Husqvarna FC 350 2016 Repair Manual Download Page 291

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Plastigauge clearance gauge

60029012000

H00627-01

Piston ring mounting tool

60029015000

H00628-01

Hose clam� lier

60029057000

H00650-01

Testing hose

61029093000

H00659-01

Art. no.: 60029012000

Feature

31 SPECIAL TOOLS

0.025 ... 0.175 mm (0.00098 ... 0.00689 in)

Art. no.: 60029015000

Feature

Height
Diameter

Art. no.: 60029057000

Art. no.: 61029093000

80 mm (3.15 in)
57 ... 125 mm (2.24 ... 4.92 in)

289

Summary of Contents for FC 350 2016

Page 1: ...PIONEERING SINCE 1903 REPAIR MANUAL2016 FC350 Art no 3403032en Husqvarna MOTORCYCLES ...

Page 2: ......

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

Page 4: ...embling the hydrostop unit 24 7 8 9 6 15 Disassembling the seal ring retainer 24 6 16 Checking the fork legs 25 6 17 Assembling the seal ring retainer 26 6 18 Assembling the hydrostop unit 27 6 19 piston rod assembling 27 6 20 cartridge assembling 29 6 21 Assembling the fork legs 30 6 22 Lubricating the steering head bearing 35 6 23 Removing the lower triple clamp 35 6 24 Installing the lower trip...

Page 5: ...ller cap 93 12 2 Closing the filler cap 93 12 3 Removing the right side cover 94 TABLE OF CONTENTS 12 4 Installing the right side cover 94 12 5 Removing the seat 94 12 6 Mounting the seat 95 12 7 Removing the fuel tank 96 12 8 Installing the fuel tank 97 12 9 Checking the fuel pressure 99 12 10 Changing the fuel pump 100 12 11 Changing the fuel filter 102 12 12 Changing the fuel screen 106 13 MASK...

Page 6: ... suction pump 172 17 3 17 Removing the water pump impeller 173 17 3 18 Removing the clutch cover 174 17 3 19 Removing the clutch discs 174 17 3 20 Removing the clutch basket 175 17 3 21 Removing the primary gear 176 17 3 22 Removing the timing chain 176 17 3 23 Removing the force pump 176 17 3 24 Removing the locking lever 177 17 3 25 Removing the shift drum locating unit 178 17 3 26 Removing the ...

Page 7: ...utch basket 221 17 5 16 Installing the clutch discs 222 17 5 17 Installing the clutch cover 222 17 5 18 Installing the water pump cover 223 17 5 19 Installing the starter drive 224 17 5 20 Installing the rotor and ignition pulse generator 224 TABLE OF CONTENTS 17 5 21 Installing the piston 225 17 5 22 Installing the cylinder head 226 17 5 23 Installing the camshafts 227 17 5 24 Installing the timi...

Page 8: ...ies 262 Engine oil 262 Coolant 262 Fuel 262 Chassis 262 Electrical system 263 Tires 263 Fork 263 Shock absorber 264 24 10 Chassis tightening torques 264 25 CLEANING 267 25 1 Cleaning the motorcycle 267 26 STORAGE 269 26 1 Storage 269 26 2 Preparing for use after storage 270 27 SERVICE SCHEDULE 271 27 1 Additional information 271 27 2 Required work 271 27 3 Recommended work 272 28 WIRING DIAGRAM 27...

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

Page 10: ...es 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 fi Indicates a danger that will lea...

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

Page 12: ... 10 H01047 10 401947 10 The chassis number O is stamped on the right side of the steer ing head The type label O is fixed to the front of the steering head Engine number O is stamped onto the engine case at the top near the engine sprocket The fork part number O is stamped on the inside of the axle clamp ...

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

Page 14: ... vehicle on a firm and level surface 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 5 3 Startin Note Danger Danger of poisoning death Exhaust gases are toxic and inhaling them may result in unconsciousness and Always make sure there is suffici...

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

Page 16: ...s correspond ing to the fork type Guideline Compression damping Comfort Standard Sport Info 17 clicks 15 clicks 13 clicks I Turn clockwise to increase damping turn counter clockwise to reduce damping Ad usting the rebound dam ing of the fork Info The hydraulic rebound damping determines the fork suspension behavior Turn the red adjusting screw O all the way clockwise Info The adjusting screw O is ...

Page 17: ...orcycle from the lift stand a p 12 6 4 Cleaning the dust boots of the fork legs Preparatory work Raise the motorcycle with a lift stand a p 12 Remove the fork protector a p 17 Main work Push dust boots O of both fork legs downward Info The dust boots remove dust and coarse dirt parti cles from the inside fork tubes Over time dirt can accumulate behind the dust boots If this dirt is not removed the...

Page 18: ...ff the clamp Remove screws 8 and take off the brake caliper 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 fD Take out the left fork leg Unscrew screws 8 Take out the right fork leg Main work Position the fork legs Bleeder screws O are positioned toward the front Info The rebound dampin...

Page 19: ...ing work Install the front wheel JI p 113 Remove screws O on the left fork leg Take off the clamp Remove screws 8 on the left fork leg Take off the left fork protector Remove screws on the right fork leg Take off the right fork protector Position the fork protector on the left fork leg Mount and tighten screws O Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake line and cla...

Page 20: ... hydrostop unit p 27 Assemble the piston rod ll l p 27 Assemble the cartridge ll l p 29 Assemble the fork legs ll l p 30 Disassemblin the fork le s Info The operations are the same on both fork legs 201700 10 Condition The fork legs have been removed Note down the current state of rebound damping O REB red adjuster on the right fork leg Note down the current state of compression damping 8 COMP whi...

Page 21: ...p Release hydrostop unit 0 and remove it Info Do not use an impact wrench Place a pan underneath since oil will run out Remove the cartridge from the fork leg Pressing tool T14051 a p 299 Info I Removing the O ring seat from the cartridge usually requires the application of considerable force Remove dust boot D Remove fork protector ring t Info I The fork protector ring does not necessarily need t...

Page 22: ... Info Lower sliding bushing must be pulled from its bearing seat Remove upper sliding bushing Info Without using a tool pull the stack slightly apart by hand Take off lower sliding bushing Take off support ring Ci Take off seal ring 48 Take off lock ring Take off dust boot D Unclamp the fork leg The operations are the same on both fork legs 201722 11 20 Preparatory work Disassemble the fork legs p...

Page 23: ...the spring with the preload spacer s Disassembling the cartridge Info The procedures are the same on both fork legs 202480 10 B04095 10 Preparatory work Disassemble the fork legs p 18 Remove the spring p 20 Main work Degrease piston rod O and clamp using the special tool I Clamping stand T14049S a p 299 Remove adjusting tube 8 Unscrew spring guide D Remove spring seat 8 Pull the piston rod out of ...

Page 24: ...ock ring D Pull reservoir out of the cartridge Pull sleeve out of the reservoir Remove spring with preload spacers Remove seal rings G and O ring G Remove pilot bushings 48 Disassembling the iston rod Info The steps are identical for both fork legs except for the hydrostop needle and valve Preparatory work Disassemble the fork legs l l p 18 Remove the spring l l p 20 Disassemble the cartridge l l ...

Page 25: ... 299 Release hydrostop needle O and remove it from the piston rod Valve 8 usually remains in the hydrostop needle Info f silver hydrostop needle on compression damp ing side G red hydrostop needle on rebound damping side Remove rebound shim stack 8 Remove piston C Remove compression shim stack 0 Remove the spring Remove adapter D with spring Remove spring D 23 ...

Page 26: ...both fork legs R00040 10 Preparatory work Disassemble the fork legs I p 18 Main work Remove nut O Remove hub 8 Remove O ring from the hub Remove shim set 5 Remove washer 8 Remove O ring 0 Disassemblin the seal rin retainer Info The steps are identical for both fork legs Preparatory work Disassemble the fork legs I p 18 Remove the spring 0 p 20 Disassemble the cartridge 0 p 21 ...

Page 27: ...damage If there is damage Change the inner tube Measure the outside diameter at multiple locations of the inner tube Outside diameter of inner tube 47 975 48 005 mm 1 88878 1 88996 in If the measured value is smaller 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 larger than the specified va...

Page 28: ...iding layer G is visible or the surface is rough Change the sliding bushings Check the spring length Guideline Spring length with preload spacer s 475 mm 18 7 in If the measured value is larger than the specified value Reduce the thickness of the preload spacers If the measured value is smaller than the specified value Increase the thickness of the preload spacers 411 Assembling the seal rin retai...

Page 29: ...ub C and position the hub Mount and tighten nut 0 Guideline I Hydro stop unit nut I M6x0 5 I 6 Nm 4 4 lbf ft 41 The steps are identical for both fork legs except for the hydrostop needle and valve 201790 10 R00033 10 Degrease the piston rod Clamp the piston rod with the special tool I Clamping stand T14049S a p 299 Grease O ring Mount valve needle O in the piston rod I Lubricant T158 ll I p 282 Mo...

Page 30: ...1166S1 I p 280 Mount the piston with chamfer f facing down Mount rebound shim stack 3 with the smaller shims facing upward Info I Note the setting list Press the piston downward against the spring Info Make sure the pistons do not squeeze the shims Position valve in hydrostop needle Mount and tighten the hydrostop needle Guideline Hydrostop needle on M6x0 5 8 Nm 5 9 lbf ft Info f silver hydrostop ...

Page 31: ...voir spring Guideline Reservoir spring length with 46 mm 1 81 in preload spacer If the length is out of tolerance Correct the preload spacers Position the spring with the preload spacers in the reservoir Position sleeve C in the reservoir Clamp cartridge with special tool I Clamping stand T14049S JI p 299 Slide reservoir 0 onto the cartridge Info Hold the sleeve in the reservoir to prevent it from...

Page 32: ... the corresponding inner tube and the right adjuster is mounted on the corresponding screw cap Compression damping side screw cap with mark COMP brake caliper holder white adjuster Rebound damping side screw cap with mark REB no brake caliper holder red adjuster e 8 8 R00037 10 Preparatory work Assemble the hydrostop unit i Jl p 27 Main work Clamp the inner tube with the axle clamp Guideline I Use...

Page 33: ...D Info I Without using a tool pull the stack slightly apart by hand Warm up the outer tube in area f of the lower sliding bush ing Guideline I so 0 c 122 F Slide the outer tube onto the inner tube Hold the lower sliding bushing with the longer side of the special tool I Mounting tool T14040S p 298 Press the sliding bushing all the way into the outer tube Position the support ring Hold the seal rin...

Page 34: ...ll the way into the fork leg Turn the fork Have the entire filling quantity of fork oil available Oil capacity per fork 670 ml Fork oil SAE 4 leg 22 65 fl oz 48601166S1 a p 280 Add some of the fork oil while pulling out and pushing in the piston rod numerous times Guideline I Fork oil quantity 1510 ml 17 24 fl oz Mount and tighten hydrostop unit Guideline I Hydrostop unit I M30x1 I 40 Nm 29 5 lbf ...

Page 35: ...Mount screw cap Info I When assembling ensure that the screw caps are cor rectly mounted according to the hydrostop needles Rebound damping side red hydrostop needle screw cap with mark REB Compression damping side silver hydrostop needle screw cap with mark COMP Mount the open end wrench on the hexagonal part Hold the open end wrench Tighten screw cap Guideline Screw cap on piston M8x0 75 rod I M...

Page 36: ...tandard 15 clicks Sport 13 clicks Compression damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Alternative 2 Warning Danger of accident Modifications to the sus pension setting may seriously alter the handling characteristic Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components Only make adjustments with...

Page 37: ... front wheel a p 112 Remove the fork legs a p 16 Remove the start number plate l JI p 109 Remove front fender l JI p 108 Remove the handlebar cushion Main work Remove the holder with Fl warning lamp Open cable holders O on the left and right and detach the wiring harness Remove screw 8 Remove screw 8 Take off the upper triple clamp with the handlebar and set it aside Info Cover the components to p...

Page 38: ...osi tioned 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 are positioned toward the front Info The rebound damping is located in right fork leg REB red adjusting screw The compression damping is located in left fork leg COMP white adjusting screw Grooves are milled into the side o...

Page 39: ... 12 Nm 8 9 lbf ft Screw top steering stem M8 20 Nm 14 8 lbf ft Loctite 243 Using a plastic hammer tap lightly on the upper triple clamp to avoid stresses Tighten screws Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Secure the wiring harness with cable holders on the left and right Mount the holder with Fl warning lamp Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 37 ...

Page 40: ...bearing play impairs the handling characteristic and damages components Correct incorrect steering head bearing play immediately Info If the bike is ridden with play in the steering head bearing the bearing and the bearing seats in the frame can become damaged over time Preparatory work Raise the motorcycle with a lift stand 1ll p 12 Main work Move the handlebar to the straight ahead position Move...

Page 41: ...16 Remove the start number plate p 109 Remove front fender i i 1 p 108 Remove the handlebar cushion Remove the lower triple clamp i i 1 p 35 Main work Remove lower bearing ring O with special tool 8 Tool bracket 58429089000 p 287 Pressing tool 58429092000 p 288 Press the new bearing ring up to the stop with special tool 6 Tool bracket 58429089000 p 287 Pressing tool 58429091000 il l p 287 Remove u...

Page 42: ...eck that the wiring harness throttle cables and brake and clutch lines can move freely and are routed correctly Check the steering head bearing play a p 38 Remove the motorcycle from the lift stand il l p 12 Mount the handlebar cushion 6 27 Adjusting the steering head bearing play 40 Preparatory work Raise the motorcycle with a lift stand 0 p 12 Remove the handlebar cushion Main work Loosen screws...

Page 43: ...CLAMP Tighten screws O Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Check the steering head bearing play i I p 38 Finishing work Mount the handlebar cushion Remove the motorcycle from the lift stand p 12 41 ...

Page 44: ...ar and lay it to one side Info Cover the components to protect them against dam age Do not kink the cables and lines Remove screws fj Remove handlebar support Position rubber bushings 8 and push through nuts from below Place the handlebar support in the required position Mount and tighten screws 8 Guideline Screw handle M10 bar support 40 Nm 29 5 lbf ft Loctite 243 Position the handlebar Info Make...

Page 45: ...any adjustments while riding Check the rubber grips on the handlebar for damage wear and looseness Info The rubber grips are vulcanized onto a sleeve on the left and onto the handle tube of the throttle grip on the right The left sleeve is clamped onto the handlebar The rubber grip can only be replaced with the sleeve or the throttle tube If a rubber grip is damaged or worn Change the rubber grip ...

Page 46: ...ver tl l p 94 7 6 Checking the play in the throttle cable 44 Check the throttle grip for smooth operation Move the handlebar to the straight ahead position Turn the throttle grip back and forth slightly and determine the play in throttle cable 6 I Play in throttle cable I 3 5 mm 0 12 0 2 in I If the throttle cable play does not meet the specified value Adjust the play in the throttle cable l ll p ...

Page 47: ...filter box cover a p 90 Remove the seat p 94 Remove the fuel tank p 96 Check the throttle cable routing a p 43 Main work Move the handlebar to the straight ahead position Push back sleeve O Loosen nut 8 Turn adjusting screw in as far as possi ble Loosen nut C Push cold start button D all the way to the stop Turn adjusting screw 0 so that the cold start button moves to the basic position when the t...

Page 48: ... grip tube Remove guide plate C from handle tube t Position the required guide plate on the grip tube Guideline The label OUTSIDE must be visible Marking f must be positioned at marking G Alternative 1 I Grey guide plate 79002014000 Alternative 2 I Black guide plate 79002014100 Info I The gray guide plate opens the throttle valve more slowly The black guide plate opens the throttle valve more quic...

Page 49: ...ion half shells CD mount and tighten screws 4i Guideline I Screw throttle grip I M6 I 5 Nm 3 7 lbf ft Slide on sleeve O and check the throttle grip for ease of movement Finishing work Check the play in the throttle cable p 44 47 ...

Page 50: ... the frame is not authorized by Husqvarna Motorcycles The procedures are the same on both footrests 311719 10 Condition The frame protectors have been removed on the left and right Remove split pin O and take off the washer Press the spring with special tool 8 I Footrest spring plier 79029083000 p 294 The special tool is applied to area f on the footrest Remove pin fD Position the new footrest and...

Page 51: ...spring as shown Spring G engages in area Press the spring with special tool I Footrest spring plier 79029083000 l l p 294 The special tool is applied to area f on the footrest Mount pin 6 Mount the washer and split pin O 8 FRAME 49 ...

Page 52: ...nfo I Do not loosen fitting Turn counterclockwise by the number of turns corresponding to the shock absorber type Guideline Compression damping high speed Comfort Standard Sport Info 2 5 turns 2 turns 1 5 turns I Turn clockwise to increase damping turn counter clockwise to reduce damping 9 2 Adjusting the low speed compression damping of the shock absorber A 50 Caution Risk of injury rectly Parts ...

Page 53: ...e damping Ad usting the rebound dam ing of the shock absorber Caution Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incor rectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Turn adjusting screw O clockwise up to the last perceptible click Turn counterclockwise by the number of clicks correspond ...

Page 54: ...motorcycle from the lift stand p 12 Checking the static sag of the shock absorber Measure dimension 6 of rear wheel unloaded i l p 52 Hold the motorcycle upright with the aid of an assistant Again measure the distance between the rear axle and mark ing SAG on the rear fender using the sag gauge Note down the value as dimension G Info The static sag is the difference between measure ments 6 and 0 C...

Page 55: ...nsion 0 Info The riding sag is the difference between measure ments G and 0 Check the riding sag I Riding sag 110 mm 4 33 in If the riding sag differs from the specified measurement Adjust the riding sag ll l p 54 reload of the shock absorber Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incor rectly The shock absorber is filled with highly compresse...

Page 56: ...ing preload Tighten screw O Guideline Screw shock M5 absorber adjusting ring Finishing work Install the shock absorber p 57 5 Nm 3 7 lbf ft Check the free travel of the foot brake lever ia p 145 Remove the motorcycle from the lift stand ia p 12 Preparatory work Raise the motorcycle with a lift stand p 12 Remove the shock absorber p 55 After removing the shock absorber clean it thoroughly Main work...

Page 57: ...he shock absorber p 51 Remove the motorcycle from the lift stand p 12 Removing the shock absorber Preparatory work Raise the motorcycle with a lift stand p 12 Main work Remove the cable ties Remove screws O Remove screws 8 with the washers Remove the frame protectors on the left and right Remove screw Remove fitting 8 Info Raise the wheel slightly to be able to remove the screws more easily Press ...

Page 58: ...he connecting link of the chain Take off the chain Info Cover the components to protect them against dam age Remove nut and pull out the swingarm pivot Push the swingarm back and secure it against falling over Hold the shock absorber and remove screw Remove the shock absorber carefully at the bottom ...

Page 59: ...arm pivot I M16x1 5 100 Nm 73 8 lbf ft Mount the chain Connect the chain with connecting link Guideline The closed side of the chain joint lock must face in the direction of travel Position the foot brake cylinder The push rod 8 engages in the foot brake cylinder Info I Ensure that the dust boot is correctly seated Mount and tighten screws 0 Guideline Remaining screws chassis M6 Position the angle...

Page 60: ...tor 1 3 Nm 2 2 lbf ft Mount and tighten screws 0 with the washers Guideline Screw frame pro tector M5 Mount the new cable ties Finishing work 3 Nm 2 2 lbf ft Check the free travel of the foot brake lever a p 145 Remove the motorcycle from the lift stand a p 12 Checking the shock absorber linkage Preparatory work Raise the motorcycle with a lift stand a p 12 Main work Remove screw O Remove fitting ...

Page 61: ...ear Change the spacers Check the shaft seal rings for damage and wear If there is damage or wear Change the shaft seal rings Check dimension f 303096 10 I 54 91 55 00 mm 2 1618 2 1654 in If dimension f is below the specified value Add the necessary spacing washers Position the angle lever Mount fitting D but do not tighten yet Guideline Nut linkage lever on M14x1 5 swingarm 80 Nm 59 lbf ft 59 ...

Page 62: ... be able to mount the screw more easily Tighten screw O Guideline Screw bottom M10 shock absorber Tighten fitting CD Guideline Nut linkage lever on M14x1 5 swingarm Finishing work 60 Nm 44 3 lbf ft Loctite 2701 TM 80 Nm 59 lbf ft Remove the motorcycle from the lift stand el p 12 Servicing the shock absorber Caution Risk of injury Parts of the shock absorber will fly off if the shock absorber is di...

Page 63: ... heim joint a p 68 Assemble the seal ring retainer p 69 Assemble the piston rod p 69 Assemble the damper p 71 Install the spring p 78 Condition The shock absorber has been removed Clamp the shock absorber into the vise with soft jaws Measure and note down the spring length in the preloaded state Loosen screw O Turn the adjusting ring until the spring is completely without tension I Hook wrench T10...

Page 64: ...work Make a note of the present state of rebound O and com pression damping 8 Open the adjusters of the rebound and compression damp ing completely Slowly open screw The nitrogen pressure dissipates Remove locking cap 8 Press in seal ring retainer 0 using the special tool I Pressing tool T1216 lll l p 297 ...

Page 65: ...Remove any burrs with sandpaper if needed Remove the piston rod Remove adjusting ring with the intermediate washer Drain the oil Remove compression adjuster Remove the spring and piston Disassembling the iston rod Preparatory work Remove the spring ill p 61 Disassemble the damper ill p 62 63 ...

Page 66: ...ck onto a screwdriver and set it down as a unit Remove piston C Remove compression shim stack 0 Info 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 0 Disassembling the seal ring retainer Preparatory work Remove the spring p 61 Disassemble the damper p 62 Disassemble the piston rod ...

Page 67: ...emove washer D for seal ring 0 Remove washer Remove dust boot 9 17 Changing the pilot bushing 200796 10 Preparatory work Remove the spring a p 61 Disassemble the damper a p 62 Disassemble the piston rod a p 63 Disassemble the seal ring retainer a p 64 Main work Press pilot bushing O out of seal ring retainer 8 with the special tool I Pressing tool T1504 a p 299 65 ...

Page 68: ...l ring retainer 8 with sleeve 9 of the special tool I Mounting tool T150S a p 300 Press the special tool through the new pilot bushing I Calibrating unit T1205 a p 296 The pilot bushing is calibrated Finishing work Assemble the seal ring retainer a p 69 Condition The damper has been disassembled Measure the inside diameter on both ends and in the middle of the damper cartridge Damper cartridge Dia...

Page 69: ...piston rod Check the piston rod for damage and wear If there is damage or wear Change the piston rod Check the piston rings for damage and wear If damage or a bronze colored surface is visible Change the piston Condition The shock absorber has been removed Clamp the shock absorber into the vise with soft jaws Remove the collar bushing of the heim joint I Drift T120 a p 296 Turn the shock absorber ...

Page 70: ...S l lll p 297 Position the new heim joint O and the special tool in the bench vise Guideline I Use soft jaws I Pressing tool T1206 l lll p 297 Press the heim joint all the way in Press the heim joint against the lock ring using the special tool I Pressing tool T1207S l lll p 297 Mount second lock ring fj Position both collar bushings D and press in ...

Page 71: ... Grease the sealing lip of the dust boot I Lubricant T625 p 282 Mount washer 8 Position washer D on seal ring C Grease seal ring C and mount with the washer facing down ward I Lubricant T14034 p 282 Mount centering disk Ci Mount rebound rubber D Grease the 0 ring groove I Lubricant T158 p 282 Mount 0 ring Mount spring Preparatory work Assemble the seal ring retainer p 69 69 ...

Page 72: ...5 I p 297 Grease the dust boot and push seal ring retainer CD onto the piston rod I Lubricant T625 ll l p 282 Remove the special tool Mount rebound washer 8 with the cut out facing down ward 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 Viewt Piston fr...

Page 73: ...152 p 282 Mount and tighten nut Guideline I Nut piston rod I M16x1 I 45 Nm 33 2 lbf ft Preparatory work Assemble the seal ring retainer I p 69 Assemble the piston rod I p 69 Main work Lubricate the O rings of the compression adjuster I Lubricant T158 I p 282 Lubricate the thread I Lubricant T159 p 282 Mount the piston with the spring Mount and tighten compression adjuster O Guideline Compression a...

Page 74: ...iston rod carefully Mount seal ring retainer C and slide it under the ring groove Mount lock ring Info I Do not scratch the inside surface Pull out the piston rod until the seal ring retainer is flush with the lock ring Mount locking cap D of the damper cartridge Bleed and fill the damper I p 73 Fill the damper with nitrogen I p 77 Alternative 1 Turn adjusting screw clockwise with a screwdriver up...

Page 75: ...ternative 2 Warning Danger of accident Modifications to the sus pension setting may seriously alter the handling characteristic Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components Only make adjustments within the recom mended range Ride slowly to start with after making adjustments to get the feel of the new handl...

Page 76: ...ith your hand Clamp the control lever as shown in the figure Control lever External tank D is set to Closed Damper 8 is set to Vacuum and Oil reservoir C is set to Vacuum Activate On Off switch D The suction process begins Pressure gauge drops to the required value I 0 bar Vacuum gauge Q drops to the required value 14 mbar Determine distance O between the floating piston and reservoir hole with th...

Page 77: ...uge drops to the required value 0 bar When the pressure gauge reaches the required value turn control lever Oil reservoir 0 to Vacuum Guideline 0 bar The vacuum gauge drops to the required value 8 mbar When the vacuum gauge reaches the required value turn control lever Oil reservoir 0 to Equalize Pressure Guideline 1 s mbar The pressure gauge drops to the required value 0 bar When the pressure gau...

Page 78: ...stance 6 minus specified value Guideline 5mm I Depth micrometer T107S p 296 Slide the floating piston into the reservoir to the shortened position using the special tool Info I The floating piston must be positioned at exactly this point when the rod is fully extended otherwise damage will occur during compression of the shock absorber Remove the special tool Remove adapter O from connector 8 of t...

Page 79: ...s pressure I 10 bar 145 psi Position the damper in the special tool The hexagonal part of the tap handle f engages in the hexagon socket of the filling port screw Open filler tap Ci Fill the damper for at least 15 seconds Guideline I Gas pressure Info I 10 bar 145 psi I Watch the pressure regulator dial Make sure that the damper is filled to the specified pressure Close the filling port screw usin...

Page 80: ...nsion the spring by turning the adjusting ring to the prescribed value Guideline I Spring preload I 7 mm 0 28 in I Hook wrench T106S ill p 295 Alternative 2 Warning Danger of accident Modifications to the sus pension setting may seriously alter the handling characteristic Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload c...

Page 81: ...arm Info I Always change a damaged swingarm Repair of the swingarm is not authorized by Husq varna Motorcycles Checkin arm bearin for play Preparatory work Raise the motorcycle with a lift stand l ll p 12 Place a load on the front of the vehicle The rear wheel is not in contact with the ground Main work Move the swingarm up and down If there is detectable play Change the swingarm bearing l ll p 83...

Page 82: ...ear wheel p 116 Remove the air filter box cover p 90 Main work Take the brake line out of the guide Push the brake caliper forward slip it out and hang it to the side Info Cover the components to protect them against dam age Remove screws O and Remove the engine sprocket cover Remove connecting link D of the chain Info Cover the components to protect them against dam age Take off the chain ...

Page 83: ...ot Remove the swingarm Main work Position the swingarm Mount the swingarm pivot Mount and tighten nut 0 Guideline I Nut swingarm pivot I M16x1 5 I 100 Nm 73 8 lbf ft I Position the frame protectors on the left and right Mount and tighten screws 8 Guideline Screw frame pro tector M5 3 Nm 2 2 lbf ft Mount and tighten screws 8 with the washers Guideline Screw frame pro tector Mount the cable ties M5 ...

Page 84: ...e closed side of the chain joint lock must face in the direction of travel Position the engine sprocket cover Mount and tighten screws D and Guideline Screw clutch slave M6 cylinder Remaining screws M8 chassis 10 Nm 7 4 lbf ft 25 Nm 18 4 lbf ft Position the brake caliper and pull it back Position the brake line in the guide Finishing work Install the air filter box cover p 90 Install the rear whee...

Page 85: ... stand I p 12 Remove the rear wheel I p 116 Remove the air filter box cover I p 90 Remove the swingarm ll p 80 Left swingarm bearing Remove collar bushings O Remove bushing 8 Remove shaft seal rings D using a suitable tool Remove stop disks C Press out bearing 0 using a suitable tool Using a suitable tool press in new bearing 0 Position stop disks C Press in shaft seal rings D 83 ...

Page 86: ...758 10 R02763 10 R02760 10 R02761 10 84 Mount bushing 8 Grease the shaft seal rings I Long life grease p 282 Position collar bushings O with the shoulder facing inward Right swingarm bearing Remove collar bushings Q Remove bushing ...

Page 87: ...table tool press in new bearing Press in shaft seal rings Mount bushing Grease the shaft seal rings I Long life grease ll ll p 282 Position collar bushings D with the shoulder facing inward Finishing work Install the swingarm a p 81 Install the air filter box cover a p 90 Install the rear wheel a p 117 Remove the motorcycle from the lift stand a p 12 85 ...

Page 88: ...ht side cover p 94 Remove the main silencer p 88 Main work Remove screw O Remove fitting 8 Info Raise the link fork slightly to be able to remove the screws more easily Press angle lever 8 toward the rear Press linkage lever C downward Detach springs C I Spring hook 50305017000 p 286 Remove screw D Lift the swingarm ...

Page 89: ... shock absorber and mount and tighten screw 0 Guideline Screw top M10 shock absorber 60 Nm 44 3 lbf ft Loctite 2701 TM Mount screw 8 but do not tighten yet Guideline Remaining screws chassis Attach springs M8 I Spring hook 50305017000 I p 286 Tighten screw 8 Guideline Remaining screws chassis Lower the swingarm M8 25 Nm 18 4 lbf ft 25 Nm 18 4 lbf ft 87 ...

Page 90: ...de cover a p 94 Remove the motorcycle from the lift stand p 12 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down before performing any work on the vehicle Preparatory work Remove the right side cover a p 94 Main work Disconnect spring O I Spring hook 50305017000 p 286 Remove screws 8 and take off the...

Page 91: ...nges Preparatory work Remove the right side cover p 94 Remove the main silencer E 1 p 88 Main work Remove all screws on the main silencer Take off silencer cap O and 0 ring 8 Take off outer tube 8 and 0 ring C Pull glass fiber yarn filling 0 off of inner tube 0 Clean the parts that need to be reinstalled and check for damage Mount new glass fiber yarn filling 0 on inner tube 0 Slide 0 ring C and o...

Page 92: ...r filter box cover in areas G C and D Engine damage Unfiltered intake air has a negative effect on the service life of the engine Dust and dirt will enter the engine without an air filter Never start to use the vehicle without an air filter 90 Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly a...

Page 93: ...ng pin 8 is secured by the retaining tab C Info If the air filter is not mounted correctly dust and dirt may enter the engine and result in damage Finishing work Install the air filter box cover p 90 Cleanin the air filter and air filter box Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and...

Page 94: ...never wring it out Oil the dry air filter with a high quality filter oil I Oil for foam air filter p 283 Clean the air filter box Check the intake flange for damage and looseness Finishing work Install the air filter il l p 91 Install the air filter box cover il l p 90 Preparatory work Remove the air filter box cover JI p 90 Main work Seal the air filter box in the marked area t Finishing work Ins...

Page 95: ...hing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Warning ...

Page 96: ...C and remove toward the front Installing the right side cover Removing the seat Position the side cover on collar bushings O and 8 and push toward the rear Engage the side cover in areas f and 4D Mount and tighten screw CD Guideline Remaining screws chassis Preparatory work M5 Remove the air filter box cover p 90 5 Nm 3 7 lbf ft ...

Page 97: ...n work Mount the front of the seat on the collar bushing of the fuel tank and the rear in the bracket Push the seat forward Make sure that the seat is locked in correctly Mount and tighten screw O Guideline Remaining screws chassis Finishing work M6 Install the air filter box cover p 90 10 Nm 7 4 lbf ft 95 ...

Page 98: ...in contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Preparatory work Remove the right side cover I p 94 Remove the air filter box cover I p 90 Remove the seat I p 94 Main ...

Page 99: ...ch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of ski...

Page 100: ...ne Remaining screws chassis M6 Plug in connector D for the fuel pump 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft Remove the wash cap set and thoroughly clean the plug in connection of the fuel line using compressed air Info Dirt should not be allowed to get into the fuel line under any circumstances Dirt in the fuel line clogs the injection valve Lubricate the 0 ring and connect plug in connection 8 for the...

Page 101: ...rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Condition The fuel tank is completely full Ensure that the battery voltage does not drop below 12 5 V The diagnostic tool is disco...

Page 102: ...n A 100 Danger Fire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueli...

Page 103: ... soil or the sewage system Preparatory work Drain the fuel from the fuel tank into a suitable container Remove the right side cover p 94 Remove the air filter box cover p 90 Remove the seat p 94 Remove the fuel tank 1 1ll p 96 Main work Remove nut O with the gasket Remove fuel connection with the gasket Remove screws 8 Pull out the fuel pump D00571 11 101 ...

Page 104: ...e seat I p 95 Install the air filter box cover I p 90 Install the right side cover JI p 94 15 Nm 11 1 lbf ft 10 Nm 7 4 lbf ft 1 2 3 Nm 1 7 lbf ft 12 11 Changing the fuel filter 102 Danger Fire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for r...

Page 105: ...ge your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system Preparatory work Drain the fuel from the fuel tank into a suitable container Remove the right side cover I p 94 Remo...

Page 106: ...12 FUEL TANK SEAT TRIM D00571 10 305317 10 104 Pull out the fuel pump Remove hose clamps C Remove fuel filter 0 Press lock D Pull back fuel pump housing Change fuel screen Mount the fuel pump housing ...

Page 107: ...tighten yet Mount and tighten nut O with the gasket Guideline Nut fuel pump fas tener M12x1 75 Tighten fuel connection Guideline Fuel port on fuel tank M8x1 25 Mount and tighten screws Guideline I Screw fuel pump I EJOT Finishing work Install the fuel tank 0 p 97 Mount the seat 0 p 95 Install the air filter box cover p 90 Install the right side cover p 94 15 Nm 11 1 lbf ft 10 Nm 7 4 lbf ft 1 2 3 N...

Page 108: ...skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system Clean plug in connection O of the f...

Page 109: ... and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Start the engine and check the response 107 ...

Page 110: ...emove the start number plate a p 109 Main work Remove screws O and 8 Remove front fender Main work Position front fender Mount and tighten screws O and 8 Guideline Remaining screws chassis Finishing work M6 Install the start number plate ilill p 109 10 Nm 7 4 lbf ft ...

Page 111: ...de Remove screw and take off the brake line guide and start number plate Installing the start number late Position the brake line and brake line guide on the start num ber plate Mount and tighten screw O Position the start number plate The holding lugs engage in the fender Mount and tighten screw 109 ...

Page 112: ...on the handling of the motorcy cle The tires mounted on the front and rear wheels must have a similar profile 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 Adhere to the legally required ...

Page 113: ... Move the rear wheel from side to side Info Hold the swingarm to check it If there is detectable play Change the rear wheel bearing l J p 125 Finishing work Remove the motorcycle from the lift stand l J p 12 Danger of accidents Worn out brake discs reduce the braking effect Make sure that worn out brake discs are replaced immediately rC n H00938 10 Check the front and rear brake disc thickness at ...

Page 114: ...Other spokes will become looser as a result Check spoke tension regularly and in particular on a new vehicle Strike each spoke briefly using a screwdriver blade Info The frequency of the sound depends on the spoke length and spoke diameter If you hear different tone frequencies from different spokes of equal length and diameter this is an indica tion of different spoke tensions Front wheel I You s...

Page 115: ...ger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork Info Do not pull the hand brake lever when the front wheel is removed Remove spacers fD IID I ill I cs H00934 10 14 6 2 Installing the front wheel Warning Danger of accidents...

Page 116: ...brake linings are seated correctly against the brake disc Remove the motorcycle from the lift stand 0 p 12 Operate the front brake and compress the fork a few times firmly The fork legs straighten Tighten screws D Guideline I Screw fork stub 1 15 Nm 11 1 lbf ft 14 6 3 Changing the front brake disc 114 Info If the brake discs are changed the brake linings must also be changed Preparatory work Raise...

Page 117: ... be pushed aside Remove the spacing tube Press out bearing 0 using a suitable tool Press in new bearing 0 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 Position spacing tube C Press in new bearing CD all the way using a suitable tool Info Only press the bearing in via the outer ring otherwise the be...

Page 118: ... the brake caliper against the spokes Remove nut O Remove chain adjuster 8 Pull out wheel spindle 8 far enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Remove the chain from the rear sprocket Info Cover the components to protect them against dam age Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down...

Page 119: ... when necessary Main work Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change the rear wheel bearing a p 125 14 WHEELS Clean and grease shaft seal rings O and contact surface 6 of the spacers I Long life grease a p 282 Insert the spacers Clean and grease the wheel spindle I Long life grease p 282 Position the rear wheel and insert wheel spindle fj The brake l...

Page 120: ...repeatedly until the brake lin ings are in contact with the brake disc and there is a pressure point Finishing work Remove the motorcycle from the lift stand ll p 12 If the brake discs are changed the brake linings must also be changed 118 Preparatory work Raise the motorcycle with a lift stand p 12 Remove the rear wheel a p 116 Main work Remove screws O Remove the brake disc Clean the contact sur...

Page 121: ...n O must be taut Chain wear is not always even so you should repeat this measurement at different chain positions 14 7 5 Adjusting the chain tension Warning I Chain tension 1 55 58 mm 2 17 2 28 in If the chain tension does not meet specifications Adjust the chain tension a p 119 Finishing work Remove the motorcycle from the lift stand a p 12 Danger of accidents Incorrect chain tension damages comp...

Page 122: ...hten nut 0 Guideline Info M25x1 5 80 Nm 59 lbf ft The wide adjustment range of the chain adjusters 32 mm 1 26 in enables different secondary ratios with the same chain length Chain adjusters 8 can be turned by 180 Finishing work Remove the motorcycle from the lift stand p 12 Checking the chain rear sprocket engine sprocket and chain guide Preparatory work 400227 01 Raise the motorcycle with a lift...

Page 123: ...ance is greater than the specified measurement Change the drivetrain kit p 123 Info When the chain is replaced the rear sprocket and engine sprocket should also be changed New chains wear out faster on an old worn rear sprocket or engine sprocket Check the chain sliding guard for wear If the lower edge of the chain pins is in line with or below the chain sliding guard Change the chain sliding guar...

Page 124: ... chain sliding piece Guideline Screw chain slid M8 ing piece 15 Nm 11 1 lbf ft Check the chain guide with a slide gauge for dimension j Minimum thickness j of 6 mm 0 24 in the chain guide If the measured value is less than the specification Change the chain guide Check that the chain guide is firmly seated If the chain guide is loose Tighten the screws on the chain guide Guideline Remaining screws...

Page 125: ...cleaner when necessary Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info The service life of the chain depends largely on its maintenance 400725 01 Preparatory work Raise the motorcycle with a lift stand l ll p 12 Main work Rinse off loose ...

Page 126: ...er Remove the rear wheel I p 116 Remove connecting link 8 of the chain Info Cover the components to protect them against dam age Take off the chain Remove engine sprocket 0 Remove fittings D Take off the rear sprocket Position new rear sprocket Mount and tighten the fittings Guideline Nut rear MB sprocket screw 35 Nm 25 8 lbf ft Loctite 2701TM ...

Page 127: ...her Guideline Screw engine sprocket M10 60 Nm 44 3 lbf ft Loctite 2701TM Position the engine sprocket cover Mount and tighten screw O Guideline Screw clutch slave cylinder M6 Mount and tighten screw Guideline 10 Nm 7 4 lbf ft Remaining screws chassis MS 25 Nm 18 4 lbf ft Finishing work Install the air filter box cover ill p 90 Remove the motorcycle from the lift stand ill p 12 14 7 10 Changing the...

Page 128: ...be 0 Using a suitable tool press bearing D out from the inside to the outside Check spacer washer for damage and wear If the spacer washer is damaged or worn Replace the spacer washer Position spacer washer Press new bearing D all the way in from the outside to the inside Info Only press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in ...

Page 129: ...bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in Grease new shaft seal ring fD and press it in until it is flush Mount lock ring 8 The lock ring engages audibly Grease new shaft seal ring O and press it in until it is flush Finishing work Install the rear wheel p 117 Remove the motorcycle from the lift stand a p 12 127 ...

Page 130: ...engine stops Remove the air filter box cover p 90 Remove the seat p 94 Main work Pull starter relay O from the holder Take off protection caps Remove faulty main fuse 5 Info You can recognize a faulty fuse by a burned out fuse wiref A spare fuse 8 is located in the starter relay Install a new main fuse I Fuse 58011109110 p 263 Check that the electrical system is functioning properly Tip I Insert a...

Page 131: ...rge is already below the minimum voltage Minimum voltage before the start of the charge 9 V Dispose of batteries with less than the minimum voltage correctly Preparatory work Press and hold the kill switch while the engine is idling until H01190 10 the engine stops Remove the air filter box cover a p 90 Remove the seat a p 94 Main work Pull back the negative terminal cover O and disconnect negativ...

Page 132: ...er D over the positive terminal Connect negative cable to the battery Guideline Screw battery termi M5 nal 2 5 Nm 1 84 lbf ft Slide negative terminal cover C over the negative terminal Finishing work Mount the seat 0 p 95 Install the air filter box cover 0 p 90 Risk of injury Batteries contain harmful substances Keep batteries out of the reach of children Keep sparks and open flames away from the ...

Page 133: ...ng current charging voltage and charging time are exceeded the battery will be destroyed If the battery is depleted from starting the vehicle repeatedly the battery must be charged immediately If the battery is left in a discharged state for an extended period it will become over discharged and sul fated destroying the battery The battery is maintenance free 311910 10 Preparatory work Remove the a...

Page 134: ... p 13 V Measure the voltage between the specified points Measuring point Plus Measuring point Ground I Charging voltage 5 000 rpm 1 13 5 15 0 V If the displayed value is less than the specified value Check the plug in connections from the alternator to the voltage regulator Check the plug in connections from the voltage regu lator to the wiring harness Check the stator winding of the alternator a ...

Page 135: ...e battery Mount the seat l i I p 95 Install the air filter box cover p 90 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 connec tor and connect it to the battery as shown in the figure Info As the charge of the capacitor increases the test lamp becomes dimmer The lamp lights up for 0...

Page 136: ...onnect the negative cable of the battery Pull off connector 8 Pull back the cover Detach cable fD from the starter relay Pull the starter relay off of the holder Connect the starter relay to a 12 V power supply as per the figure Measure the resistance between the specified points I Resistance of open circuit I 0 n If the value displayed does not meet specifications Change the starter relay Clamp c...

Page 137: ...15 WIRING HARNESS BATTERY Finishing work Mount the seat p 95 Install the air filter box cover 1ll p 90 135 ...

Page 138: ...w brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning ...

Page 139: ...not press the brake caliper against the spokes when pushing back the brake pis tons Remove cotter pins 8 pull out pin 3 and remove the brake linings Clean the brake caliper and brake caliper support Check that leaf spring D in the brake caliper and sliding plate in the brake caliper support are seated correctly Insert the new brake linings insert pin 0 and mount cotter pins 8 Info I Always change ...

Page 140: ...rake system fails in the event of overheating If there is no free travel on the hand brake lever pressure builds up on the front brake circuit Set the free travel on the hand brake lever in accordance with the specification Push the hand brake lever forward and check free travel f Free travel of hand brake lever 2 3 mm 2 0 12 in If the free travel does not match the specification Adjust the basic ...

Page 141: ...idents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the brake system is leaking or the brake linings are worn down Check the brake system and do not continue riding until the problem is eliminated Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake flui...

Page 142: ...er in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Warni...

Page 143: ...tive clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on t...

Page 144: ... filling pressure is correctly set at pressure gauge 6 If necessary adjust the filling pressure at pressure regulator G Guideline I Filling pressure I 2 2 5 bar 29 36 psi Pull off protection cap 0 of the brake caliper bleeder screw Connect the hose of the bleeder bottle I Bleeding device 00029013100 l J p 284 Open bleeder screw s by approx one half turn Info I Bleed until fresh brake fluid emerges...

Page 145: ...l ll p 143 Check the brake linings for damage and cracking If damage or wear is encountered Change the rear brake linings I p 143 Changing the rear brake linings Warning Danger of accidents Incorrect maintenance will cause the brake system to fail Ensure that service work and repairs are performed professionally Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the...

Page 146: ...ted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container H00326 10 Stand the vehicle upright Remove screw cap O with membrane 8 and the O ring Manually press the brake caliper to the brake disc to push back the brake piston Ensure that brake fluid does not flow out of the brake fluid reservoir extracting it by suction if it does Info Make sure when pushing back the br...

Page 147: ...id immediately with water Checkin the free travel of foot brake lever Warning Danger of accidents The brake system fails in the event of overheating If there is no free travel on the foot brake lever pressure builds up in the brake system on the rear brake Set the free travel on the foot brake lever in accordance with the specification 402026 10 Disconnect spring O Move the foot brake lever back a...

Page 148: ... travel 6 If necessary adjust the basic position of the foot brake lever Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in Hold push rod 3 and tighten nut C Guideline Remaining nuts chassis M6 Hold screw 8 and tighten nut 8 Guideline Nut foot brake lever M8 stop Attach spring O 10 Nm 7 4 lbf ft 20 Nm 14 8 lbf ft Checking the rear brake fluid level Warning Danger of accidents An insuffic...

Page 149: ...sult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure ...

Page 150: ... Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid...

Page 151: ... IUJ p 284 Open bleeder screw Ci by approx one half turn Info Bleed until fresh brake fluid emerges from the bleeder bottle hose without bubbles Tighten the bleeder screw Close shut off valve fi Open the bleeder screw again until brake fluid stops emerg ing Info I This prevents overfilling of the brake fluid reservoir Tighten the bleeder screw Remove the hose of the bleeder bottle Mount the protec...

Page 152: ...the right side cover p 94 Remove the air filter box cover p 90 Remove the seat p 94 Remove the fuel tank p 96 Remove the main silencer p 88 Main work Remove the cable ties Remove screw O Remove screws 8 with the washers Remove the frame protectors on the left and right Disconnect the negative cable of the battery Loosen hose clip 5 ...

Page 153: ... rollover sensor 0 off of the holder and hang to one side Remove screw D Loosen screw Repeat these steps on the opposite side Pivot up the subframe and secure it Remove screw C 17 ENGINE Pivot the shock absorber toward the rear and twist it slightly 151 ...

Page 154: ...2 Remove springs I Spring hook 50305017000 p 286 Remove screw Gi with the washer Take off the manifold Remove fittings 41 Take off the engine braces Disconnect plug in connector 48 Disconnect plug in connectors 41 ...

Page 155: ...r 4i Remove the cable tie s Remove the cable clamps and expose the cable Push back protection cap 49 Unplug the connector Loosen hose clip Gs Pull off the radiator hose Loosen hose clip 48 Pull off the radiator hose 17 ENGINE 153 ...

Page 156: ...rew Take off the engine sprocket cover Remove screws Take off the slave cylinder of the clutch and hang it to one side Info Do not kink the clutch line Do not activate the clutch lever while the slave cylin der of the clutch is removed Activate the foot brake lever Loosen screw Info The help of an assistant is useful in this step ...

Page 157: ...move screw with the washers Take off the shift lever Loosen hose clip 17 ENGINE Pull the throttle valve body off of the cylinder head toward the rear and hang it to one side Push back hose clamp and pull off the vent hose Push back protection cap and remove the nut Hang the positive cable to the side 155 ...

Page 158: ...e fitting D Remove screws Ci Remove the foot brake cylinder and allow it to hang tension free to the side Take the brake line out of the guide Remove nut G Remove the swingarm pivot Carefully pull the swingarm back and secure the swingarm ...

Page 159: ...rk Position the engine in the frame Info The help of an assistant is useful in this step Make sure that the engine is sufficiently secured against falling over Protect the frame and attachments against damage Mount screws O but do not tighten yet Guideline Engine carrying screw M10 Position the swingarm Mount the swingarm pivot Mount and tighten nut 8 Guideline 60 Nm 44 3 lbf ft I Nut swingarm piv...

Page 160: ...emaining screws chassis M6 Position the linkage lever Mount and tighten fitting Guideline Nut linkage lever to M14x1 5 angle lever Info 10 Nm 7 4 lbf ft 80 Nm 59 lbf ft Raise the wheel slightly to be able to mount the screw more easily Mount spring Q Position the positive cable on the starter motor Mount and tighten the nut Guideline Remaining nuts chassis M6 Position protection cap 10 Nm 7 4 lbf ...

Page 161: ...collar facing the engine Mount screw 41 with washer but do not tighten yet Guideline Screw engine sprocket Mount the chain M10 60 Nm 44 3 lbf ft Loctite 2701TM Connect the chain with connecting link G Guideline The closed side of the chain joint lock must face in the direction of travel Activate the foot brake lever Tighten screw 41 Guideline Screw engine sprocket M10 60 Nm 44 3 lbf ft Loctite 270...

Page 162: ...r M6 Position the engine sprocket cover Mount and tighten screw e Guideline Screw clutch slave cylinder M6 Mount and tighten screw 48 Guideline Remaining screws chassis M8 Plug in spark plug connector Gs Mount capacitor m Mount the radiator hose Position and tighten hose clip Qi 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 25 Nm 18 4 lbf ft ...

Page 163: ...ction cap i 17 ENGINE Route the cable without tension and secure with cable clips and cable ties Connect plug in connector of the gear position sensor Connect plug in connector 9 of the crankshaft position sensor Connect plug in connectors of the alternator Route the cable without tension 161 ...

Page 164: ... lbf ft Loctite 2701 TM 60 Nm 44 3 lbf ft Mount screw with washer but do not tighten yet Guideline Remaining screws chassis Mount springs M8 25 Nm 18 4 lbf ft I Spring hook 50305017000 l p 286 Tighten screw Guideline Remaining screws chassis M8 Position the shock absorber Mount and tighten screw D Guideline Screw top M10 shock absorber 25 Nm 18 4 lbf ft 60 Nm 44 3 lbf ft Loctite 2701 TM ...

Page 165: ...ew fl Guideline Screw sub frame Remove screw Ci MB Mount and tighten screw Ci Guideline Screw sub frame MB 30 Nm 22 1 lbf ft Loctite 2701 TM 30 Nm 22 1 lbf ft Loctite 2701 Repeat the operation on the opposite side Mount rollover sensor Ci Plug in the connector Mount protection cap G Position and tighten hose clip P 163 ...

Page 166: ...ectors on the left and right Mount and tighten screw Guideline I Screw frame pro tector 13Nm 2 2 lbf ft Mount and tighten screws D with the washers Guideline Screw frame pro tector Mount the cable ties M5 3 Nm 2 2 lbf ft Remove filler plug G and add engine oil Engine oil 1 0 I 1 1 qt Mount and tighten filler plug G Finishing work Install the main silencer p 88 Install the fuel tank 0 p 97 Install ...

Page 167: ... Husqvarna Motorcycles diagnostics tool Check the engine for leak tightness Check the engine oil level p 242 Check the coolant level p 239 Mount the special tool on the engine assembly stand Holder and fitting for work stand 79229002000 llt I p 294 Engine work stand 80329001000 p 295 Mount the engine on the special tool Info Work with an assistant or a motorized hoist Removing the clutch push rod ...

Page 168: ...rain plug 8 with the magnet and seal ring Remove oil drain plug with the O ring Completely drain the engine oil Remove screws 0 Remove the oil filter cover 8 with the O ring Pull oil filter 8 out of the oil filter housing I Lock ring plier 51012011000 il1ll p 286 ...

Page 169: ...rk plug Removing the valve cover Remove screws O Remove the protective plate and the gear position sensor Remove the spark plug with special tool O I Spark plug wrench with link 77229172000 p 293 Remove screws O Take off the valve cover with the valve cover seal Remove gasket fj 167 ...

Page 170: ...7 ENGINE 17 3 8 Removing the starter motor 168 Remove spark plug shaft insert D Remove screws O Take off the alternator cover Remove gasket 8 Remove torque limiter D Remove screws C and the starter motor ...

Page 171: ...h with the edge of the cylinder head Remove screw O Info Look through the hole to check that the position notch of the crankshaft is visible Mount and tighten screw O without the washer 17 3 10 Removing the timing chain tensioner Loosen screw O Remove screw 8 with the seal ring Pull out timing chain tensioner D Remove 0 ring C 169 ...

Page 172: ... outside to the inside Take off guide rail 8 Take off the camshaft bearing bridge Info Ensure that the dowel pins remain in place Take the timing chain from the camshaft gear Remove the camshafts Remove nut O with the washer Loosen nuts 8 in a crisscross pattern and remove them with the washers Remove the cylinder head ...

Page 173: ...the cylinder as far up as necessary to take the piston pin out Remove the piston pin retainer O Remove the piston pin Take off the cylinder and piston Push the piston upward out of the cylinder Info If no further work is to be performed on the cylinder and piston the piston can remain in the cylinder Take off cylinder base gasket 8 Remove screw O 171 ...

Page 174: ... 75029090000 I p 290 Attach special tool to the rotor Hold it tight using the special tool and pull off the rotor by turning the screw in I Extractor 79229032044 I p 294 Info Ensure that the woodruff key remains in place Remove screw O with the washer Take off starter idler gear Take off freewheel gear Remove screws O Take off oil pump cover ...

Page 175: ...Remove O ring D Take off suction pump C Remove needle roller 0 17 3 17 Removing the water pump impeller Remove screws 0 Take off the water pump cover Remove gasket 8 17 ENGINE 173 ...

Page 176: ...3 19 Removing the clutch discs 174 Remove nut 8 Take off two part water pump impeller C Remove screws O Take off the clutch cover Remove clutch cover gasket 8 Loosen screws O and remove together with the washers and springs Take off the pressure cap ...

Page 177: ...he lock washer Hold the inner clutch hub with the special tool Loosen nut 8 I Holding wrench 51129003000 ill p 287 Remove the nut with the lock washer Take off inner clutch hub 4D and washer C Info I The washer usually sticks to the inner clutch hub Take off clutch basket 0 Take off needle bearing D and collar sleeve 17 ENGINE 175 ...

Page 178: ...0 a p 290 Pull off primary gear 8 using the special tool I Puller 46129021000 p 286 Remove screws O Remove timing chain guide rail 8 Remove timing chain tensioning rail D Remove screw 8 Take off balancer shaft 0 together with the timing chain and timing chain securing guide Info If the timing chain is to be reused mark the direction of travel Remove lock ring O Take off washer Take off oil pump id...

Page 179: ...ove oil pump gear D Remove pin Remove screws Take off the oil pump cover Remove pin 17 ENGINE Push oil pump shaft Ci inward and take it out of the engine from the ignition side Remove force pump m Unscrew O and remove together with locking lever f washer sleeve and spring 177 ...

Page 180: ...sh sliding plate 8 away from shift drum locating unit CD Take off the shift drum locating unit Remove shift shaft O with the washer Remove spacer O of the crankshaft Remove screw 8 17 3 28 Removing the left engine case 178 Remove screws O Tilt the left section of the engine case upward and remove the screw cap of the engine fixing arm ...

Page 181: ...00 p 295 Info I Use the 792 drill hole Pull off the section of the engine case Info Do not tension the section of the engine case The washer of the main shaft usually sticks to the bearing Take off the left section of the engine case Remove the special tool Remove spacer Remove shift rail O Remove shift rail 8 Tilt shift forks O to the side Info Do not misplace the shift rollers Remove shift drum ...

Page 182: ...ove shift forks O 17 3 32 Removing the transmission shafts 17 3 33 Removing the crankshaft 180 Remove lock ring O Pull both transmission shafts 8 out of the bearing seats together Take out crankshaft O Take off the right section of the engine case ...

Page 183: ...ction 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 M4 2 Nm 1 5 lbf ft balancer shaft Loctite 243 lubrication Insert the new cold bearings in the bearing seats of the heated section of the engine case if necessary use a suitable press drift to push them all the way in and make them flush Info When pressing the be...

Page 184: ...cation 2 Nm 1 5 lbf ft Loctite 243 2 Nm 1 5 lbf ft Loctite 243 Mount the oil nozzle for piston cooling Mount and tighten screw C Guideline Screw oil noz M4 zle for piston cooling Position all bearing locks Mount and tighten screws Ci Guideline Locking screw for bearing M5 2 Nm 1 5 lbf ft Loctite 243 6 Nm 4 4 lbf ft Loctite 243 Check the oil pressure regulator valve lll l p 186 Blow out the oil cha...

Page 185: ... heated section of the engine case if necessary use a suitable press drift to push them all the way in and make them flush Info When pressing the bearing in ensure that the engine case section is level to prevent damage Only press the bearings in via the outer bearing race otherwise the bearings will be damaged when they are pressed in After the engine case section has cooled check that the bearin...

Page 186: ...ozzle pis ton cooling M5 Position all bearing locks Mount and tighten screws D Guideline Locking screw for bearing M5 2 Nm 1 5 lbf ft Loctite 243 2 Nm 1 5 lbf ft Loctite 243 6 Nm 4 4 lbf ft Loctite 243 Blow out the oil channel with compressed air and check that it is clear Remove shaft seal ring O Remove lock ring 8 Remove shaft seal ring 8 ...

Page 187: ...ay in from the inside to the outside using a suitable tool Press in shaft seal ring O all the way with the open 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 Press the shaft seal ring inward to the point where the lock ring can be mounted Provide suitable support for the clutch cover while pr...

Page 188: ...g length of the oil pressure regulator valve Oil pressure regulator valve Minimum length of 1 23 5 mm 0 925 in pressure spring If the measured value does not meet specifications Change the spring Check ball C and the sealing seat If there is damage or wear Change the ball and machine the sealing seat Install ball C and pressure spring fD Mount and tighten screw plug O with sealing washer Guideline...

Page 189: ...oil pump cover for damage and wear If there is damage or wear Change the oil pump cover 17 4 6 Removing the crankshaft bearing inner race 311613 10 Fix the crankshaft in the vise Info Use soft jaws Warm up special tool O Guideline 1150 C 302 F I Puller 58429037037 p 287 17 ENGINE Push the warmed up special tool O onto the crankshaft bearing inner race press firmly together and pull jointly from th...

Page 190: ...al tool I Crankshaft pressing tool 75029047000 a p 290 Info I Hold the lower crankweb Take off the connecting rod Press the crank pin out of the lower crankweb Press in new crank pin D as far as possible Oil hole f is aligned with oil hole G X If the oil holes are not correctly aligned the conrod bear ing will not be supplied with oil Blow compressed air through the oil channel to check that it is...

Page 191: ...insert 77229008000 l l p 291 Press in the upper crankweb as far as possible Info The press mandrel must be positioned over the crank pin Take the crankshaft out of the special tool and check that the connecting rod can move freely Measure axial play 0 between the connecting rod and the crankwebs using the special tool I Feeler gauge 59029041100 ll p 288 Connecting rod axial play of lower conrod be...

Page 192: ...ft in the vise Info Use soft jaws Slide on compensating disk 0 Info The compensating disks have a larger diameter than the crankshaft stub Ensure that the compensating disks are centered and fixed with a small amount of grease Add compensating disks equally on both sides Heat the crankshaft bearing inner race in special tool 8 and mount together Guideline 1120 C 248 F I Puller 58429037037 a p 287 ...

Page 193: ... measured value does not meet specifications Remove the crankshaft Remove the crankshaft bearing inner race p 187 Calculate the thickness of the compensating disks Add or remove compensating disks equally on both sides Info If the axial play is too small remove compen sating disks If the axial play is too large add compensating disks Install the crankshaft bearing inner race a p 190 17 4 11 Removi...

Page 194: ...oved performance low wear and a lightweight cylinder 17 4 14 Checking measuring the cylinder 311617 10 192 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 88 000 88 012 m...

Page 195: ...ring is stiff Clean the piston ring groove Tip An old piston ring can be used to clean the piston ring groove Check the piston rings for damage If the piston ring is damaged Change the piston ring Info I Mount the piston ring with the marking facing upward Check the piston pins for discoloration or signs of wear If the piston pin shows severe discoloration signs of wear Change the piston pin Place...

Page 196: ... 0 057 mm 0 00138 0 00224 in Size II 0 037 0 060 mm 0 00146 0 00236 in Wear limit 0 070 mm 0 00276 in 17 4 17 Checking the piston ring end gap 311618 10 194 Remove the piston ring from the piston Place the piston ring in the cylinder and align with the piston Guideline Below the upper edge of the 20 mm 0 79 in cylinder Measure end gap f with a feeler gauge Guideline Piston ring end gap Compression...

Page 197: ...aft gear Mount camshaft gear D Mount screw 8 but do not tighten yet Guideline Screw M12x1 70 Nm 51 6 lbf ft camshaft drive Loctite 243 cone sprocket degreased Repeat these steps for the second camshaft Check the camshaft for damage and wear If there is damage or wear Change the camshaft If the surface of the cams is damaged check the oil supply to the camshaft and cam lever Check the autodecompres...

Page 198: ...Mount and tighten the screws Guideline Screw M7x1 14 Nm 10 3 lbf ft camshaft Lubricated with engine 311627 10 311628 10 196 bearing bridge oil Info I Ensure that the dowel pins are seated properly Do not turn the camshaft Remove camshaft bearing bridge O again Compare the Plastigauge clearance gauge with the specifications on the packaging Guideline Camshaft bearing sleeve bearing Radial clearance...

Page 199: ...using the special tool Valve spring mounter 59029019000 a p 288 Insert for valve spring lever 79029060000 a p 293 Remove the valve keys and release the tension on the valve springs Remove the valve spring retainer and valve springs Mark the valve springs according to their normal built in posi tion Pull the valve down out of the valve guide Remove valve stem seal C with the special tool I Valve st...

Page 200: ...ve 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 42 40 mm 1 6693 in intake valve outer spring Minimum length 39 20 mm 1 5433 in intake valve inner spring Minimum l...

Page 201: ...shafts for damage and wear If there is damage or wear Change the cam levers and or cam lever shafts Check valve guides O using the special tool I Limit plug gauge 77229026000 l l p 291 If the special tool is easy to insert in the valve guide Change the valve guide and valve 41 41 Check the sealing area of the spark plug thread and the valve seats from damage and cracking If there is damage or crac...

Page 202: ... 8 Mount the valve corresponding to its installation position Mount the valve spring with the tighter coil facing downward according to the built in position Info Intake valves are marked with a green color coding Exhaust valves are marked with a brown color coding Mount the valve spring retainers Tension the valve spring with a special tool Valve spring mounter 59029019000 llt l p 288 Insert for ...

Page 203: ...ew plugs Cs Guideline 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 clockwise do not wedge Check the locking action of starter wheel O If the freewheel gear does not turn clockwise or if it does not lock counterclockwise Change the ...

Page 204: ...gether with suitable pliers and take off Take freewheel 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 8 Ensure that all lugs of the expansion ring pass through slots f of the freewheel and engage in groove of the primary gear ...

Page 205: ... mesh and bearing of freewheel gear 8 for damage and wear If there is damage or wear Change the freewheel gear or bearing Check freewheel 8 for damage and wear If there is damage or wear Change the free wheel Check the gear mesh of starter motor 0 for damage and wear If there is damage or wear Change the starter motor Change O ring D of the starter motor 17 ENGINE Connect the negative cable of a 1...

Page 206: ...ng chain guide rail 8 for damage and wear If there is damage or wear Replace the timing chain guide rail Check timing chain securing guide C 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 or wear Change the camshaft Check timing chain D for damage and wear If there is damage or wear Change the tim...

Page 207: ...n all the way Guideline Thickness of the compen sating disks 2 2 5 mm 0 08 0 098 in Release the timing chain tensioner The detent mechanism engages and the piston remains in place Final position of the pis ton after engagement Info 3 mm 0 12 in I 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 pre vente...

Page 208: ...If the clutch spring length is shorter than specified Change all clutch springs Check the contact surface of pressure cap 0 for damage and wear If there is damage or wear Change the pressure cap Check clutch basket 3 for damage and wear If there is damage or wear Change the clutch basket Check needle bearing and collar sleeve for damage and wear If there is damage or wear Change the needle bearing...

Page 209: ...wear If there is damage or wear Change the inner clutch hub Check sleeves 4D for damage and wear If there is damage or wear Change the sleeves 17 4 35 Checking the shift mechanism e I II Check shift forks O on plate 9 for damage and wear visual check If there is damage or wear Change the shift fork Check shift grooves Cs of shift drum 8 for wear If the shift groove is worn Change the shift drum Ch...

Page 210: ...sent Change the sliding plate Check guide pin for looseness and wear If the guide pin is loose and or worn Change the sliding plate 310356 10 17 4 36 Preassembling the shift shaft 208 Preassemble the shift shaft JI p 208 Check clearance O between the sliding plate and the shift quadrant Shift shaft sliding plate shift quadrant clearance 0 40 0 80 mm 0 0157 0 0315 in If the measured value does not ...

Page 211: ... Guideline I Use soft jaws Remove stop disk O and second gear fixed gear 8 Remove fourth gear idler gear 6 and needle bearing 8 Remove stop disk 0 Remove lockring D Remove third gear sliding gear Remove lockring Remove stop disk Remove fifth gear idler gear Ci Remove needle bearing 41 17 ENGINE 306556 10 209 ...

Page 212: ...aring D and stop disk 8 Remove fifth gear sliding gear 0 Remove lock ring D Remove stop disk Remove third gear idler gear D and needle bearing 0 Remove stop disk Gi Remove lock ring a Remove fourth gear sliding gear 48 Remove lock ring 41 Remove stop disk 4D Remove second gear idler gear 48 and needle bearing Ci 17 4 39 Checking the transmission Condition The transmission has been disassembled 210...

Page 213: ...dogs of idler gears 8 and sliding gears 0 for damage and wear If there is damage or wear Change the gear wheel pair Check the tooth faces of idler gears 8 sliding gears 0 and fixed gear D for damage and wear If there is damage or wear Change the gear wheel pair Check the tooth profiles of sliding gears 0 for damage and wear If there is damage or wear Change the gear wheel pair Check sliding gears ...

Page 214: ...parts before assembling Main work Secure the main shaft with the toothed end facing downward in the vise Guideline I Use soft jaws Mount needle bearing O Mount fifth gear idler gear 8 Mount stop disk and lock ring C Mount third gear sliding gear 0 Mount lock ring D and stop disk Mount needle bearing D Mount fourth gear idler gear Mount second gear fixed gear Gi and stop disk 48 Finally check all g...

Page 215: ...ler gear 8 onto the countershaft with the protruding collar facing downward Mount stop disk D and lockring C Mount fourth gear sliding gear 0 with the shift groove facing upward Mount lockring D and stop disk Mount needle bearing D and third gear idler gear 0 with the shift dogs facing upward Mount stop disk i and lockring 4D Mount fifth gear sliding gear 8 with the shift groove facing downward Mo...

Page 216: ... the right section of the engine case in the engine work stand Oil the bearing I Engine oil SAE 1 0W 50 p 280 Slide crankshaft O into the bearing seat Installing the transmission shafts Oil the bearing Slide both transmission shafts O into the bearing seats together Mount lock ring 8 ...

Page 217: ...de diameter mount this in the shift groove of the main shaft Mount shift fork in the lower shift groove of the counter shaft Mount shift fork D in the upper shift groove of the counter shaft Push shift drum O into the bearing seat Put shift forks in the shift drum Info Do not misplace the shift rollers Mount shift rail O Mount shift rail 215 ...

Page 218: ...afts Info 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 M6x55 10 Nm 7 4 lbf ft Mount screws fj but do not tighten yet Guideline I Screw engine case M6x65 10 Nm 7 4 lbf ft Mount screws and tighten all screws in a crisscross pat tern Guideline I Screw engine case M6x70 10 Nm 7 4 lbf ft Mount the screw ca...

Page 219: ...locating unit 17 5 10 Installing the locking lever Push away sliding plate O from the shift drum locating unit and position shift drum locating unit 8 Info The flat surfaces of the shift drum locating unit are not symmetric Mount and tighten screw fD Guideline Screw shift drum locating M6 10 Nm 7 4 lbf ft Loctite 243 Mount locking lever O with the washer sleeve and spring Mount and tighten screw 8...

Page 220: ...e engine case Mount the oil pump shaft 8 from the ignition side Mount pin Position the oil pump cover Marking G faces upward Mount and tighten screws C Guideline Screw oil pump M5 cover Insert pin 0 Position the oil pump gear 3 Mount washer Mount lock ring 6 Nm 4 4 lbf ft Loctite 243 Crank the oil pump gear and ensure that it can move easily Mount oil pump idler gear with the washer Mount washers ...

Page 221: ...n timing chain guide rail CD Mount and tighten screw 8 Guideline Screw timing M6 chain guide rail 10 Nm 7 4 lbf ft Loctite 243 10 Nm 7 4 lbf ft Loctite 243 Position timing chain tensioning rail 0 Mount and tighten screw 3 Guideline Screw timing MB chain tension ing rail Position primary gear O 15 Nm 11 1 lbf ft Loctite 243 The wide tooth of the primary gear engages in the wide recess of the cranks...

Page 222: ...ion suction pump fj The rounded sides of the external rotor face the engine case Crank the oil pump gear wheel and ensure that it can move easily Mount 0 ring fD Position the oil pump cover C Mount and tighten screws 0 Guideline Screw oil pump M5 cover 6 Nm 4 4 lbf ft Loctite 243 ...

Page 223: ...ear until the gear teeth of the clutch basket mesh Slide on washer 8 and inner clutch hub 0 Position the new lock washer and mount nut 3 Tighten the nut holding the inner clutch hub with a special tool Guideline Nut inner clutch hub M18x1 5 100 Nm 73 8 lbf ft Loctite 243 I Holding wrench 51129003000 p 287 Secure the nut with the lock washer Mount sleeves 221 ...

Page 224: ...n Mount the pressure cap Mount screws 8 with the washers and springs Tighten the screws diagonally Guideline I Screw clutch spring I M6 Mount clutch cover gasket O Info 110 Nm 7 4 lbf ft Ensure that the dowel pins are seated properly Position the clutch cover Info Ensure that the shaft seal rings of the water pump and the crankshaft are not damaged Mount screws 8 but do not tighten yet Guideline I...

Page 225: ... 4 lbfft Nut water pump wheel M6 6 Nm 4 4 lbfft Loctite 243 Mount gasket 8 Mount the water pump cover Info Ensure that the dowel pins are seated properly Mount screw 8 with the seal ring b ut to not tighten yet Guideline Screw water pump cover M6x25 Mount screw 0 b ut do not tighten yet Guideline Screw water pump cover M6x25 Mount and tighten screws 0 Guideline Screw water pump cover M6x40 Tighten...

Page 226: ...sher Guideline Screw starter idler gear M6 10 Nm 7 4 lbf ft Loctite 243 41 17 5 20 Installing the rotor and ignition pulse generator 224 Ensure that the woodruff key is seated properly Mount the rotor Info To simplify installation turn the starter idler gear coun terclockwise Mount and tighten screw 0 Guideline Rotor screw M10x1 70 Nm 51 6 lbf ft Thread oiled with engine oil cone degreased 41 ...

Page 227: ...e special tool Push the piston carefully into the cylinder from above Info The piston rings should not catch or they will be dam aged Ensure that piston mark fj faces the exhaust side Apply a thin layer of sealing compound in area I Loctite 591 O Place the cylinder base gasket on Info Ensure that the dowel pins are seated properly Cover the engine case opening with a cloth Thread the tim ing chain...

Page 228: ...l clockwise thereby pushing the piston pin retainer into the groove I Insertion for piston ring lock 77229030000 p 292 Ensure that the piston pin retainer is seated properly on both sides Remove the cloth Keep the timing chain taut Push the cylinder down carefully and let the dowel pins engage Mount dowels O Put on cylinder head gasket Put the cylinder head in place ...

Page 229: ... cone greased Mount and tighten nut 8 Guideline Nut cylinder M6 10 Nm 7 4 lbf ft head Lubricated with engine oil Pull up the timing chain and insert intake camshaft O Place the timing chain over the camshaft gear of the intake camshaft Marking 6 is aligned and flush with the edge of the cylinder head Ensure that bleeder is positioned properly Position exhaust camshaft D Place the timing chain over...

Page 230: ...ing bridge oil 17 5 24 Installing the timing chain tensioner 228 Position timing chain tensioner O and insert it with new 0 ring Mount and tighten screw plug 8 with the seal ring Guideline Plug timing chain tensioner Remove screw C M24x1 5 40 Nm 29 5 lbf ft Press the timing chain tensioner toward the timing chain using special tool 0 Release device for timing chain tensioner 61229021000 p 290 The ...

Page 231: ... the camshaft and cam lever Guideline Valve clearance Intake at 20 C 68 F 0 10 0 15 mm 0 0039 0 0059 in Exhaust at 20 C 68 F 0 13 0 18 mm 0 0051 0 0071 in I Feeler gauge 59029041100 p 288 If the valve clearance does not meet specifications Adjust the valve clearance p 229 Mount and tighten screw O with the washer Guideline Screw plug crankshaft location M8 10 Nm 7 4 lbf ft 17 5 26 Adjusting the va...

Page 232: ...l the camshafts p 227 Install the timing chain tensioner p 228 Finishing work Check the valve clearance p 229 Grease the O ring Position the starter motor I Long life grease p 282 Mount and tighten screws 0 Guideline I Screw starter motor I M6 Position torque limiter Position gasket D Info 110 Nm 7 4 lbf ft Ensure that the dowel pins are seated properly ...

Page 233: ...ideline Screw alternator cover M6 10 Nm 7 4 lbf ft Grease the O rings and mount spark plug shaft insert O Position gasket 8 Thinly apply sealing compound to area 6 I Loctite 5910 Position the valve cover with the gasket Mount and tighten screws Guideline I Screw valve cover M6 I 8 Nm 5 9 lbf ft 41 41 231 ...

Page 234: ...ing the oil filter 232 Position gear position sensor Position protective plate Mount and tighten screws Guideline Screw gear M5 position sensor 5 Nm 3 7 lbf ft Loctite 243 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 Mount and tighten screws...

Page 235: ...nd a new seal ring Guideline Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Position the oil screen with O rings on a pin wrench Position the pin wrench through the drilled hole of the screw plug in the opposite section of the engine case Push the oil screen all the way into the engine case Mount and tighten screw plug 8 with the O ring Guideline Screw plug oil screen M20x1 5 15 Nm 11 1 lbf ...

Page 236: ...ush rod 0 17 5 34 Removing the engine from the engine assembly stand 234 Remove the fitting from the special tool I Holder and fitting for work stand 79229002000 p 294 Remove the engine from the engine assembly stand Info Work with an assistant or a motorized hoist ...

Page 237: ...ange the clothing Info I The fluid level rises with increasing wear of the clutch facing discs Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and clutch lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container Move the clutch fluid reservoir mounted o...

Page 238: ...g Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws O Remove cover with membrane 8 Fill bleeding syringe 8 with the appropriate hydraulic fluid Syringe 50329...

Page 239: ...w and then extract fluid from the master cylinder reservoir to prevent overflow Tighten the bleeder screw and remove the bleeding syringe with the hose Correct the fluid level of the hydraulic clutch Guideline Fluid level below container rim 4 mm 0 16 in Position the cover with the membrane Mount and tighten the screws 41 237 ...

Page 240: ... hoses or other cooling system components if the engine or the cooling system are at operating temperature Allow the cooling system and the engine to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep...

Page 241: ...gine to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediate...

Page 242: ...iately with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing Condition The engine is cold Position the motorcycle upright Place a suitable container under the water pump cover Remove screw O Take off radiator cap Completely drain the coolant Moun...

Page 243: ...Position the motorcycle upright Pour coolant in up to measurement f above the radiator fins Guideline Dimension f over the radi 10 mm 0 39 in ator fins I Coolant ll p 280 I 0 95 I 1 qt Mount the radiator cap Take a short test ride Check the coolant level JI p 239 241 ...

Page 244: ...er lubrication Oil nozzle piston cooling Cs Oil nozzle for alternator cooling 0 Oil nozzle for clutch lubrication Suction pump 41 Oil channel transmission lubrication 48 Timing chain tensioner 401052 60 Checking the engine oil level 242 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 ...

Page 245: ...ddle of level viewer f Add engine oil p 246 Changing the engine oil and oil filter cleaning the oil screen Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden Wear suitable protective clothing and safety gloves In the event of scalding rinse the area affected immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental ...

Page 246: ...screen C with the O rings on a pin wrench Position the pin wrench through the drilled hole of the screw plug in the opposite section of the engine case Push the oil screen all the way into the engine case Mount and tighten screw plug with the O ring Guideline Screw plug oil screen M20x1 5 15 Nm 11 1 lbf ft Mount and tighten the oil drain plug O with the magnet and a new seal ring Guideline Oil dra...

Page 247: ... the motorcycle upright 10 Nm 7 4 lbf ft Remove the oil filler plug 3 with the O ring from the clutch cover and fill up with engine oil Engine oil 1 0 I 1 1 qt Engine oil SAE 10W 50 p 280 Info Too little engine oil or poor 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 th...

Page 248: ...are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Start the engine and check that it is oil tight Finishing work Check the engine oil level p 242 Checking the engine oil pressure Warning Danger of scalding Eng...

Page 249: ...ng them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Start the engine and let it warm up Check the engine oil pressure Engine oil pressure Engine oil tempera ture 80 C 176 F Engine speed 1 600 rpm Engine oil tempera ture 80 C 176 F ...

Page 250: ...hine 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 Screw unlocking M10x1 of timing chain ten sioner Finishing work Check the engine oil level a p 242 8 Nm 5 9 lbf ft ...

Page 251: ...l Checking the spark plug connector 1 601170 10 Condition Spark plug connector cylinder 1 has been removed 0 Measure the resistance between the specified points Measuring point 1 Measuring point 2 Spark plug connector Resistance at 20 C 68 F 1 3 75 6 25 kn If the specification is not reached Change the spark plug connector Alternator checkin the stator windin CR 1 63mm P00023 10 Condition The alte...

Page 252: ...correspond to the required value Change the stator Removing the stator and crankshaft ROSition sensor Condition The alternator cover has been removed Remove screws O Remove the retaining bracket Remove screws 8 Remove cable support sleeve from the alternator cover Remove the stator and crankshaft position sensor from the alternator cover Blow out oil nozzle O with compressed air and check that it ...

Page 253: ...erna tor cover Mount and tighten screws Guideline Screw stator M5 Position retaining bracket Mount and tighten screws Guideline Screw M5 crankshaft position sensor 6 Nm 4 4 lbf ft Loctite 243 6 Nm 4 4 lbf ft Loctite 243 Position cable support sleeve 8 in the alternator cover 251 ...

Page 254: ...tank a p 96 Main work Pull capacitor O away from the holder and hang to one side Push back protection cap 8 and remove the connector Disconnect spark plug connector 8 Remove the spark plug with special tool 8 1 Spark plug wrench with link 77229172000 a p 293 Push back hose clamp 0 Pull off the vent hose Remove screws D Remove the valve cover with the gasket to the right Remove gasket ...

Page 255: ... clearance between the camshaft and cam lever with the special tool Guideline Valve clearance Intake at 20 c 68 F 0 10 0 15 mm 0 0039 0 0059 in Exhaust at 20 C 68 F 0 13 0 18 mm 0 0051 0 0071 in I Feeler gauge 59029041100 I p 288 If the valve clearance does not meet specifications Adjust the valve clearance I p 255 Remove screw Crank the engine several times Check the valve clearance and correct i...

Page 256: ...3 3 lbf ft Position the valve cover with the gasket Mount and tighten screws D Guideline I Screw valve cover I M6 I 8 Nm 5 9 lbf ft Mount the vent hose and hose clamp 0 Mount and tighten the spark plug with special tool Guideline ISpark plug IM10x1 1 10 12 Nm 7 4 8 9 lbf ft I Spark plug wrench with link 77229172000 p 293 Plug in spark plug connector fD Plug in connector and position protection cap...

Page 257: ...side cover I p 94 Remove the air filter box cover I p 90 Remove the seat I p 94 Remove the fuel tank a p 96 Check the valve clearance a p 252 Remove the timing chain tensioner a p 169 Remove the camshafts a p 170 Main work Swing up cam lever O Correct the shims based on the results of the valve clearance check Finishing work Install the camshafts I p 227 Install the timing chain tensioner I p 228 ...

Page 258: ... Run the engine until warm The cold start button is deactivated The cold start but ton is in its basic position 120311 10 Set the idle speed by turning the idle speed adjusting screw O Guideline I Idle speed I 2 250 2 350 rpm I Tachometer 45129075000 a p 285 Info I Turning counterclockwise lowers the idle speed Turning clockwise raises the idle speed Executin the initialization run Condition The d...

Page 259: ...ed space Start the engine without operating the throttle grip Guideline I Coolant temperature I 25 C 77 F Let the engine idle until it reaches the specified temperature Guideline I Coolant temperature 1 ao 90 c 176 194 F Info Do not operate the throttle grip during the initialization process As soon as the specified temperature is reached switch off the ignition Info I If the initialization is not...

Page 260: ...bearings Conrod bearing Plain bearing Piston pin bearing Bearing bush Pistons Forged light alloy Piston rings 1 compression ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with two Eaton pumps Primary transmission 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 ...

Page 261: ...m 3 46279 3 46318 in Size II 87 965 87 975 mm 3 46318 3 46358 in Cylinder drill hole diameter Size I 88 000 88 012 mm 3 46456 3 46503 in Size II 88 012 88 025 mm 3 46503 3 46554 in Piston cylinder mounting clearance Size I 0 035 0 057 mm 0 00138 0 00224 in Size II 0 037 0 060 mm 0 00146 0 00236 in Wear limit 0 070 mm 0 00276 in Piston ring end gap Compression ring 5 0 40 mm 5 0 0157 in Oil scraper...

Page 262: ...2 Nm 1 5 lbf ft Loctite 243 Screw bearing bolt oil pump idler MS 6 Nm 4 4 lbf ft gear Loctite 243 Screw crankshaft position sensor MS 6 Nm 4 4 lbf ft Loctite 243 Screw locking lever MS 6 Nm 4 4 lbf ft Loctite 243 Screw oil pump cover MS 6 Nm 4 4 lbf ft Loctite 243 Screw stator MS 6 Nm 4 4 lbf ft Loctite 243 Nut cylinder head M6 10 Nm 7 4 lbf ft Lubricated with engine oil Nut water pump wheel M6 6 ...

Page 263: ... M12x1 5 M12x1 5 M14x1 5 M18x1 5 M18LHx1 5 M20x1 5 M24x1 5 M24x1 5 24 TECHNICAL DATA 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft Loctite 243 10 Nm 7 4 lbf ft Loctite 243 8 Nm 5 9 lbf ft 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 14 Nm 10 3 lbf ft Lubricated with engine oil 10 Nm 7 4 lbf ft 15 Nm 11 1 lbf ft 60 Nm 44 3 lbf ft 15 Nm 11 1 lbf ft 70 Nm 51 6 lbf ft Loctite 243 Loctite 2701 TM Loctite 243 Thread oiled wit...

Page 264: ...unloaded Weight without fuel approx Maximum permissible front axle load Maximum permissible rear axle load Maximum permissible overall weight 262 I Engine oil SAE 10W 50 p 280 I 0 95 I 1 qt I 7 I 1 8 US gal Central tube frame made of chrome molybdenum steel tubing WP Performance Systems Up Side Down 4860 MXMA4CS 300 mm 11 81 in 300 mm 11 81 in 22 mm 0 87 in WP Performance Systems 5018 DCC Link Dis...

Page 265: ...varna motorcycles com 24 8 Fork Fork part number 24 18 7P 57 Fork WP Performance Systems Up Side Down 4860 MXMA 4CS Compression damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring length with preload spacer s 475 mm 18 7 in Spring rate Weight of rider 65 75 kg 143 165 lb 4 6 N mm 26 3 lb in Weight of rider 75 85 k...

Page 266: ...ng tor ues 18 18 7P 57 WP Performance Systems 5018 DCC Link 17 clicks 15 clicks 13 clicks 2 5 turns 2 turns 1 5 turns 17 clicks 15 clicks 13 clicks 7 mm 0 28 in 45 N mm 257 lb in 48 N mm 274 lb in 51 N mm 291 lb in 247 mm 9 72 in 247 mm 9 72 in 252 mm 9 92 in 10 bar 145 psi 40 mm 1 57 in 110 mm 4 33 in 477 mm 18 78 in Shock absorber fluid SAE 2 5 50180751S1 p 281 Screw air intake temperature sen E...

Page 267: ...lever to angle lever Nut swingarm pivot Nut rear wheel spindle M6 M6 M6 M6 M6 M6 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M10 M10 M10 M10 M10 M10 M12 M14x1 5 M14x1 5 M14x1 5 M16x1 5 M20x1 5 24 TECHNICAL DATA 10 Nm 7 4 lbf ft 6 Nm 4 4 lbf ft 4 Nm 3 lbf ft 14 Nm 10 3 lbf ft 14 Nm 10 3 lbf ft 5 Nm 3 7 lbf ft 10 Nm 7 4 lbf ft 20 Nm 14 8 lbf ft 35 Nm 25 8 lbf ft 12 Nm 8 9 lbf ft 25 Nm 18 4 lbf f...

Page 268: ...24 TECHNICAL DATA Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Screw in nozzles cooling system M20x1 5 12 Nm 8 9 lbf ft Loctite 243 266 ...

Page 269: ...ing cleaning 1 111111111111111 401061 01 Close off the exhaust system to prevent water from entering First remove coarse dirt particles with a gentle spray of water Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to the dry vehicle always rinse with wat...

Page 270: ...25 CLEANING 268 Preserving materials for paints metal and rubber p 283 Treat all plastic parts and powder coated parts with a mild cleaning and care agent ...

Page 271: ...rvice repairs or replacements are necessary you should do this during the storage period less workshop overload In this way you can avoid long workshop waiting times at the start of the new season 1111 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Refuel Clean the motorcycle p 267 Change the engine oil and oil filter clean the oil screen p...

Page 272: ... short time only Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and the exhaust system to rust Preparin for use after stora e 401059 01 Install the battery p 130 Remove the motorcycle from the lift stand p 12 Perform checks and maintenance measures when preparing for use Make a test ride ...

Page 273: ... a p 110 I O I I I Check the tire air pressure 0 p 110 I O I I I Check the wheel bearing for play p 111 I I I I Check the wheel hubs I I I I Check the rim run out 0 I I Check the spoke tension 0 p 112 0 I I I I Check the chain rear sprocket engine sprocket and chain guide p 120 I I Check the chain tension I p 119 0 I I Grease all moving parts e g hand lever chain and check for smooth operation I I...

Page 274: ...urs Once after 10 operating hours Change the front brake fluid p 141 Change the rear brake fluid p 148 Change the hydraulic clutch fluid a p 236 Lubricate the steering head bearing p 35 Perform a fork service p 18 Service the shock absorber p 60 Change the fuel filter a p 102 Perform minor engine service including removing and installing the engine Change spark plug and spark plug connector Change...

Page 275: ...27 SERVICE SCHEDULE 273 ...

Page 276: ...16 1 j X7 NfC 2 S 2 C10 S 2 1 FC 2 X7 1 I m lll P 6 5 6 I I 521 l x19 r R 4 K 4 r K 4 rBR 4 1 X19 M10 II I iAF 4 i X17 II G101 1 1 I X30 2 i I lZ 3 1 X18 I 1 1 t X1 N iEB 4 ij EB 4 I 6 1 l a 2 F1 4 l a 2 F1 HlJSCl l rna FC 350 HQV 2016 1 3 j r 11 ...

Page 277: ... 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 28 WIRING DIAGRAM 275 ...

Page 278: ... 33 t t HY 33 HY 33 520 1 X16 6 I 1 X16 6 1 X16 I I 6 1 X16 t i i f is I I t X S BF 1 dA 1 E I X295 l11AP 6 1 t4 i fr12 a P25 l x2 iCX 2 W 2 W 2 CX 2 1 X2 1 xJ f1 2 Hl 2 1 x 3 f 0 0 X 3 0 1 rh 151515 I 1 xs l GA 3 GA 3 1 x 5 l l 1 FS a 1 FB at FC 350 HQV 2016 HUSQ l rna I l I I I I I 0 r 11 ...

Page 279: ...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 28 WIRING DIAGRAM 277 ...

Page 280: ... X16 X16 X16 a I t I I J a f t t 1 x12 l x11 _841 fV 2 1CR 1 B21 EE 1 t R51 I f1 x1l I HV 2 11 X12 _il s I I FC 350 HQV 2016 I 3 I 4 5 11 X16 i I I 1 1 t l X10 NIF 2 AT 2 B37 e 5 I 6 7 8 l l X16 X16 t I 1 m 11 ru X16 X16 r I I I J l i r x20 X14 X9 NJM 3 AP B NCM 2 U3 B26 B12 r B34 AP 6 lM 2 1 r u3 I 4 l g B B I I I I 11 I I IA f Is I IE I I I 6 7 I II ...

Page 281: ... B37 Crankshaft position sensor B41 Manifold absolute pressure sensor cylinder 1 B43 Throttle position sensor 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 28 WIRING DIAGRAM 279 ...

Page 282: ...protection to at least I 25 C 13 F The mixture ratio must be adjusted to the necessary antifreeze protection Use distilled water if the coolant needs to be diluted The use of premixed coolant is recommended Observe the coolant manufacturer specifications for antifreeze protection dilution and miscibility compatibility with other coolants Recommended supplier Bel Ray Moto Chill Racing Coolant En in...

Page 283: ...that exhibit the corresponding properties Super unleaded ROZ 95 RON 95 PON 91 Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info I Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100...

Page 284: ...Waterproof Grease Lubricant I158 Recommended supplier Lubcon Turmogrease PP 300 Lubricant 14034 Recommended supplier WP Performance Systems WP Racing Grease IPR 2 Lubricant 625 Recommended supplier Molykote 33 Medium Lubricant T152 Recommended supplier Bel Ray Molylube Anti Seize Lubricant T159 Recommended supplier Bel Ray MC 11 Offroad chain spray Guideline Recommended supplier Bel Ray Blue Tac C...

Page 285: ...nded supplier Bel Ray Foam Filter Oil Preserving materials for aints metal and rubber Recommended supplier Bel Ray Silicone Detailer Protectant Spray Universal oil s ra Recommended supplier Bel Ray 6 in 1 30 AUXILIARY SUBSTANCES 283 ...

Page 286: ...0029013006 I 00029013006 H00505 01 Bleeding device Art no 00029013100 00029013100 H00518 01 EU batte charger XCharge rofessional Art no 00029095050 Feature EU safety plug Nominal voltage 230 V Mains fuse 16A Power cable length 5 m 16 ft approx Charger cable 5 m 16 ft H01065 01 length approx 284 ...

Page 287: ...l H01065 01 Art no 00029095052 Feature UK safety plug Nominal voltage Mains fuse Power cable length approx Charger cable length approx rofessional H01065 01 H00525 01 Art no 00029095053 Feature CH plug Nominal voltage Mains fuse Power cable length approx Charger cable length approx Art no 45129075000 31 SPECIAL TOOLS 120V 32 A 5 m 16 ft 5 m 16 ft 230V 16 A 5 m 16 ft 5 m 16 ft 230V 16 A 5 m 16 ft 5...

Page 288: ...OOLS Puller Art no 46129021000 46129021000 H01519 01 S ring hook Art no 50305017000 50305017000 H00973 01 S ringe Art no 50329050000 50329050000 H00565 01 Lock ring lier Art no 51012011000 51012011000 H00572 01 286 ...

Page 289: ...129003000 r 51129003000 H00575 01 Puller Art no 58429037037 Feature I Inside diameter I 37 5 mm 1 476 in 58429037037 H00596 01 Tool bracket Art no 58429089000 2x 58429089000 H00603 01 Pressing tool Art no 58429091000 58429091000 H00604 01 287 ...

Page 290: ... 01 H00606 01 H00610 01 H00616 01 Art no 58429092000 Art no 58429094000 Feature Torque Open ended bit Open ended bit Open ended bit Open ended bit Bit diameter Art no 59029019000 Art no 59029041100 Feature I 5 piece 3 15 Nm 2 2 11 1 lbf ft 3 9 mm 0 154 in 4 9 mm 0 193 in 5 5 mm 0 217 in 6 8 mm 0 268 in 5 9 mm 0 232 in I 0 10 0 25 mm 0 0039 0 0098 in ...

Page 291: ...00 H00628 01 Hose clam lier 60029057000 H00650 01 Testing hose 61029093000 H00659 01 Art no 60029012000 Feature 31 SPECIAL TOOLS I 0 025 0 175 mm 0 00098 0 00689 in Art no 60029015000 Feature Height Diameter Art no 60029057000 Art no 61029093000 80 mm 3 15 in 57 125 mm 2 24 4 92 in 289 ...

Page 292: ... 61029094000 4x D 61029094000 H00660 01 Release device for timing chain tensioner Art no 61229021000 61229021000 H00675 01 Crankshaft ressing tool Art no 75029047000 75029047000 H00714 01 Protection ca Art no 75029090000 75029090000 H00726 01 290 ...

Page 293: ...g tool insert 77229008000 H00750 01 Valve stem seals lier 77229010000 H00752 01 Limit auge 77229026000 H00753 01 Art no 77229001044 Art no 77229008000 Art no 77229010000 Art no 77229026000 Feature I Diameter 31 SPECIAL TOOLS I 5 55 mm 0 2185 in 291 ...

Page 294: ...ston ring lock Art no 77229030000 77229030000 H00754 01 Protection ca Art no 77229031000 77229031000 H00755 01 Se arator late Art no 77229032000 77229032000 H00756 01 Ad ustment bush bridge Art no 77229050044 77229050044 H00759 01 292 ...

Page 295: ...H00764 01 Crankshaft ressing tool insert 79029008000 H00801 01 Insert for valve s ring lever 79029060000 H00803 01 Art no 77229172000 Feature Drive Hexagonal part Length Art no 77329006000 Art no 79029008000 Art no 79029060000 31 SPECIAL TOOLS 3 8 in 14 mm 0 55 in 130 mm 5 12 in 293 ...

Page 296: ...lier Art no 79029083000 79029083000 H00804 01 Holder and fitting for work stand 2x Art no 79229002000 79229002000 H01127 01 Se arator late Art no 79229009000 79229009000 H00807 01 Extractor Art no 79229032044 79229032044 H00808 01 294 ...

Page 297: ...047 01 Lift stand 81329955100 H00985 01 Hook wrench T106S H00841 01 Art no 79229048000 Art no 80329001000 Art no 81329955100 Feature Height Load Art no T106S Feature I Diameter 31 SPECIAL TOOLS 315 425 mm 12 4 16 73 in s 150 kg 5 331 lb I 68 75 mm 2 68 2 95 in 295 ...

Page 298: ...unting sleeve T1204 Calibrating unit T1205 296 H00842 01 H00844 01 H00878 01 H00879 01 Art no T107S Art no T120 Feature I Diameter Art no T1204 Feature I Diameter Art no T1205 Feature I Diameter I 8 mm 0 31 in I 25 5 30 5 mm 1 004 1 201 in 118 mm 0 71 in ...

Page 299: ...1 01 Mounting sleeve T1215 H00886 01 Pressing tool T1216 H00887 01 Art no T1206 Feature I Diameter Art no T1207S Art no T1215 Feature I Diameter Art no T1216 Feature I Diameter 31 SPECIAL TOOLS 115 30 mm 0 59 1 18 in 118 mm 0 71 in 138 49 mm 1 5 1 93 in 297 ...

Page 300: ...ting sleeve Art no T1401 Feature y I Diameter I 48 mm 1 89 in T1401 H00894 01 Clam ing stand Art no T1403S 2x Feature Diameter 48 mm 1 89 in Diameter 60 mm 2 36 in T1403S H00896 01 Mounting tool Art no T14040S Feature I Diameter I 48 mm 1 89 in T14040S H00922 01 298 ...

Page 301: ... tool T1504 H00899 01 Art no T14047 Feature Drive Narrow diameter Wide diameter Art no T14049S Feature Diameter Diameter Art no T14051 Feature I Diameter Art no T1504 Feature I Diameter 31 SPECIAL TOOLS 1 2 in 34 mm 1 34 in 42 7 mm 1 681 in 8 mm 0 31 in 24 8 mm 0 976 in I 50 mm 1 97 in 118 mm 0 71 in 299 ...

Page 302: ...31 SPECIAL TOOLS Mounting tool Art no T150S T150S H00852 01 Filling tool 2x 3x Art no T170S1 T170S1 H00855 01 300 ...

Page 303: ... intervals are demanded for automobile engines the focus for motorcycle engines is on high performance at high engine speeds In most motorcycle engines the transmission and clutch are lubricated with the same oil The JASO 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 according to thei...

Page 304: ...33 LIST OF ABBREVIATIONS Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly 302 ...

Page 305: ...city Engine oil 164 245 262 Cartridge of fork legs assembling 29 of fork legs disassembling 21 Chain checking cleaning 120 123 Chain guide checking 120 Chain tension adjusting 119 checking 119 Characteristic map of the throttle response adjusting 46 Charging voltage checking 132 Chassis number 10 Cleaning 267 268 Clutch fluid level checking correcting 235 fluid changing 236 Clutch lever basic posi...

Page 306: ...g on the individual parts clutch checking timing train checking Engine assembly 250 198 200 197 206 204 camshafts installing 227 clutch basket installing 221 304 clutch cover installing 222 clutch discs installing 222 clutch push rod installing 234 crankshaft installing 214 cylinder head installing 226 engine removing from the engine assembly stand 234 force pump installing 218 gear position senso...

Page 307: ...mbling 29 cartridge disassembling 21 checking 25 compression damping adjusting 14 disassembling 18 dust boots cleaning 15 fork service performing 18 hydrostop unit assembling 27 hydrostop unit disassembling 24 installing 16 piston rod assembling 27 piston rod disassembling 22 rebound damping adjusting 14 removing 16 seal ring retainer assembling 26 seal ring retainer disassembling 24 spring removi...

Page 308: ...sting 51 Riding sag adjusting 54 Right side cover installing 94 removing 94 Rubber grips checking 43 s Seal ring retainer fork legs assembling 26 fork legs disassembling 24 Seat mounting 95 removing 94 Service schedule 271 273 Servicing the shock absorber 60 Shock absorber damper assembling 71 damper bleeding and filling 73 damper checking 66 damper disassembling 62 damper filling with nitrogen 77...

Page 309: ...ging 83 checking 79 Technical data capacities 262 chassis 262 chassis tightening torques 264 electrical system 263 engine 258 engine tolerance wear limits 259 engine tightening torques 260 fork 263 shock absorber 264 tires 263 Throttle cable play checking 44 Throttle cable routing checking 43 Tire air pressure checking 110 Tire condition checking 110 Type label 10 Valve clearance checking 252 Warr...

Page 310: ...11111111111111111111IIIIIIIIIIII 3403032en 05 2017 Husqvarna MOTORCYCLES Husqvarna Motorcycles GmbH fiiiHiAvl StallhofnerstraBe 3 5230 Mattighofen Austria llmi LZZa O www husqvarna motorcycles com __ __ Photo Mitterbauer Husqvarna Motorcycles GmbH ...

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