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Husqvarna FE 250 AU 2014, Repair Manual

The Husqvarna FE 250 AU 2014 Repair Manual provides comprehensive instructions and guidance for maintaining and repairing this off-road motorcycle model. Easily downloadable and completely free from manualshive.com, this manual ensures users have the necessary resources to keep their bike in top condition.

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17 

17.7 

LIGHTING SYSTEM, INSTRUMENTS 

Ad"usting the headlight range 

If the light-dark border does not meet specifications: 

- Adjust the headlight range.  (

� 

p.  124)

Preparatory work 

-

Check the headlight setting.  (

I!!:! 

p.  123)

Main  work 

-

Loosen screw 

O.

- Adjust the headlight range by pivoting the headlight.

Guideline

124 

The boundary between light and dark must be exactly on the lower mark for 

a motorcycle with driver (instructions on how to apply the mark:  Checking the 

headlight setting). 

•

Info

I 

If you have a payload,  you may have to correct the headlight range. 

-

Tighten screw 

O.

Summary of Contents for FE 250 AU 2014

Page 1: ...PIONEERING SINCE 1903 REPAIR MANUAL2015 FE 250 EU FE 250 AU FE 250 US Art no 3403014en leJ Husqvarna MOTORCYCLES ...

Page 2: ......

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

Page 4: ...TROLS 37 7 1 Handlebar position 37 8 9 2 7 2 Adjusting the handlebar position 37 7 3 Adjusting the basic position of the clutch lever 37 7 4 Checking the routing of the throttle cable 38 7 5 Checking the play in the throttle cable 38 7 6 Adjusting the play in the throttle cable 39 FRAME 40 8 1 Removing the engine guard 40 8 2 Installing the engine guard 40 8 3 Checking the frame 40 SHOCK ABSORBER ...

Page 5: ...ront brake linings 108 17 18 3 16 3 Checking free travel of hand brake lever 110 16 4 Adjusting the basic position of the hand brake lever FE US 110 16 5 Adjusting free travel of hand brake lever FE EU AU 111 16 6 Checking the front brake fluid level 111 16 7 Adding front brake fluid 111 16 8 Changing the front brake fluid 112 16 9 Checking the rear brake linings 114 16 10 Changing the rear brake ...

Page 6: ...shaft 173 18 5 2 Installing the transmission shafts 174 18 5 3 Installing the shift forks 174 18 5 4 Installing the shift drum 174 4 18 5 5 Installing the shift rails 175 18 5 6 Installing the left engine case 175 18 5 7 Installing the spacer 176 18 5 8 Installing the timing chain 176 18 5 9 Installing the primary gear 176 18 5 10 Installing the force pump 177 18 5 11 Installing the suction pump 1...

Page 7: ...ge 215 28 SERVICE SCHEDULE 216 28 1 Service schedule 216 28 2 Service work as additional order 217 29 WIRING DIAGRAM 218 29 1 Page 1 of 8 FE EU 218 29 2 Page 2 of 8 FE EU 220 29 3 Page 3 of 8 FE EU 222 29 4 Page 4 of 8 FE EU 224 29 5 Page 5 of 8 FE EU 226 29 6 Page 6 of 8 FE EU 228 29 7 Page 7 of 8 FE EU 230 29 8 Page 8 of 8 FE EU 232 29 9 Page 1 of 8 FE AU 234 29 10 Page 2 of 8 FE AU 236 29 11 Pa...

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

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

Page 10: ...environment Do not allow fuel to enter the groundwater the soil or the sewage system Use the operating and auxiliary substances such as fuel and lubricants as specified in the manual 3 3 arts accessories Only use spare parts and accessories approved and or recommended by Husqvarna Motorcycles Husqvarna Motorcycles accepts no liability for other products and any resulting damage or loss The current...

Page 11: ...0 The chassis number O is stamped on the steering head on the right The type label O is fixed to the front of the steering head The key number O for the steering lock is stamped onto the key connector The engine number O is stamped on the left side of the engine under the engine sprocket The fork part number O is stamped on the inner side of the fork stub ...

Page 12: ...4 SERIAL NUMBERS Shock absorber article number O is stamped on the top of the shock absorber above the adjusting ring towards the engine side 10 ...

Page 13: ...ng the side stand must be folded up and secured with the rubber band 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 an effective exhaust extraction system when starting or running the engine in an enclosed space Engine damage High revving speed with a cold engine negatively impacts the l...

Page 14: ...ficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Info Press the starter for a maximum of 5 seconds Wait for at least 5 seconds before trying again Shift transmission to neutral FE AU Turn the emergency OFF switch to the position 0 Press the electric starter button Info Do not open the throttle 12 ...

Page 15: ...ckwise to increase damping turn counterclockwise to reduce damping Adjusting the rebound dam ing of the fork Info The hydraulic rebound damping determines the fork suspension behavior Bleeding the fork legs Turn the red adjusting screw O all the way clockwise Info I Adjusting screw O is located at the upper end of the right fork leg The rebound damping is located in the right fork leg REB red adju...

Page 16: ...he dust boots If this dirt is not removed the oil seals behind can start to leak Warning Danger of accidents Oil or grease on the brake discs reduces the brak ing effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Clean and oil the dust boots and inner fork tubes of both fork legs I Universal oil spray I p 265 Press the dust boots back...

Page 17: ...d take off the clamp Remove the cable tie s Remove screws and take off the brake caliper 10 Nm 7 4 lbf ft Allow the brake caliper and brake line to hang loosely to the side Loosen screws CD Take out the left fork leg Loosen screws 8 Take out the right fork leg Main work Position the fork legs Bleeder screws O are positioned toward the front Info I The compression damping is located in left fork le...

Page 18: ...ght p 87 Raise the motorcycle with a lift stand p 11 Remove the front wheel l l p 90 Remove the fork legs l l p 15 Main work Remove screws O on the left fork leg Remove the fork protector upwards Remove the screws on the right fork leg Remove the fork protector upwards Installing the fork rotector C00565 10 Main work Position the fork protector on the left fork leg Mount and tighten screws O Guide...

Page 19: ...artridge I p 26 17 0 lle Assemble the fork legs I p 27 i go 0 201926 01 Disassemblin the fork le s Info The steps are identical for both fork legs 201700 10 201701 10 Condition The fork legs are disassembled Note down the current state of rebound damping O REB red adjuster of right fork leg Note down the current state of compression damping COMP white adjuster of left fork leg Fully open the adjus...

Page 20: ...ving the O ring seat from the cartridge usually requires the applica tion of force Remove dust boot 0 Remove fork protection ring f Info I The fork protection ring does not necessarily need to be removed for repair work Remove lock ring Info I The lock ring has a ground end against which a screwdriver can be posi tioned Warm the outer tube in area C5 of the lower sliding bushing Guideline I so 0 c...

Page 21: ...0 Unclamp the fork leg The steps are identical for both fork legs 201722 11 201724 11 Preparatory work Disassemble the fork legs 1 1 p 17 Main work Pull the spring down Mount the open end wrench on the hexagonal part Clamp the open end wrench in the vise Release screw cap O but do not remove it yet I Special socket T14047 1 1 p 276 Pull the spring down Remove the open end wrench Remove the screw c...

Page 22: ...rease piston rod O and clamp it in the vise I Clamping stand T14049S l li p 276 Remove adjusting tube Unscrew spring guide D Remove spring seat C Pull the piston rod out of the cartridge Clamp the tube of the cartridge into a vise I Clamping stand T14049S 1 1 p 276 Release seal ring retainer 0 and remove with the washer Remove lock ring D Pull reservoir off of the tube Pull sleeve out of the reser...

Page 23: ...e cartridge p 20 Main work Degrease the piston rod Clamp the piston rod with the special tool as far up as possible I Clamping stand T14049S p 276 Release hydrostop needle O and remove it from the piston rod The valve usually remains in the hydrostop needle Info I O silver hydrostop needle on compression damping side C red hydrostop needle on rebound damping side Remove the rebound shim stack 6 Re...

Page 24: ...t on a fitting hexagon socket and clamp into a vice Remove sleeve O Remove shim stack Remove adapter 8 Remove hub C with washers Info I It is possible that only one washer or no washer is present Remove the O ring from the hub Remove shim stack D Remove washer Remove O ring Disassembling the seal ring retainer Info The steps are identical for both fork legs Preparatory work Disassemble the fork le...

Page 25: ...inner tube 47 975 48 005 mm 1 88878 1 88996 in If the measured value is smaller than the specified value Change the inner tube Measure the run out of the inner tube I Inner tube run out I 5 0 20 mm 5 0 0079 in If the measured value is larger than the specified value Change the inner tube Measure the inside diameter at multiple locations of the outer tube I Inside diameter of outer tube I 5 49 20 m...

Page 26: ... thickness of the preload spacers Assemblin the seal rin retainer Info The steps are identical for both fork legs Mount and grease seal ring O I Lubricant T158 i ll p 264 Mount and grease O ring 8 I Lubricant T158 p 264 Position pilot bushing support D Assembling the h drosto unit Info The steps are identical for both fork legs Mount and grease O ring O I Lubricant T158 a p 264 Mount washer 8 Moun...

Page 27: ... Add or remove washers 0 108 5 109 5 mm 4 272 4 311 in The steps are identical for both fork legs except for the hydrostop needle and valve 201730 10 Degrease the piston rod Clamp the piston rod with the special tool I Clamping stand T14049S I p 276 Lubricate the O ring Mount valve needle O in the piston rod I Lubricant T158 l p 264 Mount spring Mount and tighten adapter with spring C and washer G...

Page 28: ... Hydrostop needle on piston rod Info I M6x0 5 I 7 Nm 5 2 lbf ft I G silver hydrostop needle on compression damping side C red hydrostop needle on rebound damping side Unclamp the piston rod I The steps are identical for both fork legs 201795 11 Preparatory work Assemble the seal ring retainer ll l p 24 Assemble the piston rod p 25 Main work Mount and grease seal rings O and O ring I Lubricant T158...

Page 29: ...he vise I Clamping stand T14049S p 276 Screw spring guide Gi all the way on Info Loctite 2701 TM I The nut must be firmly tightened against the stop by hand Do not use a tool Mount adjusting tube 48 Unclamp the piston rod Mount the preload spacer s When assembling ensure that the right cartridge is mounted in the corresponding inner tube and the right adjuster is mounted on the corresponding screw...

Page 30: ...00 clean the bush ings and lubricate them I Fork oil SAE 4 48601166S1 p 262 Slide on the lower sliding bushing 0 Mount the upper sliding bushing D Info Do not use a tool pull the ends apart slightly by hand Warm the outer tube in area f of the lower sliding bushing Guideline 1 so 0 c 122 F Slide the outer tube onto the inner tube Hold the lower sliding bushing with the longer section of the specia...

Page 31: ...2 Turn the fork Have the entire filling quantity of fork oil available Oil capacity per fork leg 635 ml 21 47 fl oz Fork oil SAE 4 48601166S1 p 262 Add some of the fork oil while pulling out and pushing in the piston rod numerous times Guideline I Fork oil quantity Mount and tighten hydrostop unit Guideline I Hydrostop unit Clamp the fork vertically Add the remaining quantity of fork oil I 510 ml ...

Page 32: ...ostop needle screw cap with mark REB Compression damping side silver hydrostop needle screw cap with mark COMP Pull the spring down Mount the open end wrench on the hexagonal part Hold the open end wrench Tighten screw cap Guideline I Screw cap on piston rod I Special socket T14047 p 276 Push the outer tube up I M8x0 75 Clamp the outer tube in the area of the lower triple clamp I Clamping stand T1...

Page 33: ...ad components Only make adjustments within the recommended range Ride slowly to start with after making adjustments to get the feel of the new handling characteristic Set the adjusters to the positions determined upon removal Lubricating the steering head bearing t9 800010 10 Removin the lower tri Remove the lower triple clamp p 31 Install the lower triple clamp p 32 Preparatory work Switch off al...

Page 34: ...r triple clamp with the steering stem Mount the upper steering head bearing Check whether upper steering head seal O is correctly positioned Mount protective ring 8 and O ring D Position the upper triple clamp with the handlebar Mount screw 8 but do not tighten yet Position the clutch line next to the voltage regulator Position the fork legs Bleeder screws 0 are positioned toward the front Info I ...

Page 35: ... brake caliper M8 Mount the cable tie s 25 Nm 18 4 lbf ft 33 15 Nm 11 1 lbf ft 112 Nm 8 9 lbf ft Loctite 243 17 Nm 12 5 lbf ft Loctite 243 Position the brake line wiring harness and clamp Mount and tighten screws G Finishing work Install the front fender a p 86 Install the front wheel a p 91 Install the headlight mask with the headlight p 87 Check that the wiring harness throttle cables and brake ...

Page 36: ...entire steering range It must be possible to move the handlebar easily over the entire steering range There should be no detectable detent positions If detent positions are detected Adjust the steering head bearing play a p 34 Check the steering head bearing and replace if necessary Finishing work Remove the motorcycle from the lift stand a p 11 Ad usting the steering head bearing la Preparatory w...

Page 37: ...86 Remove the lower triple clamp p 31 Main work Remove the lower bearing race O using a suitable tool Press in the new bearing race all the way using a suitable tool Remove the upper bearing race 8 using a suitable tool Press in the new bearing race all the way using a suitable tool Pull off bearing D Remove seal ring retainer Remove O ring Grease the new O ring and mount with seal ring retainer P...

Page 38: ...e headlight mask with the headlight a p 87 Check that the wiring harness throttle cables and brake and clutch lines can move freely and are routed correctly Check the play of the steering head bearing l l p 34 Remove the motorcycle from the lift stand a p 11 Check the headlight setting p 123 36 ...

Page 39: ... not bend the cables and lines Remove screws 8 Take off the handlebar supports Place the handlebar supports in the required position Mount and tighten screws 8 Guideline Screw handlebar holder Info M10 40 Nm 29 5 lbf ft I Position the left and right handlebar holders evenly Position the handlebar Info Loctite 243 I Make sure the cables and wiring are positioned correctly Position the handlebar cla...

Page 40: ...e straight ahead position Move the throttle grip back and forth slightly to ascertain play 6 in the throttle cable I Play in throttle cable 13 5 mm 0 12 0 2 in If the throttle cable play does not meet specifications Adjust the play in the throttle cable p 39 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is suffic...

Page 41: ...ossible Loosen nut 8 Turn adjusting screw 0 so that there is play f in the throttle cable at the throttle grip Guideline I Play in throttle cable 13 5 mm 0 12 0 2 in Tighten nut 8 39 Press and hold the throttle grip in the closed setting Turn adjusting screw out until there is no play in throttle cable D Tighten nut Push sleeves O on Check the throttle grip for smooth operation Finishing work Inst...

Page 42: ... frame at the rear and swing up at the front Turn quick release O clockwise all the way Check the frame for cracks and deformation If the frame exhibits cracks or deformation due to a mechanical impact Change the frame Info I Always replace a frame that has been damaged due to a mechan ical impact Repair of the frame is not authorized by Husqvarna Motorcycles ...

Page 43: ...n clockwise to increase damping turn counterclockwise to reduce damping Adjusting the low speed compression damping of the shock absorber Caution Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Info The effect of the low speed setting can be ...

Page 44: ...in rear wheel sa unloaded Preparatory work Raise the motorcycle with a lift stand p 11 Main work Measure the distance as vertically as possible between the rear axle and a fixed point such as a mark on the side cover Make note of the value as measurement f Finishing work Remove the motorcycle from the lift stand il l p 11 Checkin the static sag of the shock absorber Measure distance f of rear whee...

Page 45: ...ding sag 1100 mm 3 94 in If the riding sag differs from the specified measurement Adjust the riding sag 0 p 44 Adjusting the s ring reload of the shock absorber Caution Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Info Before changing the ...

Page 46: ...he right side cover a p 76 Remove the motorcycle from the lift stand a p 11 Preparatory work Raise the motorcycle with a lift stand I p 11 Remove the right side cover a p 75 Remove the main silencer a p 69 Remove the seat a p 76 Remove the manifold a p 67 Remove shock absorber a p 45 After removing the shock absorber clean it thoroughly Main work Choose and mount a suitable spring Guideline Spring...

Page 47: ...move the seat a p 76 Remove the manifold I p 67 Main work Carefully take the shock absorber out of the vehicle toward the top Main work Carefully position the shock absorber into the vehicle from above Finishing work Install the manifold i ll p 68 Mount the seat i ll p 76 Install the main silencer a p 70 Install the right side cover I p 76 Remove the motorcycle from the lift stand I p 11 Checkin t...

Page 48: ... there is damage or wear Change the spacers Check the shaft seal rings for damage and wear If there is damage or wear Change the shaft seal rings Check dimension 6 303096 10 I 54 91 55 00 mm 2 1618 2 1654 in If dimension 6 is below the specified value Add the necessary spacing washers Position angle lever Mount fitting D but do not tighten yet Guideline I Nut angle lever on swingarm I M14x1 5 46 I...

Page 49: ...3 lbf ft I Nut angle lever on swingarm I M14x1 5 Servicing the shock absorber Caution Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided 201457 01 Condition The shock absorber has been removed Remove the spring a p 48 Disassemble the damper I p ...

Page 50: ...no longer under tension I Hook wrench T106S p 274 Remove ring 8 Remove spring retainer and intermediate washer C Remove the spring Disassembling the dam er 0 Preparatory work Remove the spring p 48 Main work Note down the current state of rebound damping O and compression damp ing 8 Completely open the adjusters of the rebound and compression damping Remove rubber cap of the reservoir Open screw C...

Page 51: ...mbly tool T1216 a p 275 Remove lock ring Info Do not scratch the inner surface Remove the piston rod Remove adjusting ring with the intermediate washer Drain the oil Remove compression adjuster Remove the spring and piston iston rod Preparatory work Remove the spring a p 48 Disassemble the damper a p 48 49 ...

Page 52: ...n as a unit Remove piston 8 Remove compression shim stack 0 Info I Place the compression shim stack onto a screwdriver and set it down as a unit Remove rebound washer D Remove seal ring retainer Remove locking cap and rubber buffer Disassembling the seal ring retainer 201405 10 Preparatory work Remove the spring p 48 Disassemble the damper p 48 Disassemble the piston rod p 49 Main work Remove spri...

Page 53: ...ing O onto the special tool I Press drift T1504 l t J p 277 Position the pilot bushing in the seal ring retainer using the special tool I Press drift T1504 p 277 Support seal ring retainer 8 with sleeve f of the special tool Press the pilot bushing all the way in I Assembly tool T150S 0 p 277 Lubricate the special tool Shock absorber fluid SAE 2 5 50180751S1 a p 262 Calibration pin T1205 I p 274 S...

Page 54: ...diameter of the piston rod Piston rod Diameter 17 95 mm 0 7067 in If the measured value is less than the specified value Change the piston rod Measure the run out of the piston rod I Piston rod Run out I s 0 02 mm s 0 0008 in If the measured value is greater than the specified value Change the piston rod Check the piston rod for damage and wear If there is damage or wear Change the piston rod Chec...

Page 55: ... tool f underneath and press out heim joint D with special tool I Pressing tool T1207S il l p 275 Position the new heim joint O and the special tool into a vise as shown Guideline I Use soft jaws I Pressing tool T1206 il l p 275 Press the heim joint all the way in Press the heim joint against the lock ring using the special tool I Pressing tool T1207S il l p 275 Mount the second lock ring 8 Mount ...

Page 56: ...ing sleeve T1204 a p 274 Lubricate the sealing lip of the dust boot I Lubricant T625 l ll p 264 Mount washer Position washer Don seal ring e Grease seal ring 8 and mount with the washer facing downward I Lubricant T511 l t I p 264 Mount centering disk Mount rebound rubber 0 Lubricate the groove of the O ring I Lubricant T158 I p 264 Mount O ring Mount spring 54 ...

Page 57: ...unting sleeve T1215 a p 275 Grease the dust boot and push seal ring retainer onto the piston rod I Lubricant T625 a p 264 Remove the special tool Mount rebound washer 8 with the cut out facing downward Mount the compression shim stack 0 with the smaller shims facing downward Sand both sides of piston D on a surface plate using 1200 grit sandpaper Clean the piston Assemble the piston Guideline View...

Page 58: ...icate the threads I Lubricant T159 a p 264 Mount the piston with the spring Mount and tighten the compression adjuster 0 Guideline I Compression adjuster Clamp the damper in a bench vise Guideline I Use soft jaws I M31x1 Mount adjusting ring with the intermediate washer Info 56 I 45 Nm 33 2 lbf ft I I 45 Nm 33 2 lbf ft I The adjusting ring cannot be mounted after the piston rod is mounted Fill the...

Page 59: ...pti ble click Turn counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Compression damping low speed Comfort 20 clicks Standard 18 clicks Sport 16 clicks Turn adjusting screw all the way clockwise with a socket wrench Turn counterclockwise by the number of turns corresponding to the shock absorber type Guideline Compression damping high speed Comfort 2 5 tur...

Page 60: ...10 Remove the screw of the filling port Install adapter O on the damper Info I Tighten only hand tight without the use of tools Connect the adapter O to connector of the vacuum pump I Vacuum pump T1240S l ll p 275 Clamp the damper with soft jaws or hold it as shown in the figure Info I Clamp the damper only lightly The filling port must be at the highest point The piston rod slides in and out duri...

Page 61: ...fied value turn the Damper C con trol lever to Vacuum Guideline 3 bar The pressure gauge drops to the specified value 0 bar When the pressure gauge reaches the specified value turn the Oil reservoir 0 control lever to Vacuum Guideline 0 bar The vacuum gauge falls to the specified value 8 mbar When the vacuum pressure gauge reaches the specified value turn the Oil reser voir control lever 0 to Equa...

Page 62: ...ly extended otherwise damage will occur during compression of the shock absorber Remove the special tool Remove adapter O from connection of the vacuum pump Info I Hold the damper so that the filling port is at the highest point Remove the adapter Mount and tighten screw Guideline I Screw filling port I M10x1 1 14 Nm 10 3 lbf ft I Filling the dam er with nitrogen 201396 10 201397 10 Screw in screw...

Page 63: ...ight of rider 75 85 kg 165 54 N mm 308 lb in 187 lb Weight of rider 85 95 kg 187 57 N mm 325 lb in 209 lb Mount intermediate washer 8 and spring retainer C Mount ring C Alternative 1 Tension the spring to the prescribed amount by turning the adjusting ring Guideline I Spring preload I Hook wrench T106S p 274 Alternative 2 Warning 113 mm 0 51 in Danger of accident Modifications to the suspension se...

Page 64: ...age cracking or deformation Change the swingarm Info I Always change a damaged swingarm Repair of the swingarm is not authorized by Husqvarna Motorcycles Preparatory work Raise the motorcycle with a lift stand 0 p 11 Remove the rear wheel p 93 Main work Take the brake line out of the guide Push the brake caliper forward remove it and hang it to the side Info Cover the components to protect them ag...

Page 65: ...vot Remove the swingarm Main work Position the swingarm Mount the swingarm pivot Mount and tighten nut O Guideline Nut swingarm pivot Lift the swingarm Mount and tighten fitting Guideline Nut angle lever on swingarm Mount the chain M16x1 5 M14x1 5 Connect the chain with connecting link CD Guideline 100 Nm 73 8 lbf ft I 80 Nm 59 lbf ft The closed side of the chain joint lock must face in the direct...

Page 66: ...screws chassis I 25 Nm 18 4 lbf ft I Position the brake caliper and pull it back Position the brake line in the guide Finishing work Install the rear wheel a p 94 Remove the motorcycle from the lift stand a p 11 Changing the swingarm bearing Info These operations are the same on both swingarm bearings Preparatory work Raise the motorcycle with a lift stand li l p 11 Remove the rear wheel ta p 93 R...

Page 67: ...01813 10 G01814 10 Main work Remove collar bushings 0 Remove bushing 8 Remove shaft seal rings D using a suitable tool Press out the bearing with a suitable tool Press in the new bearing until it is flush using a suitable tool 65 ...

Page 68: ...ings CD Mount bushing Grease the shaft seal rings I Long life grease 0 p 264 Position collar bushings O with the shoulder facing inward Finishing work Install the swingarm l l l p 63 Install the rear wheel l l l p 94 Remove the motorcycle from the lift stand l i p 11 66 ...

Page 69: ...I p 76 Remove the right side cover JI p 75 Remove the main silencer JI p 69 Main work Remove fitting O Info I Raise the wheel slightly to be able to remove the screws more easily Remove screw 8 Press angle lever toward the rear Press linkage lever C downward Raise the swingarm Remove screw 0 Lower the shock absorber 67 ...

Page 70: ...l p 267 Remove screw D and take off the manifold Main work Position the manifold and mount springs O I Spring hook 50305017000 I p 267 Mount and tighten screw Guideline 68 I Remaining screws chassis I 25 Nm 18 4 lbf ft I FE EU Connect plug in connector fD of the lambda sensor route the cable without tension and secure with a new cable tie Install the fuel tank ll p 78 ...

Page 71: ... ft I Nut linkage lever on angle lever I M14x1 5 Mount and tighten screw Guideline Screw bottom shock absorber Info M10 60 Nm 44 3 lbf ft Loctite 2701 TM Loctite 2701 TM Loctite 2701 TM I 80 Nm 59 lbf ft Loctite 2701 TM I Raise the wheel slightly to be able to mount the screw more easily Finishing work Install the main silencer p 70 Install the right side cover p 76 Mount the seat p 76 Remove the ...

Page 72: ...yarn escape and the damper burns out Not only is the noise level higher the performance characteristic changes Preparatory work Remove the right side cover p 75 Remove the main silencer p 69 Main work FE EU AU Remove all screws on the main silencer Take off silencer cap O and 0 ring 8 Take off outer tube and 0 ring C Remove glass fiber yarn filling 0 from inner tube D 10 Nm 7 4 lbf ft Clean the pa...

Page 73: ...ng cap with the glass fiber yarn filling in the outer tube Info I Press the glass fiber yarn filling into the outer tube using a blunt tool Mount and tighten screws O Guideline I Screws on the main silencer I MS Mount O ring on the silencer cap Position the silencer cap with O ring in the outer tube Mount and tighten screws Guideline I Screws on the main silencer Finishing work Install the main si...

Page 74: ... eye protection when cleaning the main silencer and carbon screen Clean main silencer housing C and filter 3 of the spark arrestor with compressed air Mount new 0 ring on silencer cap Position silencer cap Mount and tighten screws O Guideline I Screws on the main silencer Finishing work Install the main silencer p 70 Install the right side cover p 76 I 7 Nm 5 2 lbf ft 72 402269 10 ...

Page 75: ... filter 11 4 Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Preparatory work Remove the air filter box cover l J p 73 Main work Push air filter holding bracket O toward the air filter at position f and detach it at end G Swivel the air filter...

Page 76: ...er with fuel or petroleum since these substances attack the foam Sealin the air filter box 401559 01 Preparatory work Remove the air filter box cover a p 73 Remove the air filter a p 73 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly I Air filter cleaning agent p 264 Info I Only press the air filter to dry it never wring it out Oil the dry air filte...

Page 77: ...fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Warning Environmental hazard Improper handling of fuel is a danger to the e...

Page 78: ...7 4 lbf ft Remove screws O in the recessed grips on the left and right Raise the rear of the seat push the seat back and lift it off Mount the front of the seat on the collar bushing of the fuel tank lower the seat at the rear and simultaneously push the seat forward The seat is correctly engaged Mount and tighten seat fixing screws O Guideline I Remaining screws chassis 110 Nm 7 4 lbf ft ...

Page 79: ... 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 seat l ll p 76 Main work Unplug connector O of the fuel pump Pull the hose off the fuel tank breather on th...

Page 80: ...ine 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 rins...

Page 81: ...I Route the cable and fuel line at a safe distance from the exhaust system Finishing work Mount the seat p 76 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...

Page 82: ...the fuel tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health ha...

Page 83: ...uel connection 8 with the gasket Remove screws 8 Pull out the fuel pump Remove hose clamps C Remove fuel filter Press lock D Pull back fuel pump housing Change fuel screen fD Mount the fuel pump housing Mount fuel filter 0 Arrow f points away from the fuel pump Mount hose clamps C I Hose clamp pliers 60029057000 p 270 81 ...

Page 84: ...f the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin con...

Page 85: ...313 10 305314 10 Tighten fuel connection Guideline I Fuel connection on fuel pump Mount and tighten screws 8 Guideline I Screw fuel pump 10 Nm 7 4 lbf ft I EJOT PT I 3 Nm 2 2 lbf ft 12 12 Checking the fuel ressure mDanger 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 ciga...

Page 86: ... small metal plate and disconnect fuel hose connection O Info I Remaining fuel may flow out of the fuel hose Mount special tool 8 I Pressure tester 61029094000 p 270 Mount special tool D with nozzle label 0 60 I Testing hose 61029093000 p 270 Position the hose end in a fuel cannister Guideline I Minimum size of fuel cannister 110 I 2 6 US gal Connect the diagnostics tool and start it Select the Fu...

Page 87: ...12 FUEL TANK SEAT TRIM Remove the special tools Join the fuel hose connection 85 ...

Page 88: ... 87 Main work Remove screws O Remove screws 8 Remove the front fender Main work Position the front fender Mount and tighten screws Guideline I Remaining screws chassis Mount and tighten screws Guideline I Remaining screws chassis Finishing work Install the headlight mask with the headlight p 87 Check the headlight setting p 123 86 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft ...

Page 89: ...egs Slide the headlight mask up and swing it forward Disconnect plug in connectors 8 of the turn signals Disconnect plug in connector D and take off the headlight mask with the head light Main work Connect plug in connectors O and Position the headlight mask and fix it with rubber straps D Info I Ensure the holding lugs engage in the fender Position the brake line and wiring harness in the brake l...

Page 90: ...on the handling 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 the tread depth Info I Adhere to the legally required...

Page 91: ...er of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary damage The spokes break due to being overloaded if they are too tightly tensioned If the tension in the spokes is too low then lat eral and radial run out will form in the wheel Other spokes will become looser as a result Check spoke tension regularly and in particular on a new vehicle Strike ea...

Page 92: ...orcycle 400998 01 Front wheel Check for lateral and radial run out of the rims Lateral runout Outside the rim joint 1 8 mm 0 071 in Radial runout Outside the rim joint 1 8 mm 0 071 in If the measured value is greater than the specified value Center the rim Info I Center the rim by pulling the spoke nipple on the other side of the rim run out If there is significant deformation change the rim Corre...

Page 93: ...wheel bearing is damaged or worn Change the front wheel bearing p 92 Clean and grease shaft seal rings O and contact surface 6 of the spacers 14 6 3 I Long life grease p 264 Insert the spacers Position the front wheel and insert the wheel spindle The brake linings are correctly positioned Mount and tighten screw 8 Guideline I Screw front wheel spindle I M24x1 5 I 45 Nm 33 2 lbf ft I Operate the ha...

Page 94: ...10 3 lbf ft Loctite 243 14 6 5 Changing the front wheel bearing Preparatory work Raise the motorcycle with a lift stand I p 11 Remove the front wheel I p 90 Main work Remove shaft seal rings O and 8 Press out bearing 8 using a suitable tool Info I Spacing tube e can be pushed aside Remove the spacing tube Press out bearing 0 using a suitable tool Press in the new bearing 0 all the way using a suit...

Page 95: ...ush back the brake piston Info 93 I Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove nut O Remove chain adjuster Withdraw wheel spindle D only 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 damage...

Page 96: ...ition the rear wheel and insert wheel spindle Mount the chain The brake linings are correctly positioned Position chain adjuster Mount nut 8 but do not tighten it yet Make sure that chain adjusters are fitted correctly on adjusting screws 0 Check the chain tension l p 95 Tighten nut 8 Guideline I Nut rear wheel spindle Info I M20x1 5 I 80 Nm 59 lbf ft I The wide adjustment range of the chain adjus...

Page 97: ...d 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 specification Preparat...

Page 98: ...28 in Turn adjusting screws D 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 f The rear wheel is then correctly aligned Tighten nuts Make sure that the chain adjusters C are fitted correctly on the adjusting screws D Tighten nut 0 Guideline I Nut rear wheel spindle Info I M20x1 5 I 80 Nm 59 lbf ft I The wide adj...

Page 99: ... engine sprocket should also be changed New chains wear out faster on old worn sprockets Check the chain sliding guard for wear If the bottom edge of the chain bolt is in line with or below the chain sliding guard Change the chain sliding guard Check that the chain sliding guard is firmly seated If the chain sliding guard is loose Tighten the chain sliding guard Guideline Screw chain sliding guard...

Page 100: ...ery dirty Clean the chain p 98 14 7 9 Cleaning the chain A Warning Danger of accidents Oil or grease on the tires reduces the road grip Remove the lubricant 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 W...

Page 101: ...rom the lift stand il p 11 Preparatory work Raise the motorcycle with a lift stand Ii p 11 Main work Remove screws O and 8 Remove the engine sprocket cover Have an assistant operate the rear brake Remove screw with washer Remove the rear wheel l J p 93 Remove connecting link C of the chain Info I Cover the components to protect them against damage Take off the chain Remove engine sprocket 0 99 ...

Page 102: ...f travel Install the rear wheel 1ll p 94 Have an assistant operate the rear brake Mount and tighten screw 8 with washer Guideline Screw engine sprocket M10 Position the engine sprocket cover Mount and tighten screw O Guideline I Screw clutch slave cylinder Mount and tighten screw Guideline I Remaining screws chassis Finishing work 60 Nm 44 3 lbf ft Remove the motorcycle from the lift stand a p 11 ...

Page 103: ...to the outside Press new bearing C all the way in from the outside to the inside Info 101 I Only press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in Clean grease and mount spacing tube 0 I Long life grease ilill p 264 Press new bearing C all the way in from the outside to the inside Info I Only press the bearing in via the outer ring otherwise the be...

Page 104: ...press it in until it is flush Mount lock ring The lock ring engages audibly Grease new shaft seal ring O and press it in until it is flush Finishing work Install the rear wheel ilill p 94 Remove the motorcycle from the lift stand ilill p 11 102 ...

Page 105: ... Remove the faulty main fuse Info I A defective fuse can be identified by the burned out fuse wire e A reserve fuse 8 is located in the starter relay Install a new main fuse I Fuse 58011109120 i l p 209 Check that the electrical equipment is functioning properly Tip I Insert the spare fuse so that it is available if needed Mount the protection caps Finishing work Install the air filter box cover i...

Page 106: ...rating only I Fuse 75011088010 I p 209 Tip I Replace the spare fuse in the fuse box so that it is available if needed Check that the power consumer is functioning properly Close the fuse box cover Finishing work Mount the seat I p 76 Preparatory work Switch off all power consumers and switch off the engine Remove the seat I p 76 Remove the air filter box cover I p 73 Main work Disconnect the negat...

Page 107: ...ct the negative cable from the battery Installing the batte Pull back the positive terminal cover 8 and disconnect the positive cable from the battery Detach rubber band 8 at the bottom Lift the battery up and out Main work Insert the battery into the battery compartment with the terminals facing forward I Battery YTX5L BS p 209 Reconnect rubber band O Info I Contact disks G must be mounted under ...

Page 108: ...e battery Rapid recharging with a high charging current shortens the service life of the battery If the charging current charging voltage and charging time are exceeded the battery will be destroyed If the battery is depleted from starting the vehicle repeatedly the battery must be charged immediately 106 If the battery is left in a discharged state for an extended period it will become over disch...

Page 109: ...voltage regulator to the wiring har ness Check the stator winding of the alternator 0 p 202 If the displayed value is greater than the specified value Change the voltage regulator Preparatory work Switch off all power consumers and switch off the engine Remove the seat p 76 Main work Disconnect the negative cable from the battery Measure the current between battery ground and the negative cable In...

Page 110: ... doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the ...

Page 111: ...ons Ensure that brake fluid does not flow out of the brake fluid reservoir extracting it by suction if it does Info I Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes Remove cotter pins C pull out pin 0 and remove the brake linings Clean the brake caliper and brake caliper support Check that leaf spring D in the brake caliper and sliding plat...

Page 112: ... travel on the hand brake lever in accordance with the specification FE EU AU Push the hand brake to the handlebar and check free travel 9 I Free travel of hand brake lever I 3 mm 0 12 in FE US If the free travel does not meet specifications Adjust the free travel of the hand brake lever a p 111 Push the hand brake lever forwards and check free travel 9 I Free travel of hand brake lever I 3 mm 0 1...

Page 113: ...ents while riding Checking the front 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 down Check the brake system and do not continue riding until the problem is eliminated Warning Danger of ac...

Page 114: ... Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container Preparatory work Check the front brake linings p 108 Main work 112 Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws O Remove cover with membrane Add brake flui...

Page 115: ...66 Connect the bleeding device I Bleeding device 00029013100 lil l p 266 Open shut off valve C Info I Follow the operating instructions of the bleeding device Ensure that the filling pressure is correctly set at pressure gauge 8 If neces sary adjust the filling pressure at pressure regulator G Guideline I Filling pressure I 2 2 5 bar 29 36 psi Pull off protection cap 0 of the brake caliper bleeder...

Page 116: ...t maintenance will cause the brake system to fail Ensure that service work and repairs are performed professionally Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective 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 h...

Page 117: ...r 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 Stand the vehicle upright Remove screw cap O with membrane 8 and the O ring Press the brake caliper onto the brake disc by hand in order to push back the brake piston and ensure that brake fluid does not flow out of the brake fluid reser voir extracti...

Page 118: ...cification Disconnect spring O 116 Move the foot brake lever back and forth between the end stop and the contact 402026 10 to the foot brake cylinder piston and check free travel 6 Guideline I Free travel at foot brake lever 13 5 mm 0 12 0 2 in If the free travel does not meet specifications Adjust the basic position of the foot brake lever a p 116 Reconnect spring O Adjusting the basic osition of...

Page 119: ...ail I 20 Nm 14 8 lbf ft I 10 Nm 7 4 lbf ft If the brake fluid level drops below the specified marking or the specified value the brake system is leaking or the brake linings are worn down Check the brake system and do not continue riding until the problem is eliminated Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is ...

Page 120: ...ever use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container Preparatory work Check the rear brake linings p 114 Main work Stand the vehicle upright Remove screw cap O with membrane fj and the O ring...

Page 121: ...I Bleeding device 00029013100 0 p 266 Open shut off valve 8 Info I Follow the operating instructions of the bleeding device Ensure that the filling pressure is correctly set at pressure gauge 6 If neces sary adjust the filling pressure at pressure regulator G Guideline I Filling pressure I 2 2 5 bar 29 36 psi Pull off protection cap C of the bleeder screw Connect the hose of the bleeder bottle I B...

Page 122: ...Correct the brake fluid up to marking 9 I Brake fluid DOT 4 a p 262 Fit and tighten plug with oil screen and 0 ring Info I Clean up overflowed or spilt brake fluid immediately with water Check the foot brake lever for a firm pressure point 120 ...

Page 123: ...ss one of the buttons to select the 24h or 12h display of the clock Wait for 5 seconds The speedometer changes to the next menu item The 0 symbol flashes Resetting the time Press the left button The value decreases Advancing the time Press the right button The value increases Wait for 5 seconds The speedometer changes to the next menu item The symbol flashes Set the service Guideline One time serv...

Page 124: ...nary Press both buttons for 3 5 seconds The Setup menu is displayed The UNIT display flashes Wait for the menu of the clock 0 to flash Press one of the buttons to select the 24h or 12h display of the clock Wait for 5 seconds The speedometer changes to the next menu item The 0 symbol flashes Resetting the time Press the left button The value decreases Advancing the time Press the right button The v...

Page 125: ...ime service after Service every Shortening the service interval Press the left button The value decreases Extending the service interval Press the right button The value increases Switching off the service interval display Press and hold the left button off appears on the display 1 h 15 h Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of...

Page 126: ...the headlight setting I p 123 Main work Loosen screw O Adjust the headlight range by pivoting the headlight Guideline 124 The boundary between light and dark must be exactly on the lower mark for a motorcycle with driver instructions on how to apply the mark Checking the headlight setting Info I If you have a payload you may have to correct the headlight range Tighten screw O ...

Page 127: ...ith a lift stand p 11 Remove the right side cover ll p 75 Remove the main silencer ll p 69 Remove the seat ll p 76 Remove the fuel tank ll p 77 Main work Remove screw O Disconnect the negative cable of the battery Loosen hose clip Pull back the protection cap Unplug connector D Push back hose clamp 8 Pull off the vent hose 125 ...

Page 128: ...these steps on the opposite side Swing up the subframe and secure it Remove screw Swing back the shock absorber Remove springs I Spring hook 50305017000 p 267 Remove screw Take off the manifold Push back the cover Remove nut Gi Take off the cable 126 ...

Page 129: ...nnecting link of the chain Take off the chain Remove screws e Take off the clutch slave cylinder and hang it to one side Info I Do not kink the clutch line 127 Do not activate the clutch lever while the clutch slave cylinder is removed Unplug connector G s Unplug connector 41 Pull back the protection cap Unplug connector 4E Pull off the spark plug connector ...

Page 130: ...ngs G Take off the engine braces Remove nut Remove the swingarm pivot Pull the swingarm toward the rear slightly Remove screws Lift out the engine sideways Info I The help of an assistant is useful in this step Ensure that the motorcycle is sufficiently secured against falling over Protect the frame and attachments against damage 128 ...

Page 131: ...hten it yet Guideline Nut swingarm pivot Position the engine braces Mount and tighten fittings 8 Guideline Screw engine brace MB Tighten screws O and nut 8 Guideline Engine attachment bolt Nut swingarm pivot Mount the radiator hose Position and tighten hose clip C M16x1 5 33 Nm 24 3 lbf ft M10 M16x1 5 129 I 60 Nm 44 3 lbf ft I 100 Nm 73 8 lbf ft Loctite 2701 TM 60 Nm 44 3 lbf ft 100 Nm 73 8 lbf ft...

Page 132: ... and tighten screws Guideline I Screw clutch slave cylinder M6 Mount the chain Connect the chain with connecting link Guideline 130 110Nm 7 41bf ft The closed side of the chain joint lock must face in the direction of travel Position the engine sprocket cover Mount and tighten screw 48 Guideline I Screw clutch slave cylinder Mount and tighten screw 41 Guideline I Remaining screws chassis Mount spr...

Page 133: ...Position the cover Position the manifold and mount springs 4D I Spring hook 50305017000 l p 267 Mount and tighten screw 4D Guideline I Remaining screws chassis Position the shock absorber Mount and tighten screw 41 Guideline Screw top shock absorber M10 60 Nm 44 3 lbf ft 131 I 25 Nm 18 4 lbf ft I Loctite 2701TM ...

Page 134: ...ws Guideline Screw subframe Remove screw Mount and tighten screw Guideline Screw subframe M8 M8 Repeat these steps on the opposite side Mount the vent hose Position hose clamp G Plug in connector Position the protection cap Position and tighten hose clip 35 Nm 25 8 lbf ft 35 Nm 25 8 lbf ft 132 Loctite 2701TM Loctite 2701TM ...

Page 135: ...sult in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Start the engine and check that it is oil tight Switch off the engine Check the engine oil level I p 197 Check the coolant level I p 195 Execute the initialization run a p 205 Finishing work Ta...

Page 136: ...er Draining the engine oil Remove clutch push rod O Remove spacer O of the countershaft Remove O ring Remove plug O with oil screen and the O rings Remove the oil drain plug with the magnet and seal ring Remove oil drain plug 8 with the O ring Completely drain the engine oil 134 ...

Page 137: ...e screws O Remove the oil filter cover with the O ring Pull oil filter D out of the oil filter housing I Circlip pliers reverse 51012011000 p 268 Remove the spark plug using special tool O I Spark plug wrench 77229172000 p 273 Remove screws O Remove the valve cover with the valve cover seal Remove gasket 8 135 ...

Page 138: ... limiter Remove screws O Take off the alternator cover Take off alternator cover gasket Dowels 8 remain in the engine case Remove torque limiter O 136 18 3 10 Positioning the engine at ignition top dead center Turn the crankshaft counterclockwise until marking 6 is flush with the edge of the cylinder head ...

Page 139: ...ming chain tensioner 18 3 12 Removing the camshaft Loosen screw O Remove screw with the seal ring Pull out timing chain tensioner CD Remove O ring e Loosen screws O from the outside to the inside and remove Take off guide rail Take off the camshaft bearing bridge Info Ensure that the dowel pins remain in place Take the timing chain off the camshaft gear Remove the camshafts 137 ...

Page 140: ...e cylinder head gasket Push the cylinder upward Info 138 I Only push the cylinder as far up as necessary to take the piston pin out Remove the piston pin retainer 0 Remove the piston pin Take off the cylinder and piston Push the piston upward out of the cylinder Info I If no further work is to be performed on the cylinder and piston the piston can remain in the cylinder Take off cylinder base gask...

Page 141: ... Hold it tight using the special tool and pull off the rotor by turning the screw in Extractor 58012009000 p 268 Info I Ensure that the woodruff key remains in place Remove screws C Take off the alternator cover Take off gasket 0 Info Ensure that the dowel pins remain in place Remove screws D and the starter motor Remove lock ring Take off the starter idler gear with the washer ...

Page 142: ...18 ENGINE 18 3 16 Removing the suction pump 140 Remove freewheel gear G Remove screws O Take off oil pump cover fj Remove O ring D Take off suction pump C Remove needle roller 0 ...

Page 143: ...cover 18 3 19 Removing the clutch discs Remove screws O Take off the water pump cover Remove nut Take off the two part water pump impeller Remove screws O Take off the clutch cover Remove the clutch cover seal Remove screws O Take off spring retainer Take off spring washer 141 ...

Page 144: ...ce Bend up the lock washer Hold the inner clutch hub with the special tool Loosen nut 0 1 Clutch holder 51129003000 l l J p 268 Remove the nut with the lock washer Dispose of the lock washer Take off inner clutch hub and washer Info I The washer usually sticks to the inner clutch hub Take off clutch basket 8 Take off needle bearing 0 and collar sleeve D 142 ...

Page 145: ...e locking lever 18 3 24 Removing the force pump Remove screw O Push away locking lever from shift drum locating unit and remove the shift drum locating unit Relieve tension from the locking lever Unscrew O and remove together with locking lever washer sleeve and spring Remove lock ring O Take off washer Take off oil pump idler gear with the washer Remove lock ring C Take off washer 0 Remove oil pu...

Page 146: ... Left handed thread Position the special tool in the crankshaft I Protection cap 75029090000 a p 271 144 Pull off primary gear 8 using the special tool I Extractor 46129021000 p 267 Remove screw 8 Remove screws O Remove the timing chain tensioning rail 8 Remove the timing chain guide rail C Remove screw C Take off balancer shaft 0 with the timing chain and timing chain securing guide Info If the t...

Page 147: ...crankshaft I Protection cap 75029090000 a p 271 Mount special tool 8 with the appropriate screws I Puller 77229048000 a p 272 Info Use the drill hole marked with 772 Take off the section of the engine case Info I Do not subject the section of the engine case to any stress The washer of the main shaft usually adheres to the bearing Take off the left section of the engine case Remove the special too...

Page 148: ...ace the shift rollers Remove shift drum Remove shift forks O Info Do not misplace shift rollers 8 18 3 32 Removing the transmission shafts 18 3 33 Removing the crankshaft Remove lock ring O Pull both transmission shafts 8 out of the bearing seats together Take out crankshaft O Take off the right section of the engine case 146 ...

Page 149: ...tite 243 Insert the new cold bearings in the bearing seats of the heated section of the engine case if necessary use a suitable press drift to push them all the way in and make them flush Info I When pressing the bearing in ensure that the engine case section is level to prevent damage Only press the bearings in via the outer bearing race otherwise the bear ings will be damaged when they are press...

Page 150: ...he bearings to drop out of the bearing seats Info I Any bearings that remain in the engine case section must be removed using a suitable tool Insert the new cold bearings in the bearing seats of the heated section of the engine case if necessary use a suitable press drift to push them all the way in and make them flush Info I When pressing the bearing in ensure that the engine case section is leve...

Page 151: ...nd tighten oil nozzle 0 Guideline Oil nozzle piston cooling Position all bearing locks M5 Mount and tighten screws D Guideline Locking screw for bearing M5 6Nm 4 4 lbf ft 2 Nm 1 5 lbf ft 6Nm 4 4 lbf ft Loctite 243 Loctite 243 Loctite 243 Blow out the oil channel with compressed air and check that it is clear Remove shaft seal ring O Remove lock ring 8 Remove shaft seal ring CD Press out bearing 8 ...

Page 152: ...he open side facing inward Info I Press the shaft seal ring inward to the point where the lock ring can be mounted Provide suitable support for the clutch cover while pressing in Mount lock ring 0 Blow out the oil channel with compressed air and check that it is clear Checking the oil pressure regulator valve 308784 10 306115 10 Remove screw plug O with sealing washer 8 Remove pressure spring CD a...

Page 153: ...il pumps O for damage and wear If there is damage or wear Change the oil pumps Check oil pump shaft 8 for damage and wear If there is damage or wear Change the oil pump shaft Check the oil pump cover for damage and wear If there is damage or wear Change the oil pump cover 18 4 6 Removing the crankshaft bearing inner race Fix the crankshaft in the vise Info I Use soft jaws Warm up special tool O Gu...

Page 154: ...Guideline 1120 C 248 F I Tool for inner bearing race 58429037037 il ll p 268 Repeat the operation on the opposite side Ensure that the new crankshaft bearing inner race is flush Info I After replacing the crankshaft bearings the crankshaft end play must be measured Finishing work Measure the crankshaft end play il ll p 154 18 4 8 Changing the connecting rod conrod bearing and crank pin Main work P...

Page 155: ... Position the second crank web Position special tool with the heel pointing down I Insert for crankshaft pressing tool 77029008000 p 271 Press in the upper crank web 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 9 between the connecting rod and the cr...

Page 156: ... Mount the dial gauge support on the engine case and measure and note down the crankshaft end play Guideline I Crankshaft axial play I 0 30 0 40 mm 0 0118 0 0157 in If the measured value does not meet specifications Remove the crankshaft Remove the crankshaft bearing inner race I p 151 Calculate the thickness of the compensating disks Add or remove compensating disks equally on both sides Info I I...

Page 157: ... improved performance low wear and a lightweight cylinder 18 4 14 Checking measuring the cylinder 305004 10 Check the cylinder bearing surface for damage If the cylinder bearing surface is damaged Change the cylinder and piston Measure the cylinder diameter at several locations on the 0 and 0 axes using a micrometer to identify oval wear Guideline Cylinder drill hole diameter Size I Size II Info 7...

Page 158: ...ton ring with the marking facing upward Check the piston pins for discoloration or signs of wear If the piston pin shows severe discoloration signs of wear Change the piston pin Place the piston pin in the connecting rod and check the seating for play If the piston pin seating has excessive play Change the connecting rod and piston pin Measure the piston at the piston skirt at right angles to the ...

Page 159: ...ring I 0 40 mm 0 0157 in Oil scraper ring I 0 70 mm 0 0276 in If the end gap is greater than the specified measurement Check measure the cylinder p 155 If cylinder wear lies within the specified tolerance Replace the piston ring Mount the piston ring with the marking facing toward the piston head Check the camshaft for damage and wear If there is damage or wear Change the camshaft If the surface o...

Page 160: ... bridge O Mount and tighten the screws Guideline Screw camshaft bearing bridge Info M7x1 14 Nm 10 3 lbf ft I Ensure that the dowel pins are seated properly Do not turn the camshaft Lubricated with engine oil Remove camshaft bearing bridge O again Compare the Plastigauge clearance gauge with the specifications on the packaging Guideline Camshaft bearing sleeve bearing Radial clearance Wear limit In...

Page 161: ... tension the valve spring using the special tool Valve spring mounter 59029019000 p 269 Insert for valve spring lever 77229060000 p 273 Remove the valve keys and unload the valve spring Remove the valve spring retainer and valve springs Mark the valve spring according to its normal built in position Pull the valve down out of the valve guide Remove valve stem seal 8 with the special tool I Pliers ...

Page 162: ... Info I Intake valves are marked with a green color coding Exhaust valves are marked with a brown color coding If the valve spring is broken or worn Change the valve spring Measure the length of the valve springs Valve spring Minimum length of intake valve Minimum length of exhaust valve I 42 mm 1 65 in I 42 mm 1 65 in If the measured value does not meet specifications Change the valve springs 18 ...

Page 163: ...sealing area of the cylinder for distortion I Feeler gauge 59029041100 p 269 Cylinder cylinder head distortion of sealing area 0 10 mm 0 0039 in If the measured value does not meet specifications Change the cylinder head Check sealing seat 6 of the valves Valve sealing seat width Intake Valve sealing seat width Exhaust 1 40 mm 0 0551 in 1 40 mm 0 0551 in If the measured value does not meet specifi...

Page 164: ...amount of grease Position cam levers C in the positions they had before they were removed Mount the cam lever shafts Remove screw 0 Mount and tighten screw plugs D Guideline I Screw plug cam lever axis I M10x1 10 Nm 7 4 lbf ft Place the shims in the valve spring retainers corresponding to their installation position Insert freewheel gear O into the freewheel hub turning the freewheel gear clock wi...

Page 165: ...g the freewheel 308684 11 308685 10 Remove lock ring O Press expansion ring fj together with suitable pliers and take off Take freewheel 8 out of the primary gear Thoroughly oil all parts Slide freewheel O into the primary gear Info Note the direction of rotation Mount spreader ring 163 ...

Page 166: ...is damage or wear Change the starter idler gear Check the gear mesh and bearing of torque limiter 8 for damage and wear If there is damage or wear Change the torque limiter Check the gear mesh and bearing of freewheel gear 6 for damage and wear If there is damage or wear Change the freewheel gear or bearing Check freewheel C for damage and wear If there is damage or wear Change the free wheel Chec...

Page 167: ...g 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 wear If there is damage or wear Replace the timing chain guide rail Check the timing chain securing guide 8 for damage and wear If there is damage or wear Replace the timing chain securing guide Check camshaft gears 0 for damage and wear If there is da...

Page 168: ...ain tensioner The detent mechanism engages and the piston remains in place Final position of the piston after engagement Info 3 mm 0 12 in This position is necessary for installation If the timing chain tensioner is now pressed again and is only extended a maximum of half way it is prevented from extending completely This locks the detent mechanism and the timing chain tensioner can no longer be s...

Page 169: ...e or wear Change the inner clutch hub Check the thrust surfaces of the clutch facing discs in clutch basket 4D for damage and wear If there is damage or wear Change the clutch facing disks and the clutch basket Check needle bearing 48 and collar sleeve 8 for damage and wear If there is damage or wear Change the needle bearing and collar sleeve Check the intermediate clutch disks 41 for damage and ...

Page 170: ...rollers for damage and wear If there is damage or wear Change the shift rollers Check the springs of shift rails 8 for damage and wear If the spring is damaged or worn Change the spring of the shift rail Check the shift rails 8 for run out on a flat surface If there is run out Change the shift rail 306554 10 Check the shift rails for scoring wear and smooth operation in the shift forks If scoring ...

Page 171: ... guide pin facing downward and put the guide pin on the shift quadrant Mount pressure spring Slide on spring guide push return spring C with the offset end facing upward over the spring guide and lift the offset end over abutment bolt 0 Mount washer D 18 4 37 Disassembling the main shaft 306576 10 Secure the main shaft with the toothed end facing downward in the bench vise Guideline Use soft jaws ...

Page 172: ...d stop disk e Remove sixth gear sliding gear 0 Remove lock ring 3 Remove stop disk Remove third gear idler gear and needle bearing Remove fourth gear idler gear Remove needle bearing 48 Remove stop disk 48 Remove lock ring 41 Remove fifth gear sliding gear 4D Remove lock ring Gi Remove stop disk 4D Remove second gear idler gear 48 and needle bearing 48 18 4 39 Checking the transmission Condition T...

Page 173: ...e or wear Change the gear wheel pair Check the tooth faces of idler gears 8 sliding gears and fixed gear C for damage and wear If there is damage or wear Change the gear wheel pair Check the tooth profiles of sliding gears 0 for damage and wear If there is damage or wear Change the gear wheel pair Check sliding gears 0 for smooth operation in the profile of main shaft 8 If the sliding gear does no...

Page 174: ... D and lockring C Attach third fourth gear sliding gear 0 with the small gear wheel facing downward and mount lockring 0 Mount stop disk and needle bearing Mount sixth gear idler gear 0 with the shift dogs facing down Mount second gear fixed gear G i with the collar facing down and mount stop disk G In conclusion checkall gear wheels for smooth operation 18 4 41 Assembling the countershaft Info Us...

Page 175: ...earing G and the fourth gear idler gear with the collar facing up Mount needle bearing 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 CD with the shift groove facing down and stop disk Mount needle bearing 40 first gear idler gear 48 with the recess facing down and stop disk 4D In conclusion check all gear wheels f...

Page 176: ... ring Shift fork O has a smaller inside diameter mount this in the shift groove of the main shaft Mount shift fork in the lower shift groove of the countershaft Mount shift fork fD in the upper shift groove of the countershaft Slide on shift rollers 8 Tip Fix the shift rollers in the shift forks with grease Push shift drum O into the bearing seat Put shift forks in the shift drum Info Do not mispl...

Page 177: ...ection of the engine case If necessary strike it lightly with a rub ber mallet and turn the transmission shafts Info I Do not use the screws to pull the two sections of the engine case together Mount screws O but do not tighten yet Guideline I Screw engine case I M6x55 Mount screws 8 but do not tighten yet Guideline 10 Nm 7 4 lbf ft I Screw engine case I M6x65 I 10 Nm 7 4 lbf ft Mount screws D and...

Page 178: ...ne Screw timing chain securing guide M6 Position timing chain guide rail 8 Mount and tighten screw C Guideline Screw timing chain guide M6 rail Position timing chain tensioning rail 0 Mount and tighten screw D Guideline Screw timing chain ten sioning rail Position primary gear 0 M8 Markings f and G are aligned 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 15 Nm 11 1 lbf ft Loctite 243 Loctite 243 Loctite 243 ...

Page 179: ...Mount the oil pump shaft 8 from the ignition side Mount pin 5 Position the oil pump cover Marking 6 faces upward Mount and tighten screws C Guideline Screw oil pump cover Insert pin 0 Position oil pump gear D Mount washer Mount lock ring C M5 6Nm 4 4 lbf ft Crank the oil pump gear and ensure that it can move easily Mount oil pump idler gear 0 with the washer Mount washers i Mount lock ring 48 Inse...

Page 180: ... ft Mount locking lever O with the washer sleeve and spring Mount and tighten screw Guideline Screw locking lever M5 6Nm 4 4 lbf ft Loctite 243 Loctite 243 18 5 13 Installing the shift drum locating unit Push away locking lever O from the shift drum locating unit and position the shift drum locating unit Info I The flat areas of the shift drum locating unit are not symmetric Relieve tension from t...

Page 181: ...unit Shift through the transmission Mount collar sleeve O and both needle bearings 8 Slide the clutch basket onto the gearbox main shaft Turn the oil pump gear 8 until the gear teeth of the clutch basket mesh Slide on washer 8 and inner clutch hub 0 Position the new lock washer and mount nut Q Tighten the nut holding the inner clutch hub with a special tool Guideline Nut inner clutch hub M18x1 5 I...

Page 182: ...all other clutch fac ing discs and intermediate clutch discs into the clutch basket Mount pressure piece O Position pressure cap Mount pretension ring D with the Top marking facing up Position spring washer 8 Position spring retainer with the I marking Mount screws D and tighten in a crisscross pattern Guideline I Screw clutch spring I 6 Nm 4 4 lbf ft ...

Page 183: ...ial tool check the spring washers for distortion I Feeler gauge 59029041100 p 269 I Spring washer distortion I 0 0 10 mm 0 0 0039 in If the specified value was not attained Change the clutch facing discs Create the tool special screw A conventional screw is required Cut screw O to a length of f Guideline I Screw I Length e I M6x70 I 60 mm 2 36 in Cut a slot into the top end of the screw Position t...

Page 184: ...he dowel pins are seated properly Mount screw 8 with the seal ring b ut to not tighten yet Guideline I Screw water pump cover I M6x25 Mount screw C b ut do not tighten yet Guideline I Screw water pump cover Mount and tighten screws 0 Guideline I Screw water pump cover Tighten screws 4D and C Guideline I Screw water pump cover Positionfreewheel gear O I M6x25 I M6x40 I M6x25 Mount the starter idler...

Page 185: ...ews Guideline I Screw starter motor I 8 Nm 5 9 lbf ft 10 Nm 7 4 lbf ft Ensure that the woodruff key is seated properly Mount the rotor Info I To simplify installation turn the starter idler gear counterclockwise Mount and tighten screw D Guideline Rotor screw M10x1 Shift the gap of the piston rings by 120 70 Nm Thread oiled with 51 6 lbf ft engine oil cone degreased Place the special tool onto the...

Page 186: ...iston marking f faces the exhaust side Thinly apply sealing compound to area I Loctite 5910 Position the cylinder base gasket Info Ensure that the dowel pins are seated properly Cover the engine case opening with a cloth Feed the timing chain through the chain shaft Mount the piston pin Info I For purposes of illustration the following operations are shown on the removed piston Position the piston...

Page 187: ...eep the timing chain taut Press the cylinder down carefully and bring dowel pins into contact Position cylinder head gasket 0 Info I Ensure that the dowel pins are seated properly Put the cylinder head in place Mount nuts 8 with the washers and tighten in a crisscross pattern Guideline 185 Nut cylinder head M10x1 25 Tightening Thread oiled with sequence engine oil cone Tighten diag greased anally ...

Page 188: ...shaft D Place the timing chain over the camshaft gear and position the camshaft in the bearing seat Marking fj is positioned and is aligned with the edge of the cylinder head Clean all oil nozzles thoroughly and blow out with compressed air Mount the camshaft bearing bridge Info I Ensure that the dowel pins are seated properly Position guide rail 8 Mount screws 0 and tighten from the inside to the...

Page 189: ...4 lbf ft 18 5 24 Checking the valve clearance Remove screw O Crank over the engine repeatedly Position the engine at ignition top dead center Marking fj are aligned with the edge of the cylinder head Check the valve clearance at all valves between the camshaft and cam levers Guideline Valve clearance Intake at 20 C 68 F I 0 10 0 15 mm 0 0039 0 0059 in Exhaust at 20 c 68 F I 0 13 0 18 mm 0 0051 0 0...

Page 190: ...the alternator cover Check the valve clearance a p 187 Position torque limiter O Position the alternator cover gasket O Position the alternator cover Mount screws 8 and tighten once all of the alter nator cover screws have been mounted Guideline I Screw alternator cover M8x30 I 6 Nm 4 4 lbf ft Mount screws and tighten once all of the alternator cover screws have been mounted Guideline I Screw alte...

Page 191: ... gasket Apply a thin layer of sealing compound in area 6 I Loctite 5910 Position the valve cover with the gasket Mount and tighten screws D Guideline I Screw valve cover Mount and tighten the spark plug with special tool O Guideline ISpark plug IM10x1 I Spark plug wrench 77229172000 a p 273 189 I 8 Nm 5 9 lbf ft 1 10 12 Nm 7 4 8 9 lbf ft ...

Page 192: ...ws Guideline I Screw oil filter cover Mount and tighten screw plug O with the O ring Guideline I Oil drain plug I M14x1 5 10 Nm 7 4 lbf ft 15 Nm 11 1 lbf ft Mount and tighten the oil drain plug 8 with the magnet and the new seal ring Guideline I Oil drain plug with magnet I M12x1 5 I 20 Nm 14 8 lbf ft I Push the oil screen with O rings onto a pin wrench Push the pin wrench through the opening into...

Page 193: ... push rod Grease the shaft seal ring before mounting Position the O ring Mount spacer O with the bevel facing inward Mount clutch push rod O 18 5 34 Removing the engine from the engine assembly stand Remove the screw connection from the special tool I Engine fixing arm 77229002000 p 271 Remove the engine from the engine assembly stand Info Work with an assistant or a motorized hoist ...

Page 194: ...the clutch facing discs 192 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 Chan Warning Environmental hazard Move the clutch fluid reservoir mounted on the handlebar to a horizontal p...

Page 195: ...ject the liquid into the system until it escapes from openings D of the master cylinder without bubbles To prevent overflow drain fluid occasionally from the master cylinder reservoir Remove the bleeding syringe Mount and tighten the bleeder screw Correct the fluid level of the hydraulic clutch Guideline Fluid level below top edge of con tainer 4 mm 0 16 in Position the cover with the membrane Mou...

Page 196: ...the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature Allow the cooling system and the engine to cool down before you open the radiator the radiator hoses or other compo nents of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a healt...

Page 197: ...cle upright on a horizontal surface Remove the radiator cap Check the coolant level in the radiator Coolant level f above the radiator fins 10 mm 0 39 in If the coolant level does not match the specified value 400243 10 Draining the coolant Warning Correct the coolant level I Coolant p 262 Mount the radiator cap Danger of scalding During motorcycle operation the coolant gets very hot and is under ...

Page 198: ...he skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing Main work Make sure that the screw O is tightened Stand the vehicle uprig...

Page 199: ...tory work Stand the motorcycle upright on a horizontal surface Condition The engine is cold Check the engine oil level The engine oil reaches the lower edge of level viewer f If the engine oil does not reach the lower edge of the level viewer Add engine oil l t p 200 Condition The engine is at operating temperature Check the engine oil level Info I After switching off the engine wait one minute be...

Page 200: ...n a level surface Remove the engine guard il J p 40 Main work Place a suitable container under the engine Remove oil drain plug O with the magnet and seal ring Info Do not remove screws f on both sides Remove plug 8 with oil screen D and the O rings Completely drain the engine oil Thoroughly clean the parts and sealing surfaces Position oil screen D with the O rings on a pin wrench 198 Insert the ...

Page 201: ...over 10 Nm 7 4 lbf ft Stand the motorcycle upright Remove the oil filler plug with the 0 ring from the clutch cover and fill up with engine oil I Engine oil 11 0 I 1 1 qt I Engine oil SAE 10W 50 l l p 262 Info I Too little engine oil or poor quality engine oil results in premature wear to the engine Install and tighten the oil filler plug with 0 ring mDanger Danger of poisoning Exhaust gases are t...

Page 202: ...in an enclosed space Start the engine and check that it is oil tight Finishing work Check the engine oil level l ll p 197 ressure Check the engine oil level l ll p 197 Remove the release screw of the chain adjuster Mount and tighten special tool O Guideline I Oil pressure adapter I M10x1 I Oil pressure adapter 77329006000 Ip 273 10 Nm 7 4 lbf ft Connect pressure tester 8 to the special tool withou...

Page 203: ... Warning Danger of burns Some vehicle components get very hot when the machine is driven Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water Remove the special tools Mount and tighten the release screw of the chain adjuster Guideline 201 Screw unlocking of timing chain ten sioner M10x1 10 Nm 7 4 lbf ft ...

Page 204: ...ring point1 Measuring point 2 Spark plug connector Resistance at 20 c 68 F If the specification is not reached Change the spark plug connector 3 75 6 25 kn Alternator checking the stator winding EZ 601211 10 Condition The stator is disconnected Preparatory work Remove the seat l t I p 76 Main work Stator winding measurement I check the resistance 0 Measure the resistance between the specified poin...

Page 205: ... bracket Remove screw 8 Remove cable support sleeve 8 from the alternator cover Remove the stator and ignition pulse generator from the alternator cover Blow out oil nozzle O with compressed air and check that it is clear Guideline Oil nozzle for alternator cooling M4 2Nm Loctite 243 1 5 lbf ft Position the stator and ignition pulse generator in the alternator cover Mount and tighten screws 8 Guid...

Page 206: ...motor 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 to connector O of the starter motor If the starter motor does not turn when the circuit is closed Change the starter motor ...

Page 207: ...cted and running Execute Engine electronics Functions Delete adaptation values The adaptation values are deleted Select Engine electronics Measured values Coolant temperature sensor TW1 The coolant temperature is displayed during the initialization run Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient v...

Page 208: ...3 Clutch Multidisc clutch in oil bath hydraulically activated Transmission ratio 1st gear 13 32 2nd gear 16 30 3rd gear 16 24 4th gear 23 28 5th gear 23 23 6th gear 26 20 Alternator 12V 168W Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment Spark plug NGK LMAR9Al 10 Spark plug electrode gap 1 0 mm 0 039 in Cooling Water cooling permanent circulation of coo...

Page 209: ... Loctite 243 tion Oil nozzle for conrod bearing lubrica M4 2 Nm 1 5 lbf ft Loctite 243 tion Screw oil nozzle for piston cooling M4 2 Nm 1 5 lbf ft Loctite 243 Locking screw for bearing M5 6 Nm 4 4 lbf ft Loctite 243 Oil channel screw plug in alternator M5 1 2 Nm 0 89 lbf ft Loctite 648 cover Oil nozzle for cam lever lubrication M5 3 Nm 2 2 lbf ft Loctite 243 Oil nozzle for clutch lubrication M5 6 ...

Page 210: ...25 4 3 Fuel Totalfuel tank capacity 9 5 I 2 51 US gal approx FE EU AU Totalfuel tank capacity 8 5 I 2 25 US gal approx FE US I Fuel reserve approx 208 10 Nm 7 4 lbfft Loctite 243 10 Nm 7 4 lbfft Loctite 243 8 Nm 5 9 lbfft 10 Nm 7 4 lbfft 10 Nm 7 4 lbfft 14 Nm 10 3 lbfft Lub ricated with engine oil 10 Nm 7 4 lbfft 25 Nm 18 4 lbfft 15 Nm 11 1 lbfft 60 Nm 44 3 lbfft 15 Nm 11 1 lbfft 70 Nm 51 6 lbfft ...

Page 211: ...FE US 13 52 Chain 5 8 X 1 4 Rear sprockets available 48 50 52 Steering head angle 63 5 Wheelbase 1 482 10 mm 58 35 0 39 in Seat height unloaded 970 mm 38 19 in Ground clearance unloaded 345 mm 13 58 in Homologated weight without fuel approx FE EU AU 109 5 kg 241 4 lb Weight without fuel approx FE US 107 5 kg 237 lb Maximum permissible front axle load 145 kg 320 lb Maximum permissible rear axle loa...

Page 212: ...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 Fork length Air chamber length I Oil capacity per fork leg 25 9 Shock absorber Shock absorber part number Shock absorber I 635 ml 21 47 fl oz Compression damping low speed Comfort Standard Sport Compression damping high speed Comfort Standard Sport Rebound damping Comfort Standard Sport Spring preload...

Page 213: ...tand attachment M8 Screw subframe M8x20 Screw subframe M8x30 Screw top steering stem M8 Screw top triple clamp M8 Engine attachment bolt M10 Remaining nuts chassis M10 Remaining screws chassis M10 Screw bottom shock absorber M10 Screw handlebar holder M10 54 N mm 308 lb in 57 N mm 325 lb in 260 mm 10 24 in 10 bar 145 psi 30 mm 1 18 in 100 mm 3 94 in 490 mm 19 29 in I Shock absorber fluid SAE 2 5 5...

Page 214: ...er M14x1 5 Nut swingarm pivot M16x1 5 Nut rear wheel spindle M20x1 5 Screw top steering head M20x1 5 Screw in nozzles cooling system M20x1 5 Screw front wheel spindle M24x1 5 60 Nm 44 3 lbf ft 15 Nm 11 1 lbf ft 80 Nm 59 lbf ft 80 Nm 59 lbf ft 80 Nm 59 lbf ft 100 Nm 73 8 lbf ft 80 Nm 59 lbf ft 12 Nm 8 9 lbf ft 12 Nm 8 9 lbf ft 45 Nm 33 2 lbf ft Loctite 2701TM Loctite 243 212 ...

Page 215: ...ng Remove coarse dirt particles with a gentle water jet Spray dirty parts with a normal commercial engine cleaner and then brush off with a soft brush Info I Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to a dry vehicle always rinse the vehicle with water first After rinsing the motorcycle with a gentle spray of water allow it to dry thorough...

Page 216: ...e a p 213 Clean the brake system Info I After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings in the cooled down and installed state with cold water and dry carefully After riding on salted roads thoroughly wash the vehicle with cold water and dry it well Treat the engine swingarm and all other bright and zinc plated parts except for the brake discs with a wax based...

Page 217: ...otorcycle out of service add fuel additive Refuel Clean the motorcycle I p 213 Change the engine oil and oil filter clean the oil screen I p 198 Check the antifreeze and coolant level I p 194 Check the tire air pressure 0 p 88 Remove the battery 0 p 105 27 2 401058 01 Charge the battery Guideline Storage temperature of battery with out direct sunshine 0 35 C 32 95 F Store the vehicle in a dry loca...

Page 218: ...peration I I Check correct the fluid level of the hydraulic clutch p 192 I I I Check the front brake fluid level a p 111 I I I Check the free travel of the hand brake lever I p 110 I Check the play of the steering head bearing p 34 0 I Check the valve clearance 0 I Check the clutch I I I Change the shaft seal rings of the water pump I Change the engine oil and oil filter clean the oil screen p 198...

Page 219: ...heck camshaft and cam lever Change the connecting rod conrod bearing and crank pin Check the transmission and shift mechanism Check the oil pressure regulator valve Change the suction pump Check the force pump and lubrication system Change the timing chain Check the timing assembly Change all engine bearings Change the freewheel o One time interval Periodic interval 217 Annually Every 135 operatin...

Page 220: ...j C I Hu5 Mlrna 1 2 I I l l u N AF 4 K10 N A i1 X2 j E 1 2 I 3 I 4 5 I 6 I 7 I 8 J J A B II 0 0 0 0 u C N BR 4 G10 _J N BK 4 S21 r E 7J MBK 4 It D X4 E 1 l c X300 l l wh nl a 2 E1 E br b 2 F1 F FE 250 EU 2014 2015 I I I 1 8 I 3 I 4 5 I 6 I 7 I 8 ...

Page 221: ...29 WIRING DIAGRAM Components G10 Battery K10 Starter relay with main fuse M10 Starter motor S21 Electric starter button 219 ...

Page 222: ...iEB 4 B iEB 4 I 0 E E 1 j T20 DY 4 I 1 X9 c i X295 l AP 6 l it i iEB 4 B iEB 4 I 1 X3 E E j 1 1 EB aC Wh rd t l J 1 l x2as iBS 2 M14 J Il BS 2 1 X285 1 II I 1 xa 1 x1 ls rJ 2 J 2 fi F3 r i X40 rn 1 1 m 1 FJ 2 r FJ 2 X39 1 xa x1 c 1 l I I I iL Lye bu e 3 E1 L _b b 3 E1 IE 1 FB bC br br b 7 F1 Hu rna FE 250 EU 2014 2015 1 T r 2 s T T T T T ...

Page 223: ...G DIAGRAM Components A11 EFI control unit 833 Radiator fan temperature switch F3 Fuse F4 Fuse G20 Alternator K12 Light relay K30 Power relay M14 Radiator fan T20 Voltage regulator X295 Diagnostics connector 221 ...

Page 224: ...h f 4 B1 I 1 1 I U J l l a CR 1 X43 M BC 6 FP 1 D1 2 P15 BF 1 S22 u 1 I X22 E13 P35 X4 6 o 7 N BP 4 M DG 4 _ BA 1 E E L_ if o X44 N DG 4 M BP 4 o 1 x t X4 6 l l 1 Jf 1 x 22 o I 1 X48 1 X47 1 X48 I I I 1 f f 1P 1 i 1 E 2 EB dC Y 1 t 2 EB 1 ye bu ye bu 4 E1 E 2 EB bC br br b 4 E1 E F t 1F Hu rna FE 250 EU 2014 2015 I 318 1 2 I 3 I 4 s I 6 I 1 I s ...

Page 225: ...29 WIRING DIAGRAM Components A11 EFI control unit E13 Low beam high beam P13 Speedometer P15 Horn P35 Parking light S22 Light switch horn button kill switch 223 ...

Page 226: ... AH 2 BY 4 D1 2 AK 2 AK 2 CV 4 00 X11 B76 B77 X17 P36 CV 4 BY 4 t 0 BY 4 NM CV 4 X17 X11 N N AK 2 N AK 2 CV 4 i D l H 2 l AH 2 n B Y 4 X14 D X18 X19 X13 i i I j cf j j I I I I C w C w 3 EB 1 ye bu E 3 EB bC br E C co z 0 cc G g 0 F F 0 C I gj FE 250 EU 2014 2015 I Hu5 Mlrna I 4 8 1 2 I 3 I 4 5 I 6 I 7 I 8 ...

Page 227: ...29 WIRING DIAGRAM Components B76 Brake light switch front B77 Brake light switch rear E60 License plate lamp P36 Brake tail light 225 ...

Page 228: ...rna 1 2 I 3 I I I I 11 5 n a o um NMAJ 3 u x NF0 2 NMBG 3 S25 LR hr BG 3 iAm X42 I FE 250 EU 2014 2015 I 3 I 4 5 6 I 7 I 8 J J A B l I I s s it it X23 X25 X41 X28 C CX 2 CX 2 CX 2 CX 2 j CW 2 CW 2 CW 2 CW 2 P42 P46 P41 P45 2 w NCW 2 NCW 2 NCW 2 NCX 2 NCX 2 NCX 2 i D X23 X25 X41 X28 I I E F I I I 5 8 4 5 6 I 7 I 8 ...

Page 229: ...G DIAGRAM Components K20 Turn signal relay P21 Turn signal indicator light P41 Turn signal front left P42 Turn signal front right P45 Turn signal rear left P46 Turn signal rear right S25 Turn signal switch 227 ...

Page 230: ...t f 0 I cc C w C w E C co z 0 co cc G g 0 F 0 co C I FE 250 EU 2014 2015 Hu5 Mlrna 1 2 I 3 I 4 5 5 l n X15 X15 c l 851 5 l I X20 NCU 4 j NDY 4 t DY 4 i cu 4 X20 0 c 6 I I P13 3 A6 7 A2 1 i X15 i I 6 I 7 I 0 N CY 3 M N CZ 3 M X51 p GA 3 _ 6 D3 R IBD3 7 0 0 I 8 J J A CY 3 CZ 3 X51 B C D or g 7 E1 E bl h 8 F1 F I I I 6 8 8 ...

Page 231: ...29 WIRING DIAGRAM Components A11 EFI control unit 832 Fuel level indicator 851 Lambda sensor cylinder 1 F1 Fuse F2 Fuse M13 Fuel pump P13 Speedometer 229 ...

Page 232: ...NDQ 2 r D X26 0 0 cc C w C w E 6 E8 gC or C co z 0 cc G m 2 F8 bC br F 0 C I FE 250 EU 2014 2015 Hu5 Mlrna 1 2 I 3 I 4 5 lll X15 i I I I I B B 9 al i 5 15 ii j 15 11 NAT 2 30 X295 NM w AP 6 n 5 6 0 6 I 7 I 8 J I J A l m 11 m X15 X15 is B I 1 1 C X301 r 7 D 0 E F I I I 7 8 I 7 I 8 ...

Page 233: ...29 WIRING DIAGRAM Components A11 EFI control unit 870 Wheel speed sensor front M51 Injector cylinder 1 R30 CAN bus terminating resistor 1 P13 Speedometer X295 Diagnostics connector 231 ...

Page 234: ...I I I 4 1 l m X15 1 I I I t L 1 1 c Am rt H w ljJJ AX 2 1 XJ5 1 f X15 il I il 5 0j r m X15 9 I t 1 x30 EX 3 S O e EX 3 I 0 52 i 6 7 j 14 ij ie ym i y i X15 X15 X15 it I I I t 1 t P 6 r X 3 cM 2 B 2 6 i B41 0 B1 2 m n l 0 f AP 6 f X 3 cM 2 I 1 X33 I 1 X3 2 8 Li _g 52 i Li 6 FB hl bl _ i L J Hu rna FE 250 EU 2014 2015 1 T T T T T 8 0 r J I J IA I Is T r 8 8 ...

Page 235: ...cylinder 1 826 Rollover sensor 837 Ignition pulse generator 841 Manifold absolute pressure sensor cylinder 1 R51 Ignition coil cylinder 1 S51 Map Select switch for riding mode optional S55 Map Select switch for basic setting optional Cable colors bl Black br Brown bu Blue gn Green gr Gray lbu Light blue or Orange pk Pink pu Violet rd Red wh White ye Yellow 233 ...

Page 236: ...Hu5 Mlrna 1 2 I I l l u N AF 4 K10 N A i1 X2 j E 1 2 I 3 I II 0 0 G10 J 7J E 1 X300 l l FE 250 AU 2014 2015 I 3 I 4 5 I 6 I 7 I 8 0 J 0 J A B 0 0 u C N BR 4 N BK 4 S23 3 C2 E vfi 3 D2 MBK 4 It D X4 l c wh nl a 2 E1 E br b 2 F1 F I I I 1 8 4 5 I 6 I 7 I 8 ...

Page 237: ...29 WIRING DIAGRAM Components G10 Battery K10 Starter relay with main fuse M10 Starter motor S23 Emergency OFF switch electric starter button 235 ...

Page 238: ... iEB 4 B iEB 4 I 0 E E 1 j T20 DY 4 I 1 X9 c i X295 l AP 6 l it i iEB 4 B iEB 4 I 1 X3 E E j 1 1 EB aC Wh rd t l J 1 l x2as iBS 2 M14 J Il BS 2 1 X285 1 II I 1 xa 1 x1 ls rJ 2 J 2 fi F3 r i X40 rn 1 1 m 1 FJ 2 r FJ 2 X39 1 xa x1 c 1 l I I I iL Lye bu e 3 E1 L _b b 3 E1 IE 1 FB bC br br b 7 F1 Hu rna FE 250 AU 2014 2015 1 T r 2 s T T T T T ...

Page 239: ...G DIAGRAM Components A11 EFI control unit 833 Radiator fan temperature switch F3 Fuse F4 Fuse G20 Alternator K12 Light relay K30 Power relay M14 Radiator fan T20 Voltage regulator X295 Diagnostics connector 237 ...

Page 240: ...1 1 i mJ 1 1 a CR 1 X43 BF 1 M BC 6 FP 1 Dl 2 P15 BF 1 S23 S22 l I X22 E13 P35 X46 1 C5 1 1 N BP 4 MDG 4 ID5 E E L_ J 0 BM i i X44 Cl Cl N DG 4 MBP 4 f i i l fa f0 1 _ I 1 X48 1 X48 I I I 1 L 1P 1 i 1 E 2 EB dC Y 1 r 2 EB 1 ye bu r ye bu 4 E1 E 2 EB bC br 1 _ br b 4 E1 E F t 1F Hu rna FE 250 AU 2014 2015 I 318 1 2 I 3 I 4 s I 6 I 1 I s ...

Page 241: ...IRING DIAGRAM Components A11 EFI control unit E13 Low beam high beam P13 Speedometer P15 Horn P35 Parking light S22 Light switch horn button kill switch S23 Emergency OFF switch electric starter button 239 ...

Page 242: ... 2 AH 2 BY 4 D1 2 AK 2 AK 2 CV 4 00 X11 B76 B77 X17 P36 CV 4 BY 4 t 0 BY 4 NM CV 4 X17 X11 N N AK 2 N AK 2 CV 4 i D l H 2 l AH 2 n B Y 4 X14 D X18 X19 X13 i i I j cf j j I I I I C J C 3 EB 1 ye bu E 3 EB bC br E C co z 0 cc G g 0 F F I 0 Ii C I I FE 250 AU 2014 2015 I 4 8 Hu5 Mlrna 1 2 I 3 I 4 5 I 6 I 7 I 8 ...

Page 243: ...29 WIRING DIAGRAM Components B76 Brake light switch front B77 Brake light switch rear E60 License plate lamp P36 Brake tail light 241 ...

Page 244: ...3 X25 X41 X28 C m NMAJ 3 u x CX 2 CX 2 CX 2 CX 2 AH 2 NF0 2 j NMBG 3 CW 2 CW 2 CW 2 CW 2 S25 P42 P46 P41 P45 LR 2 w hr BG 3 NCW 2 NCW 2 NCW 2 l D X45 iAm NCX 2 NCX 2 NCX 2 i D X42 X23 X25 X41 X28 I I I I J C E E C co z 0 It cc G g 0 F F I 0 Ii C I FE 250 AU 2014 2015 I I Hu5 Mlrna I 5 8 1 2 I 3 I 4 5 6 I 7 I 8 ...

Page 245: ...G DIAGRAM Components K20 Turn signal relay P21 Turn signal indicator light P41 Turn signal front left P42 Turn signal front right P45 Turn signal rear left P46 Turn signal rear right S25 Turn signal switch 243 ...

Page 246: ...6 X29 0 t f 0 I cc C J C E C co z 0 co cc G g 0 F l f 0 Ii C I FE 250 AU 2014 2015 Hu5 Mlrna 1 2 I 3 I 4 5 4 5 l 11 X15 X15 c l 7jlir X20 M N CU 4 c 0 0 6 I I P13 3 A6 7 A2 1 i X15 i I 6 I 7 I 0 N CY 3 M N CZ 3 M X51 p GA 3 _ 6 D3 R IBD3 7 0 0 I 8 0 J 0 J A CY 3 CZ 3 X51 B C D or g 7 E1 E bl h 8 F1 F I I I 6 8 8 ...

Page 247: ...29 WIRING DIAGRAM Components A11 EFI control unit 832 Fuel level indicator F1 Fuse F2 Fuse M13 Fuel pump P13 Speedometer 245 ...

Page 248: ... r D X26 0 0 cc C J C E 6 E8 gC or C co z 0 cc G g 0 2 F8 bC br F It 0 Ii C I FE 250 AU 2014 2015 Hu5 Mlrna 1 2 I 3 I 4 5 lll X15 i I I I I B B 9 al i 5 15 ii j 15 11 NAT 2 30 X295 NM w AP 6 n 5 6 0 6 I 7 I 8 0 J I 0 J A l m 11 m X15 X15 is B I 1 1 C X301 r 7 D 0 E F I I I 7 8 I 7 I 8 ...

Page 249: ...29 WIRING DIAGRAM Components A11 EFI control unit 870 Wheel speed sensor front M51 Injector cylinder 1 R30 CAN bus terminating resistor 1 P13 Speedometer X295 Diagnostics connector 247 ...

Page 250: ...I I 4 1 l m X15 1 I I I t L 1 1 c Am rt H w ljJJ AX 2 1 XJ5 1 f X15 il I il 5 0j r m X15 9 I t 1 x30 EX 3 S O e EX 3 I 0 52 i 6 7 j 14 ij ie ym i y i X15 X15 X15 it I I I t 1 t P 6 r X 3 cM 2 B 2 6 i B41 0 B1 2 m n l 0 f AP 6 f X 3 cM 2 I 1 X33 I 1 X3 2 8 Li _g 52 i Li 6 FB hl bl _ i L J Hu rna FE 250 AU 2014 2015 1 T T T T T 8 0 J I 0 J IA I Is T r 8 8 ...

Page 251: ...cylinder 1 826 Rollover sensor 837 Ignition pulse generator 841 Manifold absolute pressure sensor cylinder 1 R51 Ignition coil cylinder 1 S51 Map Select switch for riding mode optional S55 Map Select switch for basic setting optional Cable colors bl Black br Brown bu Blue gn Green gr Gray lbu Light blue or Orange pk Pink pu Violet rd Red wh White ye Yellow 249 ...

Page 252: ...w 0 F 0 Ii C I Hu5 Mlrna 1 2 I I l l u N AF 4 K10 N A i1 X2 j E 1 I 3 I II 0 0 G10 J 7J E 1 X300 l l FE 250 US 2014 2015 2 I 3 I 4 5 I 6 I 7 I 8 J J A B 0 0 u C N BR 4 N BK 4 S21 r E MBK 4 It D X4 l c wh nl a 2 E1 E br b 2 F1 F I I I 1 6 4 5 I 6 I 7 I 8 ...

Page 253: ...29 WIRING DIAGRAM Components G10 Battery K10 Starter relay with main fuse M10 Starter motor S21 Electric starter button 251 ...

Page 254: ...4 B1 n 9 _ i r x10 i iEB 4 B iEB 4 I 0 E E 1 j T20 DY 4 I 1 X9 ls i X295 l AP 6 l it i iEB 4 B iEB 4 I 1 X3 E E j 1 1 EB aC Wh rd t l J 1 l x2as iBS 2 M14 J Il BS 2 1 X285 1 I O O ls Ill I 1 111 1 1 FJ 2 r FJ 2 X23 1 xa x1 i i r ls l L _br b 3 E1 IE 1 FB bC br br b 5 F1 Hu rna FE 250 US 2014 2015 1 T r 2 6 T T T T T ...

Page 255: ... Components A11 EFI control unit 833 Radiator fan temperature switch optional F3 Fuse F4 Fuse G20 Alternator K12 Light relay K30 Power relay M14 Radiator fan optional T20 Voltage regulator X295 Diagnostics connector 253 ...

Page 256: ... N cv 4 i m D X11 t X17 is cc X302 r 7 C 2 EB d C ye en C E 2 EB b C br C C0 z 0 cc G g 0 F 0 0 Ii C I FE 250 US 2014 2015 Hu5 Mlrna 1 2 I 3 I 4 4 5 iI I 1 l FP 1 DI 2 3 5 NBP 4 N DG 4 X16 l t i jP i X24 X21 X31 j I I 5 I 6 I 7 I 8 N N N A B is is C X16 MDG 4 MBP 4 X22 D is E F I I I 3 6 6 I 7 I 8 ...

Page 257: ...29 WIRING DIAGRAM Components A11 EFI control unit E11 Low beam P35 Parking light P37 Tail light S20 Kill switch S30 Light switch 255 ...

Page 258: ...D XS X6 X29 0 t f 0 I cc C en C C C0 z 0 cc G g 0 F 0 0 I C I gJ FE 250 US 2014 2015 Hu5 Mlrna 1 2 I 3 I 4 5 4 5 l 11 X15 X15 c l 7jlir X20 M N CU 4 c 0 0 6 I I P13 5 A2 1 i X15 i I 6 I 7 I 0 N CY 3 M N CZ 3 M X14 p GA 3 _ 4 D3 R 4 D3 7 0 0 I 8 9 J J A CY 3 CZ 3 X14 B C D or 5 E1 E bl I 6 F1 F I I I 4 6 8 ...

Page 259: ...29 WIRING DIAGRAM Components A11 EFI control unit 832 Fuel tank sensor F1 Fuse F2 Fuse M13 Fuel pump P13 Speedometer 257 ...

Page 260: ...2 r D X26 0 0 cc C en C 4 E8 e C or C C0 z 0 It cc G m 2 F8 b C br F 0 C I FE 250 US 2014 2015 Hu5 Mlrna 1 2 I 3 I 4 5 lll X15 i I I I I B B 9 al i 5 15 ii j 15 11 NAT 2 30 X295 NM w AP 6 n 5 6 0 6 I 7 I 8 N N I N A l m 11 m X15 X15 is B I 1 1 C X301 r 7 D 0 E F I I I 5 6 I 7 I 8 ...

Page 261: ...29 WIRING DIAGRAM Components A11 EFI control unit 870 Wheel speed sensor front M51 Injection valve cylinder 1 P13 Speedometer R30 CAN bus terminating resistor 1 X295 Diagnostics connector 259 ...

Page 262: ...I 4 1 l m X15 1 I I I t L 1 1 i Am rt H w ljJJ AX 2 1 XJ5 1 f X15 il I il 5 0j r m X15 9 I t 1 x30 EX 3 S O e EX 3 I 0 52 i 6 7 j 14 ij ie ym i y i X15 X15 X15 it I I I t 1 t P 6 r X 3 cM 2 B 2 6 i B41 0 B1 2 m n l 0 f AP 6 f X 3 cM 2 I 1 X 33 I 1 X 3 2 5 Li _g 52 i Li 4 FB 11 bl _ i L J Hu rna FE 250 US 2014 2015 1 T T T T T 8 0 N N I N IA I Is T r 6 6 ...

Page 263: ...nder 1 826 Rollover sensor 837 Crankshaft position sensor 841 Manifold absolute pressure sensor cylinder 1 R51 Ignition coil cylinder 1 S51 Map Select switch for ride mode optional S55 Map Select switch for basic position optional Cable colors bl Black br Brown bu Blue gn Green gr Gray lbu Light blue or Orange pk Pink pu Violet rd Red wh White ye Yellow 261 ...

Page 264: ...Use distilled water if the coolant needs to be diluted The use of premixed coolant is recommended Observe the coolant manufacturer specifications for antifreeze protection dilution and miscibility compatibility with other coolants Recommended supplier Bel Ray Moto Chill Racing Coolant Engine oil SAE 10W 50 Standard classification JASO T903 MA p 278 SAE p 278 SAE10W 50 Guideline Use only engine oil...

Page 265: ...OZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100 263 ...

Page 266: ... Recommended supplier Lubcon Turmogrease PP 300 Lubricant T511 Recommended supplier Lubcon Turmsilon GTI 300 P Lubricant T625 Recommended supplier Molykote 33 Medium Lubricant I152 Recommended supplier Bel Ray Molylube Anti Seize Lubricant I159 Recommended supplier Bel Ray MC 11 Offroad chain s ra Guideline Recommended supplier Bel Ray Blue Tac Chain Lube Oil for foam air filter Recommended suppli...

Page 267: ...31 AUXILIARY SUBSTANCES Preserving materials for aints metal and rubber Recommended supplier Bel Ray Silicone Detailer Protectant Spray Universal oil s ray Recommended supplier Bel Ray 6 in 1 265 ...

Page 268: ...5 H00504 01 Bleeder cover Art no 00029013006 00029013006 H00505 01 Bleedin device Art no 00029013100 00029013100 H00518 01 Battery charger XCharge professional EU Art no 00029095050 H01065 01 Batte charger XCharge rofessional US Art no 00029095051 H01065 01 266 ...

Page 269: ...00029095052 H01065 01 Batte rofessional CH Art no 00029095053 H01065 01 Extractor Art no 46129021000 46129021000 H01519 01 Spring hook Art no 50305017000 50305017000 H00973 01 Bleed s ringe Art no 50329050000 50329050000 H00565 01 ...

Page 270: ...3000 Extractor 58012009000 H00572 01 H00575 01 H00592 01 Tool for inner bearing race 58429037037 H00596 01 Art no 51012011000 Art no 51129003000 Art no 58012009000 Art no 58429037037 Torgue wrench with various accessories in set Art no 58429094000 58429094000 H00606 01 268 ...

Page 271: ...9029019000 H00610 01 Feeler Art no 59029041100 c 7 59029041100 H00616 01 Graduated disc Art no 60029010000 2x 60029010000 H00625 01 Plastigauge clearance gauge Art no 60029012000 60029012000 H00627 01 Piston ring mounting tool Art no 60029015000 60029015000 H00628 01 ...

Page 272: ... Pressure tester 4x D 61029094000 Engine assembly stand 61229001000 Art no 60029057000 H00650 01 Art no 61029093000 H00659 01 Art no 61029094000 H00660 01 Art no 61229001000 H00662 01 Release device for timing chain tensioner Art no 61229021000 61229021000 H00675 01 270 ...

Page 273: ...000 75029047000 H00714 01 Protection ca Art no 75029090000 75029090000 H00726 01 Insert for crankshaft pressin tool Art no 77029008000 77029008000 H00737 01 Separator plate Art no 77029009001 77029009001 H00738 01 Engine fixing arm Art no 77229002000 2x 77229002000 H00748 01 ...

Page 274: ... no 77229010000 77229010000 H00752 01 Limit Art no 77229026000 77229026000 H00753 01 Protection cap Art no 77229031000 0 77229031000 H00755 01 Separator plate Art no 77229032000 Co 77229032000 H00756 01 Puller Art no 77229048000 2x 77229048000 H00758 01 ...

Page 275: ...060000 77229060000 H00760 01 Art no 77229172000 77229172000 H00761 01 Oil pressure adapter Art no 77329006000 77329006000 H00764 01 Insertion tool for piston ring lock Art no 77729030100 77729030100 H01126 01 Lift stand Art no 81329955000 81329955000 H01015 01 ...

Page 276: ...OLS 274 Hook wrench Art no T106S T106S H00841 01 De th micrometer Art no T107S T107S H00842 01 Pin Art no T120 T120 H00844 01 Mounting sleeve Art no T1204 T1204 H00878 01 Calibration in Art no T1205 T1205 H00879 01 ...

Page 277: ...5 Pressin tool Art no T1206 T1206 H00880 01 Pressin tool Art no T1207S T1207S H00881 01 Mountin sleeve Art no T1215 T1215 H00886 01 Disassembly tool Art no T1216 l T1216 H00887 01 Vacuum um Art no T1240S T1240S H00890 01 ...

Page 278: ...g sleeve Art no T1401 SY T1401 H00894 01 Clam in stand Art no T1403S 2x T1403S H00896 01 Mountin tool Art no T14040S T14040S H00922 01 Special socket Art no T14047 T14047 H00923 01 Clam ing stand Art no T14049S 2x T14049S H00924 01 ...

Page 279: ...CIAL TOOLS 277 Press out tool Art no T14051 T14051 H00926 01 Press drift Art no T1504 T1504 H00899 01 Assembly tool Art no T150S o T150S H00852 01 Nitrogen filling tool 2x 3x Art no T170S1 i T170S1 H00855 01 ...

Page 280: ...ong service 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 the clutch are lubricated with the same oil The JASO MA standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils ac...

Page 281: ... Chassis number 9 Closed current checking 107 Clutch fluid level checking correcting 192 fluid changing 192 Clutch lever basic position adjusting 37 Compression damping fork adjusting 13 Compression damping high speed shock absorber adjusting 41 Compression damping low speed shock absorber adjusting 41 Coolant antifreeze and coolant level checking 194 draining 195 level checking 195 refilling 196 ...

Page 282: ...talling 174 shift rails installing 175 shift shaft installing 179 spacer installing 176 191 spark plug installing 189 starter drive installing 182 suction pump installing 177 timing chain tensioner installing 186 timing chain installing 176 torque limiter installing transmission shafts installing valve clearance adjusting 188 174 188 valve clearance checking 187 280 valve cover installing 189 wate...

Page 283: ...d brake lever basic position adjusting 110 free travel adjusting 111 free travel checking 110 Handlebar position 37 adjusting 37 Headlight headlight range adjusting 124 281 Headlight adjustment checking 123 Headlight mask with headlight installing 87 removing 87 Hydrostop unit fork legs assembling 24 fork legs disassembling 22 Idle speed adjusting 205 Ignition coil secondary winding checking 202 I...

Page 284: ...g 48 static sag checking 42 Shock absorber linkage checking 45 Spare parts 8 Spark plug connector checking 202 Speedometer clock setting 122 kilometers or miles setting 122 service display setting 123 282 setting 121 wheel circumference setting Spoke tension 122 checking 89 Spring fork legs removing 19 Starter motor checking 204 Starter relay checking 104 Starting 11 12 Steering head bearing chang...

Page 285: ... 2 of 6 252 page 2 of 8 220 236 page 3 of 6 254 page 3 of 8 222 238 page 4 of 6 256 page 4 of 8 224 240 page 5 of 6 258 page 5 of 8 226 242 page 6 of 6 260 page 6 of 8 228 244 page 7 of 8 230 246 page 8 of 8 232 248 Work rules 7 283 ...

Page 286: ...11111111111111111111IIIIIIIIIIII 3403014en 07 2016 Husqvarna MOTORCYCLES Husqvarna Motorcycles GmbH fiiiHiAvl StallhofnerstraBe 3 5230 Mattighofen Austria llmi LZZa O www husqvarna motorcycles com __ __ Photo Mitterbauer Husqvarna Motorcycles GmbH ...

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