Husqvarna FC 450 2018 Repair Manual Download Page 69

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9.14

Disassemblin the damper

SHOCK ABSORBER, LINK FORK 9

Remove the spring.
Remove washer

Preparatory work

Remove the spring. (

p. 66)

Main work

Make a note of the present state of rebound

and com

pression damping

Open the adjusters of the rebound and compression damp
ing completely.

Slowly open screw

@).

✓ The nitrogen pressure dissipates.

Remove screw

with the 0-ring.

Remove locking cap

Press in seal ring retainer

using the special tool.

Pressing tool (T1216) (

p. 321)

Summary of Contents for FC 450 2018

Page 1: ...PIONEERING SINCE 1903 REPAIR MANUAL2018 FC 450 Rockstar Edition Art no 3403072en Husqvarna MOTORCYCLES ...

Page 2: ......

Page 3: ...y or delete technical specifications prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice Husqvarna accepts no liability for delivery options deviations from figures and descriptions as well as misprints and other errors The models ...

Page 4: ...e air cartridge 25 7 8 9 6 15 Disassembling the shock absorber cartridge 26 6 16 Checking the fork legs 28 6 17 Assembling the shock absorber cartridge 29 6 18 Assembling the air cartridge 31 6 19 Assembling the fork legs 33 6 20 Lubricating the steering head bearing 39 6 21 Removing the lower triple clamp 40 6 22 Installing the lower triple clamp 41 6 23 Checking steering head bearing play 43 6 2...

Page 5: ...side cover 100 12 4 Installing the right side cover 100 12 5 Removing the seat 100 12 6 Mounting the seat 101 13 14 TABLE OF CONTENTS 12 7 Removing the fuel tank 102 12 8 Installing the fuel tank 103 12 9 Checking the fuel pressure 105 12 10 Changing the fuel pump 106 12 11 Changing the fuel filter 109 12 12 Changing the fuel screen 113 MASK FENDER 115 13 1 Removing front fender 115 13 2 Installin...

Page 6: ...3 17 Removing the gear position sensor 179 17 3 18 Removing the water pump cover 180 17 3 19 Removing the clutch cover 180 17 3 20 Removing the clutch discs 180 17 3 21 Removing the clutch basket 182 17 3 22 Removing the torque limiter 182 17 3 23 17 3 24 17 3 25 17 3 26 17 3 27 17 3 28 17 3 29 Removing the starter idler gear 183 Removing the force pump 183 Removing the shift shaft 184 Removing th...

Page 7: ...g the shift drum locating unit 225 Installing the shift shaft 225 Installing the force pump 225 Installing the starter idler gear 226 17 5 14 17 5 15 17 5 16 17 5 17 17 5 18 17 5 19 17 5 20 17 5 21 17 5 22 17 5 23 17 5 24 17 5 25 17 5 26 17 5 27 17 5 28 17 5 29 17 5 30 17 5 31 17 5 32 17 5 33 17 5 34 17 5 35 17 5 36 TABLE OF CONTENTS Installing the torque limiter 227 Installing the clutch basket 2...

Page 8: ... 280 25 1 Engine 280 25 2 Tolerance engine wear limits 281 25 3 Engine tightening torques 281 25 4 Capacities 283 25 4 1 Engine oil 283 25 4 2 Coolant 283 25 4 3 Fuel 283 25 5 Chassis 283 25 6 Electrical system 284 25 7 Tires 284 25 8 Fork 284 25 9 Shock absorber 285 25 10 Chassis tightening torques 286 26 CLEANING PROTECTIVE TREATMENT 288 26 1 Cleaning the motorcycle 288 27 STORAGE 290 27 1 Stora...

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

Page 10: ...s permanent injury if the appropriate measures are not taken Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken Caution Identifies a danger that may lead to minor injuries if the appropriate measures are not taken Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not ta...

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

Page 12: ...0 10 4 4 Fork Rart number 401947 10 10 The vehicle identification number O is stamped on the right side of the steering head The type label O is fixed to the front of the steering head The engine number O is stamped on the left side of the engine The fork part number O is stamped on the inside of the axle clamp ...

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

Page 14: ...f the vehicle Park the vehicle on a firm and level surface Ensure that nobody sits on the vehicle when the vehicle is parked on a stand 5 3 Note H02629 10 Starting the vehicle Danger 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 I Plug in stand 79029094000 Info I The plug in stand is included Re...

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

Page 16: ...led The time con suming mounting of harder or softer fork springs is not required If the air chamber loses air due to a damaged seal the fork will still not sag In this case the air is retained in the fork The sus pension travel is maintained as far as possible The damping becomes harder and the riding comfort reduces As with a conventional fork the damping can be adjusted in rebound and compressi...

Page 17: ...Preparatory work Raise the motorcycle with a lift stand 0 p 12 Main work Remove protection cap O Push together fork airpump 8 fully I Fork airpump 79412966000 0 p 317 Info I The fork airpump is included as part of the motorcy cle s accessory pack Connect the fork airpump to the left fork leg The fork airpump indicator switches on automatically A little air escapes from the fork leg when connecting...

Page 18: ... clockwise all the way Info Adjusting screw O is located at the upper end of the right fork leg Turn counterclockwise by the number of clicks correspond ing to the fork type Guideline Compression damping Comfort Standard Sport Info 20 clicks 15 clicks 10 clicks I Turn clockwise to increase damping turn counter clockwise to reduce damping Adjusting the rebound damping of the fork Info The hydraulic...

Page 19: ... excess pressure escapes from the interior of the fork Tighten the bleeder screws Finishing work Remove the motorcycle from the lift stand a p 12 Cleaning the dust boots of the fork legs Preparatory work Raise the motorcycle with a lift stand a p 12 Remove the fork protector a p 19 Main work Push dust boots O of both fork legs downward Info I The dust boots remove dust and coarse dirt parti cles f...

Page 20: ...k into their installation position Remove excess oil Finishing work Install the fork protector al p 20 Remove the motorcycle from the lift stand 8 p 12 Preparatory work Raise the motorcycle with a lift stand 0 p 12 Remove the front wheel 0 p 120 Main work Remove screws O and take off the clamp Remove screws 8 and take off the brake caliper Allow the brake caliper and brake line to hang loosely to ...

Page 21: ...ocated in the left fork leg The pressure and rebound damping is located in the right fork leg Tighten screws 8 Guideline Screw top triple clamp Tighten screws Guideline M8 Screw bottom triple M8 clamp 17 Nm 12 5 lbf ft 12 Nm 8 9 lbf ft Position the brake caliper Mount and tighten screws C Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Position the brake line and the clamp Mou...

Page 22: ...g Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Danger of accidents Disassembling pressurized parts can cause injuries The fork is filled with compressed air Please follow the description provided 0 Q 311645 01 Condition The fork legs have been removed Disassemble the fork legs 0 p 21 Disassemble the air cartridge 0 p 25 Disassemble the shock absorber cartridge 0 ...

Page 23: ...4 10 Condition The fork legs have been removed Left fork leg Clamp the fork leg in the area of the lower triple clamp I Clamping stand T1403S al p 323 Release cartridge O using special tool 8 I Ring wrench T14017 8 p 322 Info The cartridge cannot be taken off yet Unclamp the fork leg Drain the fork oil Clamp the fork leg with the axle clamp Guideline I Use soft jaws Remove protection cap f Remove ...

Page 24: ...ed Warm up the outside fork tube in area i of the lower sliding bushing Guideline 1 so 0 c 122 F Pull the outside fork tube off the inside fork tube with a jerk Info Lower sliding bushing C must be drawn from its bearing seat Remove upper sliding bushing Info Without using a tool pull the stack slightly apart by hand Take off lower sliding bushing C Take off support ring fD Take off seal ring Take...

Page 25: ...sion damping Open the adjusters of the rebound and compression damping completely Clamp the fork leg in the area of the lower triple clamp I Clamping stand T1403S ll I p 323 Remove the screw Remove adjuster 8 on compression damping Loosen cartridge C Ring wrench T14017 0 p 322 Info The cartridge cannot be taken off yet Unclamp the fork leg Drain the fork oil 23 ...

Page 26: ... G Info The fork protector ring does not necessarily need to be removed for repair work Remove lock ring Info The lock ring has a beveled end where a screw driver can be applied Warm up the outside fork tube in area 9 of the lower sliding bushing Guideline I so 0 c 122 F Pull the outside fork tube off the inside fork tube with a jerk Info Lower sliding bushing fD must be drawn from its bearing sea...

Page 27: ...filled with compressed air Please follow the description provided 0 e B03552 10 Preparatory work Disassemble the fork legs a p 21 Main work Remove protection cap O Slowly release the pressure from the air cartridge Info I Hold the piston rod in extended position to allow the air pressure to balance between the positive air cham ber and the negative air chamber Remove valve core 8 Clamp the air car...

Page 28: ...F Remove piston D Remove end stop Remove spring pack Remove seal ring retainer 0 6 15 Disassembling the shock absorber cartridge 26 Preparatory work Disassemble the fork legs 8 p 21 Main work Allow oil to drain from breathing hole O Degrease and clamp the top of the shock absorber cartridge I Clamping stand T14072 8 p 323 Loosen screw cap 8 1 Special socket T14084 0 p 324 Remove screw cap with sho...

Page 29: ...er cartridge f Guideline I so 0 c 122 F Loosen seal ring retainer 0 Remove piston rod with seal ring retainer and shock absorber unit Degrease piston rod and clamp underneath spring I Clamping stand T14016S 0 p 322 Heat up the thread area of piston retainer 6 Guideline I so 0 c 122 F Remove piston retainer 6 with the shock absorber unit Remove adjustment valve Qi with the spring from the piston ro...

Page 30: ... If damage is found Change the inside fork tube Measure the outside diameter of the inside fork tube at sev eral places Outside diameter of the inside fork tube 47 975 48 005 mm 1 88878 1 88996 in If the measured value is less than the specified value Change the inside fork tube Measure the run out of the inside fork tube Run out of the inside fork tube 0 20 mm 0 0079 in If the measured value is g...

Page 31: ...he surface is rough Change the slide bearing Check the piston rod for damage If damage is found Replace the piston rod Measure the outside diameter of the piston rod at several locations Outside diameter of the pis 11 965 mm 0 47106 in ton rod 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 s 0 40 mm ...

Page 32: ...f adjustment valve I Lubricant T158 0 p 304 Mount and tighten piston retainer 0 with shock absorber unit Guideline Piston retainer on piston rod M9x1 20 Nm 14 8 lbf ft Loctite 2701 TM Clamp the shock absorber cartridge at the bottom I Clamping stand T14072 0 p 323 Lubricate friction ring on the shock absorber cartridge I Fork oil SAE 4 48601166S1 0 p 303 Push the piston rod into the shock absorber...

Page 33: ...bricate seals G and friction rings 4D I Fork oil SAE 4 48601166S1 8 p 303 Lubricate O ring 41 on the screw cover I Lubricant T158 8 p 304 Mount the screw cover with pressure stage unit tighten with special tool Guideline Pressure stage unit M44x1 40 Nm 29 5 lbf ft on shock absorber cartridge I Special socket T14084 8 p 324 Assembling the air cartridge 803556 10 Slot special tool O over thread on p...

Page 34: ...rtridge Grease capacity left cartridge Clamp the air cartridge 11 ml 0 37 fl oz I Clamping stand T14072 a p 323 Multi purpose grease 00062010051 a p 305 Position the special tool in the cartridge I Mounting sleeve T14092 a p 324 Push the piston rod into the air cartridge Info The air cartridge must be absolutely clean on the inside Do not damage the gasket when inserting the piston Remove the spec...

Page 35: ...si I Fork airpump 79412966000 ra l p 317 Mount protection cap Info Only mount the protection cap by hand Preparatory work Check the fork legs ra l p 28 Left fork leg Clamp the inside fork tube using the axle clamp Guideline I Use soft jaws Mount the special tool I Protecting sleeve T1401 ra l p 322 Grease and push on dust boot O I Lubricant T14034 ra l p 304 The sealing lip is mounted with the spr...

Page 36: ...tack slightly apart by hand Warm up the outside fork tube in area 6 of the lower sliding bushings Guideline I so 0 c 122 F Hold the lower sliding bushing with the longer side of the special tool I Mounting tool T14040S 8 p 323 Slide on the outside fork tube Press the slide bearing all the way into the outside fork tube Position the support ring Hold the seal ring with the shorter side of the speci...

Page 37: ...mp with brake mount and outside fork tube with warning label 0 screw cartridge Slide the air cartridge into the inside fork tube Lubricate O ring I Lubricant T158 0 p 304 Mount and tighten the screw Guideline Screw cartridge on M20x1 45 Nm 33 2 lbf ft axle clamp Clamp the left fork leg vertically Guideline I Use soft jaws Fill with fork oil Oil capacity exter nal mechanism left 200 ig ml 6 76 g fl...

Page 38: ...h T14017 0 p 322 Right fork leg 50 Nm 36 9 lbf ft Clamp the inside fork tube using the axle clamp Guideline I Use soft jaws Mount the special tool I Protecting sleeve T1401 0 p 322 Grease and push on dust boot O I Lubricant T14034 0 p 304 The sealing lip is mounted with the spring expander facing down Info Always change the dust boot seal ring lock ring and support ring Push on lock ring 8 Grease ...

Page 39: ... G of the lower sliding bushings Guideline I so 0 c 122 F Hold the lower sliding bushing with the longer side of the special tool I Mounting tool T14040S 8 p 323 Slide on the outside fork tube Press the slide bearing all the way into the outside fork tube Position the support ring Hold the seal ring with the shorter side of the special tool I Mounting tool T14040S 8 p 323 Press the seal ring and s...

Page 40: ...und adjuster I Lubricant T158 0 p 304 Mount and tighten the rebound adjuster Guideline Rebound adjuster on the axle clamp M20x1 Clamp the left fork leg vertically Guideline I Use soft jaws Fill with fork oil Oil capacity exter nal mechanism right 200 18 ml 6 76 Jg fl oz 45 Nm 33 2 lbf ft Fork oil SAE 4 48601166S1 0 p 303 Lubricate O ring fD on the shock absorber cartridge I Lubricant T158 0 p 304 ...

Page 41: ...re sponding to the fork type Guideline Compression damping Comfort Standard Sport Rebound damping Comfort Standard Sport Mount protection cap 48 Condition Value determined on removal 20 clicks 15 clicks 10 clicks 20 clicks 15 clicks 10 clicks Turn compression adjusting screw Gi and rebound adjusting screw 48 clockwise all the way Turn the adjusting screws to the position they were in before removi...

Page 42: ...bar cushion Main work Remove the holder with the malfunction indicator lamp Open cable holder O on the left and detach the wiring har ness Remove screw 8 Remove screw fD Take off the upper triple clamp with the handlebar and place to one side Info Cover the components to protect them against dam age Do not kink the cables and lines Remove 0 ring 8 Remove protective ring 0 Remove the lower triple c...

Page 43: ...ide on protective ring 8 and 0 ring 8 Position the upper triple clamp with the handlebar Mount screw 8 but do not tighten yet Position the fork legs Air bleeder screw 0 of the right fork leg is positioned to the front Valve f of the left fork leg faces the front Info Grooves are milled into the side of the upper end of the fork legs The second milled groove from the top must be flush with the uppe...

Page 44: ...mer tap lightly on the upper triple clamp to avoid stresses Tighten screws Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Secure the wiring harness with cable holder on the left Mount the holder with the malfunction indicator lamp Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake caliper Mount and tighten screws 41 Guideline Screw front brake caliper M8 25 Nm 18 4 lb...

Page 45: ...eriod with play in the steering head bearing the bearings and the bearing seats in the frame can become damaged over time Preparatory work Raise the motorcycle with a lift stand 0 p 12 Main work Move the handlebar to the straight ahead position Move the fork legs to and fro in the direction of travel Play should not be detectable on the steering head bear ing If there is detectable play Adjust ste...

Page 46: ...amp 8 p 40 Main work Remove lower bearing ring O with special tool 8 Tool bracket 58429089000 8 p 309 Pressing tool 58429092000 8 p 310 Press the new bearing ring up to the stop with special tool CD Tool bracket 58429089000 8 p 309 Pressing tool 58429091000 8 p 310 Remove upper bearing ring C with special tool Tool bracket 58429089000 8 p 309 Pressing tool 58429092000 0 p 310 Press the new bearing...

Page 47: ...move the motorcycle from the lift stand a p 12 Mount the handlebar cushion Ad usting steering head bearing la Preparatory work Raise the motorcycle with a lift stand a p 12 Remove the handlebar cushion Main work Loosen screws O Remove screw 8 Loosen and retighten screw Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid s...

Page 48: ...0 t e e 0 0 H01189 10 Preparatory work Remove the handlebar cushion Main work Remove screws O Take off the handlebar clamp Remove the handlebar and lay it to one side Info Cover the components to protect them against dam age Do not kink the cables and lines Remove screws 8 Take off handlebar supports Position rubber bushings 8 and push through nuts 0 from below Place the handlebar supports in the ...

Page 49: ...Info When the adjusting screw is turned counterclockwise the clutch lever moves away from the handlebar When the adjusting screw is turned clockwise the clutch lever moves closer to the handlebar The range of adjustment is limited Only turn the adjusting screw by hand and do not use force Do not make any adjustments while riding Check the rubber grips on the handlebar for damage wear and looseness...

Page 50: ...ve the fuel tank 0 p 102 Main work Check throttle cable routing Both throttle cables must be routed side by side on the back of the handlebars and above the fuel tank bracket to the throttle valve body Both throttle cables must be secured behind the rubber strap of the fuel tank support If the throttle cable routing is not as specified Correct the throttle cable routing Finishing work Install the ...

Page 51: ... 49 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Start the engine and let it run at idle speed Move the handle bar to and fro over the entire steering range I The idle speed...

Page 52: ...Guideline I Throttle cable play Tighten nut Slide on sleeve O I 3 5 mm 0 12 0 2 in Check the throttle grip for smooth operation Finishing work Check throttle cable play 0 p 49 Install the fuel tank 0 p 103 Install the right side cover 0 p 100 Mount the seat 0 p 101 Install the air filter box cover 0 p 96 Ad usting the characteristic ma of the throttle res onse Info On the throttle grip the charact...

Page 53: ...ens the throttle valve more slowly The black guide plate opens the throttle valve more quickly The gray guide plate is mounted upon delivery Clean the outside of the handlebar and the inside of the grip tube Mount the grip tube on the handlebar Attach the throttle cables to the guide plate and route cor rectly Position half shells 6 mount and tighten screws i Guideline I Screw throttle grip I M6 I...

Page 54: ...Remove screw 8 Remove the engine guard Position the engine guard on the frame Mount and tighten screw O Guideline Remaining screws chassis M6 Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft ...

Page 55: ...damaged due to a mechanical impact Repair of the frame is not authorized by Husqvarna Motorcycles The frame protectors have been removed on the left and right Remove pin O and take off the washer Press the spring with special tool 8 I Footrest spring plier 79029083000 a p 316 The special tool is applied to area 6 on the footrest Remove pin CD Position the new footrest and pin Info Only insert the ...

Page 56: ...wn Spring 0 engages in area Press the spring with special tool 8 I Footrest spring plier 79029083000 8 p 316 The special tool is applied to area f on the footrest Mount pin D Mount the washer and splint O Repeat these steps on the opposite side ...

Page 57: ...ch Info I Do not loosen fitting 8 Turn counterclockwise by the number of turns corresponding to the shock absorber type Guideline Highspeed compression damping Comfort Standard Sport Info 2 5 turns 2 turns 1 5 turns I Turn clockwise to increase damping turn counter clockwise to reduce damping Adjusting the low speed compression damping of the shock absorber Caution Risk of injury Parts of the shoc...

Page 58: ...reduce damping Adjusting the rebound dam ing of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incor rectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Turn adjusting screw O clockwise up to the last perceptible click Turn counterclockwise by the number of clicks corres...

Page 59: ...le from the lift stand ra l p 12 Checking the static sag of the shock absorber Measure dimension f of rear wheel unloaded ra l p 57 Hold the motorcycle upright with the aid of an assistant Measure the distance again between the rear axle and mark ing SAG on the rear fender using the sag gage Note down the value as dimension Ce Info The static sag is the difference between measure ments f and Ce Ch...

Page 60: ...value as dimension 8 Info The riding sag is the difference between measure ments 6 and 8 Check the riding sag I Riding sag 1105 mm 4 13 in If the riding sag differs from the specified measurement Adjust the riding sag 0 p 59 reload of the shock absorber Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incor rectly The shock absorber is filled with highl...

Page 61: ...M5 absorber adjusting ring Finishing work Install the shock absorber 0 p 61 5 Nm 3 7 lbf ft Check the free travel of the foot brake lever 0 p 152 Remove the motorcycle from the lift stand 0 p 12 Preparatory work Raise the motorcycle with a lift stand 0 p 12 Remove the shock absorber 0 p 60 After removing the shock absorber clean it thoroughly Main work Choose and mount a suitable spring Guideline ...

Page 62: ... 9 9 Removin the shock absorber 60 Preparatory work Raise the motorcycle with a lift stand ll I p 12 Main work Remove the cable ties Remove screws O with the washers Detach frame protector in area 6 and take off Remove screw 8 Remove fitting Info Raise the wheel slightly to be able to remove the screws more easily Press angle lever C toward the rear Press linkage lever 0 downward Remove screws D P...

Page 63: ...he fork pivot Push the link fork back and secure it against falling over Hold the shock absorber and remove screw Remove the shock absorber carefully at the bottom Installing the shock absorber Main work Carefully position the shock absorber into the vehicle from the bottom Mount and tighten screw O Guideline Screw top M10 shock absorber 60 Nm 44 3 lbf ft Loctite 2701 TM 61 ...

Page 64: ...on the foot brake cylinder Push rod C engages in the foot brake cylinder Info Ensure that the dust boot is correctly seated Mount and tighten screws 0 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the angle lever and linkage lever Mount and tighten fitting D Guideline Nut linkage lever to M14x1 5 angle lever Info I Pay attention to flat area G Mount and tighten screw Guideline M1...

Page 65: ... work 3 Nm 2 2 lbf ft Check the free travel of the foot brake lever 0 p 152 Remove the motorcycle from the lift stand 0 p 12 9 11 Checkin the shock absorber linka e Preparatory work Raise the motorcycle with a lift stand 0 p 12 Main work Remove screw O Remove fitting 8 Info Raise the wheel slightly to be able to remove the screws more easily Remove fitting fi Take off the angle lever 63 ...

Page 66: ...nge the spacers Check the shaft seal rings for damage and wear If there is damage or wear Change the shaft seal rings Check dimension f Dimension f 303096 10 54 91 55 00 mm 2 1618 2 1654 in If dimension f is below the specified value Add the necessary spacing washers 64 Position the angle lever Mount the fitting D but do not tighten yet Guideline Nut angle lever to link fork M14x1 5 80 Nm 59 lbf f...

Page 67: ... be able to mount the screw more easily Tighten screws O Guideline Screw bottom M10 shock absorber Tighten fitting Guideline Nut angle lever to link fork Finishing work M14x1 5 60 Nm 44 3 lbf ft Loctite 2701 TM 80 Nm 59 lbf ft Remove the motorcycle from the lift stand IOI p 12 Servicing the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is ...

Page 68: ... 73 Assemble the seal ring retainer a p 73 Assemble the piston rod a p 74 Assemble the damper 0 p 76 Install the spring 0 p 82 Condition The shock absorber has been removed Clamp the shock absorber into the vise Guideline I Use soft jaws Measure and note the spring length while the spring is under tension Loosen screw O Turn the adjusting ring until the spring is completely without tension I Hook ...

Page 69: ...n work Make a note of the present state of rebound O and com pression damping 8 Open the adjusters of the rebound and compression damp ing completely Slowly open screw The nitrogen pressure dissipates Remove screw with the 0 ring Remove locking cap 8 Press in seal ring retainer 0 using the special tool I Pressing tool T1216 8 p 321 67 ...

Page 70: ...fo Check inner surface do not scratch If necessary remove any burrs with sandpaper Remove the piston rod Remove adjusting ring with the clamping ring Drain the oil Remove compression adjuster fD Remove the spring and piston Preparatory work Remove the spring 8 p 66 Disassemble the damper 8 p 67 ...

Page 71: ...o a screwdriver and put them aside together Remove piston 8 Remove compression shim stack 0 Info Guide the compression shim stackonto a screwdriver and put them aside together Remove rebound washer D Remove seal ring retainer Remove protection cap and rubber buffer Disassembling the seal rin retainer Preparatory work Remove the spring 0 p 66 Disassemble the damper 0 p 67 Disassemble the piston rod...

Page 72: ...emove washer D from seal ring 0 Remove washer Remove dust boot 9 17 Changing the pilot bushing 200796 10 70 Preparatory work Remove the spring 0 p 66 Disassemble the damper 0 p 67 Disassemble the piston rod 0 p 68 Disassemble the seal ring retainer 0 p 69 Main work Press pilot bushing O out of seal ring retainer 8 with the special tool I Pressing tool T1504 0 p 324 ...

Page 73: ...eal ring retainer with sleeve 6 of the special tool I Mounting tool T150S 0 p 324 Press the special tool through the new pilot bushing I Calibrating unit T1205 8 p 320 The pilot bushing is calibrated Finishing work Assemble the seal ring retainer 8 p 73 Condition The damper has been disassembled Measure the inside diameter on both ends and in the middle of the damper cartridge Damper cartridge Dia...

Page 74: ...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 the piston rings for damage and wear If damage or a bronze colored surface is visible Change the piston Condition The shock absorber has been removed Clamp the shock absorber into the vise Guideline I Use soft jaws Remove both collar bushings O of the heim joint wit...

Page 75: ...in the bench vise Guideline I Use soft jaws I Pressing tool T1206 0 p 321 Press the heim joint all the way in Press the heim joint against the lock ring using the special tool I Pressing tool T1207S 0 p 321 Mount second lock ring 8 Position both collar bushings Dand press in Mount dust boot O with the special tool I Mounting sleeve T1204 0 p 320 Grease the sealing lip of the dust boot I Lubricant ...

Page 76: ...ring C Mount rebound rubber Grease the 0 ring groove I Lubricant T158 0 p 304 Mount 0 ring Preparatory work Assemble the seal ring retainer g p 73 Main work Clamp the piston rod with the fork in a bench vise Guideline I Use soft jaws Mount rubber buffer O and protection cap 8 Position special tool on the piston rod I Mounting sleeve T1515 0 p 325 Grease the dust boot and slide the seal ring retain...

Page 77: ...ith the smaller washers facing downward Sand down piston Q on both sides on a surface plate using 1200 grit sandpaper Clean the piston Mount the piston Guideline Viewf of piston from above ViewG of piston from below Mount rebound shim stack with the smaller washers fac ing upward Mount washer with the groove facing downward 75 ...

Page 78: ...t T158 0 p 304 Lubricate the thread I Lubricant T159 0 p 305 Mount the piston with the spring Mount and tighten compression adjuster O Guideline Compression damp M31x1 ing adjuster Clamp the damper in a bench vise Guideline I Use soft jaws 35 Nm 25 8 lbf ft Mount adjusting ring 8 with the clamping ring Info The adjusting ring cannot be mounted after the piston rod has been mounted Fill the damper ...

Page 79: ...rn counterclockwise by the number of clicks corre sponding to the shock absorber type Guideline Lowspeed compression damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Turn adjusting screw fD all the way clockwise with a socket wrench Turn counterclockwise by the number of turns corre sponding to the shock absorber type Guideline Highspeed compression damping Comfort 2 5 turns Standard 2...

Page 80: ...crews and Q in the location determined during disassembly Bleeding and filling the dam er Info Before working with the vacuum pump carefully read the operating manual included with the vacuum pump Open the adjusters of the rebound and compression damping completely Clamp the damper as shown Guideline I Use soft jaws Info I The filling port must be located at the highest position The piston rod mov...

Page 81: ... I Depth micrometer T1 07S a p 320 The floating piston is located in the lowermost position When the vacuum gauge reaches the required value turn control lever Oil reservoir 0 to Equalize pressure Guideline I 4 mbar The pressure gauge increases to the required value 0 bar When the pressure gauge reaches the specified value turn control lever Damper C to Pressure Guideline 0 bar Oil is pumped into ...

Page 82: ...amper C to Pressure Guideline 0 bar Oil is pumped into the damper The pressure gauge increases to the required value 3 bar When the pressure gauge reaches the specified value turn control lever Damper C to Vacuum Guideline 3 bar The pressure gauge drops to the required value 0 bar When the pressure gauge reaches the required value acti vate the On Off switch Guideline 0 bar The vacuum pump is swit...

Page 83: ...10 3 lbf ft Mount screw O with the O ring and screw in approx 2 full turns but do not tighten it fully Info The piston rod is fully extended Fix the special tool in the vise Filling tool T170S1 0 p 325 Filling adapter T1296 0 p 322 Connect the special tool to the pressure regulator of the filling cylinder I Filling gas nitrogen Adjust the pressure regulator Guideline I Gas pressure I 10 bar 145 ps...

Page 84: ... O is mounted with the clamping ring Mount washer 8 Measure the overall spring length while the spring is not under tension Position the spring Guideline Spring rate Weight of rider 65 75 kg 143 165 lb Weight of rider 75 85 kg 165 187 lb Weight of rider 85 95 kg 187 209 lb Mount washer fD Mount spring retainer 8 Mount lock ring 0 Alternative 1 42 N mm 240 lb in 45 N mm 257 lb in 48 N mm 274 lb in ...

Page 85: ...ndling characteristic Tension the spring to the length measured during disas sembly by turning the adjusting ring I Hook wrench 90129051000 a p 319 Tighten screw D Guideline Screw shock MS 5 Nm 3 7 lbf ft absorber adjusting ring Checking the heim joint for la T01328 10 Preparatory work Raise the motorcycle with a lift stand a p 12 Place a load on the front of the vehicle The rear wheel is not in c...

Page 86: ...move both collar bushings O of the heim joint with a spe cial tool I Drift T120 8 p 320 Press the heim joint against a lock ring using the special tool I Pressing tool T1207S 0 p 321 Remove second lock ring Place special tool f underneath and press out heim joint using special tool C I Pressing tool T1207S 8 p 321 Position the new heim joint and the special tool Guideline I Use soft jaws I Pressin...

Page 87: ...f the foot brake lever 0 p 152 Remove the motorcycle from the lift stand 0 p 12 Check the link fork for damage cracking and deformation If the link fork exhibits damage cracking or deformation Change the link fork Info Always replace a damaged link fork Repair of the link fork is not authorized by Husqvarna Motorcycles Checking the fork bearing for lay Preparatory work Raise the motorcycle with a ...

Page 88: ...bearing 0 p 87 Finishing work Remove the motorcycle from the lift stand 0 p 12 Preparatory work Raise the motorcycle with a lift stand 0 p 12 Remove the rear wheel 0 p 124 Main work Take the brake line out of the guide Push the brake caliper forward slip it out and hang it to the side Info Cover the components to protect them against dam age Remove connecting link O of the chain Take off the chain...

Page 89: ...ink fork Remove the cable ties Remove screws 8 with the washers Detach frame protector in area f and take off Remove nut C Remove the swingarm pivot Remove the link fork Preparatory work Raise the motorcycle with a lift stand p 12 Remove the rear wheel p 124 Remove the link fork p 86 87 ...

Page 90: ...earing Remove collar bushings O Remove bushing 8 Remove shaft seal rings D using a suitable tool Remove stop disks C Press out bearing 0 using a suitable tool Using a suitable tool press in new bearing 0 Position the stop disks C Press in shaft seal rings D Mount bushing 8 ...

Page 91: ... grease 8 p 304 Position the collar bushings O with the shoulder facing inward Right fork bearing Remove collar bushings CD Remove bushing Remove shaft seal rings using a suitable tool Press out bearing 0 using a suitable tool Using a suitable tool press in new bearing Press in shaft seal rings 89 ...

Page 92: ...tall the link fork 0 p 90 Install the rear wheel 0 p 125 Remove the motorcycle from the lift stand 8 p 12 Main work Position the link fork Mount the fork pivot Mount and tighten nut O Guideline I Nut fork pivot I M16x1 5 1100 Nm 73 8 lbf ft I Attach frame protector in area G and position Mount and tighten screws 8 with the washers Guideline Screw frame pro tector Mount the cable ties M5 3 Nm 2 2 l...

Page 93: ...M14x1 5 80 Nm 59 lbf ft Connect the chain with connecting link C Guideline The closed side of the chain joint lock must face in the direction of travel Position the brake caliper and pull it back Position the brake line in the guide Finishing work Install the rear wheel 8 p 125 Remove the motorcycle from the lift stand 8 p 12 91 ...

Page 94: ...ow the exhaust system to cool down before performing any work on the vehicle Detach springs O I Spring hook 5030501700004 0 p 319 Detach spring I Spring hook 5030501700004 0 p 319 Remove screw CD Take off the manifold Position the manifold Mount screw O but do not tighten yet Guideline Remaining screws chassis M8 25 Nm 18 4 lbf ft ...

Page 95: ...aining screws chassis M8 25 Nm 18 4 lbf ft Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down before performing any work on the vehicle Detach spring O I Spring hook 5030501700004 l p 319 Remove screws 8 with the washers and take off the main silencer 93 ...

Page 96: ...s fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven 10 Nm 7 4 lbf ft Allow the exhaust system to cool down before performing any work on the vehicle Info Over time the fibers of the glass fiber yarn escape and the damper burns out Not only is the noise level higher the performance characteristic changes Preparatory work Remo...

Page 97: ... C from the inner tube Clean the parts that need to be reinstalled and check for damage Mount new glass fiber yarn filling C on the inner tube Position new glass fiber yarn filling CD in the silencer cap Insert O ring and silencer cap into outer tube 0 Mount all screws on the silencer cap and tighten Guideline Screws on main silencer Finishing work M5 Install the main silencer 0 p 94 7 Nm 5 2 lbf ...

Page 98: ...ine damage Unfiltered intake air has a negative effect on the service life of the engine Dust and dirt will enter the engine without an air filter Never start to use the vehicle without an air filter 96 Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulat...

Page 99: ...ning pin D is secured by retaining tab Info If the air filter is not mounted correctly dust and dirt may enter the engine and result in damage Finishing work Install the air filter box cover a p 96 Cleanin the air filter and air filter box Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in c...

Page 100: ...leaner 0 p 304 Info I Only press the air filter to dry it never wring it out Oil the dry air filter with a high grade air filter oil I Oil for foam air filter a p 305 Clean the air filter box Clean the intake flange and check it for damage and tight ness Finishing work Install the air filter a p 97 Install the air filter box cover 0 p 96 ...

Page 101: ...contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Note Environm...

Page 102: ...ng the right side cover Removing the seat Caution Main work Attach side cover with the holding lugs G from below and push upward Engage the side cover in areas 0 and Finishing work Mount the seat 8 p 101 Install the air filter box cover a p 96 Danger of burns The voltage regulator gets very hot when the vehicle is driven Allow the voltage regulator to cool down before performing any work Preparato...

Page 103: ...it off Main work Mount the front of the seat on the collar bushing of the fuel tank and the rear in the bracket Push the seat forward Make sure that the seat is locked in correctly Mount and tighten screw O Guideline Remaining screws chassis Finishing work M6 Install the air filter box cover al p 96 10 Nm 7 4 lbf ft 41 41 101 ...

Page 104: ...case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Preparatory work Remove the air filter box cover 8 p 96 Remove the seat 8 p 100 Remove the right side cover 8...

Page 105: ...e engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact...

Page 106: ... Guideline Remaining screws chassis M6 Plug in connector D for the fuel pump 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft Remove the wash cap set and thoroughly clean the plug in connection of the fuel line using compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Lubricate the 0 ring and connect plug in connection 8 for the fuel lin...

Page 107: ...nse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Condition The fuel tank is completely full Ensure that the battery voltage does not drop below 12 5 V The diagnostic tool is disconn...

Page 108: ...tion of the fuel line 12 10 Changing the fuel pump A 106 Danger Fire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off i...

Page 109: ...eparatory work Drain the fuel from the fuel tank into a suitable container Remove the air filter box cover el p 96 Remove the seat el p 100 Remove the right side cover el p 100 Remove the fuel tank el p 102 Main work Remove screws O Detach front side cover in area 9 to the front and take it off Remove nut 8 with the gasket Remove fuel connection D with gaskets Remove screws C 107 ...

Page 110: ... TRIM 108 Pull out the fuel pump Position the new fuel pump Mount nut 8 with gasket but do not tighten yet Mount and tighten screws C Guideline I Screw fuel pump I EJOT The connector points downwards 1 2 3 Nm 1 7 lbf ft ...

Page 111: ... covers in area G and position 12 11 Changing the fuel filter Danger Fire hazard Fuel is highly flammable Mount and tighten screws O Finishing work Install the fuel tank a p 103 Install the right side cover a p 100 Mount the seat a p 101 Install the air filter box cover a p 96 The fuel in the fuel tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open...

Page 112: ...pills on them Keep fuels correctly in a suitable canister and out of the reach of children Note Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system Preparatory work Drain the fuel from the fuel tank into a suitable container Remove the air filter box cover 0 p 96 Remove the seat 0 p 100 Remove the ri...

Page 113: ...uel pump Remove hose clamps 0 Remove fuel filter D Press locking mechanism Pull back fuel pump housing Change fuel screen Mount the fuel pump housing Mount the new fuel filter D Arrow C points away from the fuel pump Mount hose clamps 0 I Hose clamp plier 60029057000 8 p 312 111 ...

Page 114: ...00062010051 8 p 305 Info I Make sure that no grease gets into the fuel connec tion Mount fuel connection fD with gaskets but do not tighten yet The cut out 0 is aligned to the nut 8 Tighten nut 8 Guideline Nut fuel pump fas tener M12x1 75 Tighten fuel connection fD Guideline Fuel connection on fuel tank M8x1 25 15 Nm 11 1 lbf ft 10 Nm 7 4 lbf ft Attach side covers in area 6 and position Mount and ...

Page 115: ...le fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Note Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system Clean plug i...

Page 116: ...are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Start the engine and check the response ...

Page 117: ...ove the start number plate 8 p 116 Main work Remove screws O and Take off front fender Main work Position front fender Mount and tighten screws O and 8 Guideline Remaining screws chassis Finishing work M6 Install the start number plate 0 p 116 10 Nm 7 4 lbf ft 115 ...

Page 118: ...side Remove screw 8 and take off the brake line guide and start number plate Installing the start number late Position the brake line and brake line guide on the start num ber plate Mount and tighten screw O Position the start number plate The holding lugs engage in the fender Mount and tighten screw 8 ...

Page 119: ...e of the tires all have a major impact on the handling characteristic of the motorcycle The tires mounted on the front and rear wheels must have a similar profile Worn tires have a negative effect on handling characteristics especially on wet surfaces Check the front and rear tires for cuts run in objects and other damage If the tires have cuts run in objects or other damage Change the tires Check...

Page 120: ...heck it If there is detectable play Change the rear wheel bearing 8 p 133 Finishing work Remove the motorcycle from the lift stand 8 p 12 Danger of accidents Worn out brake discs reduce the braking effect Make sure that worn out brake discs are replaced immediately rCnJ ____ H00939 10 Check the front and rear brake disc thickness at multiple points for the dimension 6 Info I Wear reduces the thick...

Page 121: ...on the spoke length and spoke diameter If you hear different tone frequencies from different spokes of equal length and diameter this is an indica tion of different spoke tensions I You should hear a high note If the spoke tension differs Correct the spoke tension Check the spoke torque Guideline Spoke nipple front wheel Spoke nipple rear wheel M4 5 M4 5 6 Nm 4 4 lbf ft 6 Nm 4 4 lbf ft I Torque wr...

Page 122: ...than the specified value Center the rim Info Center the rim by pulling the spoke nipple on the other side of the rim run out If there is sig nificant deformation change the rim Correct the spoke tension 14 7 1 Removing the front wheel 120 Preparatory work Raise the motorcycle with a lift stand 8 p 12 Main work Press the brake caliper onto the brake disc by hand in order to push back the brake pist...

Page 123: ...rning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary H00935 10 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change front wheel bearing 0 p 122 Clean and grease shaft seal rings O and contact surfaces f of the spacers I Lo...

Page 124: ...ew fork stub Changing the front brake disc 1 15 Nm 11 1 lbf ft Info If the brake discs are changed the brake linings must also be changed 14 7 4 122 Preparatory work Raise the motorcycle with a lift stand 0 p 12 Remove the front wheel 0 p 120 Main work Remove screws O Remove the brake disc Clean the contact surface of the brake disc Position the new brake disc with the label facing outward Mount a...

Page 125: ...press the bearing in via the outer bearing race otherwise the bearing will be damaged when it is pressed in Clean grease and mount spacing tube C I Long life grease a p 304 Press in new bearing D all the way using a suitable tool Info Only press the bearing in via the outer bearing race otherwise the bearing will be damaged when it is pressed in Grease new shaft seal rings 8 and O and press in unt...

Page 126: ...ve chain adjuster 8 Pull out wheel spindle 8 far enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Remove the chain from the rear sprocket Info Cover the components to protect them against dam age Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Hold ...

Page 127: ...rease IOJ p 304 Position the rear wheel and insert wheel spindle 8 The brake linings are correctly positioned Mount the chain Position chain adjuster 4D Mount nut C but do not tighten it yet Make sure that chain adjusters 8 are fitted correctly on adjusting screws 0 Check the chain tension IOJ p 126 Tighten nut C Guideline Nut rear wheel spin M25x1 5 die Info 80 Nm 59 lbf ft I The wide adjustment ...

Page 128: ...hain is tensioned too much the chain engine sprocket rear sprocket transmission and rear wheel bearings wear more quickly Some components may break if overloaded If the chain is too loose the chain may fall off the engine sprocket or the rear sprocket As a result the rear wheel locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the specif...

Page 129: ...nut O Loosen nuts 8 Adjust the chain tension by turning adjusting screws left and right Guideline Chain tension 1 55 58 mm 2 17 2 28 in Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks t The rear wheel is then correctly aligned Tighten nuts 8 Make sure that chain adjusters 8 are fitted correc...

Page 130: ...weight O Guideline Weight chain wear mea surement 10 15 kg 22 33 lb Measure distance G of 18 chain rollers in the lower chain section Info Chain wear is not always even so you should repeat this measurement at different chain positions Maximum distance G from 18 chain rollers at the longest chain section 272 mm 10 71 in If distance G is greater than the specified measurement Change the drivetrain ...

Page 131: ... ft Loctite 243 Check the chain sliding piece for wear If the lower edge of the chain pins is in line with or below the chain sliding piece Change the chain sliding piece Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten the screw on the chain sliding piece Guideline Screw chain slid MS ing piece 15 Nm 11 1 lbf ft Check the chain guide with a slide gau...

Page 132: ...ents Lubricants on the tires reduces the road grip Remove lubricants from the tires using a suitable cleaning agent Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils...

Page 133: ...otorcycle from the lift stand el p 12 Preparatory work Remove the air filter box cover el p 96 Raise the motorcycle with a lift stand el p 12 Main work Remove screw O with the washer Remove screw 8 Take off the engine sprocket cover Have an assistant operate the rear brake Remove screw with the washer Remove the rear wheel el p 124 Remove connecting link C of the chain Take off the chain Info WHEE...

Page 134: ...ft Loctite 2701 TM Slide new engine sprocket 0 onto the countershaft Mount the new chain Connect the chain with connecting link C Guideline The closed side of the chain joint lock must face in the direction of travel Install the rear wheel I p 125 Have an assistant operate the rear brake Mount and tighten screw CD with the washer Guideline Screw engine sprocket M10 60 Nm 44 3 lbf ft Loctite 2701 T...

Page 135: ... 14 8 lbf ft Finishing work Remove the motorcycle from the lift stand p 12 Install the air filter box cover p 96 14 8 10 Changing the rear wheel bearing Preparatory work Raise the motorcycle with a lift stand p 12 Remove the rear wheel p 124 Main work Remove shaft seal ring O Remove lock ring Remove shaft seal ring D Using a suitable tool press bearing 8 out from the inside to the outside Remove s...

Page 136: ...ing will be damaged when it is pressed in Clean grease and mount spacing tube 0 I Long life grease 8 p 304 Press new bearing C all the way in from the outside to the inside Info Only press the bearing in via the outer bearing race otherwise the bearing will be damaged when it is pressed in Grease new shaft seal ring CD and press it in until it is flush Mount lock ring 8 The lock ring engages audib...

Page 137: ...r relay housing under the seat Preparatory work Press and hold the kill switch while the engine is idling until the engine stops Remove the air filter box cover 0 p 96 Remove the seat 0 p 100 Main work Pull starter relay O from the holder Take off protection caps Remove faulty main fuse 6 Info A faulty fuse has a burned out fuse wire 6 A spare fuse C is located in the starter relay Insert a new ma...

Page 138: ... Remove the air filter box cover 0 p 96 Remove the seat 0 p 100 Main work Disconnect negative cable O of the 12 V battery Connecting the negative cable of the 12 V battery I T02638 10 Main work Connect negative cable O of the 12 V battery Guideline Screw battery termi M5 nal 2 5 Nm 1 84 lbf ft Contact disk 6 must be mounted under screw and cable lug D with the claws toward the battery terminal Fin...

Page 139: ...m voltage before the start of the charge 9 V Dispose of 12 V batteries with less than the minimum voltage correctly Caution Danger of burns The voltage regulator gets very hot when the vehicle is driven Allow the voltage regulator to cool down before performing any work S02336 10 Preparatory work Press and hold the kill switch c q while the engine is idling until the engine stops Remove the air fi...

Page 140: ...ttery termi M5 nal Finishing work Mount the seat p 101 Install the air filter box cover p 96 Risk of injury Battery acid and battery gases cause serious chemical burns Keep 12 V batteries out of the reach of children Wear suitable protective clothing and safety glasses Avoid contact with battery acid and battery gases Keep sparks or open flames away from the 12 V battery Only charge 12 V batteries...

Page 141: ... sulfating occurs destroying the battery The 12 V battery is maintenance free The acid level does not have to be checked 311910 10 Preparatory work Press and hold the kill switch while the engine is idling until the engine stops Remove the air filter box cover IUI p 96 Remove the seat IUI p 100 Disconnect the negative cable of the 12 V battery 0 p 136 Main work Connect the battery charger to the 1...

Page 142: ...g point Ground I Charging voltage 5 000 rpm 1 13 5 15 0 V If the displayed value is less than the specified value Check the plug in connections from the alternator to the voltage regulator Check the plug in connections from the voltage regu lator to the wiring harness Check the stator winding of the alternator 0 p 270 If the displayed value is greater than the specified value Change the voltage re...

Page 143: ... 8 p 101 Install the air filter box cover lell p 96 Condition The 12 V battery is disconnected Remove the capacitor Discharge the capacitor by bridging the two contacts Connect the capacitor to a 12 V test lamp to a connection and connect to the 12 V battery as shown in the figure Info As the capacitor charge increases the test lamp becomes dimmer The bulb lights up for 0 5 2 0 s The capacitor is ...

Page 144: ...back the cable covers Disconnect cables 8 and fD on the starter relay Connect the starter relay to a 12 V power supply as per the figure Measure the resistance between the specified points I Resistance of open circuit I O n If the value displayed does not meet specifications Change the starter relay Connect cables 8 and fD on the starter relay Pull back the cable covers Plug in connector O Mount t...

Page 145: ...thing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your c...

Page 146: ...e pistons Ensure that brake fluid does not flow out of the brake fluid reservoir if necessary extract excess Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pis tons Remove cotter pins 8 pull out pin and remove the brake linings Clean the brake caliper and brake caliper bracket Check that spring plate Cs in the brake caliper and sliding plate i...

Page 147: ... in the event of overheating If there is no free travel on the hand brake lever pressure builds up on the front brake circuit Set the free travel on the hand brake lever in accordance with the specification Push the hand brake lever forward and check free travel f Free travel of hand brake lever 3 mm 0 12 in If the free travel does not match the specification Adjust the basic position of the hand ...

Page 148: ...e brake system and do not continue riding until the problem is eliminated Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Preparatory work Check the front brake linings 8 p 143 Main work Move the brake reservoir mounted on the handlebar to a hori zontal position Addin f...

Page 149: ...rvice schedule Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painte...

Page 150: ...ause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean brake fluid fr...

Page 151: ...rake fluid emerges in the bleeder bottle hose without bubbles Tighten the bleeder screw Close shut off valve C Open the bleeder screw again until brake fluid stops emerg ing Info I Overfilling the brake fluid reservoir is prevented Tighten the bleeder screw Remove the bleeder bottle hose Attach the protection cap Disconnect the bleeding device Remove the bleeder cover Add brake fluid up to level G...

Page 152: ... clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to yo...

Page 153: ...o Make sure that you do not press the brake caliper against the spokes when pushing back the brake pis ton Remove cotter pins pull out pin C and remove the brake linings Clean the brake caliper and brake caliper bracket Check that spring plate 0 in the brake caliper and sliding plate D in the brake caliper bracket are seated properly Info I The arrow on the spring plate points in the direction of ...

Page 154: ...dance with the specification l 402026 10 Disconnect spring O Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel f Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in If the free travel does not meet specifications Adjust the basic position of the foot brake lever p 152 Reconnect spring O Ad usting the basic...

Page 155: ...sis M6 Hold screw fD and tighten nut Guideline Nut foot brake lever M8 stop Attach spring O 10 Nm 7 4 lbf ft 20 Nm 14 8 lbf ft Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the brake system is leaking or the brake linings are worn...

Page 156: ...y if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the...

Page 157: ... with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Ne...

Page 158: ...eding device 00029013100 8 p 306 Open bleeder screw 0 by approx one half turn Info Drain until fresh brake fluid emerges in the bleeder bottle hose without bubbles Tighten the bleeder screw Close shut off valve 8 Open the bleeder screw again until brake fluid stops emerg ing Info I Overfilling the brake fluid reservoir is prevented Tighten the bleeder screw Remove the bleeder bottle hose Attach th...

Page 159: ...BRAKE SYSTEM 16 Check the foot brake lever for a firm pressure point 157 ...

Page 160: ...ir filter box cover 0 p 96 Remove the seat 0 p 100 Remove the right side cover 8 p 100 Remove the fuel tank 0 p 102 Remove the main silencer a p 93 Main work Remove the cable ties Remove screws O with the washers Detach frame protector in area 6 and take off Disconnect the negative cable of the 12 V battery Loosen hose clip 8 Push back protection cap Unplug the connector ...

Page 161: ...ull off the vent hose Remove screw 0 Loosen screw D Repeat these steps on the opposite side Pivot the subframe up and secure it Remove springs I Spring hook 5030501700004 l p 319 Remove screw C Take off the manifold ENGINE 17 159 ...

Page 162: ...17 ENGINE 160 Remove screws Take off the engine braces Remove the cable ties Remove the cable clamps and expose the cable Disconnect plug in connector Ci Disconnect plug in connectors G Expose the cable ...

Page 163: ... plug in connector 48 Push back protection cap 48 Unplug the connector Loosen hose clip 4D Pull off the radiator hose Loosen hose clips 48 Pull off the radiator hoses Disconnect spark plug connector ENGINE 17 161 ...

Page 164: ... Info Do not kink the clutch line Do not activate the clutch lever while the slave cylin der of the clutch is removed Actuate the foot brake lever Loosen screw fl Info The help of an assistant is useful in this step Remove connecting link of the chain Take off the chain Info Cover the components to protect them against dam age Remove screw fl with the washer Take off the engine sprocket ...

Page 165: ... shift lever Loosen hose clip ENGINE 17 Pull the throttle valve body off of the cylinder head toward the rear and hang it to one side Push back protection cap and remove the nut Hang the positive cable to the side Remove spring Remove fitting 163 ...

Page 166: ...ure that the engine is sufficiently secured against falling over Cover the components to protect them against dam age Main work Position the engine in the frame Info The help of an assistant is useful in this step Make sure that the engine is sufficiently secured against falling over Cover the components to protect them against dam age Mount screws O but do not tighten yet Guideline Engine carryin...

Page 167: ...hten fitting Guideline Nut linkage lever to M14x1 5 angle lever Info 80 Nm 59 lbf ft I Raise the wheel slightly to be able to mount the screw more easily Mount spring 8 Position the positive cable on the starter motor Mount and tighten the nut Guideline Nut cable on starter M6 motor Position protection cap 0 Position the throttle valve body Tighten hose clip D 4 Nm 3 lbf ft 165 ...

Page 168: ...t Mount the chain M10 60 Nm 44 3 lbf ft Loctite 2701TM Connect the chain with connecting link Guideline The closed side of the chain joint lock must face in the direction of travel Actuate the foot brake lever Tighten screw G Guideline Screw engine sprocket Info M10 60 Nm 44 3 lbf ft Loctite 2701TM The help of an assistant is useful in this step Position clutch slave cylinder with the new gasket M...

Page 169: ...ave cylinder M6 Mount and tighten screw 48 Guideline Screw engine sprocket cover M8 Plug in spark plug connector 41 Mount the radiator hoses Position and tighten hose clips 4D Mount the radiator hose Position and tighten hose clip e Plug in the connector Mount protection cap Ci 10 Nm 7 4 lbfft 20 Nm 14 8 lbfft 167 ...

Page 170: ...4D of the gear position sensor Join plug in connectors Gi of the alternator Join plug in connector G of the crankshaft speed sensor Route the cable without tension Route the cable without tension and secure with cable clips and cable ties ...

Page 171: ... screw but do not tighten yet Guideline Remaining screws chassis Mount springs MB 25 Nm 18 4 lbf ft I Spring hook 5030501700004 0 p 319 Tighten screw Guideline Remaining screws chassis MB 25 Nm 18 4 lbf ft Remove the locking piece and position the subframe Info Watch out for the intake flange Mount and tighten screw Guideline Screw sub frame Remove screw e MB Mount and tighten screw e 30 Nm 22 1 l...

Page 172: ...n the opposite side Mount the vent hose and position hose clamp Plug in the connector Mount protection cap Position and tighten hose clip 9 Attach frame protector in area G and position Mount and tighten screws with the washers Guideline Screw frame pro tector Mount the cable ties MS 3 Nm 2 2 lbf ft ...

Page 173: ... the O ring Finishing work Install the main silencer 0 p 94 Install the fuel tank 0 p 103 Install the right side cover 0 p 100 Mount the seat 0 p 101 Install the air filter box cover 0 p 96 Remove the motorcycle from the lift stand 0 p 12 Refill with coolant 0 p 255 Install the engine guard 0 p 52 Perform the initialization run 0 p 278 Go for a short test ride Read out the fault memory using the H...

Page 174: ...mbly stand Holder and fitting for work stand 79429002000 ll l p 317 Engine assembly stand 80329001000 ll l p 318 Mount the engine on the special tool Info Work with an assistant or 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 ...

Page 175: ... oil screen Removing the clutch push rod Removing the oil filter Remove clutch push rod O Remove screws O Remove the oil filter cover 8 with the O ring Pull oil filter 8 out of the oil filter housing I Lock ring plier 51012011000 p 309 ENGINE 17 173 ...

Page 176: ... 3 7 Removing the valve cover D05026 11 174 Remove screws O and take off the starter motor Remove the spark plug using the special tool I Spark plug wrench with link 77229172000 0 p 315 Remove screws O Take off the valve cover with the valve cover seal Remove gasket 8 from the engine vent ...

Page 177: ...nator cover Take off alternator cover gasket Positioning the engine at ignition top dead center ENGINE 17 Align camshaft marking 9 with the center of the retaining bracket G on the cylinder head Remove screw O with washer Screw in special tool Locking screw 113080802 0 p 307 175 ...

Page 178: ...camshaft Remove screw O with the washer and spring Remove screws 8 Take off the chain adjuster with the gasket Remove screws O Take off camshaft retaining bracket 8 176 Pull the camshaft out of the bearing seats Take the timing chain from the camshaft gear Remove the camshaft ...

Page 179: ... Push the cylinder upward Info Only push the cylinder as far up as necessary to take the piston pin out Remove piston ring lock O Remove the piston pin Take off the cylinder and piston Push the piston upward out of the cylinder Info If no further work is to be performed on the cylinder and piston the piston can remain in the cylinder Remove cylinder base gasket 8 Info Ensure locating pins D remain...

Page 180: ...move nut O with the spring washer Mount special tool 8 on the rotor I Extractor 79229032044 p 316 Hold it tight using the special tool and pull off the rotor by turning the screw in Remove the woodruff key Remove screw O Remove timing chain tensioning rail 8 toward the top Remove screw Remove the timing chain securing guide ...

Page 181: ...he direction of travel 17 3 16 Removing suction pump 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 O ring D 17 3 17 Removing the gear position sensor Remove screws O Take off the gear position sensor 179 ...

Page 182: ...ws O Take off the water pump cover Take off the water pump cover seal Remove screws O Take off the clutch cover Info If work is to be performed on the water pump unscrew the nut of the water pump impeller Remove dowels 8 Take off clutch cover gasket fD Loosen screws O in a crisscross pattern and remove them Take off spring retainer ...

Page 183: ...ff spring washer CD Take off pretension ring C Remove clutch pressure cap 0 Remove clutch disc pack D completely Remove clutch throw out Remove special tool C I Locking screw 113080802 IUI p 307 ENGINE 17 181 ...

Page 184: ...ve nut Info LH thread Bend up the lock washer Hold the inner clutch hub with the special tool I Holding wrench 51129003000 IUI p 309 Remove nut 8 with the lock washer Take off inner clutch hub C and washer 0 Info The washer usually sticks to the inner clutch hub Take off clutch basket D Take off both needle bearings and collar bushing Remove screw O with the washer Take off the torque limiter ...

Page 185: ...emoving the force pump Take off starter idler gear O Remove lock ring O Take off washer f Remove oil pump idler gear D Remove lock ring C Take off washer 0 Take off oil pump gear wheel i Remove pin Remove screws Take off oil pump cover 6 ENGINE 17 183 ...

Page 186: ...ding plate O away from the shift drum locating unit Remove shift shaft with the washer 17 3 26 Removing the shift drum locating unit 17 3 27 Removing the locking lever 184 Remove screw O Push away locking lever from shift drum locating unit fs and remove the shift drum locating unit Relieve tension from the locking lever Unscrew O and remove together with locking lever washer sleeve and spring ...

Page 187: ...ount special tool 8 I Puller 75029021000 8 p 313 ENGINE 17 Hold the special tool firm and pull off the primary gear wheel 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 185 ...

Page 188: ...of the engine case upward and remove the fitting of the engine fixing arm Pull off the section of the engine case Info Ensure that washer 6 is not damaged Do not tension the section of the engine case Remove the special tool Take off the left section of the engine case Remove spacer 4D Remove dowel C Remove shift rails O together with upper springs 8 and lower springs ...

Page 189: ...t forks O to one side Info I Do not misplace the shift rollers Remove shift drum Take shift forks O out of the shift grooves Info Do not misplace shift rollers 8 17 3 34 Removing the transmission shafts Remove 0 ring O Position the engine upright Remove lock ring ENGINE 17 187 ...

Page 190: ...the washers 17 3 35 Removing the crankshaft 17 4 17 4 1 188 Remove crankshaft O Working on individual parts Info I Ensure that washer 8 is not damaged Take off the right section of the engine case Working on the right section of the engine case Preparatory work Remove the oil pressure control valve 0 p 191 ...

Page 191: ...1150 C 302 F Position washer CD Insert the new cold bearings into the bearing seats of the hot section of the engine case and if necessary use a suitable press drift to push the bearings from the inside to the out side all the way to the stop or until flush Info When pressing in ensure that the section of the engine case lies flat in order prevent damage Only press the bearings in using the outer ...

Page 192: ...hift shaft Remove any remnants of sealing compound and clean the section of the engine case thoroughly Warm the section of the engine case in an oven Guideline 1150 C 302 F Knock the section of the engine case against a level wooden board This will cause the bearings to drop out of the bearing seats Info Any bearings that remain in the section of the engine case must be removed using a suitable to...

Page 193: ...is case the engine case must be renewed Press in shaft seal ring 8 of the countershaft and shaft seal ring C of the shift shaft with the open side facing inward until it is flush Position the bearing retainers Mount and tighten screws Guideline Screw bearing retainer MS Position oil spray tube 8 Mount and tighten screw O Guideline Screw oil spray M4 tube Mount the dowels 6 Nm 4 4 lbf ft Loctite 24...

Page 194: ...0 p 192 oil pressure control valve installing D01669 11 Insert ball O and pressure spring 8 Mount and tighten screw plug D with sealing washer C Guideline Screw plug oil pres M12x1 5 sure control valve 20 Nm 14 8 lbf ft crankshaft seal ring in the clutch cover changing Removing the water pump Remove lock ring O Remove crankshaft seal ring 8 Press the new crankshaft seal ring into the clutch cover ...

Page 195: ...h an appropriate tool Info Suitably support the clutch cover while pressing it out Press bearing O of the water pump shaft up to the stop with a suitable tool I Pressing tool 79429006000 a p 317 Info I Provide suitable support for the clutch cover while pressing in Press shaft seal ring 8 all the way in I Pressing tool 60029043040 al p 312 The narrower chamfer faces the balancer shaft 193 ...

Page 196: ... Loctite 243 17 4 9 Removing the timing chain sprocket Warm up the timing chain sprocket O with a blow dryer Pull off the timing chain sprocket with the special tool I Puller 60029033000 a p 311 Info I The timing chain sprocket is usually damaged by the disassembly and must be replaced 17 4 10 Installing the timing chain sprocket 194 Info Never clamp the crankshaft with a crankshaft journal in the...

Page 197: ...ensating disk Repeat these steps on the opposite side 17 4 12 Installing the crankshaft bearing inner race 310069 11 Main work Fix the crankshaft in the vise Guideline I Use soft jaws Slide on compensating disk O Info The compensating disks have a larger diameter than the crankshaft stub Ensure that the compensating disks are centered and fixed with a small amount of grease Only add the compensati...

Page 198: ...ecial tool I Crankshaft pressing tool 75029047000 l p 313 Info I Hold the lower crankweb Remove the connecting rod and bearing Press crank pin fD out of the lower crankweb Place the crankweb onto special tool C Insert for crankshaft pressing tool 79429008000 l p 317 Info The special tool must be positioned with the flat sur face facing downward Press in new crank pin 0 all the way Oil channel 6 is...

Page 199: ...8929008000 8 p 315 Press in the upper crankweb as far as possible Info I The press mandrel must be positioned over the crank pin Take the crankshaft out of the special tool and check that the connecting rod can move freely Measure axial play O between the connecting rod and the crankwebs using the special tool I Feeler gauge 59029041100 8 p 311 Connecting rod end play of lower conrod bearing 0 20 ...

Page 200: ...nt the left section of the engine case Mount and tighten the screws Guideline I Screw engine case I M6 110 Nm 7 4 lbf ft Mount the dial gauge support on the engine case and mea sure and note down the crankshaft axial play Guideline Crankshaft axial play 0 50 0 60 mm 0 0197 0 0236 in If the measured value does not meet specifications Remove the crankshaft Remove the crankshaft bearing inner race 0 ...

Page 201: ...10 Check the cylinder bearing surface for damage If the cylinder bearing surface is damaged Change the cylinder and piston Measure the bore diameter at several locations on the 0 axis and 0 axis using a micrometer to identify oval wear Guideline Cylinder drill hole diameter Size I 95 000 95 012 mm 3 74015 3 74062 in Size II 95 013 95 025 mm 3 74066 3 74113 in The cylinder size O is marked on the s...

Page 202: ... piston ring grooves If the piston ring is stiff Clean the piston ring groove Tip An old piston ring can be used to clean the piston ring groove Check the piston rings for damage If the piston ring is damaged Change the piston ring Info I Mount the piston ring with the marking facing upward Check the piston pins for discoloration or signs of wear If the piston pin shows severe discoloration signs ...

Page 203: ...ideline Piston ring end gap Compression ring I 1 00 mm 0 0394 in Oil scraper ring I 1 20 mm 0 0472 in I Feeler gauge 59029041100 0 p 311 If the end gap is greater than the specified value Check measure the cylinder 0 p 199 If cylinder wear lies within the specified tolerance Change the piston ring Mount the piston ring with the marking facing upward 41 17 4 20 Measuring the piston cylinder mountin...

Page 204: ...1 Oil pump External rotor engine case clearance I S 0 20 mm S 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 measure the play between the exter nal rotor and the internal rotor I Feeler gauge 59029041100 ra l p 311 Oil pump External rotor internal rotor clearance I s 0 20 mm s 0 0079 in If the measured value d...

Page 205: ...1 304674 11 304673 11 Insert long flange O of the autodecompression spring in the hole push the autodecompression spring over bearing bolt 4 and hook it into autodecompression weight fi Mount autodecompression shaft 8 in the camshaft Mount new lock ring Perform a function check The autodecompression spring does not turn the autode compression shaft back to the stop Pre tension the autodecompressio...

Page 206: ...he camshaft 17 4 25 Checking the timing assembly 0 v e Clean all parts well Check the timing chain gear 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 8 for damage and wear If there is damage or wear Replace the timing chain tensioning rail Check the timing chain guide rail D for damage and wea...

Page 207: ... appropriate screw 8 into the rocker arm shafts Pull out rocker arm shafts Guideline I Screw Take off the rocker arm C Take the shims out of the valve spring retainers and lay them to one side according to their normal built in position Pretension the valve springs using the special tool Valve spring mounter 59029019000 8 p 310 Insert for valve spring lever 77029041200 8 p 314 Remove valve keys O ...

Page 208: ...206 The valves are removed and the exhaust flange is removed Mount the cylinder head I Clamping plate 75029050000 a p 314 Remove the large camshaft bearing using special tool O I Pressing tool 75029051000 0 p 314 Remove small camshaft bearing 8 using the special tool Bearing puller 15112017000 0 p 308 Internal bearing puller 15112018100 0 p 308 Remove shaft seal ring fD using a suitable tool Press...

Page 209: ...ay using special tool 0 Pressing tool 75029044010 IUI p 313 The valve stem is hard chrome plated wear generally appears at the valve guide 302808 10 Check the valve plate for run out Valve Run out at valve plate 0 05 mm 0 002 in If the measured value does not meet specifications Change the valve Check sealing seat f on valve for damage and wear If the sealing surface is damaged or worn Machine the...

Page 210: ... 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 1 9 2 1 mm 0 075 0 083 in If the measured value does not meet specifications Change the valve spring seat Check exhaust valve guides O using the special tool I Limit plug gauge 59029026006 8 p 311 If the special tool is easy to i...

Page 211: ...he cylinder head Check sealing seat 6 of the valves Valve Intake sealing seat width 2 00 mm 0 0787 in Valve Exhaust sealing seat width 1 2 00 mm 0 0787 in 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 Check the rocker arm shafts for damage and wear If there is damage or wear Change the rocker arm ...

Page 212: ...stallation position Position the rocker arm O and mount rocker arm shafts 8 The rocker arm shaft with lubrication bore 6 is installed on the intake side The cut outs 0 face upward Info Make sure that the tapped hole of the rocker arm shaft is facing outward Align drill holes D in the rocker arm shafts with drill holes 8 in the cylinder head Remove appropriate screw M6 Use special tool 0 to adjust ...

Page 213: ...urface and check for run out If there is run out Change the clutch push rod Check spring retainer D for damage and wear If there is damage or wear Change the spring retainer Check pretension ring C for damage and wear If there is damage or wear Change the pretension ring Check spring washer 0 for damage and wear If there is damage or wear Change the spring washer Check the contact surface of clutc...

Page 214: ... bushing 48 for damage and wear If there is damage or wear Change the needle bearings and collar bushing Check intermediate clutch discs for damage and wear If the intermediate clutch discs are not level and are pitted Change all intermediate clutch discs Check clutch facing discs e for discoloration and scoring If there is discoloration or scoring Change all clutch facing discs Check the thicknes...

Page 215: ...ails D on a flat surface for run out If there is run out Change the shift rail Check the shift rails for scoring seizure marks and stiffness in the shift fork If the shift rail has scoring seizure marks or does not move easily in the shift fork Change the shift rail Check sliding plate in contact areas for wear If the sliding plate is worn Change the sliding plate Check return surface 0 on the sli...

Page 216: ...return spring C with the offset end facing upward over the spring guide and lift the offset end over abutment bolt 0 Mount stop disk D 17 4 39 Disassembling the main shaft Secure the main shaft in the vise with the gear teeth facing downward Guideline I Use soft jaws Remove stop disk O and second gear fixed gear 8 Remove distance sleeve D Remove lockring C Remove third fourth gear sliding gear 0 R...

Page 217: ...k C Remove the fifth gear sliding gear 0 and lock ring D Remove stop disk and third gear idler gear fD Remove needle bearing and fourth gear idler gear Gi Remove needle bearing G and stop disk 48 Remove lockring G and second fourth gear shift collar 4D Remove lockring and stop disk 41 Remove second gear idler gear 48 and needle bearing Qi 17 4 41 Checking the transmission Condition The transmissio...

Page 218: ...s 0 for damage and wear If there is damage or wear Change the gear wheel pair Check the tooth faces of idler gears C sliding gears 0 and fixed gear D for damage and wear If there is damage or wear Change the gear wheel pair Check the tooth profiles of sliding gears 0 for damage and wear If there is damage or wear Change the gear wheel pair Check sliding gear 0 for smooth operation in the profile o...

Page 219: ...sembling Check the transmission 0 p 215 Main work Secure the main shaft in the vise with the gear teeth facing downward Guideline I Use soft jaws D04977 11 Mount needle bearing O and mount fifth gear idler gear 8 with the shift dogs facing up Mount stop disk D and lock ring C Mount third fourth gear sliding gear 0 with the small gear wheel facing downward Mount lock ring D Mount distance sleeve Mo...

Page 220: ... collar facing downward Mount stop disk C and lock ring C Mount second fourth gear shift collar 0 with the shift groove facing up Mount lock ring 3 and stop disk Mount needle bearing and the fourth gear idler gear with the collar facing up Mount needle bearing 4D and the third gear idler gear 48 with the collar facing down Mount stop disk 48 and lock ring 41 Mount the fifth gear sliding gear e wit...

Page 221: ...mage or wear Change the freewheel gear or bearing Check freewheel C for damage and wear when it is disassembled If there is damage or wear Change the freewheel 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 3 of the starter motor ENGINE 17 Connect the negative cable of a 12 volt power supply to the housing of the sta...

Page 222: ... primary gear wheel clockwise do not wedge Check the locking action of freewheel gear O The primary gear wheel cannot be turned clockwise or does not lock counterclockwise Change the freewheel Press expansion ring O together with suitable pliers and take off Take freewheel 8 out of the primary gear wheel Thoroughly oil all parts Slide freewheel O into the primary gear wheel Info Note the direction...

Page 223: ...lugs of the expansion ring pass through slots 8 of the freewheel and engage in groove G of the primary gear wheel Position the right section of the engine case in the engine assembly stand Oil the bearing I Engine oil SAE 1 0W 50 0 p 302 Slide crankshaft O into the bearing seat Info Ensure that washer 8 is not damaged 221 ...

Page 224: ...fo 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 8 in the lower shift groove of the counter shaft 222 Mount shift fork D in the upper shift groove of the counter shaft Mount shift rollers C Info Fix the shift rollers in the shift forks with grease ...

Page 225: ...Install shift rails O together with upper springs 8 and lower springs Info Fix the springs in the shift rails with grease ENGINE 17 Installing the left engine case Install dowel O Degrease the sealing surfaces Apply sealing compound to the left section of the engine case I Loctite 591 O Info I To prevent sealing compound from entering into the oil channel dowel O must be mounted first 223 ...

Page 226: ... 7 4 lbf ft Mount screws but do not tighten yet Guideline I Screw engine case I M6x70 110 Nm 7 4 lbf ft Mount screws C and tighten all screws in a crisscross pat tern Guideline I Screw engine case I M6x80 Mount the O ring on the countershaft Lightly grease and mount spacer Ci Mount freewheel gear O 110 Nm 7 4 lbf ft primary gear wheel installing Mount woodruff key O Degrease the cone and thinly ap...

Page 227: ...ift drum locating unit are not symmetric Relieve tension from the locking lever Mount and tighten screw i Guideline Screw shift drum locating M6 10 Nm 7 4 lbf ft Loctite 243 Slide shift shaft O with the washer into the bearing seat 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 i Shift ...

Page 228: ...in D Position oil pump gear wheel Position washer fD Mount lock ring Mount oil pump idler gear Gi Mount washer 4D 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 17 5 13 Installing the starter idler gear 226 Slide on starter idler gear O with the collar facing the engine case ...

Page 229: ...r bushing O and both needle bearings Slide clutch basket D onto the gearbox main shaft Turn oil pump gear wheel 8 until the gear teeth of the clutch basket engage Slide on washer 0 and inner clutch hub D Position the new lock washer and mount nut Tighten the nut holding the inner clutch hub with a special tool Guideline I Nut inner clutch hub I M18x1 5 I 80 Nm 59 lbf ft I Holding wrench 5112900300...

Page 230: ...th special tool I Locking screw 113080802 IUI p 307 Thoroughly oil the clutch facing discs Mount intermediate clutch disc 6 with marking S Guideline Thickness of intermediate clutch disc 6 1 0 mm 0 039 in Alternately place the clutch facing and 7 intermediate discs into the clutch basket Guideline Thickness of intermediate clutch discs 1 4 mm 0 055 in Place intermediate clutch disc C into the clut...

Page 231: ...t pretension ring 8 with marking Top facing up Position spring washer 8 Position spring retainer 0 with marking I Mount screws D and tighten in a crisscross pattern Guideline Screw clutch spring M5 retainer 6 Nm 4 4 lbf ft ENGINE 17 229 ...

Page 232: ... I Feeler gauge 59029041100 0 p 311 Spring washer distortion 0 0 10 mm 0 0 0039 in If the specified value is not reached Remove screws CD and mount the spring retainer with marking Ill Using a straightedge and the special tool check the spring washer for distortion I Feeler gauge 59029041100 0 p 311 Spring washer distortion 0 0 10 mm 0 0 0039 in If the specified value is not reached Change the clu...

Page 233: ...lling the water pump cover Put the water pump cover seal in place Mount the water pump cover Mount screw O with the sealing washer but do not tighten yet Guideline Screw water pump cover M6x25 Mount screw 8 but do not tighten yet Guideline 10Nm 7 4 lbf ft 41 Screw water pump cover M6x25 10Nm 7 4lbf ft Loctite 243 Mount screw and tighten all screws in a crisscross pat tern Guideline Screw water pum...

Page 234: ...rnal rotor face the engine case Position the oil pump cover 0 Mount and tighten screws D Guideline Screw suction pump cover M5 6 Nm 4 4 lbf ft Loctite 243 Thread in the timing chain and place it over the timing chain sprocket Info I If the timing chain was used before ensure it is run ning in the correct direction Position the timing chain securing guide Mount and tighten screw O Guideline Screw t...

Page 235: ...gine oil cone degreased Move the joints of the compression ring and oil scraper ring so they are offset by 180 Place the oiled piston on the cylinder Clamp the piston rings together using the special tool I Piston ring compressor 60029015000 0 p 311 Tap lightly on the piston ring compressor from the top with a plastic hammer so that it lies flush with the cylinder The special tool must press the p...

Page 236: ...d with the rotor removed for a clearer view Mount cylinder base gasket 8 Info Ensure that locating pins 8 are seated properly Ensure that piston marking 8 faces the exhaust side Cover the engine case opening with a cloth Feed the timing chain through the timing chain shaft and mount the piston pin Info For purposes of illustration the following operations are shown on the removed piston ...

Page 237: ...pecial tool clockwise thereby pushing the piston ring lock into the groove I Insertion for piston ring lock 77329030100 8 p 315 Ensure that the piston ring lock is in the correct position on both sides Remove the cloth Keep the timing chain taut Carefully push the cylinder downward letting the dowels engage Mount dowels O and fit cylinder head gasket 235 ...

Page 238: ... cylinder head I M6 110 Nm 7 4 lbf ft Place the timing chain over the camshaft gear Push the camshaft into the bearing seat The marking G on the camshaft and hole 0 on the cylinder head are aligned with each other Info I Make sure that the crankshaft is at top dead center Position the camshaft retaining bracket Mount and tighten screws O Guideline Screw camshaft retaining bracket M7x1 15 Nm 11 1 l...

Page 239: ...special tool O MS I Locking screw 113080802 il I p 307 Crank the engine several times 8 Nm 5 9 lbf ft Position the engine at ignition top dead center il I p 175 Check the valve clearance at all valves between the valve and rocker arm Guideline Valve clearance Intake at 20 C 68 F 0 10 0 15 mm 0 0039 0 0059 in Exhaust at 20 c 68 F 0 12 0 17 mm 0 0047 0 0067 in I Feeler gauge 59029041100 0 p 311 If t...

Page 240: ... installation position Correct the shims based on the results of the valve clearance check Insert suitable shims Install the camshaft 8 p 236 Install the timing chain tensioner l p 236 Finishing work Check the valve clearance 8 p 237 17 5 29 Installing the alternator cover 238 Position alternator cover gasket O Position the alternator cover Mount screw 8 with the washer but do not tighten yet Guid...

Page 241: ...sition the valve cover Mount and tighten screws Guideline I Screw valve cover I M6 10 Nm 7 4 lbf ft Mount and tighten the spark plug using the special tool Guideline I Spark plug I M10x1 1 10 12 Nm 7 4 8 9 lbf ft I Spark plug wrench with link 77229172000 8 p 315 Grease the O ring Mount the starter motor I Long life grease 8 p 304 Mount and tighten screws O Guideline I Screw starter motor I M6 110 ...

Page 242: ...ine oil Insert oil filter O into the oil filter housing Oil the O ring of the oil filter cover Mount oil filter cover Mount and tighten screws fi Guideline I Screw oil filter cover I M6 Mount clutch push rod O 110 Nm 7 4 lbf ft The rounded side of the clutch push rod faces the clutch Mount and tighten screw plug O with the short oil screen and the O ring Guideline Screw plug oil screen M20x1 5 15 ...

Page 243: ...lug 8 with the O ring Guideline Screw plug oil screen M20x1 5 15 Nm 11 1 lbf ft Mount and tighten oil drain plug D with the magnet and a new seal ring Guideline Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft 17 5 36 Removing the engine from the engine assembly stand Remove the fitting from the special tool I Holder and fitting for work stand 79429002000 al p 317 Remove the engine from the en...

Page 244: ...the clothing Info I The fluid level rises with increasing wear of the clutch facing discs 242 Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and clutch lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container Move the clutch fluid reservoir mounted on...

Page 245: ...mental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws O Take off cover 8 with membrane Fill bleeding syringe 8 with the appropriate hydraulic fluid Syringe 50329050000 ...

Page 246: ...ngine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact ri...

Page 247: ...Detach spring O Remove screws 8 Take off the clutch cover with the gasket Loosen screws 8 in a crisscross pattern and remove them Take off spring retainer C Take off spring washer 0 Take off pretension ring D 245 ...

Page 248: ...ff clutch throw out with clutch push rod Remove sleeves Remove clutch discs 48 completely Bend up the lock washer Hold the inner clutch hub with the special tool Loosen nut 48 I Holding wrench 51129003000 IUI p 309 Remove the nut with the lock washer ...

Page 249: ...ge the clutch push rod Info The needle bearing and collar sleeve may be in the clutch basket T00332 10 Place the clutch push rod on a flat surface and check for run out If there is run out Change the clutch push rod Check spring retainer C for damage and wear If there is damage or wear Change the spring retainer Check pretension ring D for damage and wear If there is damage or wear Change the pret...

Page 250: ...clutch basket 48 for damage and wear If there is damage or wear Change the clutch facing discs and the clutch basket Check needle bearings 4B and collar bushing 48 for damage and wear If there is damage or wear Change the needle bearings and collar bushing Check intermediate clutch discs 1 for damage and wear If the intermediate clutch discs are not level and are pitted Change all intermediate clu...

Page 251: ...f ft I Holding wrench 51129003000 p 309 Secure the nut with the lock washer Mount sleeves Ci Thoroughly oil the clutch facing discs Mount intermediate clutch disc G with marking S Guideline Thickness of intermediate clutch disc G 1 0 mm 0 039 in Alternately place the clutch facing and 7 intermediate discs into the clutch basket Guideline Thickness of middle inter mediate clutch discs 1 4 mm 0 055 ...

Page 252: ...lutch push rod faces the clutch Position clutch pressure cap Mount pretension ring Q with marking Top facing up Position spring washer 0 Position spring retainer C with marking I Mount screws CD and tighten in a crisscross pattern Guideline Screw clutch spring MS 6 Nm 4 4 lbf ft retainer ...

Page 253: ... I Feeler gauge 59029041100 8 p 311 Spring washer distortion 0 0 10 mm 0 0 0039 in If the specified value is not reached Remove screws 8 and mount the spring retainer with marking Ill Using a straightedge and the special tool check the spring washer for distortion I Feeler gauge 59029041100 8 p 311 Spring washer distortion 0 0 10 mm 0 0 0039 in If the specified value is not reached Change the clut...

Page 254: ...18 CLUTCH R03480 10 252 Place vehicle in upright position and rest on the plug in stand Finishing work Check the engine oil level 8 p 262 ...

Page 255: ...es or other cooling system components if the engine or the cooling system are at operating temperature Allow the cooling system and the engine to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coo...

Page 256: ...e engine to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immed...

Page 257: ...nt of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing Refilling with coolant Warning Condition The engine is cold Preparatory work Remove the engine guard a p 52 Main work Position the motorcycle upright Place an appropriate container under the water pump cover Remove screw O ...

Page 258: ...ooling system are at operating temperature Allow the cooling system and the engine to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to co...

Page 259: ...Pour coolant in up to measurement f above the radiator fins Guideline Distance f above the radi 10 mm 0 39 in ator fins Coolant Mount the radiator cap Go for a short test ride 1 20 I 1 27 qt Check the coolant level 0 p 254 Finishing work Install the engine guard 0 p 52 Preparatory work Remove the engine guard I p 52 Drain the coolant I p 255 Remove the air filter box cover I p 96 Remove the seat 0...

Page 260: ...G SYSTEM 258 Remove screws 8 Remove radiator shield on both sides Loosen hose clips Pull off the radiator hoses Remove the hose clips C Detach radiator 0 and remove to the side Loosen hose clip D Pull off the radiator hose ...

Page 261: ...8 p 316 Pull off connecting piece to the side and remove Mount new connecting piece in the frame Mount new coolant pipe with special tool fa and tighten Guideline I Coolant pipe I M24x1 5 12 Nm 8 9 lbf ft I Mounting tool 79129081000 8 p 316 Mount the radiator hose Position and tighten hose clip D 259 ...

Page 262: ...nt the radiator hoses Position and tighten hose clips 8 Position the radiator shield on both sides Mount and tighten screws 8 Guideline Remaining screws chassis M6 Mount overflow hose O Finishing work Install the fuel tank a p 103 Install the right side cover a p 100 Mount the seat a p 101 10 Nm 7 4 lbf ft ...

Page 263: ...WATER PUMP COOLING SYSTEM 19 Install the air filter box cover p 96 Refill with coolant p 255 Install the engine guard p 52 261 ...

Page 264: ...ing Oil nozzle for cam follower lubrication fD Suction pump Ci Oil channel transmission lubrication 4l Oil nozzle for timing chain lubrication 41 Oil nozzle for clutch lubrication 48 Oil screen Checking the engine oil level Info The engine oil level can be checked when the engine is cold or warm Preparatory work T02009 10 Stand the motorcycle upright on a horizontal surface 262 ...

Page 265: ... level viewer If the engine oil does not reach the middle of level viewer G Add engine oil 0 p 266 Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden Wear suitable protective clothing and safety gloves In the event of scalding rinse the area affected immediately with lukewarm water Note Environmental hazard Hazardous substances cause environmental damage Dispose of o...

Page 266: ... oil screen C and the O rings Completely drain the engine oil Thoroughly clean the parts and sealing surfaces Mount and tighten screw plug with the short oil screen and the O rings Guideline Screw plug oil screen M20x1 5 15 Nm 11 1 lbf ft Position long oil screen C with the O rings on a pin wrench Position the pin wrench through the drill hole of the screw plug in the opposite section of the engin...

Page 267: ...ne oil Thoroughly clean the parts and sealing surfaces Lay the motorcycle on its side and fill the oil filter housing to about full with engine oil Place the oil filter into the housing Lubricate the O ring of the oil filter cover and mount it with the oil filter cover Mount and tighten the screws Guideline I Screw oil filter cover I M6 Stand the motorcycle upright 110 Nm 7 4 lbf ft Remove filler ...

Page 268: ...0 401955 10 Main work Remove filler plug O with the O ring Add the same engine oil used when the last oil change was carried out I Engine oil SAE 1 0W 50 p 302 Info I For optimal performance of the engine oil do not mix different types of engine oil We recommended changing the engine oil when nec essary Mount and tighten the filler plug together with the O ring Danger Danger of poisoning Exhaust g...

Page 269: ...ng tool 61029094000 0 p 312 Check the engine oil level 0 p 262 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Start the engine and let it warm up Check the oil pressure Oil pr...

Page 270: ...iate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water Remove the special tools Grease the O ring of the oil filter cover Mount the oil filter cover Mount and tighten the screws Guideline I Screw oil filter cover I M6 Finishing work Check the engine oil level a p 262 110 Nm 7 4 lbf ft ...

Page 271: ...Ignition coil pin 2 Ignition coil pin 3 Ignition coil Secondary winding 11 075 15 525 kn resistance at 20 C 68 F If the displayed value does not correspond to specifica tions Change the ignition coil connector Condition Spark plug connector cylinder 1 has been removed 0 Measure the resistance between the specified points Measuring point 1 Measuring point 2 Spark plug connector Resistance at 20 C 6...

Page 272: ...he alternator is disconnected Stator winding check the resistance 0 Measure the resistance between the specified points Alternator connector CR pin 1 Alternator connec tor CR pin 1 Alternator Resistance of stator 1 1 19 1 61 n winding at 20 C 68 F If the indicated value does not correspond to the setpoint value Change the stator Stator winding checking the short circuit to ground terminal 31 Measu...

Page 273: ...ber grommet from the alternator cover Remove the stator from the alternator cover Position the stator in the alternator cover Mount and tighten screws O Guideline 41 Screw stator M5 6 Nm 4 4 lbf ft Loctite 243 Position the retaining bracket Mount and tighten screws 8 Guideline Crankshaft M5 speed sen sor screw and cable retainer 6 Nm 4 4 lbf ft Loctite 243 Position rubber grommet in the alternator...

Page 274: ... p 96 Remove the seat 0 p 100 Remove the right side cover 0 p 100 Remove the fuel tank 0 p 102 Main work Disconnect spark plug connector O Remove the spark plug using the special tool I Spark plug wrench with link 77229172000 0 p 315 Push back hose clamp 8 Pull off the air release hose Remove screws 8 Take off the valve cover with the valve cover seal Remove gasket 8 from the engine vent ...

Page 275: ...the washer Check the valve clearance at all valves between the valve and rocker arm Guideline Valve clearance Intake at 20 C 68 F 0 10 0 15 mm 0 0039 0 0059 in Exhaust at 20 C 68 F 0 12 0 17 mm 0 0047 0 0067 in Feeler gauge 59029041100 a p 311 If the valve clearance does not meet specifications Adjust the valve clearance a p 274 Remove locking screw 0 Crank the engine several times Check the valve...

Page 276: ...with link 77229172000 0 p 315 Plug in spark plug connector O Finishing work Remove the motorcycle from the lift stand 0 p 12 Install the fuel tank 0 p 103 Install the right side cover 0 p 100 Mount the seat 0 p 101 Install the air filter box cover l p 96 Install the engine guard 0 p 52 22 2 Adjusting the valve clearance 274 Preparatory work Remove the engine guard l p 52 Raise the motorcycle with ...

Page 277: ...Remove screws 8 Screw in a suitable screw 8 into rocker arm shafts 0 Guideline I Screw M6 Remove the rocker arm D Remove shims and set them down according to the installation position Correct the shims based on the results of the valve clearance check Insert suitable shims 275 22 ...

Page 278: ...e sure that the tapped hole of the rocker arm shaft is facing outward Align drill holes in the rocker arm shafts with drill holes 0 in the cylinder head Remove appropriate screw M6 Mount and tighten screws 8 Guideline Screw rocker arm bearing M7 Position camshaft retaining bracket Mount and tighten screws 0 Guideline Screw camshaft retaining bracket M7x1 15 Nm 11 1 lbf ft 15 Nm 11 1 lbf ft ...

Page 279: ...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 O of the starter motor If the starter motor does not turn when the circuit is closed Change the starter motor 277 ...

Page 280: ...urning idle speed adjusting screw O Guideline I Idle speed I 2 250 2 350 rpm I Tachometer 45129075000 IUI p 308 Info I Turning counterclockwise lowers the idle speed Turning clockwise raises the idle speed Performing the initialization run Condition The diagnostic tool is connected and running Execute Engine electronics Functions Clear adaptation values The adaptation values are deleted Select Eng...

Page 281: ...ecified temperature at idle speed Guideline I Coolant temperature I ao 90 c 176 194 F Info Do not operate the throttle grip during the initialization process Switch off the ignition when the specified temperature is reached Info If initialization is not completed or if the initialization process was interrupted the entire process must be restarted 279 ...

Page 282: ...g Piston pin bearing No bearing bush DLC coated piston pin Pistons Forged light alloy Piston rings 1 compression ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with two Eaton pumps Primary transmission 31 76 Clutch Multidisc clutch in oil bath hydraulically activated Gearbox 5 gear transmission claw shifted Transmission ratio First gear 16 32 Second gear 18 30 Third ge...

Page 283: ...imit 0 120 mm 0 00472 in Piston ring end gap Compression ring s 1 00 mm S 0 0394 in Oil scraper ring s 1 20 mm s 0 0472 in Piston ring groove clearance s 0 08 mm S 0 0031 in Connecting rod end play of lower conrod bearing 0 20 0 45 mm 0 0079 0 0177 in Crankshaft axial play 0 50 0 60 mm 0 0197 0 0236 in Crankshaft run out on bearing pin s 0 16 mm s 0 0063 in Clutch disc pack thickness Wear limit 26...

Page 284: ... 4 lbfft Screw pressure pump cover M6 10 Nm 7 4 lbfft Loctite 243 Screw shi ft drum locating M6 10 Nm 7 4 lbfft Loctite 243 Screw shi ft lever M6 14 Nm 10 3 lbfft Loctite 243 Screw starter motor M6 10 Nm 7 4 lbfft Screw timing chain securing M6 10 Nm 7 4 lbfft guide Loctite 243 Screw timing chain tensioner M6 10 Nm 7 4 lbfft Screw timing chain tensioning rail M6 10 Nm 7 4 lbfft Loctite 243 Screw t...

Page 285: ...Frame Fork Suspension travel front rear Fork offset Shock absorber Brake system Brake discs diameter TECHNICAL DATA 25 60 Nm 44 3 lbf ft Loctite 2701 TM 10 12 Nm 7 4 8 9 lbf ft 12 Nm 8 9 lbf ft 10 Nm 7 4 lbf ft 1st stage 10 Nm 7 4 lbf ft 2nd stage 30 Nm 22 1 lbf ft 3rd stage 50 Nm 36 9 lbf ft Collar and thread oiled 60 Nm 44 3 lbf ft Thread oiled with engine oil cone degreased 20 Nm 14 8 lbf ft 20...

Page 286: ...n 2 5 mm 0 098 in 3 5 mm 0 138 in 1 0 bar 15 psi 1 0 bar 15 psi 13 48 5 8 X 1 4 48 49 50 51 52 63 9 1 485 10 mm 58 46 0 39 in 370 mm 14 57 in 960 mm 37 8 in 101 5 kg 223 8 lb 145 kg 320 lb 190 kg 419 lb 335 kg 739 lb HJTZ5S FP Lithium ion battery Battery voltage 12 V Nominal capacity 2 0 Ah Maintenance free 58011109110 10 A Rear tire 120 80 19 63M TT Dunlop GEOMAX MX 3S The tires specified represe...

Page 287: ...l oz Fork oil SAE 4 48601166S1 a p 303 200 g ml 6 76 6 fl oz Fork oil SAE 4 48601166S1 0 p 303 380 ml 12 85 fl oz Fork oil SAE 4 48601166S1 0 p 303 11 ml 0 37 fl oz Multi purpose grease 00062010051 0 p 305 18 18 7R 99 WP Suspension 5018 DCC Link 17 clicks 15 clicks 13 clicks 2 5 turns 2 turns 1 5 turns 17 clicks 15 clicks 13 clicks 7 mm 0 28 in Weight of rider 65 75 kg 143 165 lb 42 N mm 240 lb in...

Page 288: ... Nut rear sprocket screw MB Nut rim lock MB Remaining nuts chassis MB Remaining screws chassis MB Screw bottom triple clamp MB Screw chain sliding piece MB Screw engine brace MB Screw fork stub MB Screw front brake caliper MB Screw handlebar clamp MB Screw subframe MB 286 2 Nm 1 5 lbf ft 0 7 Nm 0 52 lbf ft 2 3 Nm 1 7 lbf ft 1 Nm 0 7 lbf ft 1 Nm 0 7 lbf ft 5 Nm 3 7 lbf ft 1 Nm 0 7 lbf ft 6 Nm 4 4 l...

Page 289: ...lant pipe Screw in fitting cooling system Nut rear wheel spindle M8 M8 M8x1 25 M10 M10 M10 M10 M10 M10 M12 M14x1 5 M14x1 5 M14x1 5 M16x1 5 M20x1 5 M20x1 5 M24x1 5 M24x1 5 M25x1 5 TECHNICAL DATA 25 20 Nm 14 8 lbf ft 17 Nm 12 5 lbf ft 10 Nm 7 4 lbf ft 60 Nm 44 3 lbf ft 45 Nm 33 2 lbf ft 45 Nm 33 2 lbf ft 60 Nm 44 3 lbf ft 40 Nm 29 5 lbf ft 60 Nm 44 3 lbf ft 15 Nm 11 1 lbf ft 80 Nm 59 lbf ft 80 Nm 59...

Page 290: ...motorcycle over a long period clean it regularly Avoid direct sunshine when cleaning the motorcycle 7 11111111111111 401061 01 Close off the exhaust system to keep water from entering Remove loose dirt first with a soft jet of water Spray heavily soiled parts with a normal commercial motorcy cle cleaner and then brush off with a soft brush Motorcycle cleaner 0 p 305 I Info Use warm water containin...

Page 291: ... all moving parts and bearings Clean the chain 0 p 130 Treat bare metal except for brake discs and the exhaust sys tem with a corrosion inhibitor Preserving materials for paints metal and rubber 0 p 305 Treat all plastic parts and powder coated parts with a mild cleaning and care product Special cleaner for glossy and matte paint finishes metal and plastic surfaces 0 p 305 41 289 26 ...

Page 292: ...replacements are necessary you should do this during the storage period less workshop overload In this way you can avoid long workshop waiting times at the start of the new season 1111 When refueling for the last time before taking the motorcycle out of service add fuel additive I Fuel additive p 304 Refuel Clean the motorcycle p 288 Change the engine oil and oil filter and clean the oil screens p...

Page 293: ...me only Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust Preparin for use after stora e 401059 01 Install the 12 V battery 8 p 138 Remove the motorcycle from the lift stand 8 p 12 Perform checks and maintenance measures when preparing for use Make a test ride 41 41 291 ...

Page 294: ...ines for damage and leakage I I I I I Check the rear brake fluid level 0 p 153 I I I I I I Check the free travel of the foot brake lever 0 p 152 I I I I I I Check the frame 0 p 53 I I I I I Check the link fork 0 p 85 I I I I I Check the fork bearing for play 0 p 85 I I I I I Check the heim joint for play 0 p 83 I I I I I Check the shock absorber linkage 0 p 63 I I I I I I Check the tire condition ...

Page 295: ...eck the idle speed 0 I I I I Final check Check the vehicle for operating safety and take a test ride Read out the fault memory after the test ride using the Husqvarna Motorcycles diagnostics tool Make the service entry in Husqvarna Motorcycles Dealer net and in the Service Manufacturer Warranty Booklet o One time interval Periodic interval 28 3 Recommended work 0 I I I I I O I I I I 0 I I I Annual...

Page 296: ...valve springs valve spring seats and valve spring retainers Change the con necting rod conrod bearing and crank pin Check the transmission and shift mecha nism Check the oil pressure control valve Change the suction pump Check the force pump and lubrication system Change the timing chain Change all engine bearings Change the shaft seal rings and bearing seals of the main bearing o One time interva...

Page 297: ...SERVICE SCHEDULE 28 295 ...

Page 298: ...0 l K 10 AF 4 G 10 T 2 0 N EY G2 0 K3 0 a N EB 4 S f 1 u tlJ 5 IY X295 lr17 D 1F r 1 r ffi r f i4 D X7 I 1 X1 9 I 1 1 X1 8 I I l U 1 11 1 1 l l E E c__ __ b 2 F1 c___ _______________________________ _ a 2 F1 Fe F reJ FC 450 Rockstar Edition US 2018 I L_ Husqy ma I 1 3 1 2 I J 4 s I 6 I 1 I a ...

Page 299: ...ontrol unit C10 Capacitor G10 12 V battery G20 Alternator K10 Starter relay with main fuse K30 Power relay M10 Electric starter system T20 Voltage regulator S21 E tip switch X295 Diagnostics connector WIRING DIAGRAM 29 297 ...

Page 300: ...oil 15 E q 5 B B I I I t jj H 15 C f C j xs j X2 C BF 1 NCX 2 AT 2 Hl 2 NGA 3 BA 1 I ITT s20 R30 P25 f X295 f E l N AP 6 W 2 t t D 1 CX 2 X3 XS D X2 5 5 5 151 i 5 l f E E E M a C I nr f 1 FB b b 3 F1 1 FB a a 3 F1 F F c I I z tel FC 450 Rockstar Edition US 2018 I Husqy ma 1 2 I 3 I 4 5 I 6 I 7 I 8 a ...

Page 301: ...mponents A11 EFI control unit M13 Fuel pump M51 Injection valve cylinder 1 P25 Malfunction indicator lamp R30 CAN bus terminating resistor S20 Kill switch X295 Diagnostics connector WIRING DIAGRAM 29 299 ...

Page 302: ...1 I I l x11 j 1 x10 I I l x20 c r 6 ti11P 4 r 15 r 12 iCR 1 NIF 2 it4 rg iJM 3 NFT 3 JJJ ICE 4 NDX 3 HV 2 1 AT 2 A P 5 NCM 2 JU3 B43 555 B41 B21 R51 B37 B26 B12 B34 X301 n MAP TC e n n 11 1 1r w il s 5 E il s o s il s E s s il E t 1 o E 2 FB b C ___ 2 FB at Ft F reJ FC 450 Rockstar Edition US 2018 I L_ Husqy ma I 3 3 1 2 I J I 4 s I 6 I 1 a ...

Page 303: ...or B34 Gear position sensor B37 Crankshaft speed sensor B41 Induction manifold pressure sensor cylinder 1 B43 Throttle valve position sensor R51 Ignition coil S55 Map select switch 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 WIRING DIAGRAM 29 301 ...

Page 304: ...use coolant that complies with the requirements stated see specifications on the container and that has the relevant properties I Antifreeze protection to at least I 25 C 13 F The mixture ratio must be adjusted to the necessary antifreeze protection Use distilled water if the coolant needs to be diluted The use of premixed coolant is recommended Observe the coolant manufacturer specifications for ...

Page 305: ...5 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding properties Su er unleaded ROZ 95 RON 95 PON 91 Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to u...

Page 306: ...uel Stabilizer High viscosi grease Recommended supplier SKF LGHB 2 Long life grease Recommended supplier MOTOREX Bike Grease 2000 Lubricant 14034 Recommended supplier WP Performance Systems WP Racing Grease IPR 2 Lubricant T158 Recommended supplier Lubcon Turmogrease PP 300 Lubricant T625 Recommended supplier Molykote 33 Medium Lubricant T152 Recommended supplier Bel Ray Molylube Anti Seize 304 ...

Page 307: ... road chain SRra Recommended supplier MOTOREX Chainlube Offroad Oil for foam air filter Recommended supplier MOTOREX Racing Bio Liquid Power Preservin materials for aints metal and rubber Recommended supplier MOTOREX Moto Protect Special cleaner for lossy and matte paint finishes metal and plastic surfaces Recommended supplier MOTOREX Quick Cleaner Universal oil spray Recommended supplier MOTOREX ...

Page 308: ...0029013006 I 00029013006 H00505 01 Bleeding device Art no 00029013100 00029013100 H00518 01 EU batte charger XCharge rofessional Art no 00029095050 Feature EU safety plug Nominal voltage 230 V Mains fuse 16A Power cable length 5 m 16 ft approx Charger cable 5 m 16 ft H01065 01 length approx 306 ...

Page 309: ...essional Art no 00029095052 Feature UK safety plug Nominal voltage 230V Mains fuse 16 A Power cable length 5 m 16 ft approx Charger cable 5 m 16 ft H01065 01 length approx CH batte charger XChar e rofessional Art no 00029095053 Feature CH plug Nominal voltage 230V Mains fuse 16 A Power cable length 5 m 16 ft approx Charger cable 5 m 16 ft H01065 01 length approx Locking screw Art no 113080802 1130...

Page 310: ...17000 Internal bearing uller p 15112018100 Tachometer M 45129075000 s ringe 50329050000 308 H00520 01 H00522 01 H00525 01 H00565 01 Art no 15112017000 Art no 15112018100 Feature 118 23 mm 0 71 0 91 in Art no 45129075000 Art no 50329050000 ...

Page 311: ...012011000 51012011000 H00572 01 Holding wrench Art no 51129003000 r 51129003000 H00575 01 Puller Art no 58429037043 Feature I Inside diameter I 43 9 mm 1 728 in 58429037043 H00598 01 Tool bracket Art no 58429089000 2x 58429089000 H00603 01 309 ...

Page 312: ...0606 01 Valve s ring mounter 59029019000 H00610 01 310 Art no 58429091000 Art no 58429092000 Art no 58429094000 Feature Torque Open ended bit Open ended bit Open ended bit Open ended bit Bit diameter Art no 59029019000 3 15 Nm 2 2 11 1 lbf ft 3 9 mm 0 154 in 4 9 mm 0 193 in 5 5 mm 0 217 in 6 8 mm 0 268 in 5 9 mm 0 232 in ...

Page 313: ...r 60029015000 H00628 01 Puller 2x 60029033000 H00633 01 Art no 59029026006 Feature I Diameter Art no 59029041100 Feature 15 piece Art no 60029015000 Feature Height Diameter Art no 60029033000 SPECIAL TOOLS 32 I 6 05 mm 0 2382 in I 0 10 0 25 mm 0 0039 0 0098 in 80 mm 3 15 in 57 125 mm 2 24 4 92 in 311 ...

Page 314: ...tool Art no 60029043040 60029043040 H00639 01 Hose clamQ Qlier Art no 60029057000 60029057000 H00650 01 Testing hose Art no 61029093000 61029093000 H00659 01 Pressure testin tool Art no 61029094000 4x D 61029094000 H00660 01 312 ...

Page 315: ...OOLS 32 Puller Art no 75029021000 75029021000 H00707 01 Pressing tool Art no 75029044010 75029044010 H00712 01 Pressing tool Art no 75029044020 75029044020 H00713 01 Art no 75029047000 75029047000 H00714 01 313 ...

Page 316: ...ate Art no 75029050000 75029050000 H00719 01 Pressing tool Art no 75029051000 75029051000 H00721 01 Protection ca Art no 75029090000 75029090000 H00726 01 Insert for valve s ring lever Art no 77029041200 77029041200 H00746 01 314 ...

Page 317: ...7329030100 H00768 01 Locking screw 78129032000 H00796 01 Insert for crankshaft ressing tool 78929008000 H01016 01 Art no 77229172000 Feature Drive Hexagonal part Length Art no 77329030100 Art no 78129032000 Art no 78929008000 SPECIAL TOOLS 32 3 8 in 14 mm 0 55 in 130 mm 5 12 in 315 ...

Page 318: ...79029083000 Mounting tool 79129081000 Extractor 79229032044 Puller 79229048000 316 H00804 01 H02653 01 H00808 01 H00809 01 Art no 79029083000 Art no 79129081000 Feature I Hexagonal driver Art no 79229032044 Art no 79229048000 I 13mm 0 51 in ...

Page 319: ...0 H01018 01 Insert for crankshaft ressing tool 79428008000 H01169 01 Art no 79412966000 Feature Maximum pressure Display Valve connection Units Material Art no 79429002000 Art no 79429006000 Art no 79429008000 SPECIAL TOOLS 32 20 bar 290 psi Digital pressure gauge Schrader valve bar psi and kg cm2 Aluminum tube 317 ...

Page 320: ... late Art no 79429009000 79429009000 H00812 01 Oil ressure ada ter Art no 79429094000 79429094000 H01045 01 Gear segment Art no 80029004000 80029004000 H00813 01 En ine assembl stand Art no 80329001000 80329001000 H01047 01 318 ...

Page 321: ...00 Hook wrench 90129051000 s ring hook 5030501700004 H00985 01 H00816 01 H00831 01 H00973 01 Art no 81329955100 Feature Height Load Art no 90129005000 Art no 90129051000 SPECIAL TOOLS 32 315 425 mm 12 4 16 73 in 150 kg 331 lb Art no 5030501700004 319 ...

Page 322: ...unting sleeve T1204 Calibrating unit T1205 320 H00842 01 H00844 01 H00878 01 H00879 01 Art no T107S Art no T120 Feature I Diameter Art no T1204 Feature I Diameter Art no T1205 Feature I Diameter I 8 mm 0 31 in I 25 5 30 5 mm 1 004 1 201 in 118 mm 0 71 in ...

Page 323: ...1207S Pressing tool T1216 Vacuum T1240S H00880 01 H00881 01 H00887 01 H00890 01 Art no T1206 Feature I Diameter Art no T1207S Art no T1216 Feature I Diameter Art no T1240S SPECIAL TOOLS 32 115 30 mm 0 59 1 18 in 138 49 mm 1 5 1 93 in 321 ...

Page 324: ... Protecting sleeve Art no T1401 Feature y I Diameter I 48 mm 1 89 in T1401 H00894 01 Clam ing stand 2xffi Art no T14016S Feature ill I Diameter I 12 mm 0 47in T14016S H01036 01 Rin wrench Art no T14017 Feature I Hexagonal part I 50 mm 1 97in T14017 H00904 01 322 ...

Page 325: ...ve T14073 H00896 01 H00922 01 H00928 01 H00929 01 Art no T1403S Feature Diameter Diameter Art no T14040S Feature I Diameter Art no T14072 Feature I Diameter Art no T14073 Feature I Diameter SPECIAL TOOLS 32 48 mm 1 89 in 60 mm 2 36 in I 48 mm 1 89 in I 37 mm 1 46 in 111 5 mm 0 453 in 323 ...

Page 326: ...4092 Pressing tool T1504 Mounting tool T150S 324 H01518 01 H02261 01 H00899 01 H00852 01 Art no T14084 Feature I Drive Diameter Art no T14092 Feature I Diameter Art no T1504 Feature I Diameter Art no T150S 1 1 2 in 24 mm 0 94 in I 34 mm 1 34 in 118 mm 0 71 in ...

Page 327: ...Mounting sleeve T1515 H00900 01 Filling tool 2x 3x T170S1 H00855 01 Art no T1515 Feature I Diameter Art no T170S1 118 mm 0 71 in SPECIAL TOOLS 32 325 ...

Page 328: ...intervals are demanded for automobile engines the focus for motorcycle engines is on high performance at high engine speeds In most motorcycle engines the transmission and clutch are lubricated with the same oil The JASO T903 MA2 standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to...

Page 329: ...LIST OF ABBREVIATIONS 34 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly 327 ...

Page 330: ...rake changing 143 front brake checking 143 of rear brake changing 150 rear brake checking 150 328 Capacitor checking 141 Capacity coolant 256 257 283 engine oil 171 265 283 Fuel 283 Chain checking cleaning Chain guide checking Chain tension adjusting checking 127 130 127 127 126 Characteristic map of the throttle response adjusting 50 Charging voltage checking 140 Clutch checking 244 fluid level c...

Page 331: ...emoving 205 water pump installing 193 Engine assembly alternator cover installing 238 camshaft installing 236 clutch basket installing clutch cover installing clutch discs installing 227 230 228 clutch push rod installing 240 crankshaft installing 221 cylinder head installing 235 engine removing from the engine assembly stand 241 force pump installing 225 freewheel gear installing 224 gear positio...

Page 332: ...87 checking for play 85 Fork legs air cartridge assembling 31 air cartridge disassembling 25 air pressure adjusting 15 assembling 33 basic setting checking 14 bleeding 17 checking 28 compression damping adjusting 16 disassembling 21 330 dust boots cleaning 17 fork servicing 20 installing 19 rebound damping adjusting 16 removing 18 shock absorber cartridge assembling 29 shock absorber cartridge dis...

Page 333: ..._____ removing 93 Seat Manifold installing 92 removing 92 Manufacturer warranty 9 Motorcycle 0 cleaning 288 lift stand raising with 12 lift stand removing from 12 Oil circuit Oil filter changing 262 263 Oil pressure checking 267 Oil pressure control valve installing 192 removing 191 spring length checking 192 Oil screens cleaning 263 mounting 101 removing 100 Service schedule 292 295 Servicing the...

Page 334: ...tion 13 Stator installing 271 removing 271 Steering head bearing changing 44 lubricating 39 Steering head bearing play adjusting 45 checking 43 Storage 290 iT Technical data capac es 283 chassis 283 chassis tightening torques 286 electrical system 284 engine 280 engine tolerance wear limits 281 engine tightening torques 281 332 fork 284 shock absorber 285 tires 284 Throttle cable play adjusting 49...

Page 335: ...111111111111111111111111111IIIIIIIIIIII 3403072en 07 2018 Husqvarna MOTORCYCLES Husqvarna Motorcycles GmbH _ _ StallhofnerstraBe 3 5230 Mattighofen Austria LZZa JUV Photo Mitterbauer www husqvarna motorcycles com Husqvarna Motorcycles GmbH ...

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Husqvarna FC 450 2018, Repair Manual

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