exhaust camshaft first Tighten screws C Guideline Screw camshaft drive sprocket Remove screws D Remove the special tool M12x1 70 Nm 51 6 lbf ft I Adjustment bush bridge 77229050044 p 228 Mount and tighten screws 8 Guideline Screw camshaft bearing bridge M7x...

Page 185: ... Guideline I Plug timing chain tensioner I M24x1 5 Remove screw C I 40 Nm 29 5 lbf ft I Press the timing chain tensioner toward the timing chain using special tool 0 1 Release device for timing chain tensioner 61229021000 p 225 The timing chain tensioner unlocks Mount and tighten screw C 17 5 27 Checking the valve clearance Guideline Screw unlocking of timing chain ten sioner Remove screw O Crank ...

Page 186: ...ust the valve clearance or p 184 Mount and tighten screw O with the washer Guideline I Screw plug crankshaft location 10Nm 7 4 lbf ft 17 5 28 Adjusting the valve clearance 17 5 29 Installing the starter motor Main work Remove the timing chain tensioner or p 134 Remove the camshaft or p 134 Raise cam levers O Correct the shims according to the findings from checking the valve clearance Install the ...

Page 187: ...iter D Position the gasket Info I Ensure that the dowel pins are seated properly Position the cover Mount and tighten screws Guideline I Screw cover of torque limiter Mount and tighten screw 0 Guideline I Screw cover of torque limiter Tighten screws O Guideline I Screw starter motor I M6x50 I M6x25 Grease the O rings and mount the spark plug shaft insert 185 10 Nm 7 4 lbf ft 110 Nm 7 4 lbf ft 10 N...

Page 188: ...and tighten the spark plug with special tool O Guideline ISpark plug IM1Ox1 I Spark plug wrench 77229172000 p 228 I 8 Nm 5 9 lbf ft 1 10 12 Nm 7 4 8 9 lbf ft Tilt the motorcycle to one side and fill the oil filter housing to about full with engine oil Insert oil filter O into the oil filter housing Oil the O ring of the oil filter cover Mount oil filter cover 8 Mount and tighten screws D Guideline...

Page 189: ...rain plug with magnet I M12x1 5 Push the oil screen with O rings onto a pin wrench I 20 Nm 14 8 lbf ft I Push the pin wrench through the opening into the drill hole of the opposite engine case wall and push the oil screen as far as possible into the engine case Mount and tighten screw plug D with the O ring Guideline I Screw plug oil screen I M20x1 5 Grease the shaft seal ring before mounting 15 N...

Page 190: ...h push rod O 17 5 36 Removing the engine from the engine assembly stand Remove the screw connection from the special tool I Engine fixing arm 77229002000 p 226 Remove the engine from the engine assembly stand Info Work with an assistant or a motorized hoist 188 ...

Page 191: ...lated in applicable regulations Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws O Remove cover 8 with membrane CD Fill bleeding syringe 8 with the appropriate hydraulic fluid Bleed syringe 50329050000 p 222 Brake fluid DOT 4 p 218 Mount bleeding syringe 8 on bleeder screw 3 using a fitting hose piece Only loosen bleeder screw 0 on the clutch slave cy...

Page 192: ...18 CLUTCH 190 Position the cover with the membrane Mount and tighten the screws ...

Page 193: ...scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clot...

Page 194: ...olant level 6 above the radiator fins 10 mm 0 39 in If the coolant level does not match the specified value Correct the coolant level I Coolant r p 218 Mount the radiator cap Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow the engine and cooli...

Page 195: ...taminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children Make sure that screw O is tightened Position the motorcycle upright Pour coolant in up to measurement 6 above the radiator fins Guideline I Dimension e over the radiator fins I Coolant I 0 95 I 1 qt Mount the ra...

Page 196: ...vel Info The engine oil level can be checked when the engine is cold or warm Preparatory work Stand the motorcycle upright on a horizontal surface Condition The engine is cold Check the engine oil level IThe engine oil level reaches the middle of sight glass G Condition If the engine oil does not reach the middle of the sight glass Add engine oil p 196 The engine is at operating temperature Check ...

Page 197: ...k the motorcycle on a level surface Main work Place a suitable container under the engine Remove oil drain plug O with the magnet and seal ring Info Do not remove screws 8 on both sides Remove screw plug fD with oil screen C Completely drain the engine oil Thoroughly clean the parts and sealing surfaces Position oil screen with the O rings on a pin wrench 195 Insert the pin wrench through the dril...

Page 198: ... quality engine oil results in premature wear to the engine Install and tighten the oil filler plug with O ring Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in an enclosed space without an effective exhaust extraction system...

Page 199: ...095 01 Main work Remove screw O Position the special tool Mount and tighten the banjo bolt Guideline I Banjo bolt I M10x1 I Oil pressure adapter 77329006000 p 228 I 8 Nm 5 9 lbf ft Connect the pressure tester to the special tool without the T plate I Pressure tester 61029094000 p 224 Check the engine oil level p 194 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in...

Page 200: ...the machine is driven Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water Remove the special tools Mount and tighten screw O Guideline 198 Screw unlocking of timing chain ten sioner M10x1 10 Nm 7 4 lbf ft Finishing work Check the engine oil level r p 194 ...

Page 201: ...en removed Measure the resistance between the specified points Measuring point 1 Measuring point 2 Spark plug connector Resistance at 20 c 68 F If the specification is not reached Change the spark plug connector 3 75 6 25 kn Alternator checking stator winding Condition The alternator is disconnected Stator winding checking the resistance Measure the resistance between the specified points 0 Altern...

Page 202: ...m the alternator cover Blow out oil nozzle O with compressed air and check that it is clear Guideline Oil nozzle for alternator cooling M4 2Nm Loctite 243 1 5 lbf ft Position the stator and ignition pulse generator in the alternator cover Mount and tighten screws 8 Guideline I Screw stator I 4 Nm 3 lbf ft I Loctite 2701 TM Position retaining bracket Mount and tighten screws C Guideline Screw crank...

Page 203: ...ization run Danger mDanger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine without operating the throttle grip Guideline I Coolant temperature I 25 C 77 F L...

Page 204: ...n 24 73 Clutch Multidisc clutch in oil bath hydraulically activated Gearbox 5 gear claw shifted Transmission ratio 1st gear 14 28 2nd gear 16 26 3rd gear 18 24 4th gear 21 24 5th gear 22 21 Alternator 12V 66W Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment Spark plug NGK LMAR9Al 8 Spark plug electrode gap 0 8 mm 0 031 in Cooling Water cooling permanent c...

Page 205: ...locking lever M5 Screw oil pump cover M5 Nut cylinder head M6 Nut water pump wheel M6 Screw alternator cover M6 Screw clutch cover M6 Screw clutch slave cylinder M6 Screw clutch spring M6 Screw cover of torque limiter M6 Screw engine case M6 5 0 10 mm 5 0 0039 in 87 955 87 965 mm 3 46279 3 46318 in 87 965 87 975 mm 3 46318 3 46358 in 88 000 88 012 mm 3 46456 3 46503 in 88 012 88 025 mm 3 46503 3 4...

Page 206: ...1 Engine oil I Engine oil 11 10 I 1 16 qt 23 4 2 Coolant I Coolant 23 4 3 Fuel Totalfuel tank capacity approx I 0 95 I 1 qt 7 5 I 1 98 US gal 10 Nm 7 4 lbfft 10 Nm 7 4 lbfft 10 Nm 7 4 lbfft 14 Nm 10 3 lbfft 10 Nm 7 4 lbfft 10 Nm 7 4 lbfft 10 Nm 7 4 lbfft 8 Nm 5 9 lbfft 10 Nm 7 4 lbfft 10 Nm 7 4 lbfft 14 Nm 10 3 lbfft 10 Nm 7 4 lbfft 15 Nm 11 1 lbfft 60 Nm 44 3 lbfft 15 Nm 11 1 lbfft 70 Nm 51 6 lbf...

Page 207: ... Secondary ratio 14 50 Chain 5 8 X 1 4 Rear sprockets available 48 50 52 Steering head angle 63 5 Wheelbase 1 495 10 mm 58 86 0 39 in Seat height unloaded 992 mm 39 06 in Ground clearance unloaded 375 mm 14 76 in Weight without fuel approx 106 4 kg 234 6 lb Maximum permissible front axle load 145 kg 320 lb Maximum permissible rear axle load 190 kg 419 lb Maximum permissible overall weight 335 kg 7...

Page 208: ...y fork leg without 390 ml 13 19 fl oz Fork oil SAE 4 48601166S1 p 218 cartridge 23 9 Shock absorber Shock absorber part number 18 15 7N 57 Shock absorber WP Suspension 5018 BAVP DCC Compression damping low speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping high speed Comfort 2 5 turns Standard 2 turns Sport 1 5 turns Rebound damping Comfort 17 clicks Standard 15 clicks ...

Page 209: ...k absorber M10 Nut fuel pump M12 Nut frame to linkage lever M14x1 5 Nut linkage lever on swingarm M14x1 5 Nut linkage lever to angle lever M14x1 5 Nut swingarm pivot M16x1 5 Nut rear wheel spindle M20x1 5 Screw top steering head M20x1 5 Screw in nozzles cooling system M20x1 5 Screw front wheel spindle M24x1 5 3 Nm 2 2 lbf ft 5 6 Nm 3 7 4 4 lbf ft 5 6 Nm 3 7 4 4 lbf ft 2 5 Nm 1 84 lbf ft 2 Nm 1 5 l...

Page 210: ...dirt particles with a gentle spray of water Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush Info I Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to the dry vehicle always rinse with water first After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the plug from the ...

Page 211: ... taking the motorcycle out of service add fuel additive Refuel Clean the motorcycle p 208 Change the engine oil and oil filter clean the oil screen p 195 Check the antifreeze and coolant level p 191 Check the tire air pressure p 91 Remove the battery p 105 25 2 401058 01 Charge the battery Guideline Storage temperature of battery with out direct sunshine 0 35 C 32 95 F Store the vehicle in a dry l...

Page 212: ...k the rim run out 0 I I I Check the spoke tension p 92 0 I I I Check the chain rear sprocket engine sprocket and chain guide p 99 I I I I I Check the chain tension p 98 I o I I I I Grease all moving parts e g hand lever chain and check for smooth operation I I I I I Check correct the fluid level of the hydraulic clutch p 189 I I I I I Check the brake fluid level of the front brake p 111 I I I I I ...

Page 213: ... I I I Change the spark plug and spark plug connector I I I Change the piston I I I Check measure the cylinder I I I Check the cylinder head I I I Change the valves valve springs and valve spring seats I I I Check the camshaft and cam lever I I I Change the connecting rod conrod bearing and crank pin I I I Check the transmission and shift mechanism I I I Check the oil pressure regulator valve I I ...

Page 214: ... 1 FC 2 X7 1 l X16 1 1 1 1AP 6 X295 col S21 l5 l x19 iBR 4 I N K 4 s E 1 MBI I K 4 BR 4 1 X19 j 4 II I I II 0 0 0 0 M10 G L n J G10 X17 il 1 5 X302 l 0 ls 1 l N EB 4 1 TI0nt1 WB U w u 1 _ 1 r If EB 4 i EZ 3 X1 X18 j j 0 I 0 l5 l a 2 F1 __ l b 2 F1 Hu rna FC 350 2014 2015 1 3 J J IC ...

Page 215: ...Components A11 EFI control unit C10 Capacitor G10 Battery G20 Alternator K10 Starter relay with main fuse K30 Power relay M10 Starter motor T20 Voltage regulator S21 Electric starter button X295 Diagnostics connector 213 ...

Page 216: ...DD I 0 B B I I I I I cc t l 11 9 1 9 0 ii C j xs X2 C BF 1 I NCX 2 N AT 2 j NDQ 2 M GA 3 BA 1 30 NCW 2 ru S20 P25 X295 t X301 E 1 N AP 6 r 7 0 n CW 2 i D W r G M D CX 2 X3 XS D X2 0 0 0 0 DDD X300 l C E E C C I z 0 1 FB a cc G 1 FB b g 0 F F C I FC 350 2014 2015 I Hu5 Mlrna I 2 3 1 2 I 3 I 4 5 I 6 I 7 I 8 ...

Page 217: ...27 WIRING DIAGRAM Components A11 EFI control unit M13 Fuel pump M51 Injection valve cylinder 1 P25 Fl warning lamp MIL R30 CAN bus terminating resistor S20 Kill switch X295 Diagnostics connector 215 ...

Page 218: ... 9 5 9 5 l x13 tv12 DV 2 1 X13 T 3 l X16 il I il 1 x1s om M 6 f o 3 I 5 _5 c 4 ii ii iDTI or X16 X16 I l I 5 i i X16 I I i t11 1 1 X10 i J H _ l J LtiJ AX 2 1 X12 5 FC 350 2014 2015 T T 6 7 1 me X16 X16 I I t t P 6 cM 2 m f AP 6 cM 2 I 4 0 5 T T 8 0 co J I 0 J IA tj iome i I X16 X16 5 il I I Is il 1 T r 3 3 ...

Page 219: ...ature sensor cylinder 1 826 Rollover sensor 837 Crankshaft position sensor 841 Manifold absolute pressure sensor cylinder 1 R51 Ignition coil cylinder 1 S51 Map switch for ride mode optional S55 Map Select switch optional Cable colors bl Black br Brown bu Blue gn Green gr Gray lbu Light blue or Orange pk Pink pu Violet rd Red wh White ye Yellow 217 ...

Page 220: ...ds see specifications on the container and that possess the corre sponding properties I Synthetic engine oil Recommended supplier Bel Ray Works Thumper Racing Synthetic Ester 4T Fork oil SAE 4 48601166S1 Standard classification SAE p 235 SAE 4 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding properties Shock abs...

Page 221: ... Recommended supplier Lubcon Turmogrease PP 300 Lubricant T511 Recommended supplier Lubcon Turmsilon GTI 300 P Lubricant T625 Recommended supplier Molykote 33 Medium Lubricant I152 Recommended supplier Bel Ray Molylube Anti Seize Lubricant I159 Recommended supplier Bel Ray MC 11 Offroad chain s ra Guideline Recommended supplier Bel Ray Blue Tac Chain Lube Oil for foam air filter Recommended suppli...

Page 222: ...29 AUXILIARY SUBSTANCES Preserving materials for aints metal and rubber Recommended supplier Bel Ray Silicone Detailer Protectant Spray Universal oil s ray Recommended supplier Bel Ray 6 in 1 220 ...

Page 223: ...029013005 00029013005 H00504 01 Bleeder cover Art no 00029013006 00029013006 H00505 01 Bleedin device Art no 00029013100 00029013100 H00518 01 Extractor Art no 46129021000 46129021000 H00539 01 S ring hook Art no 50305017000 50305017000 H00973 01 ...

Page 224: ...s reverse 51012011000 Lift stand 54829055000 Extractor 58012009000 H00565 01 H00572 01 H00974 01 H00592 01 Tool for inner bearing race 58429037037 H00596 01 Art no 50329050000 Art no 51012011000 Art no 54829055000 Art no 58012009000 Art no 58429037037 222 ...

Page 225: ...o 58429094000 fl 58429094000 H00606 01 Clutch holder Art no 59029003100 59029003100 H00609 01 Valve sprin mounter Art no 59029019000 2x 59029019000 H00610 01 Feeler gauge Art no 59029041100 CJ 59029041100 H00616 01 Graduated disc Art no 60029010000 2x 60029010000 H00625 01 ...

Page 226: ... 60029012000 60029012000 H00627 01 tool Art no 60029015000 60029015000 H00628 01 Hose clamp pliers Art no 60029057000 60029057000 H00650 01 Testing hose Art no 61029093000 61029093000 H00659 01 Pressure tester Art no 61029094000 4x D 61029094000 H00660 01 ...

Page 227: ...lease device for timin chain tensioner Art no 61229021000 61229021000 H00675 01 Pressin tool for crankshaft complete Art no 75029047000 75029047000 H00714 01 Protection cap Art no 75029090000 75029090000 H00726 01 Extractor camshaft gear Art no 77229001044 77229001044 H00747 01 225 ...

Page 228: ...00 H00748 01 Insert for crankshaft tool Art no 77229008000 J 77229008000 H00750 01 Extrude plate base 2x Art no 77229009000 77229009000 H00751 01 Pliers for valve stem seals Art no 77229010000 77229010000 H00752 01 Limit lug gauge Art no 77229026000 77229026000 H00753 01 ...

Page 229: ...4 01 Protection ca 0 77229031000 H00755 01 Separator plate Cb 77229032000 H00756 01 Insert timing chain tensioner 77229035000 H00757 01 Puller 2x 77229048000 H00758 01 Art no 77229030000 Art no 77229031000 Art no 77229032000 Art no 77229035000 Art no 77229048000 227 ...

Page 230: ... 77229050044 77229050044 H00759 01 Insert for valve s Art no 77229060000 77229060000 H00760 01 Spark plu wrench Art no 77229172000 77229172000 H00761 01 Oil pressure adapter Art no 77329006000 77329006000 H00764 01 Pin wrench Art no T103 T103 H00838 01 ...

Page 231: ...OLS 229 Hook wrench Art no T106S T106S H00841 01 De th micrometer Art no T107S T107S H00842 01 Pin Art no T120 T120 H00844 01 Mounting sleeve Art no T1204 T1204 H00878 01 Calibration in Art no T1205 T1205 H00879 01 ...

Page 232: ...0 Pressin tool Art no T1206 T1206 H00880 01 Pressin tool Art no T1207S T1207S H00881 01 Mountin sleeve Art no T1215 T1215 H00886 01 Disassembly tool Art no T1216 l T1216 H00887 01 Vacuum um Art no T1240S T1240S H00890 01 ...

Page 233: ... sleeve Art no T1401 cs T1401 H00894 01 Clam in stand Art no T14016S ill T14016S H01036 01 Rin wrench Art no T14017 T14017 H00904 01 Nitrogen charging tool Art no T14019 2x T14019 H00906 01 Su ort tool Art no T14020 T14020 H00907 01 ...

Page 234: ...rating unit Art no T14021 T14021 H00908 01 Mountin tool Art no T14022 T14022 H00909 01 Threaded bushin Art no T14023 T14023 H00911 01 Mounting sleeve Art no T14029 T14029 H00917 01 Filling ada ter Art no T14030 T14030 H00918 01 ...

Page 235: ...33 Tweezers Art no T14033 T14033 H00921 01 Clam in stand Art no T1403S 2x T1403S H00896 01 Mountin tool Art no T14040S T14040S H00922 01 Press drift Art no T1504 T1504 H00899 01 Assembl tool Art no T150S T150S H00852 01 ...

Page 236: ...30 SPECIAL TOOLS 234 Nitro en filling tool Art no T170S1 2x 3x T170S1 H00855 01 ...

Page 237: ...vice 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 a...

Page 238: ...recting the fluid level 189 fluid changing 189 Clutch lever basic position adjusting 42 Compression damping fork adjusting 12 Compression damping high speed shock absorber adjusting 46 Compression damping low speed shock absorber adjusting 46 Conducting major fork service 15 Conducting minor fork service 16 Coolant checking the antifreeze and coolant level 191 checking the level 192 draining 192 r...

Page 239: ...ng 171 shift shaft installing 175 spacer installing 172 187 spark plug installing 186 starter drive installing 177 starter motor installing 184 suction pump installing 173 timing chain tensioner installing 183 timing chain installing 172 transmission shafts installing 170 valve clearance adjusting 184 valve clearance checking 183 valve cover installing 185 237 valve timing adjusting 181 valve timi...

Page 240: ...uel pressure checking 82 Fuel pump changing Fuel screen changing Fuel tank installing removing Fuse 83 87 81 80 main fuse changing 105 H Hand brake lever basic position adjusting 111 free travel checking 110 Handlebar position 42 adjusting 42 Idle speed adjusting Ignition coil secondary winding checking 238 201 199 Implied warranty 8 Initialization run executing 201 L Lower triple clamp installing...

Page 241: ... ring retainer disassembling 56 shock absorber servicing 53 spring preload adjusting 48 spring installing 67 spring removing 54 static sag checking 47 Shock absorber linkage checking 51 Spare parts 8 Spark plug connector checking 199 Spoke tension checking 92 Start number plate installing 90 removing 89 Starter relay checking 108 239 Starting 1O for checking 11 Steering head bearing changing 40 gr...

Page 242: ...1111111111111111111111111111111111111111IIIIII 3403006en 08 2015 Husqvarna MOTORCYCLES Husqvarna Motorcycles GmbH StallhofnerstraBe 3 5230 Mattighofen Austria www husqvarna motorcycles com Photo Mitterbauer Husqvarna Motorcycles GmbH ...

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Husqvarna FC 350 2014, Repair Manual

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