Husqvarna FC 450 2014 Repair Manual Download

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FORK, TRIPLE CLAMP

6. 7

Removin the fork le s

Installing the fork legs

B00300-11

Preparatory work

- Raise the motorcycle with a lift stand. (.- p. 10)
- Remove the front wheel. (.- p. 92)

Main work

- Remove screws

and take off the clamp.

- Remove screws

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 (5). Take out the left fork leg.
- Unscrew screws

C,.

Take out the right fork leg.

Main work

- Position the fork legs.

✓ Bleeder screws

face forward.

•

Info

Grooves are milled into the side of the upper end of the fork legs. The sec

ond milled groove (from the top) must be flush with the top edge of the

upper triple clamp.

- Tighten screws

Guideline

Screw, top triple clamp

- Tighten screws (5).

Guideline

Screw, bottom triple clamp

- Position the brake caliper. Mount and tighten screws

@).

Guideline

Screw, front brake caliper M8

25 Nm

(18.4 lbf ft)

17 Nm (12.5 lbf ft)

12 Nm (8.9 lbf ft)

Loctite

243

™

- Position the brake line and clamp. Mount and tighten screws

C,.

Finishing work

- Install the front wheel. (.- p. 92)

Summary of Contents for FC 450 2014

Page 1: ...PIONEERING SINCE 1903 REPAIR MANUAL2014 FC 450 EU Art no 3403000en Husqvarna MOTORCYCLES ...

Page 2: ......

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

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

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

Page 6: ...ine case 170 Installing the freewheel gear 171 Installing the primary gear 171 Installing the force pump 171 Installing the locking lever 172 Installing the shift drum locating unit 173 18 17 5 12 Installing the shift shaft 17 5 13 Installing the starter idler gear 17 5 14 Installing the torque limiter 17 5 15 Installing the outer clutch hub 17 5 16 Installing the clutch discs 17 5 17 Installing t...

Page 7: ...orques 204 25 CLEANING PROTECTIVE TREATMENT 206 25 1 Cleaning the motorcycle 206 26 STORAGE 207 26 1 Storage 207 26 2 Preparing for use after storage 207 27 SERVICE SCHEDULE 208 27 1 Service schedule 208 27 2 Service work as additional order 209 28 WIRING DIAGRAM 210 28 1 Page1 of3 210 28 2 Page2 of3 212 28 3 Page3 of3 214 29 SUBSTANCES 216 30 AUXILIARY SUBSTANCES 217 31 SPECIAL TOOLS 219 32 STAND...

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

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

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

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

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

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

Page 14: ...ing of the fork Info The hydraulic rebound damping determines the fork suspension behavior Remove protection caps O Turn adjusting screws 8 clockwise all the way Info I Adjusting screws 8 are located at the bottom end of the fork legs Make the same adjustment on both fork legs Turn counterclockwise by the number of clicks corresponding to the fork type Guideline Rebound damping Comfort Standard Sp...

Page 15: ...se and clean them with brake cleaner when necessary Clean and oil the dust boots and inside fork tube of both fork legs I Universal oil spray p 218 Press the dust boots back into their normal position Remove excess oil Finishing work Position the fork protection p 13 Remove the motorcycle from the lift stand p 10 Remove screws O and take off the clamp Remove screws 8 on the left fork leg Push the ...

Page 16: ...rk leg Unscrew screws C Take out the right fork leg Main work Position the fork legs Bleeder screws O face forward Info I Grooves are milled into the side of the upper end of the fork legs The sec ond milled groove from the top must be flush with the top edge of the upper triple clamp Tighten screws 8 Guideline I Screw top triple clamp Tighten screws 5 Guideline I Screw bottom triple clamp Positio...

Page 17: ... the right fork leg Mount and tighten the screws Guideline I Remaining screws chassis Finishing work Install the fork legs p 14 Install the front wheel p 92 I10Nm 7 41bf ft Conducting major fork service Info The steps are identical for both fork legs u C 200974 01 Condition The fork legs are disassembled Disassemble the fork legs p 16 Disassemble the cartridge p 19 Disassemble the piston rod p 21 ...

Page 18: ...r fork service p 25 Assemble the fork legs p 31 Disassembling the fork legs Info The steps are identical for both fork legs Condition The fork legs are disassembled Remove protection cap 6 Note down the present state of rebound damping O and compression damp ing 8 Fully open the adjusters of the rebound and compression damping Clamp the fork leg in the area of the lower triple clamp I Clamping sta...

Page 19: ...xle clamp Guideline I Use soft jaws Loosen rebound adjustment Info I Do not use an impact wrench Place a fluid collector beneath it as usually some oil will drain out The rebound adjustment cannot be removed yet Press the cartridge against the spring and mount special tool D on the piston rod I Support tool T14020 p 230 Hold nut and remove the rebound adjuster Press the cartridge against the sprin...

Page 20: ...screwdriver can be posi tioned Warm the outer tube in area 9 of the lower sliding bushing Guideline 1 so 0 c 122 F Pull the outer tube forcefully off of the inner tube Info The lower sliding bushing C must be pulled out of its bearing seat Remove upper sliding bushing 48 Info I Without using a tool carefully pull the stack apart by hand Take off the lower sliding bushing Take off support ring 48 T...

Page 21: ...p 16 Main work Remove adjusting tube O and nut 8 Clamp the cartridge into a vise Info I Use soft jaws Remove filling screw D Pierce the membrane with the needle of the special tool I Nitrogen charging tool T14019 p 230 The pressurized nitrogen is bled off Loosen and remove screw cap 8 with the membrane holder I Pin wrench T103 p 227 Unclamp the cartridge 19 ...

Page 22: ...idge upside down Guideline I Use soft jaws Heat the cartridge in area f of pilot bushing Guideline 1100 C 212 F Loosen the screw sleeve and remove the piston rod Remove spring guide s and ring Remove guide ring Remove filling screw and O ring Press check valve G against the spring and remove it 20 ...

Page 23: ...assemble the cartridge p 19 Main work Remove screw sleeve O and washer 8 from the piston rod Degrease the piston rod Clamp the piston rod with the special tool as far up as possible I Clamping stand T14016S p 230 Remove nut Remove rebound shim stack C Remove rebound piston 0 Remove the piston ring from the piston Remove compression shim stack D Remove spring 21 ...

Page 24: ...ork legs Preparatory work Disassemble the fork legs p 16 Disassemble the cartridge p 19 Main work 22 Clamp the screw cap with the membrane holder and the special tool into a vise Guideline I Use soft jaws I Pin wrench T103 p 227 Info I Only tighten the vise lightly Remove compression holder Q Remove membrane Unclamp the special tool Remove 0 ring 8 Clamp the open end wrench in a vise Position comp...

Page 25: ...00867 10 Preparatory work Disassemble the forklegs p 16 Disassemble the cartridge p 19 Disassemble the piston rod p 21 Main work Remove 0 ring O Remove lockring 8 Remove ring 8 Screw the special tool onto the screw sleeve I Threaded bushing T14023 p 231 The special tool must have an overhang to protect the thread I Overhang 11 mm 0 04 in Pry out seal ring C being sure only to brace the lever again...

Page 26: ... the inner tube Measure the run out of the inner tube I Inner tube run out I s 0 20 mm S 0 0079 in If the measured value is greater than the specified value Change the inner tube Measure the inside diameter of the outer tube at several locations I Inside diameter of the outer tube I s 49 20 mm s 1 937 in If the measured value is greater than the specified value Change the outer tube Check the oute...

Page 27: ...d Measure the outside diameter of the piston rod at several locations I Outside diameter of the piston rod I 11 965 mm 0 47106 in If the measured value is less than the specified value Replace the piston rod Measure the run out of the piston rod I Run out of the piston rod I 5 0 40 mm 5 0 0157 in If the measured value is greater than the specified value Replace the piston rod Checking the fork leg...

Page 28: ...e sliding bushing If the bronze colored layer f under the sliding layer G is visible or the sur face is rough Replace the sliding bushing Check the spring length Guideline I Spring length with preload spacer s I 490 mm 19 29 in If the measured value is greater than the specified value Reduce the thickness of the preload spacers If the measured value is less than the specified value Increase the th...

Page 29: ... the new pilot bushing a number of times I Calibrating unit T14021 p 230 The pilot bushing is calibrated Finishing work Assemble the screw sleeve p 27 Assemblin the screw sleeve Info The steps are identical for both fork legs 200866 11 Mount and lubricate O ring O I Lubricant T158 p 217 Mount ring Mount lock ring fD Info The seal ring is mounted when the piston rod is assembled Assembling the scre...

Page 30: ...ssion piston I M6x0 5 I 3Nm 2 2 lbf ft The collar centers the rebound washer and the spring Check the freedom of movement of the rebound washer against the spring Secure the nut by locking Mount and grease O ring I Lubricant T158 p 217 Clamp the screw cap with the membrane holder and the special tool into a vise I Pin wrench T103 p 227 Info I Only tighten the vise lightly Mount membrane Mount and ...

Page 31: ...th 1200 grit sandpa per Clean the rebound piston Wrap the piston ring around the shaft of a screwdriver before mounting Mount the piston ring Lubricate the piston ring I Fork oil SAE 4 48601166S1 p 216 Mount rebound piston 0 Guideline ViewG ViewC Mount rebound shim stack D Info Rebound piston from above Rebound piston from below Align triangular plates exactly with the openings of the rebound pist...

Page 32: ...ng guide C and ring Clamp the cartridge in a bench vise Guideline I Use soft jaws Push the piston rod into the cartridge Info I Check that the piston ring is correctly seated Slide washer Cs onto the piston rod with the open side forward Place the special tool onto the piston rod I Mounting sleeve T14029 p 231 Grease seal ring and slide onto the piston rod with the open side forward Remove the spe...

Page 33: ...ll the cartridge p 34 Fill the cartridge with nitrogen p 36 Mount adjusting tube G i I M41x1 Screw nut G all the way on with the collar facing forward Info I 30 Nm 22 1 lbf ft I The nut must be screwed tightly against the stop Do not use a tool The steps are identical for both fork legs 200669 10 Preparatory work Check the fork legs p 24 Assemble the screw cap with the membrane holder p 27 Assembl...

Page 34: ... sandpaper I Fork oil SAE 4 48601166S1 r p 216 Slide on lower sliding bushing Ci Mount upper sliding bushing C Info Gently pull them apart without using a tool Slide on the outer tube Warm up the outer tube in area f of the lower sliding bushing Guideline 1 so 0 c 122 F Hold the lower sliding bushing with the longer shoulder of the special tool I Mounting tool T14040S r p 232 Press the outer tube ...

Page 35: ...juster The rebound adjuster must reach the stop before the piston rod turns with it In case of tight piston rod threads it must be held to keep it from turning X If the rebound adjuster is not turned all the way to the stop the rebound damping cannot be correctly adjusted Hold onto nut and tighten the rebound adjuster Guideline I Rebound adjuster on the piston rod I M12x1 I 30 Nm 22 1 lbf ft I Pre...

Page 36: ...umber of clicks corresponding to the fork type Guideline Rebound damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Alternative 2 Warning Danger of accident Modifications to the suspension setting may seriously alter the handling characteristic Extreme modifications to the suspension setting may cause a serious dete...

Page 37: ...Connect adapter to the filling port of vacuum pump 0 I Vacuum pump T1240S p 229 Clamp the control lever as shown in the figure Control lever External tank CD is set to Closed Damper e is set to Vac uum and Oil reservoir 0 is set to Vacuum Activate On Off switch D The suction process begins Pressure gauge drops to the required value 0 bar Vacuum gauge drops to the required value 10 mbar When the va...

Page 38: ... cartridge in a vise using soft jaws Info I Clamp the cartridge only lightly Connect the connector of the special tool to the pressure regulator of the nitrogen bottle Nitrogen charging tool T14019 or p 230 Filling gas nitrogen Adjust the pressure regulator of the nitrogen bottle Guideline I Gas pressure 11 2 bar 17 psi Pierce the membrane with the needle of the special tool Open valve O Fill the ...

Page 39: ... fork legs p 14 Remove the start number plate p 88 Remove the front fender p 88 Main work Take off cable holder O in front of the left radiator Remove screw 8 Remove screw 8 Take off the top triple clamp with the handlebar and set it aside Info I Protect the components against damage by covering them Do not bend the cables and lines Remove O ring e Remove protective ring 0 Take out the lower tripl...

Page 40: ...sitioned Slide on protective ring 8 and O ring Position the upper triple clamp with the handlebar Mount screw C but do not tighten yet Position the fork legs Bleeder screws 0 face forward Info I Grooves are milled into the side of the upper end of the fork legs The sec ond milled groove from the top must be flush with the top edge of the upper triple clamp Fully tighten screws D Guideline I Screw ...

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

Page 42: ...ork Remove the motorcycle from the lift stand p 10 Changing the steering head bearing ff Preparatory work Raise the motorcycle with a lift stand p 10 Remove the front wheel p 92 Remove the fork legs p 14 Remove the start number plate p 88 Remove the front fender p 88 Remove the lower triple clamp p 37 Main work Remove the lower bearing race O using a suitable tool Press in the new bearing race all...

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

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

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

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

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

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

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

Page 50: ...d parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Info Before changing the spring preload make a note of the present setting e g by measuring the length of the spring Preparatory work Raise the motorcycle with a lift stand p 10 Remove the seat p 79 Remove the right side cover p 78 Remove the main silencer p 74 Remove the shock abs...

Page 51: ...ider 65 75 kg 143 165 lb Weight of rider 75 85 kg 165 187 lb Weight of rider 85 95 kg 187 209 lb Info 54 N mm 308 lb in 57 N mm 325 lb in 60 N mm 343 lb in I The spring rate is shown on the outside of the spring Finishing work Install the shock absorber p 50 Install the main silencer p 74 Install the right side cover p 79 Mount the seat p 79 Check the static sag of the shock absorber p 47 Check th...

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

Page 53: ...eline 30 Nm 22 1 lbf ft 30 Nm 22 1 lbf ft I Nut linkage lever to angle lever I M14x1 5 Mount and tighten screw Guideline Screw bottom shock absorber Finishing work M10 Install the main silencer p 74 Install the right side cover p 79 Mount the seat p 79 60 Nm 44 3 lbf ft Remove the motorcycle from the lift stand p 10 9 11 Checkin the shock absorber linkage Preparatory work Raise the motorcycle with...

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

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

Page 56: ...no longer under tension I Hook wrench T106S p 227 Remove ring 8 Remove spring retainer and intermediate washer C Remove the spring Disassembling the dam er 0 Preparatory work Remove the spring p 54 Main work Note down the current state of rebound damping O and compression damp ing 8 Completely open the adjusters of the rebound and compression damping Remove rubber cap of the reservoir Open screw C...

Page 57: ...ssembly tool T1216 p 229 Remove lock ring Info Do not scratch the inner surface Remove the piston rod Remove adjusting ring with the intermediate washer Drain the oil Remove compression adjuster Remove the spring and piston iston rod Preparatory work Remove the spring p 54 Disassemble the damper p 54 55 ...

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

Page 59: ...shing O onto the special tool I Press drift T1504 r p 232 Position the pilot bushing in the seal ring retainer using the special tool I Press drift T1504 r p 232 Support seal ring retainer 8 with sleeve f of the special tool Press the pilot bushing all the way in I Assembly tool T150S r p 232 Lubricate the special tool Shock absorber fluid SAE 2 5 50180751S1 r p 216 Calibration pin T1205 r p 228 S...

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

Page 61: ...ecial tool f underneath and press out heim joint D with special tool I Pressing tool T1207S p 229 Position the new heim joint O and the special tool into a vise as shown Guideline I Use soft jaws I Pressing tool T1206 p 228 Press the heim joint all the way in Press the heim joint against the lock ring using the special tool I Pressing tool T1207S p 229 Mount the second lock ring 8 Mount seal rings...

Page 62: ...I Mounting sleeve T1204 p 228 Lubricate the sealing lip of the dust boot I Lubricant T625 p 217 Mount washer Position washer Don seal ring e Grease seal ring 8 and mount with the washer facing downward I Lubricant T511 p 217 Mount centering disk Mount rebound rubber 0 Lubricate the groove of the O ring I Lubricant T158 p 217 Mount O ring Mount spring 60 ...

Page 63: ...nting sleeve T1215 p 229 Grease the dust boot and push seal ring retainer onto the piston rod I Lubricant T625 p 217 Remove the special tool Mount rebound washer 8 with the cut out facing downward Mount the compression shim stack 0 with the smaller shims facing downward Sand both sides of piston D on a surface plate using 1200 grit sandpaper Clean the piston Assemble the piston Guideline ViewO Pis...

Page 64: ...cate the threads I Lubricant T159 p 217 Mount the piston with the spring Mount and tighten the compression adjuster 0 Guideline I Compression adjuster Clamp the damper in a bench vise Guideline I Use soft jaws I M31x1 Mount adjusting ring with the intermediate washer Info 62 I 45 Nm 33 2 lbf ft I I 45 Nm 33 2 lbf ft I The adjusting ring cannot be mounted after the piston rod is mounted Fill the da...

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

Page 66: ...99 10 Remove the screw of the filling port Install adapter O on the damper Info I Tighten only hand tight without the use of tools Connect the adapter O to connector of the vacuum pump I Vacuum pump T1240S p 229 Clamp the damper with soft jaws or hold it as shown in the figure Info I Clamp the damper only lightly The filling port must be at the highest point The piston rod slides in and out during...

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

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

Page 69: ...eight of rider 75 85 kg 165 57 N mm 325 lb in 187 lb Weight of rider 85 95 kg 187 60 N mm 343 lb in 209 lb Mount intermediate washer 8 and spring retainer C Mount ring C Alternative 1 Tension the spring to the prescribed amount by turning the adjusting ring Guideline I Spring preload I Hook wrench T106S p 227 Alternative 2 Warning 112 mm 0 47 in Danger of accident Modifications to the suspension s...

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

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

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

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

Page 74: ...ft seal rings CD Mount bushing Grease the shaft seal rings I Long life grease p 217 Position collar bushings O with the shoulder facing inward Finishing work Install the swingarm p 69 Install the rear wheel p 95 Remove the motorcycle from the lift stand p 10 72 ...

Page 75: ...move screw Take off manifold Position the manifold Mount screw O but do not tighten yet Guideline I Screw manifold holder Attach springs I Spring hook 50305017000 p 220 Tighten screw O Guideline I Screw manifold holder 73 115 Nm 11 1 lbf ft I 115 Nm 11 1 lbf ft I ...

Page 76: ...t Reconnect spring Tighten screws O Guideline I Remaining screws chassis Finishing work Install the right side cover p 79 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down Do not touch hot components Info Over time the fibers of the glass fiber yarn escape and the damp...

Page 77: ...ff of inner tube D Clean the parts that need to be reinstalled and check for damage Mount new glass fiber yarn filling 0 on inner tube D Slide O ring eand outer tube CD over the glass fiber yarn filling 0 Insert O ring and silencer cap O into outer tube CD Mount and tighten all of the screws Finishing work Install the main silencer p 74 Install the right side cover p 79 75 ...

Page 78: ...ncreased wear 11 4 Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations lnstallin the air filter Preparatory work Remove the air filter box lid or p 76 Main work Push air filter holder O toward the air filter at position f and detach it at end G Swing the air filte...

Page 79: ...ilter with fuel or petroleum since these substances attack the foam Sealing the air filter box 401559 01 Preparatory work Remove the air filter box lid p 76 Remove the air filter p 76 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly I Air filter cleaning agent p 217 Info I Only press the air filter to dry it never wring it out Oil the dry air filter ...

Page 80: ...apors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that has been contaminated with fuel Store fuel properly in a suitable canister and keep away from children Warning Environmental hazard Improper handling of fuel is a dan...

Page 81: ...hicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately The fuel in the fuel tank expands when warm and may emerge if overfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with t...

Page 82: ...e Disconnect the plug in connection of the fuel line Mount wash cap set f I Wash cap set 81212016100 Remove screws D with the collar bushing Remove screw C with the rubber bushing Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spi...

Page 83: ...r into the fuel line Dirt in the fuel line clogs the injection valve Lubricate the O ring and connect plug in connection 8 of the fuel line Info I Route the cable and fuel line at a safe distance from the exhaust system Finishing work Mount the seat r p 79 Checking the fuel ressure Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and alway...

Page 84: ...clear Change the fuel filter p 84 Change the fuel pump p 82 3 3 3 7 bar 48 54 psi Stop the Function test of fuel pump control actuator test by pressing the Quit button Remove the special tools Join the fuel hose connection 82 12 10 Changing the fuel pump m A Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine ...

Page 85: ... container Remove the seat p 79 Remove the fuel tank p 79 Main work Remove nut O with the gasket Remove fuel connection i with the gasket Remove screws CD Pull out the fuel pump Position the fuel pump Mount fuel connection i with the gasket but do not tighten yet Mount and tighten nut O with the gasket Guideline 83 I Nut fuel pump fastener I M12x1 75 15 Nm 11 1 lbf ft Tighten fuel connection i Gui...

Page 86: ... hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that has been contaminated with fuel Store fuel properly in a suitable c...

Page 87: ...hose clamps C Remove fuel filter 0 Press locking mechanism D Pull back fuel pump housing Change fuel screen Mount the fuel pump housing Mount fuel filter 0 Arrow 6 points away from the fuel pump Mount hose clamps C I Hose clamp pliers 60029057000 p 222 85 ...

Page 88: ...ning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contamina...

Page 89: ...d inhaling them may result in unconsciousness and or death 87 When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and check the response ...

Page 90: ...d Remove the front fender Main work Position the front fender Mount and tighten screws O and Guideline I Remaining screws chassis 110Nm 7 41bf ft Finishing work Install the start number plate p 89 13 3 Removing the start number plate Take brake line O out of the brake line guide Remove screw Take off the start number plate 88 ...

Page 91: ...R Installing the start number late Position the start number plate Mount and tighten screw O Guideline I Remaining screws chassis 110 Nm 7 4 lbf ft The holding lugs engage Position brake line 8 in the brake line guide 89 ...

Page 92: ...Worn tires have a negative effect on handling characteristics especially on wet surfaces Check the front and rear tires for cuts run in objects and other damage If the tires have cuts run in objects or other damage Change the tires Check the tread depth Info I Adhere to the legally required minimum tread depth I Minimum tread depth I 2 mm 0 08 in If the tread depth is less than the minimum tread d...

Page 93: ...table handling due to incorrect spoke tension Ensure that the spoke tension is correct Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes If the spokes are too tight they can break due to local overload Check the spoke tension regularly especially on a new motorcycle Briefly strike each spoke with the tip of a screwdriver Info I The tone frequency depends on the lengt...

Page 94: ...ush the wheel spindle out of the axle clamp Remove screw O Warning Danger of accidents Reduced braking efficiency due to damaged brake disc 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 I Do not pull the hand brake lever when the front wheel is removed Always lay the wheel down...

Page 95: ...m the lift stand r p 10 Pull the front brake and compress the fork powerfully a few times The fork legs straighten Tighten screws 8 Guideline I Screw fork stub 1 1 5 Nm 11 1 lbf ft I Removing the brake disc of the front brake Preparatory work Raise the motorcycle with a lift stand r p 10 Remove the front wheel r p 92 Main work Remove screws O Take off the brake disc Installing the brake disc of th...

Page 96: ... suitable tool Info 94 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 the new bearing D all the way using a suitable tool Info I Only press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in Grease the new shaft seal rings 8 and O and press in until they are flush...

Page 97: ...et Info I Protect the motorcycle and its attachments against damage by covering them Holding the rear wheel withdraw the wheel spindle Take the rear wheel out of the swing arm Info I Do not operate the foot brake when the rear wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged Remove spacers C Danger of accidents Reduced braking efficiency due to oil or gr...

Page 98: ... can be turned by 180 96 Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Finishing work Remove the motorcycle from the lift stand p 10 Removing the brake disc of the rear brake Preparatory work Raise the motorcycle with a lift stand p 10 Remove the rear wheel p 95 Main work Remove screws O Take off the brake disc Inst...

Page 99: ...ain tension r p 97 Finishing work Remove the motorcycle from the lift stand r p 10 Warning Danger of accidents Danger caused by incorrect chain tension If the chain is too taut the components of the secondary power transmission chain engine sprocket rear sprocket bearings in the transmission and in the rear wheel will be under additional load In addition to premature wear this can cause the chain ...

Page 100: ...hten screw O Guideline 98 I Remaining screws chassis I10Nm 7 41bf ft Condition Number of teeth 2 45 teeth Insert collar bushing D into drill hole G Position the chain guide Mount and tighten screw Tighten screw O Guideline I Remaining screws chassis 110Nm 7 4 lbf ft 14 6 8 Checking the chain rear sprocket engine sprocket and chain guide 400227 01 Preparatory work Raise the motorcycle with a lift s...

Page 101: ...rocket should be changed as well New chains wear more rapidly on old worn rear sprockets and engine sprockets Check the chain sliding guard for wear If the lower edge of the chain pin is at the level of or below the chain sliding guard Change the chain sliding guard Check that the chain sliding guard is firmly seated If the chain sliding guard is loose Tighten the chain sliding guard Guideline Scr...

Page 102: ...hain p 100 14 6 10 Cleaning the chain A Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Environmental hazard Hazard...

Page 103: ...om the lift stand p 10 Preparatory work Raise the motorcycle with a lift stand p 10 Remove the rear wheel p 95 Main work Remove screws O and 8 Remove the engine sprocket cover Have an assistant operate the rear brake Remove screw 8 with the washer Remove connecting link C of the chain Info I Cover the components to protect them against damage Take off the chain Remove engine sprocket 0 101 ...

Page 104: ...tighten screw 8 with the washer Guideline Screw engine sprocket M10 Position the engine sprocket cover Mount and tighten screw Guideline I Screw clutch slave cylinder Mount and tighten screw Guideline I Remaining screws chassis Finishing work Install the rear wheel p 95 M6 MB 60 Nm 44 3 lbf ft Remove the motorcycle from the lift stand p 10 14 6 12 Changing the rear wheel bearing Preparatory work R...

Page 105: ...o the outside Press the new bearing C all the way in from the outside to the inside Info 103 I Only press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in Clean grease and mount spacing tube 0 I Long life grease p 217 Press the new bearing C all the way in from the outside to the inside Info I Only press the bearing in via the outer ring otherwise the b...

Page 106: ...CD and press it in until it is flush Mount lock ring The lock ring engages audibly Grease the new shaft seal ring O and press it in until it is flush Finishing work Install the rear wheel p 95 Remove the motorcycle from the lift stand p 10 104 ...

Page 107: ...nctioning properly Tip I Insert the spare fuse so that it is available if needed Mount the protection caps Finishing work Install the air filter box lid p 76 Risk of injury Battery acid and battery gases cause serious chemical burns Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Keep sparks and open flames...

Page 108: ...be fully functional and completely charged Preparatory work Remove the seat p 79 Main work Pull back the positive terminal cover Start the motorcycle for a check p 11 Measure the voltage between the specified points Measuring point Plus Measuring point Ground I Charging voltage 5 000 rpm 1 1 3 5 15 0 V If the displayed value is less than the specified value 2 5 Nm 1 84 lbf ft 2 5 Nm 1 84 lbf ft Ch...

Page 109: ...V test lamp on one connector and connect it to the battery as shown in the figure Info I As the charge of the capacitor increases the test lamp becomes dimmer The lamp lights up for 0 5 2 0 s The capacitor is functional The lamp lights up for 0 5 s Change the capacitor The lamp lights up for 2 0 s Change the capacitor Discharge the capacitor with a 12 V test lamp as shown in the figure Info I As t...

Page 110: ... of open circuit I O n If the value displayed does not meet specifications Change the starter relay Mount the starter relay onto the holder and lay the cable Clamp cable 8 on the starter relay Position the cover Plug in connector O Clamp on the negative cable of the battery Finishing work Install the air filter box lid p 76 Mount the seat p 79 108 ...

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

Page 112: ...ings insert pin 0 and mount cotter pins 8 Info I Always change the brake linings in pairs Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Add brake fluid to level 6 Guideline Dimension O brake fluid level below 5 mm 0 2 in top edge of container I Brake fluid DOT 4 p 216 Position cover with membrane D Mount and tighten...

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

Page 114: ...nd rear brake according to the service schedule Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between bra...

Page 115: ...position Cover the painted parts Remove screws O Remove cover 8 with the membrane Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid Bleed syringe 50329050000 p 220 Brake fluid DOT 4 p 216 Mount bleeder cover D I Bleeder cover 00029013005 p 219 Connect the bleeding device I Bleeding device 00029013100 p 219 Open shut off valve 8 Info I Follow ...

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

Page 117: ...liper against the spokes Remove cotter pins 8 pull out pin 8 and remove the brake linings Clean the brake caliper and brake caliper support Check that leaf spring 0 in the brake caliper and sliding plate D in the brake caliper support are seated correctly Info I The arrow on the leaf spring points in the rotation direction of the brake disc Insert the new brake linings insert pin 8 and mount cotte...

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

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

Page 120: ...rew cap O with membrane and the O ring Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid Bleed syringe 50329050000 or p 220 Brake fluid DOT 4 or p 216 Mount bleeder cover 8 I Bleeder cover 00029013006 or p 219 Connect the bleeding device I Bleeding device 00029013100 or p 219 Open shut off valve fD Info I Follow the operating instructions of ...

Page 121: ...e hose of the bleeder bottle Mount the pro tection cap Lock the bleeding device Remove the bleeder cover Stand the vehicle upright Correct the brake fluid up to marking i I Brake fluid DOT 4 p 216 Mount and tighten the screw cap with the membrane and O ring Info I Clean up overflowed or spilt brake fluid immediately with water Check the foot brake lever for a firm pressure point ...

Page 122: ...cover p 78 Remove the main silencer p 74 Main work Disconnect negative cable O of the battery Remove cable binder 8 Pull the EFI control unit D from the holder and hang it to one side Disconnect plug in connectors C Remove cable binder 0 Disconnect plug in connector D Loosen hose clip Pull back the protection cap Unplug connector Remove screws Remove the intake air temperature sensor 120 ...

Page 123: ...bframe Push back hose clamp 48 Detach the vent hose Swing up the subframe and secure it Remove screw 49 Swing back the shock absorber and twist it slightly Remove springs 4D I Spring hook 50305017000 or p 220 Remove screw 48 Take off the manifold Loosen hose clips 41 Detach the radiator hoses 121 ...

Page 124: ...w Ci Take off the engine sprocket cover Remove screws Remove the cable binders Remove cable holder Take off the clutch slave cylinder and hang it to the side Info I Do not kink the clutch line Do not activate the clutch lever if the clutch slave cylinder has been removed Remove the chain connecting link Take off the chain 122 ...

Page 125: ... off the spark plug connector Loosen hose clip 123 Pull the throttle valve body toward the rear out of the intake flange and hang it to one side Remove fittings Remove the engine braces Remove the vent hose Remove spring Remove nut Remove the swingarm pivot Pull the swingarm slightly toward the rear ...

Page 126: ...Info I You should have an assistant for this step Make sure that the motorcycle is sufficiently secured against falling over Protect the frame and attachments from damage Mount screws O but do not tighten yet Guideline I Engine carrying screw Position the swingarm Insert the swingarm pivot Mount and tighten nut 8 Guideline Nut swingarm pivot Tighten screws O Guideline I Engine carrying screw Mount...

Page 127: ...he spark plug connector Position the shift lever Mount and tighten screw Guideline Screw shift lever Mount the chain M6 M8 Connect the chain with connecting link 14 Nm 10 3 lbf ft Position the clutch slave cylinder with the gasket Mount and tighten screws _ Guideline I Screw clutch slave cylinder M6 125 I 33 Nm 24 3 lbf ft I Loctite 243 10 Nm 7 4 lbf ft Position the wiring harness Mount cable bind...

Page 128: ...ble on the starter motor Mount and tighten nut 48 Guideline I Remaining nuts chassis Mount the protection cap Mount the radiator hose Position and tighten hose clips 4D Mount the radiator hoses Position and tighten hose clips 48 Slip in the manifold Mount screw 4D but do not tighten yet Guideline I Screw manifold holder M6 M8 126 10 Nm 7 4 lbf ft I 25 Nm 18 4 lbf ft I 10 Nm 7 4 lbf ft 15 Nm 11 1 l...

Page 129: ...ition the subframe Info I Watch out for the intake flange Mount and tighten screws B Guideline Screw subframe Remove screw Mount and tighten screw Guideline Screw subframe MB MB Repeat the operation on the opposite side Position the intake air temperature sensor Mount and tighten screws e Guideline I Screw intake air temperature sensor I M5 Plug in connector c Mount the protection cap 30 Nm 22 1 l...

Page 130: ...and fill in the engine oil I Engine oil 11 50 I 1 59 qt I Engine oil SAE 10W 50 p 216 Mount and tighten filler plug G Finishing work Install the main silencer p 74 Install the right side cover p 79 Install the fuel tank p 80 Mount the seat p 79 Remove the motorcycle from the lift stand p 10 Refill the coolant p 189 Execute the initialization run p 198 Take a short test ride Read out the fault memo...

Page 131: ...ial tool on the engine assembly stand Engine fixing arm 78029002000 or p 225 Engine assembly stand 61229001000 or p 223 Mount the engine on the special tool Info Have an assistant help you or use a motorized hoist Remove oil drain plug O with the magnet and seal ring Remove screw plug 8 Completely drain the engine oil Remove the long oil screen fD Remove screw plug C with the short oil screen 129 ...

Page 132: ...ark plug 309417 10 Remove clutch push rod O Remove screws O Remove the oil filter cover 8 with the O ring Pull oil filter out of the oil filter housing I Circlip pliers reverse 51012011000 or p 220 Remove screws O and take off the starter motor Remove the spark plug using the special tool I Spark plug wrench 77229172000 or p 225 130 ...

Page 133: ...er with the valve cover seal Removing the alternator cover Remove screws O Take off the alternator cover Remove locating pins 8 Take off the alternator cover gasket Positioning the engine at ignition top dead center Align camshaft marking G with marking Cs on the cylinder head Remove screw O 131 ...

Page 134: ...hain tensioner 17 3 11 Removing the camshaft Remove screw O with the washer and spring Remove screws 8 Take off the chain adjuster with the gasket Remove screw O Remove the camshaft support plate Pull the camshaft out of the bearing seats Take the timing chain off the camshaft gear Remove the camshaft ...

Page 135: ... gasket C Push the cylinder upward Info 133 I Only push 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 I If no further work is to be performed on the cylinder and piston the piston can remain in the cylinder Take off dowels 8 and cylinder base gask...

Page 136: ...ing the special tool and pull off the rotor by turning the screw in Remove the woodruff key Remove screw O Take off timing chain guide rail toward the top Remove screw 8 Remove timing chain tensioning rail C toward the top Remove screws 0 Remove the timing chain securing guide Take off the timing chain Info 134 If the timing chain is going to be used again mark the direction of travel ...

Page 137: ...f the engine case Take off the crankshaft position sensor Remove screws O Take off oil pump cover 8 of the suction pump Remove external rotor and internal rotor C Take off pin 0 Remove pin D upward Remove O ring 17 3 18 Removing the water pump cover Remove screws O Take off the water pump cover Take off the water pump cover seal 135 ...

Page 138: ... Remove screws O Take off the clutch cover Info I If work is to be performed on the water pump unscrew the nut of the water pump impeller Remove dowels Take off clutch cover gasket s Remove screws O Take off spring retainer Take off spring washer s Take off pretension ring C 136 ...

Page 139: ... hub Lock the outer clutch hub and primary gear using special tool O I Gear segment 80029004000 p 226 Remove nut Info Left handed thread Bend up the lock washer Hold the inner clutch hub with the special tool I Clutch holder 51129003000 p 221 Remove nut with the lock washer Take off inner clutch hub C and washer Ci Info I The washer usually sticks to the inner clutch hub Take off D 137 ...

Page 140: ...ar 17 3 24 Removing the shift shaft Remove the lock ring and washer Take off starter idler gear 0 Push sliding plate O away from the shift drum locating unit Remove shift shaft 8 with the washer 17 3 25 Removing the shift drum locating unit Remove screw O 138 Push away locking lever 8 from shift drum locating unit D and remove the shift drum locating unit Relieve tension from the locking lever ...

Page 141: ...e pump Unscrew O and remove together with locking lever 8 washer sleeve and spring Remove lock ring O Take off washer 8 Remove oil pump idler gear D Remove lock washer C Take off washer 0 Take off oil pump gear wheel 0 Remove pin Remove screws Take off oil pump cover 139 ...

Page 142: ...ary gear by turning the screw in Remove the special tools 17 3 29 Removing the freewheel gear Remove woodruff key O Take off freewheel gear 17 3 30 Removing the left engine case section Remove screws O Mount special tool with the appropriate screws I Case separating tool 90129048000 p 227 Info I Use the drill hole marked with 781 Tilt the left section of the engine case upward and remove the screw...

Page 143: ...f the left section of the engine case Remove spacer fD Remove dowels 8 Remove shift rails O together with upper springs 8 and lower springs Swing shift forks O to one side Info I Do not misplace the shift rollers Remove shift drum 8 Take shift forks O out of the shift grooves Info Do not misplace shift rollers 8 141 ...

Page 144: ...7 4 17 4 1 Work on individual arts Attach the special tool to the crankshaft I Protection cap 75029090000 p 224 Mount special tool O onto the engine case with suitable screws I Removal tool 78029049100 p 226 Press the crankshaft out of the bearing seat Take out crankshaft Remove the special tools Take off the right section of the engine case Work on the right section of the engine case Preparatory...

Page 145: ...s of the hot engine case section and if necessary use a suitable press drift to push the bearing from the inside to the outside all the way to the stop or so it is flush Info I 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 bear ings will be damaged when they are pressed in After the en...

Page 146: ...section against a level wooden plate This will cause the bearings to drop out of the bearing seats Info I Any bearings that remain in the engine case section must be removed using a suitable tool Press shaft seal ring of the crankshaft from the inside to the outside Warm the engine case section again Guideline 1150 C 302 F Insert the new cold bearings into the bearing seats of the hot engine case ...

Page 147: ... 5 Nm 1 11 lbf ft Loctite 243 Position membrane support plate 8 together with the membrane Mount and tighten screws CD Guideline Screw membrane Position oil spray tube 8 Mount and tighten screw O Guideline Screw oil spray tube Mount the dowels M3 M4 1 5 Nm 1 11 lbf ft 5 Nm 3 7 lbf ft Loctite 243 Loctite 243 Blow compressed air through all oil channels and check that they are clear Removing the oil...

Page 148: ...e spring 8 Mount and tighten plug with sealing washer C Guideline I Plug oil pressure regulator valve I M12x1 5 146 I 20 Nm 14 8 lbf ft I 17 4 6 Changing the crankshaft seal ring in the clutch cover 309432 10 17 4 7 Removing the water pump 309434 10 Remove crankshaft seal ring O Press the new crankshaft seal ring into the clutch cover with the open side facing inward until it is flush Grease the s...

Page 149: ...over while pressing out 147 Press water pump shaft bearing O in until it is flush using the appropriate tool Info Support the clutch cover sufficiently when pressing in Press shaft seal ring 8 all the way in Mount special tool 8 on the water pump shaft I Mounting sleeve 90129005000 or p 227 Mount balancer shaft 8 Info I Be careful not to damage the shaft seal rings Remove the special tool I Mounti...

Page 150: ...crankshaft journal in the bench vise and try to hammer on the timing chain sprocket In such a case the crank webs will be distorted rendering the crankshaft unserviceable Warm up the new timing chain sprocket and immediately push it onto the crankshaft Guideline 11ao 0 c 356 F 17 4 11 Changing the connecting rod conrod bearing and crank pin 306595 10 Main work Position the crankshaft with special ...

Page 151: ...sert for crankshaft pressing tool 78929008000 r p 226 Place the crank web in with the connecting rod and the bearing Position the sec ond crank web Position special tool 8 with the heel at the bottom I Insert for crankshaft pressing tool 78929008000 r p 226 Press the upper crank web in as far as possible Info I The press mandrel must be applied above the crank pin Take the crankshaft out of the sp...

Page 152: ...ting are very good heat conduc tivity resulting in much improved performance low wear and a lightweight cylinder 17 4 14 Checking measuring the cylinder 306590 10 304696 10 Check the cylinder bearing surface for damage If the cylinder bearing surface is damaged Change the cylinder and piston Measure the cylinder diameter at several locations on the 0 and 0 axes using a micrometer to identify oval ...

Page 153: ...seating has excessive play Replace the connecting rod and piston pin 151 Measure the piston at the piston skirt parallel to the gudgeon pin at a distance ofG Guideline Distance G Piston diameter Size I Size II Info 7 mm 0 28 in 94 93 94 96 mm 3 7374 3 7386 in 94 94 94 97 mm 3 7378 3 739 in I Piston dimensions O are marked on the piston head 17 4 16 Checking the piston ring end gap 304694 10 Remove...

Page 154: ...5 in Wear limit 0 120 mm 0 00472 in The following steps apply to both oil pumps Use special tool O to measure the play between the external rotor and the engine case I Feeler gauge 59029041100 or p 222 Oil pump External rotor engine case clear ance I 0 20 mm 0 0079 in If the measured value does not meet specifications Change the oil pump and if necessary the engine case Use special tool O to measu...

Page 155: ...or 304674 11 304673 11 Insert long flange O of the autodecompression spring in the hole push the autodecompression spring over bearing bolt and hook it into autodecompression weight 8 Mount autodecompression shaft C in the camshaft Mount new lock ring 3 Perform a function check The autodecompression spring does not turn the autodecompression shaft back to the stop Pre tension the autodecompression...

Page 156: ... timing chain sprocket O for damage and wear If there is damage or wear Change the camshaft timing chain sprocket Check the timing chain tensioning rail for damage and wear If there is damage or wear Replace the timing chain tensioning rail Check the timing chain guide rail fD for damage and wear If there is damage or wear Replace the timing chain guide rail Check the timing chain securing guide C...

Page 157: ...ring retainers and lay them to one side accord ing to their normal built in position Pretension the valve springs using the special tool Valve spring mounter 59029019000 p 221 Insert for valve spring lever 77029041000 p 225 Remove valve keys O and relax the valve springs Remove valve spring retainer 8 and the valve spring Pull the valve out of the valve guide from below and remove valve stem seal ...

Page 158: ...17000 p 219 Internal bearing puller 15112018100 p 220 Press the small camshaft bearing in until flush using the special tool I Push in drift 75029044020 p 223 Press the large camshaft bearing in until flush using special tool D I Push in drift 75029044010 p 223 The valve shaft is hard chrome plated wear generally appears at the valve guide 200193 10 Check the run out at the valve plate Valve Run o...

Page 159: ... 1 602 in If the measured value does not meet specifications Change the valve spring Check the valve spring seat for breakage and wear visual check If the valve spring seat is broken or worn Change the valve spring seat Measure the thickness of the valve spring seat Valve spring Valve spring seat 1 8 mm 0 071 in If the measured value does not meet specifications Change the valve spring seat Check ...

Page 160: ...n If the measured value does not meet specifications Rework the valve seat Blow compressed air through all oil channels and check that they are clear 17 4 30 Checking the rocker arm shafts 306609 10 17 4 31 Installing the valves Check the rocker arm shafts for damage and wear If there is damage or wear Change the rocker arm shafts Position valve spring seats O Install new valve stem seals Mount th...

Page 161: ... outward Align drill holes CD of the rocker arm shafts with drill holes e of the cylin der head Use special tool 0 to set the distance of the intake rocker arm Guideline I Rocker arm axial play I 0 10 mm 0 0039 in I Feeler gauge 59029041100 p 222 Press the rocker arm shaft of the intake side all the way into the cylinder head Mount and tighten screw 0 Guideline I Screw rocker arm bearing Remove sp...

Page 162: ...ge the spring washer Check the thrust face of pressure cap D for damage and wear If there is damage or wear Change the pressure cap Check clutch center for damage and wear If there is damage or wear Change the clutch center Check damping rubber 0 for damage and wear If there is damage or wear Change the damping rubbers Check the inner clutch hub for damage and wear If there is damage or wear Chang...

Page 163: ... 0 Check shift forks O at leaf 9 for wear Shift fork Thickness at leaf If the measured value does not meet specifications Change the shift fork Check shift grooves of shift drum for wear If the shift groove is worn Change the shift drum Check the seat of the shift drum in bearing 8 If the shift drum is not correctly seated Change the shift drum and or bearing Check bearing 8 for stiffness and wear...

Page 164: ... guide bolts are loose or worn Change the sliding plate Preassemble the shift shaft p 162 Check clearance O between the sliding plate and the shift quadrant 162 Shift shaft play in sliding plate shift quadrant 0 40 0 80 mm 0 0157 0 0315 in 304682 10 17 4 35 Preassembling the shift shaft 304683 10 If the measured value does not meet specifications Change the sliding plate Secure the short end of th...

Page 165: ... and 2nd gear fixed gear 8 Remove lockring fD Remove needle bearing 8 and distance sleeve Remove 3rd 4th gear sliding gear D Remove lockring and stop disk Remove 5th gear idler gear Remove needle bearing C 17 4 37 Disassembling the countershaft Fix the countershaft in the vice with the toothed end facing downward Guideline Use soft jaws 163 306610 10 306612 10 ...

Page 166: ...bearings Check the pivot points of main shaft 8 and countershaft CD for damage and wear If there is damage or wear Change the main shaft and or countershaft Check the tooth profiles of main shaft 8 and countershaft CD for damage and wear If there is damage or wear Change the main shaft and or countershaft Checkthe pivot points of idler gears 8 for damage and wear If there is damage or wear Change ...

Page 167: ...If there is damage or wear Change the stop disks Use new lock rings C with every repair Check distance sleeves Gi for damage and wear If there is damage or wear Change the distance sleeves 17 4 39 Assembling the main shaft Info I Use new lock rings with every repair Preparatory work Carefully grease all parts before assembling Check the transmission p 164 Main work Secure the main shaft with the t...

Page 168: ...aring O and 2nd gear idler gear 8 onto the countershaft with the protruding collar facing downward Mount stop disk D and lock ring 8 Mount 2nd 4th gear shift collar 0 with the shift groove facing up Mount lock ring D and stop disk Mount needle bearing CD and the 4th gear idler gear with the collar facing up Mount needle bearing and the 3rd gear idler gear G with the collar facing down Mount stop d...

Page 169: ...Check the gear mesh of starter motor 0 for damage and wear If there is damage or wear Change the starter motor Change the O ring D of the starter motor Connect the negative cable of a 12 volt power supply to the housing of the starter motor Connect the positive cable of the power supply briefly with connector of the starter motor If the starter motor does not turn when the circuit is closed Change...

Page 170: ... together with suitable pliers and take off Take the freewheel out of the primary gear Thoroughly oil all parts Push the freewheel O into the primary gear Info Note the direction of rotation Mount spreader ring 168 Ensure that all lugs of the spreader ring pass through slots 6 of the freewheel and engage in groove C of the primary gear ...

Page 171: ... right section of the engine case Remove the special tool 17 5 2 Installing the transmission shafts 17 5 3 Installing the shift forks 0 Lubricate all bearings Slide both transmission shafts into the bearing seats Info Make sure not to misplace the washers Mount lock ring O Lubricate all parts thoroughly Mount shift fork O in the upper shift groove of the main shaft Mount shift fork in the lower sh...

Page 172: ...e Grease the sealing surfaces Apply the sealing compound to the left section of the engine case I Loctite 5910 Info I To prevent sealing compound from entering into the oil channels dow els O must be mounted first Mount the left engine casing If necessary strike it lightly with a rubber mallet Info I Do not use the screws to pull the two sections of the engine case together Mount screws 8 but do n...

Page 173: ...ttern Guideline I Screw engine case I M6x85 Mount the O ring on the countershaft Lightly grease and mount spacer Mount freewheel gear O Mount woodruff key O Degrease the cone and thinly apply thread locker to it I Loctite 648 Mount primary gear 8 Info Turn the freewheel gear to ease engagement 10 Nm 7 4 lbf ft Oil the oil pump shaft internal rotor and external rotor before assembly Mount oil pump ...

Page 174: ...D M6 Position oil pump gear wheel Position washers fD Mount lock washer Mount oil pump idler gear Gi Mount washer a and lock ring 48 10 Nm 7 4 lbf ft Loctite 243 Crank the oil pump gear wheels and ensure that they can move easily Mount locking lever O with the washer sleeve and spring Mount and tighten screw 8 Guideline Screw locking lever M5 6Nm 4 4 lbf ft Loctite 243 172 ...

Page 175: ...ctite 243 173 Push sliding plate 8 away from the shift drum locating unit and insert the shift shaft all the way Let the sliding plate engage in the shift drum locating unit 8 17 5 13 Installing the starter idler gear Shift through the transmission Slide on starter idler gear O with the collar facing the engine case 17 5 14 Installing the torque limiter Position the washer and mount the lock ring ...

Page 176: ...Nm 59 lbf ft I Clutch holder 51129003000 p 221 Secure the nut with the lock washer Lock the outer clutch hub and primary gear using special tool I Gear segment 80029004000 p 226 Mount and tighten nut Guideline Nut primary gear M20LHx1 5 100 Nm 73 8 lbf ft Loctite 648 Set the crankshaft to top dead center and lock it with special tool Gi I Locking screw 113080802 p 219 Thoroughly oil the clutch fac...

Page 177: ...unt pretension ring D with the Top marking facing up Position spring washer C Position spring retainer 0 with the I marking Install the screws D and tighten them diagonally Guideline I Screw clutch spring retainer M5 175 I 6 Nm 4 4 lbf ft ...

Page 178: ...ghtedge and the special tool check the spring washer for distortion I Feeler gauge 59029041100 p 222 I Spring washer distortion I 0 0 10 mm 0 0 0039 in If the specified value is not reached Change the clutch facing discs Position the balancer shaft with special tool O I Fixing drift 78129032000 p 226 Marking O and the special tool are aligned Mount dowels and position the clutch cover gasket fs Mo...

Page 179: ...ternal rotor and external rotor before mounting Insert 0 ring O Position pin 8 into the oil pump shaft from above Position pin ti Mount internal rotor 8 and external rotor 10Nm 7 4 lbf ft 10Nm 7 4 lbf ft The rounded sides of the external rotor face the engine case Position oil pump cover D Mount and tighten screws Guideline Screw suction pump cover 17 5 20 Installing the ignition pulse generator M...

Page 180: ... Mount and tighten screw Ci Guideline Screw timing chain ten sioning rail M6 10 Nm 7 4 lbf ft Slip in the timing chain guide rail C from above Mount and tighten screw 0 Guideline Screw timing chain guide M6 rail Mount the woodruff key Mount the rotor 10 Nm 7 4 lbf ft Mount and tighten nut O with the spring washer Guideline Loctite 243 Loctite 243 Loctite 243 178 Nut rotor M12x1 60 Nm Thread oiled ...

Page 181: ...y tap the piston into the cylinder using the handle of the hammer The piston rings should not catch or they will be damaged Mount dowels O and put cylinder base gasket i in place Ensure that piston mark fD faces toward the exhaust side Cover the engine housing opening with a cloth Feed the timing chain through the timing chain shaft and mount the piston pin Info I In order to present them more cle...

Page 182: ...counterclockwise thereby pushing the piston pin retainer into the groove I Insertion tool for piston ring lock 77329030100 or p 225 Ensure that the piston pin retainer is seated properly on both sides Remove the cloth Keep the timing chain taut Carefully push the cylinder downward letting the dowels engage Mount dowels O and put cylinder base gasket 8 in place 180 ...

Page 183: ...7 4 lbf ft 17 5 25 Installing the camshaft Place the timing chain over the camshaft gear Push the camshaft into the bearing seats The camshaft f and cylinder head G markings are lined up with each other Info Ensure that the crankshaft is at top dead center TDC Position the camshaft support plate Mount and tighten screw O Guideline Screw camshaft support M6 plate 10 Nm 7 4 lbf ft Loctite 243 17 5 2...

Page 184: ... ignition top dead center or p 131 Check the valve clearance at all valves between the valve and rocker arm Guideline Valve clearance Intake at 20 C 68 F I 0 10 0 15 mm 0 0039 0 0059 in Exhaust at 20 C 68 F I 0 12 0 17 mm 0 0047 0 0067 in I Feeler gauge 59029041100 or p 222 If the valve clearance does not meet specifications Adjust the valve clearance or p 182 Remove the special tool I Locking scr...

Page 185: ...he spark plug 308929 10 Mount locating pins O Position alternator cover gasket 8 Position the alternator cover Mount screw fD with washer b ut do not tighten it yet Guideline I Screw alternator cover I M6x25 10Nm 7 4 lbfft Mount screws C and tighten all screws in a crisscross pattern Guideline I Screw alternator cover Position the valve cover seal Position the valve cover Mount and tighten screws ...

Page 186: ... Nm 7 4 lbf ft Tilt the motorcycle to one side and fill the oil filter housing to about 1 3 full with engine oil Insert oil filter O into the oil filter housing Oil the O ring of the oil filter cover Mount oil filter cover 8 Mount and tighten screws 5 Guideline I Screw oil filter cover Mount clutch push rod O I 6 Nm 4 4 lbf ft Mount and tighten screw plug O with the short oil screen and the O ring...

Page 187: ... O ring Guideline I Screw plug oil screen I M20x1 5 I1s Nm 11 1 lbf ft I Mount and tighten the oil drain plug D with the magnet and the new seal ring Guideline I Oil drain plug with magnet I M12x1 5 I 20 Nm 14 8 lbf ft I 17 5 36 Removing the engine from the engine assembly stand Remove the screw connection from the special tool I Engine fixing arm 78029002000 p 225 Remove the engine from the engin...

Page 188: ...e handlebar to a horizontal position Remove screws O Remove cover 8 with membrane CD Fill bleeding syringe 8 with the appropriate hydraulic fluid Bleed syringe 50329050000 p 220 Brake fluid DOT 4 p 216 Mount bleeding syringe 8 on bleeder screw 3 using a fitting section of hose Only loosen bleeder screw 0 on the clutch slave cylinder to the point where fill ing is possible Info I Immediately wash o...

Page 189: ...scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clot...

Page 190: ...olant level 6 above the radiator fins 10 mm 0 39 in If the coolant level does not match the specified value Correct the coolant level I Coolant r p 216 Mount the radiator cap Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow the engine and cooli...

Page 191: ...ted areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children B01933 10 Make sure that screw O is tightened Position the motorcycle upright Pour coolant in up to measurement 6 above the radiator fins Guideline I Dimension e over the radiator fins I Coolant 11 20 I 1 27 qt Mount ...

Page 192: ...annel transmission lubrication ine oil level Condition The engine is at operating temperature Preparatory work Stand the motorcycle upright on a horizontal surface Main work Check the engine oil level Info I After switching off the engine wait one minute before checking the level The engine oil level is between f and C If the engine oil level is below marking G Add engine oil or p 193 If the engin...

Page 193: ...d of as stipulated in applicable regulations Info Drain the engine oil only when the engine is warm Preparatory work Park the motorcycle on a level surface Main work Place a suitable container under the engine Remove oil drain plug O with the magnet and seal ring Remove screw plug 8 with the short oil screen and the O rings Info Do not remove screw f Remove screw plug D with the long oil screen C ...

Page 194: ... of the oil filter housing I Circlip pliers reverse 51012011000 or p 220 Completely drain the engine oil Thoroughly clean the parts and sealing surface Lay the motorcycle on its side and fill the oil filter housing to about full with engine oil Insert the oil filter into the oil filter housing Lubricate the O ring of the oil filter cover and mount it with the oil filter cover Mount and tighten the...

Page 195: ... do not mix different types of engine oil If appropriate change the engine oil Install and tighten the oil filler plug with O ring Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in an enclosed space without an effective exhaus...

Page 196: ...0 rpm Engine oil temperature 80 c 176 F Engine speed 6 000 rpm 0 9 bar 13 psi 2 5 bar 36 psi If the measured value is less than the specification Check the oil pump for wear Check all oil channels for free flow Switch off the engine Warning Danger of burns Some vehicle components get very hot when the machine is driven Wear appropriate protective clothing and safety gloves In case of burns rinse i...

Page 197: ...en removed Measure the resistance between the specified points Measuring point 1 Measuring point 2 Spark plug connector Resistance at 20 c 68 F If the specification is not reached Change the spark plug connector 3 75 6 25 kn Alternator checking stator winding Condition The alternator is disconnected Stator winding checking the resistance Measure the resistance between the specified points 0 Altern...

Page 198: ...ve 8 from the alternator case Remove screws 8 Take the stator out of the alternator cover Position the stator in the alternator cover Mount and tighten screws O Guideline I Screw stator I M4 I 4 Nm 3 lbf ft I Loctite 648 Position cable support sleeve 8 in the alternator case Position the cable holder Mount and tighten screw 8 Guideline Screw cable holder in alternator cover M4 4 Nm 3 lbf ft Loctit...

Page 199: ...otor has been removed Connect the negative cable of a 12 volt power supply to the housing of the starter motor Connect the positive cable of the power supply briefly with connector 0 of the starter motor If the starter motor does not turn when the circuit is closed Change the starter motor ...

Page 200: ...dle speed Turning clockwise raises the idle speed Condition The diagnostic tool is connected and running Execute Engine electronics Functions Deleting adaptation values The adaptation values are deleted Select Engine electronics Measured values Engine coolant tempera ture sensor TW1 The coolant temperature is displayed during the initialization run Danger mDanger of poisoning Exhaust gases are tox...

Page 201: ...ALVE BODY As soon as the specified temperature is reached switch off the ignition Info I If the initialization is not completed or the initialization process is inter rupted the entire process must be restarted 199 ...

Page 202: ...cally activated Gearbox 5 gear claw shifted Transmission ratio 1st gear 16 32 2nd gear 18 30 3rd gear 20 28 4th gear 22 26 5th gear 24 24 Alternator 12 V 75 W Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment Spark plug NGK LKAR8Al 9 Spark plug electrode gap 0 9 mm 0 035 in Cooling Water cooling permanent circulation of coolant by water pump Starting aid E...

Page 203: ...r M6 Screw starter motor M6 Screw timing chain guide rail M6 Screw timing chain securing guide M6 Screw timing chain tensioner M6 Screw timing chain tensioning rail M6 Screw valve cover M6 Screw water pump cover M6 Oil nozzle for conrod bearing lubrica M6x0 75 tion 0 040 0 082 mm 0 00157 0 00323 in 0 043 0 085 mm 0 00169 0 00335 in 0 120 mm 0 00472 in s 1 00 mm s 0 0394 in s 1 20 mm s 0 0472 in 0 ...

Page 204: ... M18x1 5 M18x1 5 M20LHx1 5 M20x1 5 11 50 1 1 59 qt 11 20 I 1 27 qt 7 5 I 1 98 US gal 9 Nm 6 6 lbf ft 15 Nm 11 1 lbf ft 8 Nm 5 9 lbf ft 10 Nm 7 4 lbf ft 15 Nm 11 1 lbf ft 60 Nm 44 3 lbf ft Loctite 243 Loctite 243 Loctite 2701 TM 202 Step 1 Lubricated with engine oil 10 Nm 7 4 lbf ft Step 2 30 Nm 22 1 lbf ft Step 3 50 Nm 36 9 lbf ft 60 Nm 44 3 lbf ft Thread oiled with engine oil cone degreased 15 20...

Page 205: ...62M TT Dunlop GEOMAX MX 51 FA Dunlop GEOMAX MX 51 Additional information is available in the Service section under www husqvarna motorcycles com 24 8 Fork Fork part number 14 18 7N 59 Fork WP Suspension Up Side Down 4860 MXMA CC Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Rebound damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Spring length with preload sp...

Page 206: ... brake disc Screw throttle grip Fuel connection on fuel tank Nut foot brake lever stop Nut rear sprocket screw Nut rim lock Remaining nuts chassis Remaining screws chassis Screw bottom triple clamp EJOT PT K60x25 Z M4 5 M4 5 M5 M5 M5 M6 M6 M6 M6 M6 M6 M6 M6 M8 M8 M8 M8 M8 M8 M8 18 15 7N 57 WP Suspension 5018 BAVP DCC 17 clicks 15 clicks 13 clicks 2 5 turns 2 turns 1 5 turns 17 clicks 15 clicks 13 ...

Page 207: ...r to angle lever M14x1 5 Nut swingarm pivot M16x1 5 Nut rear wheel spindle M20x1 5 Screw top steering head M20x1 5 Screw in nozzles cooling system M20x1 5 Screw front wheel spindle M24x1 5 15 Nm 11 1 lbf ft 33 Nm 24 3 lbf ft 15 Nm 11 1 lbf ft 25 Nm 18 4 lbf ft 20 Nm 14 8 lbf ft 30 Nm 22 1 lbf ft 17 Nm 12 5 lbf ft 17 Nm 12 5 lbf ft 60 Nm 44 3 lbf ft 45 Nm 33 2 lbf ft 45 Nm 33 2 lbf ft 60 Nm 44 3 lb...

Page 208: ...ove 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 I Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to the dry vehicle always rinse with water first After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the plu...

Page 209: ...taking the motorcycle out of service add fuel additive Refuel Clean the motorcycle p 206 Change the engine oil and oil filter and clean the oil screens p 191 Check the antifreeze and coolant level p 187 Check the tire air pressure p 90 Remove the battery p 105 26 2 401058 01 Charge the battery Guideline Storage temperature of battery with out direct sunshine 0 35 C 32 95 F Store the vehicle in a d...

Page 210: ...1 0 I Check the chain rear sprocket engine sprocket and chain guide p 98 I I I Check the chain tension p 97 I o I I Grease all moving parts e g hand lever chain and check for smooth operation I I I Check correct the fluid level of the hydraulic clutch p 186 I I I Check the brake fluid level of the front brake p 111 I I I Check the free travel of the hand brake lever p 110 I Check the steering head...

Page 211: ... Change the piston Check measure the cylinder Check the cylinder head Change the valves valve springs and valve spring seats Check the camshaft and rocker arm Change the connecting rod conrod bearing and crank pin Change the shaft seal rings of the water pump Check the transmission and shift mechanism Check the oil pressure regulator valve Change the suction pump Check the pressure pump and lubric...

Page 212: ... FC 2 X7 1 l X16 1 1 1 1AP 6 X295 col S21 l5 l x19 iBR 4 I N K 4 s E 1 MBI I K 4 BR 4 1 X19 j 4 II I I II 0 0 0 0 M10 G L n J G10 X17 il 1 5 X302 l 0 ls 1 l N EB 4 1 TI0nt1 WB U w u 1 _ 1 r If EB 4 i EZ 3 X1 X18 j j 0 I 0 l5 l a 2 F1 __ l b 2 F1 Hu rna FC 450 EU 2014 2015 1 3 J J IC ...

Page 213: ...Components A11 EFI control unit C10 Capacitor G10 Battery G20 Alternator K10 Starter relay with main fuse K30 Power relay M10 Starter motor T20 Voltage regulator S21 Electric starter button X295 Diagnostics connector 211 ...

Page 214: ... DD I 0 B B I I I I I cc t l 11 9 1 9 0 ii C j xs X2 C BF 1 I NCX 2 N AT 2 j NDQ 2 M GA 3 BA 1 30 NCW 2 ru S20 P25 X295 t X301 E 1 N AP 6 r 7 0 n CW 2 i D W r G M D CX 2 X3 XS D X2 0 0 0 0 DDD X300 l C E E C C I z 0 1 FB a cc G 1 FB b g 0 F F C0 C I FC 450 EU 2014 2015 I Hu5 Mlrna I 2 3 1 2 I 3 I 4 5 I 6 I 7 I 8 ...

Page 215: ...28 WIRING DIAGRAM Components A11 EFI control unit M13 Fuel pump M51 Injection valve cylinder 1 P25 Fl warning lamp MIL R30 CAN bus terminating resistor S20 Kill switch X295 Diagnostics connector 213 ...

Page 216: ...6 9 5 9 5 l x13 tv12 DV 2 1 X13 3 l X16 il I il 1 x1s om M 6 f o 3 I 5 _5 c 4 ii ii iDTI or X16 X16 I l I 5 i i X16 I I i t11 1 1 X10 i J H _ l J LtiJ AX 2 1 X12 5 FC 450 EU 2014 2015 T T T 6 7 1 me X16 X16 I I t t P 6 cM 2 m f AP 6 cM 2 I 4 0 5 T T 8 0 0 J I 0 J IA tj iome i I X16 X16 5 il I I Is il 1 T r 3 3 ...

Page 217: ...e sensor cylinder 1 826 Rollover sensor 837 Crankshaft position sensor 841 Manifold absolute pressure sensor cylinder 1 R51 Ignition coil cylinder 1 S51 Map Select 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 215 ...

Page 218: ...ds see specifications on the container and that possess the corre sponding properties I Synthetic engine oil Recommended supplier Bel Ray Works Thumper Racing Synthetic Ester 4T Fork oil SAE 4 48601166S1 Standard classification SAE p 233 SAE 4 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding properties Shock abs...

Page 219: ... Recommended supplier Lubcon Turmogrease PP 300 Lubricant T511 Recommended supplier Lubcon Turmsilon GTI 300 P Lubricant T625 Recommended supplier Molykote 33 Medium Lubricant I152 Recommended supplier Bel Ray Molylube Anti Seize Lubricant I159 Recommended supplier Bel Ray MC 11 Offroad chain s ra Guideline Recommended supplier Bel Ray Blue Tac Chain Lube Oil for foam air filter Recommended suppli...

Page 220: ...30 AUXILIARY SUBSTANCES Preserving materials for aints metal and rubber Recommended supplier Bel Ray Silicone Detailer Protectant Spray Universal oil s ray Recommended supplier Bel Ray 6 in 1 218 ...

Page 221: ...29013005 00029013005 H00504 01 Bleeder cover Art no 00029013006 00029013006 H00505 01 Bleedin device Art no 00029013100 00029013100 H00518 01 Locking screw Art no 113080802 113080802 H00944 01 Bearing uller Art no 15112017000 15112017000 H00520 01 ...

Page 222: ...9075000 Sprin hook 50305017000 Bleed syringe 50329050000 Circli liers reverse 51012011000 H00522 01 H00525 01 H00973 01 H00565 01 H00572 01 Art no 15112018100 Feature 118 23 mm 0 71 0 91 in Art no 45129075000 Art no 50305017000 Art no 50329050000 Art no 51012011000 220 ...

Page 223: ...575 01 Extractor Art no 58012009000 58012009000 H00592 01 Torque wrench with various accessories in set Art no 58429094000 58429094000 H00606 01 Valve spring mounter Art no 59029019000 59029019000 H00610 01 Limit lug gauge Art no 59029026006 59029026006 H00612 01 221 ...

Page 224: ...29041100 59029041100 H00616 01 tool Art no 60029015000 60029015000 H00628 01 Puller 2 arm Art no 60029033000 2x 60029033000 H00633 01 Hose clamp pliers Art no 60029057000 60029057000 H00650 01 Testing hose Art no 61029093000 61029093000 H00659 01 ...

Page 225: ...4000 4x 61029094000 H00660 01 En ine assembl stand Art no 61229001000 61229001000 H00662 01 Extractor Art no 75029021000 75029021000 H00707 01 Push in drift Art no 75029044010 75029044010 H00712 01 Push in drift Art no 75029044020 75029044020 H00713 01 ...

Page 226: ...5029047000 75029047000 H00714 01 Clam late Art no 75029050000 75029050000 H00719 01 Push out drift Art no 75029051000 ij 75029051000 H00721 01 Protection cap Art no 75029090000 75029090000 H00726 01 Oil ressure ada ter Art no 75029094000 75029094000 H00728 01 224 ...

Page 227: ...4 01 77229172000 H00761 01 Insertion tool for piston rin lock 77329030100 H00768 01 Engine fixing arm 78029002000 H00783 01 Mounting sleeve 78029005100 H00785 01 Art no 77029041 000 Art no 77229172000 Art no 77329030100 Art no 78029002000 Art no 78029005100 225 ...

Page 228: ...in drift 78129032000 H00796 01 Insert for crankshaft pressin tool 78929008000 H01016 01 Separator plate 78929009000 H00799 01 Gear segment 80029004000 H00813 01 Art no 78029049100 Art no 78129032000 Art no 78929008000 Art no 78929009000 Art no 80029004000 226 ...

Page 229: ...rt no 81329955000 81329955000 H01015 01 Mountin sleeve Art no 90129005000 90129005000 H00816 01 Case separatin tool Art no 90129048000 90129048000 H00827 01 Pin wrench Art no T103 T103 H00838 01 Hook wrench Art no T106S T106S H00841 01 ...

Page 230: ...LS 228 De th micrometer Art no T107S T107S H00842 01 Pin Art no T120 T120 H00844 01 Mountin sleeve Art no T1204 T1204 H00878 01 Calibration pin Art no T1205 T1205 H00879 01 Pressing tool Art no T1206 T1206 H00880 01 ...

Page 231: ...in tool Art no T1207S T1207S H00881 01 Mountin sleeve Art no T1215 T1215 H00886 01 Disassembly tool Art no T1216 CJ T1216 H00887 01 Vacuum pump Art no T1240S diJ T1240S H00890 01 Protecting sleeve Art no T1401 cs T1401 H00894 01 ...

Page 232: ...30 Clam ing stand Art no T14016S T14016S H01036 01 Rin wrench Art no T14017 T14017 H00904 01 tool Art no T14019 T14019 H00906 01 Support tool Art no T14020 T14020 H00907 01 Calibrating unit Art no T14021 T14021 H00908 01 ...

Page 233: ...ounting tool Art no T14022 T14022 H00909 01 Threaded bushin Art no T14023 T14023 H00911 01 Mountin sleeve Art no T14029 T14029 H00917 01 Filling adapter Art no T14030 T14030 H00918 01 Tweezers Art no T14033 T14033 H00921 01 ...

Page 234: ...stand Art no T1403S 2x T1403S H00896 01 Mountin tool Art no T14040S T14040S H00922 01 Press drift Art no T1504 T1504 H00899 01 Assembly tool Art no T150S 0 Q T150S H00852 01 Nitrogen filling tool 2x 3x Art no T170S1 T170S1 H00855 01 ...

Page 235: ...vice intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils a...

Page 236: ...ting 97 checking 97 Charging voltage checking 106 Chassis number 9 Clutch fluid level checking correcting 186 fluid changing 186 Clutch lever basic position adjusting 42 Compression damping fork adjusting 12 Compression damping high speed shock absorber adjusting 46 Compression damping low speed shock absorber adjusting 46 Conducting major fork service 15 Conducting minor fork service 16 Coolant c...

Page 237: ...rum installing 170 shift forks installing 169 shift rails installing 170 shift shaft installing 173 spark plug installing 183 starter idler gear installing 173 starter motor installing 184 suction pump installing 177 timing chain tensioner installing 181 timing chain installing 178 torque limiter installing 173 235 transmission shafts installing 169 valve clearance adjusting 182 valve cover instal...

Page 238: ... bearing changing 93 Fuel filter changing 84 Fuel pressure checking 81 Fuel pump changing 82 Fuel screen changing 86 Fuel tank installing 80 removing 79 Fuse main fuse changing 105 H Hand brake lever basic position adjusting 111 236 free travel checking 110 Handlebar position 42 adjusting 42 Idle speed adjusting 198 Ignition coil secondary winding checking 195 Implied warranty 8 Initialization run...

Page 239: ...ng 49 riding sag checking 48 seal ring retainer assembling 60 seal ring retainer disassembling 56 shock absorber servicing 53 spring preload adjusting 48 spring installing 67 spring removing 54 static sag checking 47 Shock absorber article number 9 Shock absorber linkage checking 51 237 Spare parts 8 Spark plug connector checking 195 Spoke tension checking 91 Start number plate installing 89 remov...

Page 240: ...INDEX Wiring diagram 210 215 page 1 of 3 210 page 2 of 3 212 page 3 of 3 214 Work rules 7 238 ...

Page 241: ...1111111111111111111111111111111111111111IIIIII 3403000en 08 2015 Husqvarna MOTORCYCLES Husqvarna Motorcycles GmbH StallhofnerstraBe 3 5230 Mattighofen Austria www husqvarna motorcycles com Photo Mitterbauer Husqvarna Motorcycles GmbH ...

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Husqvarna FC 450 2014, Repair Manual

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Summary of Contents for FC 450 2014

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