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Husqvarna FE 350 2014, Repair Manual, Page: 107 / 279

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Husqvarna FE 350 2014 Repair Manual Download Page 107

16 

BRAKE SYSTEM 

r-----

M00411-10 

105 

-

Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

-

Remove screws 

O.

-

Remove cover 

8 

with membrane@).

-

Manually press the brake caliper to the brake disc to push back the brake

pistons.  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 

8, 

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 plate  @  in the brake

caliper support are seated correctly.

-

Insert the new brake linings,  insert pin 

0, 

and mount cotter pins 

8.

•

Info

I 

Always change the brake linings in pairs. 

-

Operate the hand brake lever repeatedly until the brake linings are in contact with

the brake disc and there is a pressure point.

-

Correct the brake fluid to level  fj.
Guideline

Level  fj (brake fluid level below con-

5 mm (0.2 in) 

tainer rim) 

I 

Brake fluid DOT 4  (�  p. 256)

-

Position cover 

8 

with membrane @).

-

Mount and tighten screws 

O.

Info 

Clean up overflowed or spilt brake fluid immediately with water. 

Summary of Contents for FE 350 2014

Page 1: ...PIONEERING SINCE 1903 REPAIR MANUAL2014 FE 350 EU FE 350 AU FE 350 US Art no 3403001 en 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: ... Changing the steering head bearing 35 7 8 9 6 31 Adjusting the play of the steering head 2 bearing 36 HANDLEBAR CONTROLS 38 7 1 Handlebar position 38 7 2 Adjusting the handlebar position 38 7 3 Adjusting the basic position of the clutch lever 38 7 4 Checking the routing of the throttle cable 39 7 5 Checking the play in the throttle cable 39 7 6 Adjusting the play in the throttle cable 40 FRAME 41...

Page 5: ... brake linings 104 17 18 3 16 3 Checking free travel of hand brake lever 106 16 4 Adjusting the basic position of the hand brake lever FE 350 US 106 16 5 Adjusting free travel of hand brake lever FE 350 EU AU 106 16 6 Checking the front brake fluid level 107 16 7 Adding front brake fluid 107 16 8 Changing the front brake fluid 108 16 9 Checking the rear brake linings 109 16 10 Changing the rear br...

Page 6: ... 18 5 2 Installing the transmission shafts 168 18 5 3 Installing the shift forks 169 18 5 4 Installing the shift drum 169 4 18 5 5 Installing the shift rails 169 18 5 6 Installing the left engine case 170 18 5 7 Installing the spacer 170 18 5 8 Installing the timing chain 170 18 5 9 Installing the primary gear 171 18 5 10 Installing the force pump 171 18 5 11 Installing the suction pump 172 18 5 1...

Page 7: ...ICE SCHEDULE 210 28 1 Service schedule 210 28 2 Service work as additional order 211 29 WIRING DIAGRAM 212 29 1 Page 1 of 8 FE 350 EU 212 29 2 Page 2 of 8 FE 350 EU 214 29 3 Page 3 of 8 FE 350 EU 216 29 4 Page 4 of 8 FE 350 EU 218 29 5 Page 5 of 8 FE 350 EU 220 29 6 Page 6 of 8 FE 350 EU 222 29 7 Page 7 of 8 FE 350 EU 224 29 8 Page 8 of 8 FE 350 EU 226 29 9 Page 1 of 8 FE 350 AU 228 29 10 Page 2 o...

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

Page 11: ...fixed to the front of the steering head 4 3 Key number FE350 EU AU 402247 10 Engine number 401949 10 4 5 Fork art number 401947 10 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 10 The shock absorber article number O is stamped on the top of the shock absorber above the adjusting ring towards the engine side ...

Page 13: ...e side stand must be folded up and secured with the rubber band Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Engine failure High engine speeds in cold engines have a negative effect on...

Page 14: ...ke sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Info I Press the starter for a maximum of 5 seconds Wait for at least 5 seconds before trying again Shift transmission to neutral FE 350 AU Turn the emergency OFF switch to the position 0 Press the electric starter button Info I Do not open the throttle 12 ...

Page 15: ...e damping turn counterclockwise to reduce damping Adjusting the rebound dam ing of the fork Info The hydraulic rebound damping determines the fork suspension behavior y 1 N 1i J_ I _ 1 lit 1 11 U 6 3 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 ...

Page 16: ...hind the dust boots If this dirt is not removed the oil seals behind can start to leak Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Clean and oil the dust boots and inner fork tubes of both fork legs I Universal oil spray p 258 Press the dust boots b...

Page 17: ...ake 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 tension free 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 ...

Page 18: ...headlight p 85 Raise the motorcycle with a lift stand p 11 Remove the front wheel p 88 Remove the fork legs 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 Guideli...

Page 19: ...26 17 0 lle Assemble the fork legs 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 adjusters of the reb...

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: ...oot 0 Unclamp the fork leg The steps are identical for both fork legs 201722 11 201724 11 Preparatory work Disassemble the fork legs 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 p 269 Pull the spring down Remove the open end wrench Remove the screw cap R...

Page 22: ...ease piston rod O and clamp it in the vise I Clamping stand T14049S p 269 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 p 269 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 reservoir Remov...

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 269 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: ...it 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 l...

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: ... the 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 p 257 Mount and grease O ring 8 I Lubricant T158 p 257 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 p 257 Mount washer 8 Mount s...

Page 27: ...ce 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 p 269 Lubricate the O ring Mount valve needle O in the piston rod I Lubricant T158 p 257 Mount spring Mount and tighten adapter with spring C and washer Gui...

Page 28: ...I 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 or p 24 Assemble the piston rod or p 25 Main work Mount and grease seal rings O and O ring I Lubricant T1...

Page 29: ...n the vise I Clamping stand T14049S p 269 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 sc...

Page 30: ...00 clean the bush ings and lubricate them I Fork oil SAE 4 48601166S1 r p 256 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 I 50 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: ...6 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 256 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 269 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: ...onents 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 r p 31 Install the lower triple clamp r p 32 Preparatory work Switch off all p...

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

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 r p 84 Install the front wheel r p 88 Install the headlight mask with the headlight r p 85 Check that the wiring harness throttle cables and brak...

Page 36: ...tire steering range The handlebar must be able to move easily over the entire steering range No resting locations should be noticeable If click positions are noticeable Adjust the play of the steering head bearing p 34 Check the steering head bearing and replace if required Finishing work Remove the motorcycle from the lift stand p 11 Ad usting the la of the steering head bearing Preparatory work ...

Page 37: ...steering head bearing p 34 Move the handlebar to and fro over the entire steering range The handlebar must be able to move easily over the entire steering range No resting locations should be noticeable If click positions are noticeable Adjust the play of the steering head bearing p 36 Check the steering head bearing and replace if required Finishing work Remove the motorcycle from the lift stand ...

Page 38: ... the wiring harness throttle cables and brake and clutch lines can move freely and are routed correctly Check the steering head bearing play r p 35 Remove the motorcycle from the lift stand r p 11 Check the headlight setting r p 118 Adjusting the la of the steering head bearing Preparatory work Raise the motorcycle with a lift stand r p 11 Main work Loosen screws O Remove screw Loosen and retighte...

Page 39: ...6 FORK TRIPLE CLAMP Finishing work Check the steering head bearing play p 35 Remove the motorcycle from the lift stand p 11 37 ...

Page 40: ... 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 clamps Mount and tighten screws O...

Page 41: ...ight 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 40 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death 39 When running the engine always m...

Page 42: ...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 40 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 43: ... 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 44: ...s 2 turns 1 5 turns I Turn clockwise to increase damping turn counterclockwise to reduce damping ression dam in of the shock absorber Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Info The effect of the low speed setting can be seen in slow to normal compression of the shock absorbe...

Page 45: ...ded Preparatory work Raise the motorcycle with a lift stand or 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 G Finishing work Remove the motorcycle from the lift stand or p 11 Checking the static sag of the shock absorber Measure distance G of rear wheel unloaded or p 43 H...

Page 46: ...lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Info Before changing the spring preload make a note of the present setting e g by measuring the length of the spring Preparatory work Raise the motorcycle with a lift stand p 11 Remove the right side cover p 75 Remove the main silencer p 71 Remove the seat p 76 Remove the manifold p 68 Remove ...

Page 47: ...5 lb Weight of rider 75 85 kg 165 187 lb Weight of rider 85 95 kg 187 209 lb Info 51 N mm 291 lb in 54 N mm 308 lb in 57 N mm 325 lb in I The spring rate is shown on the outside of the spring Smaller weight differences can be compensated by changing the spring preload Finishing work Install the shock absorber p 46 Install the manifold p 69 Mount the seat p 76 Install the main silencer p 71 Install...

Page 48: ...ifold r p 69 Mount the seat r p 76 Install the main silencer r p 71 Install the right side cover p 76 Remove the motorcycle from the lift stand p 11 9 11 Checkin the shock absorber linka e Preparatory work Raise the motorcycle with a lift stand r p 11 Main work Remove screw O Remove fitting 8 Info Raise the wheel slightly to be able to remove the screws more easily Remove fitting 8 Take off the an...

Page 49: ... or wear Change the shaft seal rings Check dimension t 303096 10 I 54 91 55 00 mm 2 1618 2 1654 in If dimension t is below the specified value Add the necessary spacing washers fD Position angle lever Mount fitting 8 but do not tighten yet Guideline I Nut angle lever on swingarm Mount screw O but do not tighten yet Guideline Screw bottom shock absorber Info M10 I M14x1 5 60 Nm 44 3 lbf ft I 80 Nm ...

Page 50: ...absorber is filled with high density nitrogen Adhere to the description provided 201457 01 201370 10 Condition The shock absorber has been removed Remove the spring p 48 Disassemble the damper p 49 Disassemble the piston rod p 50 Disassemble the seal ring retainer p 51 Check the damper p 53 Remove the heim joint p 53 Install the heim joint p 54 Assemble the seal ring retainer p 55 Assemble the pis...

Page 51: ...the spring p 48 Main work Note down the current state of rebound damping O and compression damp ing Completely open the adjusters of the rebound and compression damping Remove rubber cap of the reservoir Open screw 8 slowly The pressurized nitrogen escapes Remove locking cap 0 Press in seal ring retainer 0 using the special tool I Disassembly tool T1216 p 268 49 ...

Page 52: ...sting ring fD with the intermediate washer Drain the oil Remove compression adjuster Remove the spring and piston Disassembling the iston rod Preparatory work Remove the spring p 48 Disassemble the damper p 49 Main work Clamp the piston rod with the fork in a vise Guideline I Use soft jaws Remove nut O Remove washer 50 ...

Page 53: ...ression shim stack onto a screwdriver and set it down as a unit Remove rebound washer Cs Remove seal ring retainer Remove locking cap and rubber buffer Disassembling the seal ring retainer 201405 10 201406 10 Preparatory work Remove the spring p 48 Disassemble the damper p 49 Disassemble the piston rod p 50 Main work Remove spring 0 Remove O ring Remove rebound rubber Remove centering disk 8 Remov...

Page 54: ... tool I Press drift T1504 p 269 Position the pilot bushing in the seal ring retainer using the special tool I Press drift T1504 p 269 Support seal ring retainer fj with sleeve 6 of the special tool Press the pilot bushing all the way in I Assembly tool T150S p 269 Lubricate the special tool Shock absorber fluid SAE 2 5 50180751S1 p 256 Calibration pin T1205 p 267 Support seal ring retainer fj with...

Page 55: ...iameter of the piston rod Piston rod Diameter 17 95 mm 0 7067 in If the measured value is less than the specified value Change the piston rod Measure the run out of the piston rod I Piston rod Run out I s 0 02 mm s 0 0008 in If the measured value is greater than the specified value Change the piston rod Check the piston rod for damage and wear If there is damage or wear Change the piston rod Check...

Page 56: ...ecial tool f underneath and press out heim joint D with special tool I Pressing tool T1207S p 267 Position the new heim joint O and the special tool into a vise as shown Guideline I Use soft jaws I Pressing tool T1206 p 267 Press the heim joint all the way in Press the heim joint against the lock ring using the special tool I Pressing tool T1207S p 267 Mount the second lock ring 8 Mount seal rings...

Page 57: ...I Mounting sleeve T1204 p 267 Lubricate the sealing lip of the dust boot I Lubricant T625 p 257 Mount washer Position washer Don seal ring e Grease seal ring 8 and mount with the washer facing downward I Lubricant T511 p 257 Mount centering disk Mount rebound rubber 0 Lubricate the groove of the O ring I Lubricant T158 p 257 Mount O ring Mount spring 55 ...

Page 58: ...nting sleeve T1215 p 267 Grease the dust boot and push seal ring retainer onto the piston rod I Lubricant T625 p 257 Remove the special tool Mount rebound washer 8 with the cut out facing downward Mount the compression shim stack 0 with the smaller shims facing downward Sand both sides of piston D on a surface plate using 1200 grit sandpaper Clean the piston Assemble the piston Guideline ViewO Pis...

Page 59: ...cate the threads I Lubricant T159 p 257 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 57 I 45 Nm 33 2 lbf ft I I 45 Nm 33 2 lbf ft I The adjusting ring cannot be mounted after the piston rod is mounted Fill the da...

Page 60: ...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 61: ...99 10 Remove the screw of the filling port Install adapter O on the damper Info I Tighten only hand tight without the use of tools Connect the adapter O to connector of the vacuum pump I Vacuum pump T1240S p 268 Clamp the damper with soft jaws or hold it as shown in the figure Info I Clamp the damper only lightly The filling port must be at the highest point The piston rod slides in and out during...

Page 62: ...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 63: ...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 64: ...eight 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 266 Alternative 2 Warning 113 mm 0 51 in Danger of accident Modifications to the suspension s...

Page 65: ...age cracking or deformation Change the swingarm Info I Always change a damaged swingarm Repair of the swingarm is not authorized by Husqvarna Motorcycles Preparatory work Raise the motorcycle with a lift stand r p 11 Remove the rear wheel p 90 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 66: ...ingarm Remove nut 0 Remove the swingarm pivot Remove the swingarm Main work Position the swingarm Mount the swingarm pivot Mount and tighten nut O Guideline Nut swingarm pivot Lift the swingarm Mount and tighten screw cap Guideline Nut angle lever on swingarm Mount the chain M16x1 5 M14x1 5 Connect the chain with connecting link CD 100 Nm 73 8 lbf ft I 80 Nm 59 lbf ft 64 ...

Page 67: ...n the brake caliper and pull it back Position the brake line in the guide Finishing work Install the rear wheel or p 91 Remove the motorcycle from the lift stand or 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 or p 11 Remove the rear wheel or p 90 Remove the swingarm or p 63 65 10 Nm 7 4 lbf ...

Page 68: ...in work Remove the outer collar bushings O Remove bushing 8 Remove shaft seal rings D using a suitable tool Using a suitable tool press the bearing out from the inside to the outside Press in the new bearing until it is flush using a suitable tool 66 ...

Page 69: ...ft seal rings CD Mount bushing Grease the shaft seal rings I Long life grease p 257 Position collar bushings O with the shoulder facing inward Finishing work Install the swingarm p 64 Install the rear wheel p 91 Remove the motorcycle from the lift stand p 11 67 ...

Page 70: ...ft stand p 11 Remove the seat p 76 Remove the right side cover p 75 Remove the main silencer p 71 Main work Remove fitting O Remove screw 8 Press angle lever toward the rear Press linkage lever C downward Raise the swingarm Remove screws 0 on both sides Loosen screws D on both sides 68 ...

Page 71: ... 350 EU Remove the fuel tank p 76 69 Disconnect plug in connector fD of the lambda sensor and remove the cable binder Remove springs I Spring hook 50305017000 p 259 Remove screw and take off the manifold Main work Position the manifold and mount springs O I Spring hook 50305017000 p 259 ...

Page 72: ...r frame M10 Mount and tighten screws 0 on both sides Guideline Screw subframe M8 Remove screws CD on both sides Mount and tighten screws CD on both sides Guideline Screw subframe M8 Lower the swingarm Position the angle lever and linkage lever Mount and tighten fitting Guideline 60 Nm 44 3 lbf ft 35 Nm 25 8 lbf ft 35 Nm 25 8 lbf ft I Nut linkage lever on angle lever I M14x1 5 Mount and tighten scr...

Page 73: ...t the main silencer Mount screws O but do not tighten yet Reconnect spring I Spring hook 50305017000 or p 259 Tighten screws O Guideline I Remaining screws chassis Finishing work Install the right side cover or p 76 Changing the glass fiber arn filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down Do n...

Page 74: ...ncer cap D with 0 ring Remove screws and insert together with insulating pad G Remove the insulating pad from the insert Clean the parts that need to be reinstalled and check for damage Mount the new insulating pad on the insert and fasten with adhesive tape Position the insert with the insulating pad in outer tube 41 Mount and tighten screws Guideline I Screws on the main silencer I MS Mount 0 ri...

Page 75: ...nd lead to increased wear Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Preparatory work Remove the air filter box cover r 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 holdi...

Page 76: ... with fuel or petroleum since these substances attack the foam Sealing the air filter box 401559 01 Preparatory work Remove the air filter box cover p 73 Remove the air filter 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 257 Info I Only press the air filter to dry it never wring it out Oil the dry air filter wit...

Page 77: ...ith the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that has been contaminated with fuel Store fuel properly in a suitable canister and keep away from children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do...

Page 78: ...ever refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately The fuel in the fuel tank expands when warm and may emerge if overfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come i...

Page 79: ...ces Dirt in the fuel line clogs the injection valve Disconnect the plug in connection of the fuel line Info I Remaining fuel may run out of the fuel pipe Mount wash cap set 8 I Wash cap set 81212016100 FE 350 EU AU Disconnect the connector of the horn Remove screws 8 with the collar bushings and horn FE 350 US Remove screws 8 with the collar bushings Remove screw C with the rubber bushing 77 Pull ...

Page 80: ...act a physician immediately Change clothing that is contaminated with fuel Main work Check the routing of the throttle cable r p 39 Position the fuel tank and fit the two spoilers to the sides of the radiator bracket Make sure that no cables are trapped or damaged Mount the fuel tank breather Mount and tighten screw O with the rubber bushing Guideline I Remaining screws chassis 10 Nm 7 4 lbf ft Po...

Page 81: ... the connecting piece Slide the new fuel screen all the way into the connecting piece Lubricate the O ring and connect plug in connection of the fuel line mDanger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in an enclosed space wi...

Page 82: ... a suitable container Remove the seat p 76 Remove the fuel tank p 76 Main work Remove nut O with the gasket Remove fuel connection with the gasket Remove screws fD 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 80 ...

Page 83: ... engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately The fuel in the fuel tank expands when warm and may emerge if overfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact ...

Page 84: ...en flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately The fuel in the fuel tank expands when warm and may emerge if overfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes ...

Page 85: ...the diagnostics tool and start it 110 I 2 6 US gal Select the Function test of fuel pump control actuator test Guideline I Maximum duration of the actuator test I 3 min Check the fuel pressure with the filler cap closed Fuel pressure When the fuel pump is active If the specification is not reached Open the filler cap p 75 Check the tank air vent system 3 35 3 65 bar 48 6 52 9 psi Check the fuel pr...

Page 86: ...s out of the brake line guide Remove screws Take off the fender Main work Position the front fender Mount and tighten screws 0 Guideline I Remaining screws chassis 10 Nm 7 4 lbf ft Position the brake line and wiring harness in the brake line guide Mount and tighten screws 8 Guideline I Remaining screws chassis I M6 Connect plug in connectors 8 of the turn signals Finishing work Install the headlig...

Page 87: ...nd detach at catch 8 Disconnect connector Take off the headlight mask with headlight Main work Plug in connector O Check that the lighting is functioning properly Attach headlight holder 8 at catch and position the headlight mask Position rubber bands C around the fork legs and close them The wiring harness and brake line 0 are routed in front of the headlight mask Finishing work Check the headlig...

Page 88: ...t 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 requir...

Page 89: ... or deformation Change the brake disc Danger of accidents Instable handling due to incorrect spoke tension Ensure that the spoke tension is correct Info A loose spoke can cause wheel imbalance which leads to more loose spokes in a short time If the spokes are too tight they can break due to local overload Check the spoke tension regularly especially on a new motorcycle Tap each spoke with a screwd...

Page 90: ...Remove screw O Hold the front wheel and remove the wheel spindle Take the front wheel out of the fork Info I Do not pull the hand brake lever when the front wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged Remove spacers 8 Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and gr...

Page 91: ...en screws D Guideline I Screw fork stub I1s Nm 11 1 lbf ft I Removing the front brake disc Preparatory work Raise the motorcycle with a lift stand r p 11 Remove the front wheel r p 88 Main work Remove screws 0 Take off the brake disc Installing the front brake disc Main work Clean the contact surface of the brake disc Position the brake disc with the label facing outward Mount and tighten screws O...

Page 92: ...nly press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in Position spacing tube C Press in the new bearing D all the way using a suitable tool Info I Only press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in Grease the new shaft seal rings 8 and O and press in until they are flush Finishing work Install th...

Page 93: ...rm Info I Do not operate the foot brake when the rear wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged Remove spacers C 14 6 2 Installing the rear wheel Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Main wor...

Page 94: ...ake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Finishing work Remove the motorcycle from the lift stand p 11 Removing the rear brake disc Installing the rear brake disc Preparatory work Raise the motorcycle with a lift stand p 11 Remove the rear wheel p 90 Main work Remove screws 0 Take off the brake disc Main work Clean the contact su...

Page 95: ...tension r p 93 Finishing work Remove the motorcycle from the lift stand r p 11 Warning Danger of accidents Danger caused by incorrect chain tension If the chain is too taut the components of the secondary power transmission chain engine sprocket rear sprocket bearings in the transmission and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or t...

Page 96: ...ideline I Weight of chain wear measurement 110 15 kg 22 33 lb Measure the distance 0 of 18 chain links in the lower chain section Info I Chain wear is not always even so you should repeat this measurement at different chain positions Maximum distance 0 at the longest chain section 272 mm 10 71 in If distance Ci is greater than the specified measurement Change the drivetrain kit p 96 o l o o 0 o o ...

Page 97: ... of the chain guide is worn Change the chain guide Check that the chain guide is firmly seated If the chain guide is loose Tighten the chain guide Guideline Remaining screws chassis Remaining nuts chassis Finishing work M6 M6 Remove the motorcycle from the lift stand p 11 14 6 8 Checking for chain dirt accumulation 400678 01 14 6 9 Cleaning the chain Warning Check the chain for coarse dirt accumul...

Page 98: ...pends largely on its maintenance Preparatory work Raise the motorcycle with a lift stand p 11 Main work Clean the chain regularly and then treat with chain spray I Offroad chain spray p 257 400725 01 Finishing work Remove the motorcycle from the lift stand p 11 14 6 10 Changing the drivetrain kit Preparatory work Raise the motorcycle with a lift stand p 11 Remove the rear wheel p 90 Main work Remo...

Page 99: ...with connecting link C Have an assistant operate the rear brake Mount and tighten screw CD with the washer Guideline Screw engine sprocket M10 Position the engine sprocket cover Mount and tighten screw O Guideline I Screw clutch slave cylinder Mount and tighten screw 8 Guideline I Remaining screws chassis Finishing work Install the rear wheel p 91 M6 MB 60 Nm 44 3 lbf ft Remove the motorcycle from...

Page 100: ...e lock ring 8 Remove shaft seal ring Using a suitable tool press bearing C out from the inside to the outside Remove spacing tube 0 Using a suitable tool press bearing 0 out from the inside to the outside Press the new bearing 0 all the way in from the outside to the inside Info I Only press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in ...

Page 101: ...the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in Grease the new shaft seal ring D and press it in until it is flush Mount lock ring i The lock ring engages audibly Grease the new shaft seal ring O and press it in until it is flush Finishing work Install the rear wheel p 91 Remove the motorcycle from the lift stand p 11 ...

Page 102: ...ection caps O Remove the faulty main fuse Info I A defective fuse can be identified by the burned out fuse wire e A reserve fuse D is located in the starter relay Install a new main fuse I Fuse 58011109120 p 204 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 bo...

Page 103: ... the correct rating only I Fuse 75011088010 p 204 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 p 76 Preparatory work Switch off all power consumers and switch off the engine Remove the seat p 76 Remove the air filter box cover p 73 Main work Disconnect the ...

Page 104: ... terminal cover O and disconnect the negative cable from the battery 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 battery into the battery compartment with the terminals facing to the front I Battery YTX5L BS p 204 Reconnect rubber band O Info I Contact disk e must be mount...

Page 105: ...oltage regulator to the wiring har ness Check the stator winding of the alternator p 196 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 Info ...

Page 106: ...ule Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accident Reduced braking efficiency due to the use of non approved brake linings Brake linings available in accessories stores often have not been tested and approved for use in Husqv...

Page 107: ... and remove the brake linings Clean the brake caliper and brake caliper support Check that leaf spring D in the brake caliper and sliding plate in the brake caliper support are seated correctly Insert the new brake linings insert pin 0 and mount cotter pins 8 Info I Always change the brake linings in pairs Operate the hand brake lever repeatedly until the brake linings are in contact with the brak...

Page 108: ...travel of the hand brake lever or p 106 Adjust the basic setting of the hand brake lever to your hand size by turning adjusting screw O Info I Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the handlebar The range of adjustment is limited T...

Page 109: ...rake sys tem is leaking or that the brake linings are completely worn down Check the brake system and do not continue riding Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flush the eyes thoroughly with water ...

Page 110: ...to contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from...

Page 111: ...erfilling of the brake fluid reservoir Tighten the bleeder screw Remove the hose of the bleeder bottle Mount the pro tection cap Disconnect the bleeding device Remove the bleeder cover Add brake fluid to level D Guideline I Measurement of D I Brake fluid DOT 4 p 256 I 5 mm 0 2 in Position the cover with the membrane Mount and tighten the screws Info I Clean up overflowed or spilt brake fluid immed...

Page 112: ...linings and thus their brake power may vary greatly from that of original Husqvarna Motorcycles bake linings If brake linings that differ from the original equipment are used it cannot be guaranteed that these are in keeping with the original homologation In this case the vehicle will not correspond to its condition at delivery and the warranty shall be void Warning Environmental hazard Hazardous ...

Page 113: ... DOT 4 p 256 Mount screw cap O with membrane 8 and O ring Info Clean up overflowed or spilt brake fluid immediately with water Checkin the free travel of foot brake lever Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to overheating Adjust the free travel on foot brake leve...

Page 114: ...er Guideline I Free travel at foot brake lever 13 5 mm 0 12 0 2 in Hold screw fD and tighten nut 8 Guideline I Nut foot brake lever stop I M8 Hold push rod and tighten nut 8 Guideline I Remaining nuts chassis Reconnect spring O I 20 Nm 14 8 lbf ft I 10 Nm 7 4 lbf ft Checking the rear brake fluid level Warning Danger of accidents Brake system failure If the brake fluid level drops below the specifi...

Page 115: ...ng efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and br...

Page 116: ...screw cap O with membrane and the O ring Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid Bleed syringe 50329050000 or p 259 Brake fluid DOT 4 or p 256 Mount bleeder cover 8 I Bleeder cover 00029013006 or p 259 Connect the bleeding device I Bleeding device 00029013100 or p 259 Open shut off valve fD Info I Follow the operating instructions o...

Page 117: ...e the hose of the bleeder bottle Mount the pro tection cap Disconnect the bleeding device Remove the bleeder cover Stand the vehicle upright Correct the brake fluid up to marking i I Brake fluid DOT 4 p 256 Fit and tighten plug with oil screen and O ring Info I Clean up overflowed or spilt brake fluid immediately with water Check the foot brake lever for a firm pressure point ...

Page 118: ...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 119: ...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 120: ...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 121: ...headlight range of the headlight by turning adjusting screw O Guideline 119 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 Turn clockwise to reduce the headlight range turn counterclockwise to increase the headlight range A change in weight on the vehicle may require a co...

Page 122: ...ycle with a lift stand p 11 Remove the right side cover p 75 Remove the main silencer p 71 Remove the seat p 76 Remove the fuel tank p 76 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 120 ...

Page 123: ...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 259 Remove screw Take off the manifold Push back the cover Remove nut Gi Take off the cable 121 ...

Page 124: ...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 122 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 125: ...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 123 ...

Page 126: ...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 5 124 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 127: ...he clutch slave cylinder with the gasket Mount and tighten screws Guideline I Screw clutch slave cylinder M6 Mount the chain Connect the chain with connecting link 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 spring M6 M8 125 110Nm 7 41bfft 110Nm 7 4lbfft I 25 Nm 18 4lbfft...

Page 128: ...Position the cover Position the manifold and mount springs 4D I Spring hook 50305017000 r p 259 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 126 I 25 Nm 18 4 lbf ft I Loctite 2701 TM ...

Page 129: ...s Guideline Screw subframe Remove screw Mount and tighten screw Guideline Screw subframe M8 M8 Repeat these steps on the opposite side Mount 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 127 Loctite 2701TM Loctite 2701TM ...

Page 130: ... inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and check that it is sealed Switch off the engine Check the engine oil level p 191 Check the coolant level p 189 Execute the initialization run p 20...

Page 131: ...g the engine oil Removing the oil filter 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 oil drain plug with the magnet Completely drain the engine oil Remove screws O Remove the oil filter cover with the O ring 129 ...

Page 132: ...ilter housing I Circlip pliers reverse 51012011000 r p 260 Remove the spark plug using special tool O I Spark plug wrench 77229172000 p 265 Remove screws O Remove the valve cover with the valve cover seal Remove the spark plug shaft insert Removing the alternator cover Remove screws O Remove the alternator cover 130 ...

Page 133: ...131 Turn the crankshaft counterclockwise until markings f on the cylinder head are located flush above the flat areas G of the camshafts Remove screw O with the washer Info I Check through the hole whether the position notch of the crankshaft is visible Mount and tighten screw O without the washer 18 3 11 Removing the timing chain tensioner G00421 10 Loosen screw O Remove screw with the seal ring ...

Page 134: ... ring e Loosen screws O from the outside to the inside and remove Take off guide rail fj Take off the camshaft bearing bridge Take the timing chain off the camshaft gear Remove the camshafts Remove nut O with the washer Loosen nuts fj in a crisscross pattern and remove them with the washers Remove the cylinder head 132 ...

Page 135: ...er 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 gasket Remove screw O Insert special tool into the crankshaft I Protection cap 75029090000 p 263 Attach special tool CD to the rotor Hold it tight using the special tool and pull off the rotor by turning the sc...

Page 136: ...134 Remove lock ring 8 Take off the starter idler gear with the washer Remove freewheel gear 0 Remove screws CD Remove the inside alternator cover Take off gasket Remove screws Take off the starter motor Remove screws O Take off oil pump cover 8 ...

Page 137: ...NE Remove O ring CD Remove suction pump C Remove needle roller 18 3 17 Removing the water pump wheel Remove screws O Take off the water pump cover Remove nut 8 Take off the two part water pump impeller CD 135 ...

Page 138: ...utch cover 18 3 19 Removing the clutch discs Remove screws O Take off the clutch cover Remove the clutch cover seal Remove screws O Take off spring retainer Take off spring washer Take off pretension ring C Take off pressure cap 0 136 ...

Page 139: ...he special tool Loosen nut O I Clutch holder 51129003000 p 260 Remove the nut with the lock washer Dispose of the lock washer Take off inner clutch hub 8 and washer CD 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 Push sliding plate O away from the shift drum locating unit 8 Remove shift shaft CD with the washer 137 ...

Page 140: ...ft 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 Take off oil pump gear wheel 0 Remove pin Remove screws fD Take off the oil pump cover ...

Page 141: ... side Remove force pump 4 Remove nut O Info I Left handed thread Take off primary gear Remove screws O Remove the timing chain tensioning rail Remove the timing chain guide rail 6 Remove screw C Take off balancer shaft 0 with the timing chain and timing chain securing guide Info If the timing chain is going to be used again mark its direction of travel Remove spacer O of the crankshaft Remove scre...

Page 142: ...p 263 Mount special tool 8 with the appropriate screws I Puller 77229048000 p 265 Info I Use the drill hole marked with 772 Take off the section of the engine case Info I Do not subject the section of the engine case to any stress The washer of the main shaft usually adheres to the bearing Take off the left section of the engine case Remove the dowels Remove the special tools Remove shift rail O t...

Page 143: ...llers 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 _ a _ I 1 f4 f t 11 1 t j EBEi 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 141 ...

Page 144: ...243 Insert the new cold bearings into the bearing seats of the hot engine case section and if necessary use a suitable press drift to push the bearing all the way to the stop or so that it is flush Info I When pressing the bearing in ensure that the engine case section is level to prevent damage Only press the bearings in via the outer bearing race otherwise the bear ings will be damaged when they...

Page 145: ...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 146: ...unt and tighten oil nozzle 0 Guideline Oil nozzle piston cooling Position all bearing locks M5 Mount and tighten screws D Guideline Locking screw for bearing 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 beari...

Page 147: ...utside using a suitable tool Press in shaft seal ring O all the way with the open side facing outward Remove lock ring 0 Remove shaft seal ring D of the crankshaft Press the new shaft seal ring all the way in with the open side facing outward Info 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 clea...

Page 148: ...et specifications Change the spring Check ball 8 and the sealing seat If there is damage or wear Change the ball and machine the sealing seat Install ball 8 and pressure spring fs Mount and tighten screw plug O with sealing washer Guideline I Plug oil pressure regulator valve I M12x1 5 18 4 5 Checking the lubrication system OJ 305003 10 Check the internal rotor and external rotor of oil pumps O fo...

Page 149: ...x the crankshaft in the vise Info I Use soft jaws Slide on the compensating disk Heat the crankshaft bearing inner race in special tool O and mount together Guideline 1120 C 248 F I Tool for inner bearing race 58429037037 r p 260 Repeat the operation on the opposite side Ensure that the new crankshaft bearing inner race is flush Info 147 I After replacing the crankshaft bearings the crankshaft end...

Page 150: ... crank web with connecting rod and bearing Position the second crank web Position special tool with the heel pointing down I Insert for crankshaft pressing tool 77229008000 or p 263 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 the a...

Page 151: ...4 lbf ft Mount the dial gauge support on the engine case and measure and note down the crankshaft end play Guideline I Crankshaft axial play I 0 50 0 60 mm 0 0197 0 0236 in If the measured value does not meet specifications Remove the crankshaft Remove the crankshaft bearing inner race p 147 Calculate the thickness of the compensating disks Add or remove compensating disks equally on both sides In...

Page 152: ...mproved 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 88 ...

Page 153: ...piston ring with the marking facing upward Check the piston pins for discoloration or signs of wear If the piston pin shows severe discoloration signs of wear Change the piston pin Place 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 t...

Page 154: ...e the cylinder r p 150 If cylinder wear lies within the specified tolerance Change the piston ring Mount the piston ring with the marking facing toward the piston head 18 4 18 Changing the camshaft bearing 308666 10 302767 10 Clamp special tool O into a vise I Adjustment bush bridge 77229050044 r p 265 Mount the camshaft on the special tool Remove screw 8 Pull camshaft gear D off of the camshaft I...

Page 155: ...mshafts If there is damage or wear Change the cylinder head with the camshaft bearing bridge Position the camshafts The valves are not activated Insert the Plastigauge clearance gauge in area G I Plastigauge clearance gauge 60029012000 r p 261 Position camshaft bearing bridge O Mount and tighten the screws Guideline Screw camshaft bearing bridge Info M7x1 14 Nm 10 3 lbf ft Lubricated with engine o...

Page 156: ...e side accord ing to their normal built in position Pre tension the valve spring using the special tool Valve spring mounter 59029019000 p 261 Insert for valve spring lever 77229060000 p 265 Remove the valve keys and unload the valve spring Remove the valve spring retainer and valve springs Pull the valve down out of the valve guide Remove valve stem seal 8 with the special tool I Pliers for valve...

Page 157: ... the valve spring is broken or worn Change the valve spring Measure the length of the valve springs Valve spring Minimum length 42 00 mm 1 6535 in If the measured value does not meet specifications Change the valve springs 18 4 24 Checking the valve spring seat 305014 10 18 4 25 Checking the cam levers 302718 10 Check the valve spring seat for breakage and wear visual check If the valve spring sea...

Page 158: ...r 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 fj 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 specifications Rework the valve seat Blow compressed air through all oil channels and chec...

Page 159: ...ey had before they were removed Mount the cam lever shafts Remove screw 0 Mount and tighten screw plugs D Guideline I Screw plug cam lever axis M10x1 10 Nm 7 4 lbf ft Place shims into the valve spring retainers according to the installation position Insert freewheel gear O into the freewheel hub turning the freewheel gear clock wise do not wedge Check the locking action of starter wheel O If the f...

Page 160: ...e off Take freewheel D 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 158 Ensure that all lugs of the expansion ring pass through slots O of the freewheel and engage in groove C of the primary gear Mount lock ring D ...

Page 161: ...mage and wear If there is damage or wear Change the freewheel gear or bearing Check freewheel 8 for damage and wear If there is damage or wear Change the free wheel Check the gear mesh of starter motor 0 for damage and wear If there is damage or wear Change the starter motor Change O ring D of the starter motor Connect the negative cable of a 12 volt power supply to the housing of the starter moto...

Page 162: ...ear Replace the timing chain securing guide Check camshaft gears 0 for damage and wear If there is damage or wear Change the camshaft gears Check timing chain D for damage and wear If there is damage or wear Replace the timing chain 305007 10 Let the timing chain hang down freely Check the timing chain links for smooth operation The chain links no longer align in a straight line Replace the timing...

Page 163: ...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 squeezed together This function is necessary in order to ensure suffi cient timing chain tension even at low oil pressures 304690 10 Place push rod 8 on a level surface and check for run out If there is r...

Page 164: ...s damage or wear Change the needle bearing and collar sleeve Check the intermediate disc G for damage and wear If the intermediate discs are not flat or have punctiform outbreaks Change all intermediate discs Check clutch facing discs 4D for discoloration and scoring If there is discoloration or scoring Change all clutch lining discs Check the thickness of clutch facing discs 4D I Clutch facing di...

Page 165: ...rail Check sliding plate 0 for wear on contact areas 0 If the sliding plate is worn Change the sliding plate Check return surface ti on the sliding plate for wear If there is severe grooving Change the sliding plate Check guide bolts 4 for firm seating and wear If the guide bolts are loose or worn Change the sliding plate Preassemble the shift shaft p 163 Check clearance O between the sliding plat...

Page 166: ...nd gear fixed gear 8 Remove 5th gear idler gear Ci and needle bearing 8 Remove stop disk 0 Remove lock ring 3 Remove 3rd 4th gear sliding gear Remove lock ring Remove stop disk Remove 6th gear idler gear Ci Remove needle bearing 48 18 4 38 Disassembling the countershaft 305011 10 lo Fix the countershaft in the vice with the toothed end facing downward 305012 10 164 ...

Page 167: ...ve the 2nd gear idler gear I Remove needle bearing Gi 18 4 39 Checking the transmission Condition The transmission has been disassembled Check needle bearings O for damage and wear If there is damage or wear Change the needle bearings 305013 10 Check the pivot points of main shaft 8 and countershaft D for damage and wear If there is damage or wear Change the main shaft and or countershaft Check th...

Page 168: ...eration in the profile of main shaft 8 lf the sliding gear does not move freely Change the sliding gear or the main shaft Check sliding gears 0 for smooth operation in the profile of countershaft If the sliding gear does not move freely Change the sliding gear or the countershaft Check stop disks for damage and wear If there is damage or wear Change the stop disks Use new lock rings with every rep...

Page 169: ...ntershaft Info Use new lockrings with every repair Preparatory work Carefully lubricate all parts before assembling Checkthe transmission p 165 Main work Fix the countershaft in the vice with the toothed end facing downward Guideline Use soft jaws Mount needle bearing O Mount 2nd gear idler gear Mount stop disk and lockring 8 Mount 5th gear sliding gear 0 with the shift groove facing up Mount lock...

Page 170: ...ally check all gear wheels for smooth operation 18 5 18 5 1 18 5 2 Engine assembl Installing the crankshaft Position the right section of the engine case in the engine work stand Oil the bearing Push crankshaft O into the bearing seat Installing the transmission shafts Oil the bearing Slide both transmission shafts O into the bearing seats together Mount lock ring fi 168 ...

Page 171: ... in the lower shift groove of the countershaft Mount shift fork D 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 misplace the shift rollers Install shift rail O together with upper spring and the lower spring Install shift rail D tog...

Page 172: ... yet Guideline I Screw engine case I M6x55 Mount screws 8 but do not tighten yet Guideline I Screw engine case I M6x65 Mount screws but do not tighten yet Guideline I Screw engine case Tighten screws 0 8 and Guideline I M6x85 I Screw engine case I M6 Mount the screw connection of the engine fixing arm Grease the shaft seal ring Mount spacer O 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 110 ...

Page 173: ... primary gear engages in the wide recess of the crankshaft Markings f and G are aligned Set the crankshaft to top dead center and lock it with screw 8 Mount and tighten nut D Guideline Nut primary gear M18LHx1 5 100Nm 73 8 lbf ft Loctite 243 Oil the oil pump shaft internal rotor and external rotor before assembly Position force pump O Info I The rounded side of the force pump faces the engine case...

Page 174: ...re that it can move easily Mount oil pump idler gear with the washer Mount washers 41 Mount lock ring G Insert needle roller O Position suction pump 8 Crank the oil pump gear wheel and ensure that it can move easily Mount O ring Position oil pump cover 8 Mount and tighten screws 0 Guideline Screw oil pump cover M5 6Nm 4 4 lbf ft Loctite 243 172 ...

Page 175: ... I The flat areas of the shift drum locating unit are not symmetric Relieve tension from the locking lever Mount and tighten screw CD Guideline Screw shift drum locating M6 10 Nm 7 4 lbf ft Slide shift shaft O with the washer into the bearing seat Loctite 243 Push sliding plate 8 away from the shift drum locating unit CD Insert the shift shaft all the way Let the sliding plate engage in the shift ...

Page 176: ...hub M18x1 5 I Clutch holder 51129003000 p 260 Secure the nut with the lock washer Thoroughly oil the clutch facing discs 100 Nm 73 8 lbf ft Loctite 243 174 Beginning with an intermediate clutch disc alternately insert all other clutch fac ing discs and intermediate clutch discs into the clutch basket Mount pressure piece O Position pressure cap i Mount pretension ring with the Top marking facing u...

Page 177: ...for distortion I Feeler gauge 59029041100 p 261 I Spring washer distortion I 0 0 10 mm 0 0 0039 in If the specified value is not reached Remove screws D and mount spring retainer with marking Ill Using a straightedge and the special tool check the spring washer for distortion I Feeler gauge 59029041100 p 261 I Spring washer distortion I 0 0 10 mm 0 0 0039 in If the specified value is not reached C...

Page 178: ...impeller O Mount and tighten nut Guideline Nut water pump wheel M6 5Nm 3 7 lbf ft Mount the water pump cover with the seal ring Info I Ensure that the dowel pins are seated properly Mount screw D but do not tighten yet Guideline I Screw water pump cover I M6x25 Mount screws 8 but do not tighten them yet Guideline I Screw water pump cover I M6x40 Mount screw 0 with the washer but to not tighten yet...

Page 179: ...deline I Screw starter motor Position freewheel gear 8 M6 M6 Mount the starter idler gear with the washer Mount lock ring 0 Position the rotor Info I Ensure that the woodruff key is seated properly Mount and tighten screw 0 Guideline Rotor screw M10x1 70 Nm 51 6 lbf ft 177 I 6 Nm 4 4 lbf ft 10 Nm 7 4 lbf ft Thread oiled with engine oil cone degreased ...

Page 180: ...he piston carefully into the cylinder from above Info The piston rings should not catch or they will be damaged Ensure that piston mark fj faces the exhaust side Apply a thin layer of sealing compound in area G I Loctite 591O Place the cylinder base gasket on Info Ensure that the dowel pins are seated properly 178 Cover the engine case opening with a cloth Thread the timing chain through the chain...

Page 181: ...es Remove the cloth Keep the timing chain taut Push the cylinder down carefully and let the dowel pins engage Position cylinder head gasket 0 Info I Ensure that the dowels are seated properly Put the cylinder head in place Mount nut 8 with the washers and tighten in a crisscross pattern Guideline Nut cylinder head M10x1 25 Tightening Thread oiled with sequence engine oil cone Tighten diag greased ...

Page 182: ...th compressed air Mount the camshaft bearing bridge Markings f are aligned with the flat areas of the camshaft Lock ring G engages in groove 9 Info Ensure that the dowel pins are seated properly Position guide rail 8 Mount screws 0 and tighten from the inside to the outside Guideline Screw camshaft bearing bridge Condition M7x1 Camshaft gears were not loosened 14 Nm 10 3 lbf ft Mount the special t...

Page 183: ...al tool I Adjustment bush bridge 77229050044 r p 265 The valves are not activated 181 The special tool must be in full contact with the flat areas of the cam shafts Mount and tighten screws Guideline Screw special tool adjustment bush bridge Info M7x1 10 Nm 7 4 lbf ft I Tighten the screws of the exhaust camshaft first Tighten screws 8 Guideline Screw camshaft drive sprocket Remove screws Remove th...

Page 184: ... installation p 160 Main work Position timing chain tensioner O and insert it with new O ring 8 Mount and tighten screw plug D with the seal ring Guideline I Plug timing chain tensioner I M24x1 5 Remove screw C I 40 Nm 29 5 lbf ft I Press the timing chain tensioner toward the timing chain using special tool I Release device for timing chain tensioner 61229021000 p 262 The timing chain tensioner un...

Page 185: ... 68 F I 0 13 0 18 mm 0 0051 0 0071 in I Feeler gauge 59029041100 r p 261 If the valve clearance does not meet specifications Adjust the valve clearance r p 183 Mount and tighten screw O with the washer 18 5 27 Adjusting the valve clearance Guideline I Screw plug crankshaft location Main work Remove the timing chain tensioner r p 131 Remove the camshaft r p 132 Raise cam levers O 110 Nm 7 4 lbf ft ...

Page 186: ... have been mounted Guideline I Screw alternator cover I M6x30 I 6 Nm 4 4 lbf ft Mount screws 8 and tighten once all of the alternator cover screws have been mounted Guideline I Screw alternator cover I M6x50 I 6 Nm 4 4 lbf ft Mount screw 8 with the seal ring and tighten all screws in a crisscross pattern Guideline I Screw alternator cover I M6x25 Grease the O rings and mount the spark plug shaft i...

Page 187: ...g wrench 77229172000 p 265 185 I 8 Nm 5 9 lbf ft 1 10 12 Nm 7 4 8 9 lbf ft Tilt the motorcycle to one side and fill the oil filter housing to about full with engine oil Insert oil filter O into the oil filter housing Oil the O ring of the oil filter cover Mount oil filter cover Mount and tighten screws Guideline I Screw oil filter cover 110 Nm 7 4 lbf ft Mount and tighten the oil drain plug O with...

Page 188: ...se Mount and tighten screw plug 8 with the O ring Guideline I Screw plug oil screen I M20x1 5 Grease the shaft seal ring before mounting I1s Nm 11 1 lbf ft I Position the O ring Mount spacer O with the bevel facing inward Mount clutch push rod O 18 5 36 Removing the engine from the engine assembly stand Remove the screw connection from the special tool I Engine fixing arm 77229002000 p 263 Remove ...

Page 189: ...ause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws O Remove cover 8 with membrane CD Fill bleeding syringe 8 with the appropriate hydraulic fluid Bleed syringe 50329050000 p 259 Brake fluid DOT 4 p 256 On the clutch sl...

Page 190: ...motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin ey...

Page 191: ...olant level 6 above the radiator fins 10 mm 0 39 in If the coolant level does not match the specified value Correct the coolant level I Coolant r p 256 Mount the radiator cap Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow the engine and cooli...

Page 192: ...an contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children Main work Make sure that the screw O is tightened Stand the vehicle upright Pour coolant in up to measurement 6 above the radiator fins Guideline I 10 mm 0 39 in I Coolant 11 2 I 1 3 qt Refit the radiator ...

Page 193: ...paratory 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 Condition If the engine oil does not reach the lower edge of the level viewer Add engine oil p 194 The engine is at operating temperature Check the engine oil level Info I After switching off the engine wait one minute be...

Page 194: ...emove the engine guard p 41 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 screw 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 192 Position the pin wrench throu...

Page 195: ... cover Stand the motorcycle upright 10 Nm 7 4 lbf ft Remove the oil filler plug with the O ring from the clutch cover and fill up with engine oil I Engine oil 11 20 I 1 27 qt I Engine oil SAE 10W 50 p 256 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 O ring mDanger Danger of poisoning Exhaust gases are t...

Page 196: ... the engine and check that it is oil tight Finishing work Check the engine oil level p 191 Check the engine oil level p 191 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 p 266 10 Nm 7 4 lbf ft Connect pressure tester 8 to the special tool without the T plate I Pressure tester 61029094000 p...

Page 197: ...ome 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 Screw unlocking of timing chain ten sioner M10x1 8 Nm 5 9 lbf ft 195 ...

Page 198: ...asuring 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 p 76 Main work Stator winding measurement I check the resistance 0 Measure the resistance between the specified points ...

Page 199: ...ce 22 4 If the value displayed does not meet specifications Change the stator Removin the stator and i nition pulse enerator 305319 10 305321 10 Condition The alternator cover has been removed Remove screw O Remove the retaining bracket Pull the cable sleeve from the alternator cover Take off cable retainer plate Remove screws 8 Remove the stator and ignition pulse generator from the alternator co...

Page 200: ... in the alternator cover Mount and tighten screws 8 Guideline Screw stator M5 Position cable retainer plate 2Nm 1 5 lbf ft 6Nm 4 4 lbf ft Position cable support sleeve in the alternator cover Loctite 243 Loctite 243 Position the ignition pulse generator with the cable retainer plate in the alternator cover Position the retaining bracket Mount and tighten screws 8 Guideline Screw crankshaft posi ti...

Page 201: ...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 202: ...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 or death When running the engine always make...

Page 203: ...umps Primary transmission 24 73 Clutch Damped multidisc clutch in oil bath hydraulically activated Transmission ratio 1st gear 14 32 2nd gear 16 26 3rd gear 20 25 4th gear 22 23 5th gear 25 22 6th gear 26 20 Alternator 12V 168W Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment Spark plug NGK LMAR9Al 8 Spark plug electrode gap 0 8 mm 0 031 in Cooling Water ...

Page 204: ...M4 2 Nm 1 5 lbf ft 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...

Page 205: ...l 11 20 I 1 27 qt 25 4 2 Coolant I Coolant 25 4 3 Fuel Totalfuel tank capacity approx I Fuel reserve approx 11 2 I 1 3 qt 9 5 I 2 51 US gal 10 Nm 7 4 lbfft 10 Nm 7 4 lbfft 8 Nm 5 9 lbfft 10 Nm 7 4 lbfft 10 Nm 7 4 lbfft 14 Nm 10 3 lbfft 10 Nm 7 4 lbfft 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 10 Nm 7 4 lbfft 8 Nm 5 9 lbfft 10 12 Nm 7 4 8 9 lbfft Tightenin...

Page 206: ...2 13 52 Final drive FE 350 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 Weight without fuel approx FE 350 US 109 2 kg 240 7 lb Maximum permissible front axle load 145 kg 320 lb Maximum permissible rear axle load 190 kg 419 lb Maximum permissible ...

Page 207: ...5 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 Spring...

Page 208: ...steering head Screw in nozzles cooling system Screw front wheel spindle M4 5 M4 5 M5 M5 M5 M5x12 M6 M6 M6 M6 M6 M6 MB MB MB MB MB MB MB MB MB MB MB MB MB MB MB MB M10 M10 M10 M10 M10 M10 M12 M12x1 M16x1 5 M20x1 5 M20x1 5 M20x1 5 M24x1 5 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 50180751S1 p 256 6 Nm 4 4 lbf ft 6 Nm ...

Page 209: ...r Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush Info I Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to a dry vehicle always rinse the vehicle with water first After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the closure of the exhaust system Warning Danger o...

Page 210: ...cle p 207 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 211: ... time before taking the motorcycle out of service add fuel additive Refuel Clean the motorcycle p 207 Change the engine oil and oil filter clean the oil screen p 192 Check the antifreeze and coolant level p 188 Check the tire air pressure p 86 Remove the battery p 102 27 2 401058 01 Charge the battery Guideline Storage temperature of battery with out direct sunshine 0 35 C 32 95 F Store the vehicl...

Page 212: ...eration I I Check rectify the fluid level of the hydraulic clutch p 187 I I I Check the front brake fluid level p 107 I I I Check the free travel of the hand brake lever p 106 I Check the steering head bearing play p 35 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 192 0 I Check a...

Page 213: ...k 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 211 Annually Every 135 operating h...

Page 214: ... 0 cc G m F 0 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 350 EU 2014 2015 I I I 1 8 I 3 I 4 5 I 6 I 7 I 8 ...

Page 215: ...29 WIRING DIAGRAM Components G10 Battery K10 Starter relay with main fuse M10 Starter motor S21 Electric starter button 213 ...

Page 216: ... j T20 DY 4 I 1 X9 ls l l t i t J 2 i iEB 4 F2 ffi K30 B X295 lAP 6 J 2 iEB 4 1 X 6 I 1 X3 E E E j j 1 1 EB aC Wh rd t l J 1 l x2a5 iBS 2 M14 J Il BS 2 1 X285 1 II I 1 xa 1 x1 ls rJ 2 J 2 fi F3r 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 350 EU 2014 2015 1 T r 2 s T T T T T ...

Page 217: ...AGRAM Components A11 EFI control unit 833 Radiator fan temperature switch F2 Fuse F3 Fuse F4 Fuse G20 Alternator K12 Light relay K30 Power relay M14 Radiator fan T20 Voltage regulator X295 Diagnostics connector 215 ...

Page 218: ... wh 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_ f 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 350 EU 2014 2015 I 318 1 2 I 3 I 4 s I 6 I 1 I s ...

Page 219: ...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 217 ...

Page 220: ... AH 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 I 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 FE 350 EU 2014 2015 I Hu5 Mlrna I 4 8 1 2 I 3 I 4 5 I 6 I 7 I 8 ...

Page 221: ...29 WIRING DIAGRAM Components B76 Brake light switch front B77 Brake light switch rear E60 License plate lamp P36 Brake tail light 219 ...

Page 222: ...Mlrna 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 350 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 223: ...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 221 ...

Page 224: ...Mlrna 1 2 I 3 I 4 5 I 7 A4 l X15 5 5 FE 350 EU 2014 2015 2 I 3 I 4 5 l wll X15 X15 c l B51 5 1 I X20 NCLJ 4 j NDY 4 r t DY 4 f CU 4 X20 0 c 6 I I P13 3 A6 7 A2 l X15 I 6 I 7 I 0 N CY 3 M N CZ 3 M X51 p GA 3 m o 17 07 R ll D7 7 5 5 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 225: ...29 WIRING DIAGRAM Components A11 EFI control unit 832 Fuel level indicator 851 Lambda sensor cylinder 1 F1 Fuse P13 Speedometer 223 ...

Page 226: ...C w 6 E8 g C or E C co z 0 cc G m 2 F8 b C br F 0 C I FE 350 EU 2014 2015 Hu5 Mlrna 1 2 I 3 I 4 5 1 11 D 1 6 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 I 4 i X15 is I1 1 X301 r 7 0 0 6 I 7 I 8 J I J A I W m i X15 X15 I B 9 B C 1 M GA 3 d 6 D7 M 6 D7 r X29 D E F I I I 7 8 7 I 8 ...

Page 227: ...29 WIRING DIAGRAM Components A11 EFI control unit 870 Wheel speed sensor front M13 Fuel pump M51 Injector cylinder 1 R30 CAN bus terminating resistor 1 P13 Speedometer X295 Diagnostics connector 225 ...

Page 228: ... I I I 4 11 X15 1 I I I t L 1 1 c Am rt H w ljJJ AX 2 1 XJ5 tj i o m X15 il I il 5 4 i X15 9 I t 1 x30 EX 3 S O e EX 3 I 0 52 i 6 7 1 4 iii i iD l S 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 350 EU 2014 2015 1 T T T T T 8 0 J I J IA I Is T r 8 8 ...

Page 229: ...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 227 ...

Page 230: ...0 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 II 0 0 G10 J 7J E 1 X300 l l FE 350 AU 2014 2015 I 3 I 4 5 I 6 I 7 I 8 N N N 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 231: ...29 WIRING DIAGRAM Components G10 Battery K10 Starter relay with main fuse M10 Starter motor S23 Emergency OFF switch electric starter button 229 ...

Page 232: ... 1 j T20 DY 4 I 1 X9 ls l l t i t J 2 i iEB 4 F2 ffi K30 B X295 lAP 6 J 2 iEB 4 1 X 6 I 1 X3 E E E j j 1 1 EB aC Wh rd t l J 1 l x2a5 iBS 2 M14 J D BS 2 1 X285 1 II I 1 xa 1 x1 ls rJ 2 J 2 fi F3r 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 350 AU 2014 2015 1 T r 2 s T T T T T ...

Page 233: ...AGRAM Components A11 EFI control unit 833 Radiator fan temperature switch F2 Fuse F3 Fuse F4 Fuse G20 Alternator K12 Light relay K30 Power relay M14 Radiator fan T20 Voltage regulator X295 Diagnostics connector 231 ...

Page 234: ... wh f 4 B1 I 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 FE350AU2014 2015 I 318 1 2 I 3 I 4 s I 6 I 1 I s ...

Page 235: ...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 233 ...

Page 236: ...AH 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 I 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 FE 350 AU 2014 2015 I Hu5 Mlrna I 4 8 1 2 I 3 I 4 5 I 6 I 7 I 8 ...

Page 237: ...29 WIRING DIAGRAM Components B76 Brake light switch front B77 Brake light switch rear E60 License plate lamp P36 Brake tail light 235 ...

Page 238: ...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 It I C E E C co z 0 It cc G g 0 F F I 0 Ii C I FE 350 AU 2014 2015 I I Hu5 Mlrna I 5 8 1 2 I 3 I 4 5 6 I 7 I 8 ...

Page 239: ...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 237 ...

Page 240: ...co z 0 co cc g 0 F l f 0 Ii C I FE 350 AU 2014 2015 Hu5 Mlrna 1 2 I 3 I 4 5 1D 3S ll X15 X15 c l 7jlir X20 M N CU 4 c 0 0 6 I I P13 3 A6 7 A2 l X15 i 6 I 7 I 0 N CY 3 M N CZ 3 M X51 p GA 3 _ 7 D7 R ff DI 7 0 0 I CY 3 CZ 3 X51 I 8 or g 7 E1 bl h 8 F1 I I 6 8 8 N N N A B C D E F ...

Page 241: ...29 WIRING DIAGRAM Components A11 EFI control unit 832 Fuel level indicator F1 Fuse P13 Speedometer 239 ...

Page 242: ...6 E8 g C or E C co z 0 cc G g 0 2 F8 b C br F It 0 Ii C I FE 350 AU 2014 2015 Hu5 Mlrna 1 2 I 3 I 4 5 1 11 D 1 6 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 I 4 i X15 is I1 1 X301 r 7 0 0 6 I 7 I 8 J I J A I W m i X15 X15 I B 9 B C 1 M GA 3 d 6 D7 M 6 D7 r X29 D E F I I I 7 8 7 I 8 ...

Page 243: ...29 WIRING DIAGRAM Components A11 EFI control unit 870 Wheel speed sensor front M13 Fuel pump M51 Injector cylinder 1 R30 CAN bus terminating resistor 1 P13 Speedometer X295 Diagnostics connector 241 ...

Page 244: ...I I I 4 1 1 X15 1 I I I t L 1 1 c Am rt H w ljJJ AX 2 1 XJ5 tj i o m X15 il I il 5 4 i X15 9 I t 1 x30 EX 3 S O e EX 3 I 0 52 i 6 7 1 4 iii i iD l S 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 350 AU 2014 2015 1 T T T T T 8 0 J I J IA I Is T r 8 8 ...

Page 245: ...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 243 ...

Page 246: ...G g 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 i I 3 I II 0 0 G10 J 7J E i X300 l l FE 350 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 247: ...29 WIRING DIAGRAM Components G10 Battery K10 Starter relay with main fuse M10 Starter motor S21 Electric starter button 245 ...

Page 248: ...20 F2 ffi K30 sv 2 1 F4 ffi F3 ffi I 1 x19 1 1 X295 N M BG 3 1 1 1 0 I i r x i f i 1 t J t i f l I I I J t l l l l l i i I r t m 25 1 IEI L__b b 3 E1 IE u C z o 1 l 1 C l I a G C V 1 FB bC br 1 1 1 br b 5 F1 0 F r IF I FE350US2014 2015 I l 2 6 O c Husqyarna 1 C I C lol L 1 ia iiiii 2 l 3 l 4 s l 6 l 1 1 a ...

Page 249: ...ponents A11 EFI control unit 833 Radiator fan temperature switch optional F2 Fuse F3 Fuse F4 Fuse G20 Alternator K12 Light relay K30 Power relay M14 Radiator fan optional T20 Voltage regulator X295 Diagnostics connector 247 ...

Page 250: ... cv 4 i m D X11 t Y I X17 is cc Cl C X302 r 7 2 EB d C ye I C E 2 EB b C br C C0 z 0 I cc G g 0 F 0 0 Ii C I FE 350 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 J J 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 251: ...29 WIRING DIAGRAM Components A11 EFI control unit E11 Low beam P35 Parking light P37 Tail light S20 Kill switch S30 Light switch 249 ...

Page 252: ... I C C C0 z 0 cc G g 0 F 0 0 I C I gJ FE 350 US 2014 2015 Hu5 Mlrna 1 2 I 3 I 4 5 1D 3S ll X15 X15 c l 7jlir X20 M N CU 4 c 0 0 6 I I P13 5 A2 l X15 i 6 I 7 I 0 N CY 3 M N CZ 3 M X14 p GA 3 _ 5 D7 R 5 D 7 0 0 I 8 J J A CY 3 CZ 3 X14 B C D or 5 E1 E bl f 6 F1 F I I I 4 6 8 ...

Page 253: ...29 WIRING DIAGRAM Components A11 EFI control unit 832 Fuel tank sensor F1 Fuse P13 Speedometer 251 ...

Page 254: ...C 4 E8 e C or C C0 z 0 It cc G m 2 F8 b C br F 0 C I FE 350 US 2014 2015 Hu5 Mlrna 1 2 I 3 I 4 5 1 11 D 1 6 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 I 4 i X15 is I1 1 X301 r 7 0 0 6 I 7 I 8 J I J A I W m i X15 X15 I B 9 B C 1 M GA 3 d 4 D7 M 4 D7 r X29 D E F I I I 5 6 7 I 8 ...

Page 255: ... WIRING DIAGRAM Components A11 EFI control unit 870 Wheel speed sensor front M13 Fuel pump M51 Injection valve cylinder 1 P13 Speedometer R30 CAN bus terminating resistor 1 X295 Diagnostics connector 253 ...

Page 256: ...I 4 11 X15 1 I I I t L 1 1 i Am rt H w ljJJ AX 2 1 XJ5 tj iome X15 il I il 5 4 i X15 9 I t 1 x30 EX 3 S O e EX 3 I 0 52 i 6 7 1 4 iii I iD l S 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 350 US 2014 2015 1 T T T T T 8 0 J I J IA I Is T r 6 6 ...

Page 257: ...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 255 ...

Page 258: ...ds see specifications on the container and that possess the corre sponding properties I Synthetic engine oil Recommended supplier Bel Ray Works Thumper Racing Synthetic Ester 4T Fork oil SAE 4 48601166S1 Standard classification SAE p 271 SAE 4 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding properties Shock abs...

Page 259: ... 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 260: ...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 1 258 ...

Page 261: ...9013005 00029013005 H00504 01 Bleeder cover Art no 00029013006 00029013006 H00505 01 Bleedin device Art no 00029013100 00029013100 H00518 01 Spring hook Art no 50305017000 50305017000 H00973 01 Bleed s ringe Art no 50329050000 50329050000 H00565 01 ...

Page 262: ...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 01 260 ...

Page 263: ... 2x 59029019000 H00610 01 Feeler Art no 59029041100 c 7 59029041100 H00616 01 Plasti e clearance Art no 60029012000 60029012000 H00627 01 Piston ring mounting tool Art no 60029015000 60029015000 H00628 01 Hose clam liers Art no 60029057000 60029057000 H00650 01 ...

Page 264: ...ure tester Art no 61029094000 4x D 61029094000 H00660 01 En ine assembly stand Art no 61229001000 61229001000 H00662 01 Release device for timing chain tensioner Art no 61229021000 61229021000 H00675 01 Pressing tool for crankshaft com lete Art no 75029047000 75029047000 H00714 01 ...

Page 265: ... H00726 01 Extractor camshaft ear Art no 77229001044 77229001044 H00747 01 En arm 2x Art no 77229002000 77229002000 H00748 01 Insert for crankshaft pressing tool Art no 77229008000 B 77229008000 H00750 01 Extrude late base 2x Art no 77229009000 77229009000 H00751 01 ...

Page 266: ...52 01 Limit 77229026000 H00753 01 Insertion for piston rin lock 77229030000 H00754 01 Protection cap 0 77229031000 H00755 01 Se arator late Cb 77229032000 H00756 01 Art no 77229010000 Art no 77229026000 Art no 77229030000 Art no 77229031000 Art no 77229032000 264 ...

Page 267: ... 77229035000 H00757 01 Puller Art no 77229048000 2x 77229048000 H00758 01 Adjustment bush brid e Art no 77229050044 2x 77229050044 H00759 01 Insert for valve spring lever Art no 77229060000 77229060000 H00760 01 S ark lug wrench Art no 77229172000 77229172000 H00761 01 ...

Page 268: ...ressure ada ter Art no 77329006000 77329006000 H00764 01 Lift stand Art no 81329955000 81329955000 H01015 01 Hook wrench Art no T106S T106S H00841 01 Depth micrometer Art no T107S T107S H00842 01 Pin Art no T120 T120 H00844 01 ...

Page 269: ...Mounting sleeve Art no T1204 T1204 H00878 01 Calibration in Art no T1205 T1205 H00879 01 Pressin tool Art no T1206 T1206 H00880 01 Pressing tool Art no T1207S S T1207S H00881 01 Mounting sleeve Art no T1215 T1215 H00886 01 ...

Page 270: ...assembl tool Art no T1216 C T1216 H00887 01 Vacuum Art no T1240S T1240S H00890 01 Protectin sleeve Art no T1401 cs T1401 H00894 01 Clamping stand 2x Art no T1403S T1403S H00896 01 Mounting tool Art no T14040S T14040S H00922 01 ...

Page 271: ... ecial socket Art no T14047 T14047 H00923 01 Clam in stand Art no T14049S 2x T14049S H00924 01 Press out tool Art no T14051 T14051 H00926 01 Press drift Art no T1504 T1504 H00899 01 Assembl tool Art no T150S T150S H00852 01 ...

Page 272: ...32 SPECIAL TOOLS 270 Nitro en filling tool Art no T170S1 2x 3x T170S1 H00855 01 ...

Page 273: ...vice intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils a...

Page 274: ...d current checking 103 Clutch fluid level checking rectifying 187 fluid changing 187 Clutch lever basic position adjusting 38 Compression damping fork adjusting 13 Compression damping high speed shock absorber adjusting 42 Compression damping low speed shock absorber adjusting 42 Coolant draining 189 refilling 190 Coolant level checking 188 189 Cooling system 188 Cylinder Nikasil coating 150 D Dri...

Page 275: ...3 spacer installing 170 186 spark plug installing 185 starter drive installing 176 suction pump installing 172 timing chain tensioner installing 182 timing chain installing 170 torque limiter installing 184 transmission shafts installing 168 valve clearance adjusting 183 valve clearance checking 183 valve cover installing 184 valve timing adjusting 181 273 valve timing checking 180 water pump cove...

Page 276: ...d brake lever basic position adjusting 106 free travel adjusting 106 free travel checking 106 Handlebar position 38 adjusting 38 Headlight headlight range adjusting Headlight adjustment 119 checking 118 274 Headlight mask with headlight installing 85 removing 85 Hydrostop unit fork legs assembling 24 fork legs disassembling 22 Idle speed adjusting 200 Ignition coil secondary winding checking 196 I...

Page 277: ...8 static sag checking 43 Shock absorber linkage checking 46 Spare parts 8 Spark plug connector checking 196 Speedometer clock setting 117 kilometers or miles setting 117 service display setting 118 275 setting 116 wheel circumference setting Spoke tension 117 checking 87 Spring fork legs removing 19 Starter motor checking 199 Starter relay checking 101 Starting 11 12 Steering head bearing changing...

Page 278: ...DEX page 3 of 6 248 page 3 of 8 216 232 page 4 of 6 250 page 4 of 8 218 234 page 5 of 6 252 page 5 of 8 220 236 page 6 of 6 254 page 6 of 8 222 238 page 7 of 8 224 240 page 8 of 8 226 242 Work rules 7 276 ...

Page 279: ...11111111111111111111111111IIIIII 3403001en 08 2015 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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