Husqvarna FE 350 2015 Repair Manual Download Page 162

Page: 162 / 308

18 ENGINE

160

18.4.15 Checking/measuring the piston

e-•

400995-10

305017-10

Use the special tool to measure clearance

of the piston rings in the piston ring

groove.

Guideline

Piston ring - groove clearance

$ 0.08 mm ($ 0.0031 in)

Feeler gauge (59029041100) (

�

p. 291)

If play

is larger than the specified value:

Change the piston and piston rings.

Check/measure the cylinder. (

�

p. 159)

Check the piston sliding surface for damage.

If the piston sliding surface is damaged:

Replace the piston and, if necessary, the cylinder.

Check that the piston rings move easily in the piston ring grooves.

If the piston ring is stiff:

Clean the piston ring groove.

•

Tip

An old piston ring can be used to clean the piston ring groove.

Check the piston rings for damage.

If the piston ring is damaged:

Replace the piston ring.

•

Info

Mount the piston ring with the marking facing upward.

Check the piston pins for discoloration or signs of wear.

If the piston pin shows severe discoloration/signs of wear:

Change the piston pin.

Place the piston pin in the connecting rod and check the seating for play.

If the piston pin seating has excessive play:

Change the connecting rod and piston pin.

Measure the piston at the piston skirt, at right angles to the piston pin, at a

distance

C,.

Guideline

Distance

Piston - diameter

Size I

Size II

•

Info

27 mm (1.06 in)

87.965 ... 87.975 mm (3.46318 ...

3.46358 in)

87.976 ... 87.985 mm (3.46362 ...

3.46397 in)

Piston dimensions

are marked on the piston head.

18.4.16 Measuring the piston/cylinder mounting clearance

302699-10

Check/measure the cylinder. (

I!!',!!

p. 159)

Check/measure the piston. (

I!!',!!

p. 160)

The smallest piston/cylinder mounting clearance equals the smallest cylinder bore

diameter minus the largest piston diameter. The largest piston/cylinder mount

ing clearance equals the largest cylinder bore diameter minus the smallest piston

diameter.

Summary of Contents for FE 350 2015

Page 1: ...PIONEERING SINCE 1903 REPAIR MANUAL2015 FE 350 EU FE 350 AU FE 350 US FE 350S US Art no 340301 Sen 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: ...the steering head bearing 36 7 8 9 2 HANDLEBAR CONTROLS 38 7 1 7 2 7 3 7 4 7 5 Handlebar position 38 Adjusting the handlebar position 38 Adjusting the basic position of the clutch lever 38 Checking the routing of the throttle cable 39 Checking the play in the throttle cable 39 7 6 Adjusting the play in the throttle cable 40 FRAME 41 8 1 Removing the engine guard 41 8 2 Installing the engine guard ...

Page 5: ...6 Recharging the battery 109 15 7 Checking the charging voltage 110 15 8 Checking the quiescent current 110 16 BRAKE SYSTEM 111 17 16 1 Checking the front brake linings 111 16 2 Changing the front brake linings 111 16 3 Checking free travel of hand brake lever 113 16 4 Adjusting the basic position of the hand brake lever FE 350 US 114 16 5 Adjusting free travel of hand brake lever FE EU AU FE 350S...

Page 6: ...aft 173 18 4 39 Checking the transmission 174 18 4 40 Assembling the main shaft 175 4 18 4 41 Assembling the countershaft 176 18 5 Engine assembly 177 18 5 1 Installing the crankshaft 177 18 5 2 Installing the transmission shafts 177 18 5 3 Installing the shift forks 178 18 5 4 Installing the shift drum 178 18 5 5 Installing the shift rails 178 18 5 6 Installing the left engine case 179 18 5 7 Ins...

Page 7: ... absorber 216 25 10 Chassis tightening torques 217 26 CLEANING CARE 219 26 1 Cleaning the motorcycle 219 26 2 Checks and maintenance steps for winter operation 220 27 STORAGE 221 27 1 Storage 221 27 2 Preparing for use after storage 221 28 SERVICE SCHEDULE 222 28 1 Service schedule 222 28 2 Service work as additional order 223 29 WIRING DIAGRAM 224 29 1 Page 1 of 8 FE EU 224 29 2 Page 2 of 8 FE EU...

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

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

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

Page 11: ...he type label O is fixed to the front of the steering head FE 350S US The type label O is fixed to the front of the steering head The additional type label for Canada is fixed to the front of the front pipe 4 3 Key number FE EU AU FE 350S US FE EU AU The key number O for the steering lock is stamped onto the key connector 402247 10 ...

Page 12: ...indicated on the KEYCODECARD Info I You need the key number to order a spare key Keep the KEYCODECARD in a safe place 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 Shock absorber article number O is stamped on the top of the shock absorber above the adjusting ring towards the engine side ...

Page 13: ...oot and lean the motorcycle on it Info I When you are riding the side stand must be folded up and secured with the rubber band Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Engine damage High...

Page 14: ...in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Info Press the starter for a maximum of 5 seconds Wait for at least 5 seconds before trying again Shift transmission to neutral FE 350S US Turn the key in the ignition lock to the position 0 Turn th...

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

Page 16: ...he dust boots If this dirt is not removed the oil seals behind can start to leak Warning Danger of accidents Oil or grease on the brake discs reduces the brak ing effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Clean and oil the dust boots and inner fork tubes of both fork legs I Universal oil spray I p 287 Press the dust boots back...

Page 17: ...ork Remove screws O and take off the clamp Remove the cable tie s Remove screws and take off the brake caliper 10 Nm 7 4 lbf ft Allow the brake caliper and brake line to hang tension free to the side FE EU AU US Release screws D Take out the left fork leg Release screws C Take out the right fork leg FE 350S US Release screws D Take out the left fork leg Release screws C Take out the right fork leg...

Page 18: ...Nm 11 1 lbf ft Loctite 243 Position the brake line wiring harness and clamp Mount and tighten screws 0 Finishing work Install the front wheel 0 p 94 Install the headlight mask with the headlight 0 p 89 Check the headlight setting 0 p 127 Removing the fork rotector C00565 10 Preparatory work Switch off all power consumers and switch off the engine Remove the headlight mask with the headlight I p 88...

Page 19: ...le the fork legs p 17 Remove the spring p 19 Disassemble the cartridge p 20 Disassemble the piston rod il ll p 21 Disassemble the hydrostop unit il ll p 22 Disassemble the seal ring retainer p 23 Check the fork legs p 23 Assemble the seal ring retainer p 24 Assemble the hydrostop unit p 25 Assemble the piston rod a p 25 Assemble the cartridge a p 27 110 Nm 7 4 lbf ft 17 0 f 8 Assemble the fork leg...

Page 20: ...he outer tube down Drain the fork oil Clamp the fork leg with the axle clamp Release hydrostop unit 0 and remove it Info I Do not use an impact wrench Place a pan underneath since oil will run out Remove the cartridge from the fork leg I Press out tool T14051 p 299 Info I Removing the O ring seat from the cartridge usually requires the applica tion of force Remove dust boot 3 Remove fork protectio...

Page 21: ... Info I The lower sliding bushing must be pulled out of its bearing seat Remove the upper sliding bushing Info Do not use a tool pull the ends apart slightly by hand Take off the lower sliding bushing Take off support ring Take off seal ring a Take off lock ring Take off dust boot D Unclamp the fork leg The steps are identical for both fork legs Preparatory work Disassemble the fork legs l l p 17 ...

Page 22: ... e Info The steps are identical for both fork legs 202480 10 201726 12 Preparatory work Disassemble the fork legs ill p 17 Remove the spring ill p 19 Main work Degrease piston rod O and clamp it in the vise I Clamping stand T14049S ill p 299 Remove adjusting tube Unscrew spring guide CD Remove spring seat 8 Pull the piston rod out of the cartridge Clamp the tube of the cartridge into a vise I Clam...

Page 23: ... 10 Preparatory work Disassemble the fork legs a p 17 Remove the spring a p 19 Disassemble the cartridge a 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 a p 299 Release hydrostop needle O and remove it from the piston rod The valve usually remains in the hydrostop needle Info I e silver hydrostop needle on compressi...

Page 24: ... be used for this Disassembling the hydrostop unit Info The steps are identical for both fork legs Preparatory work Disassemble the fork legs a p 17 Main work Mount the hydrostop unit on a fitting hexagon socket and clamp into a vice Remove sleeve O Remove shim stack 8 Remove adapter D Remove hub C with washers C Info I It is possible that only one washer or no washer is present Remove the O ring ...

Page 25: ...19 Disassemble the cartridge p 20 Main work Remove pilot bushing support O Remove 0 ring 8 and seal ring 8 Condition The fork legs have been disassembled Check the inner tube and axle clamp for damage If there is damage Change the inner tube Measure the outside diameter at multiple locations of the inner tube Outside diameter of inner tube 47 975 48 005 mm 1 88878 1 88996 in If the measured value ...

Page 26: ...e of the sliding bushings 24 If the bronze colored layer f under sliding layer is visible or the surface is rough e 200665 10 200666 10 Change the sliding bushings Check the spring length Guideline I Spring length with preload spacer s I 472 mm 18 58 in If the measured value is larger than the specified value Reduce the thickness of the preload spacers If the measured value is smaller than the spe...

Page 27: ...I 7 Nm 5 2 lbf ft Mount shim stack with the smaller washers facing downward Mount and tighten sleeve Guideline I Hydrostop unit sleeve I M6x0 5 Check distance 6 and total length C of the hydrostop Guideline I 7 Nm 5 2 lbf ft Hydrostop distance 1 5 mm 0 059 in Hydrostop length If the dimensions are out of tolerance Add or remove washers 0 108 5 109 5 mm 4 272 4 311 in The steps are identical for bo...

Page 28: ...n the piston Lubricate the piston ring I Fork oil SAE 4 48601166S1 p 284 Mount the piston with chamfer f facing down Mount the rebound shim stack Ci with the smaller washers facing upward Press the piston downward against the spring The piston should not squeeze the shims Position valve in the hydrostop needle fD Mount and tighten the hydrostop needle Guideline I Hydrostop needle on piston rod Inf...

Page 29: ...acer If the length is out of tolerance Correct the preload spacers 46 mm 1 81 in Position the spring with the preload spacers in the reservoir Position sleeve C in the reservoir Clamp the tube of the cartridge into a vise I Clamping stand T14049S 1 1 p 299 Slide reservoir 0 onto the tube Info I Hold the sleeve in the reservoir to prevent it from sliding out Mount lock ring D Mount seal ring retain...

Page 30: ...h mark REB no brake caliper holder red adjuster e 8 8 201714 10 Preparatory work Assemble the hydrostop unit ll ll p 25 Main work Clamp the inner tube with the axle clamp Guideline I Use soft jaws Mount special tool I Protecting sleeve T1401 J p 298 Lubricate and mount dust boot O I Lubricant T511 0 p 286 Info I Always change the dust boot seal ring lock ring and support ring Mount the sealing lip...

Page 31: ...ger section of the special tool I Mounting tool T14040S I p 298 Push the sliding bushing all the way into the outer tube Position the support ring Hold the seal ring with the shorter section of the special tool I Mounting tool T14040S I p 298 Push the seal ring and support ring all the way into the outer tube Mount lock ring Info The lock ring must engage audibly Mount dust boot O Mount fork prote...

Page 32: ...lightly Air bubbles emerge and the cartridge is bled Keep bleeding until no more air bubbles emerge The piston rod moves out automatically to the middle of the total stroke distance Info I When fully bled the correct air chamber length is achieved automatically Position spring Pull the spring down Mount screw cap Info I When assembling ensure that the screw caps are correctly mounted according to ...

Page 33: ...clicks Sport 11 clicks Compression damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks Turn counterclockwise by the number of clicks corresponding to the fork type Alternative 2 Warning Danger of accident Modifications to the suspension setting may seriously alter the handling characteristic Extreme modifications to the suspension setting may cause a serious deterioration in the handling ...

Page 34: ...work FE EU AU US Open cable holder O in front of the right radiator and detach the wiring har ness FE 3505 US Open cable holder O in front of the right radiator and detach the wiring har ness Remove screw Remove screw D take off the upper triple clamp with the handlebar and set it aside Info I Cover the components to protect them against damage Do not kink the cables and lines Remove O ring 8 Remo...

Page 35: ... not tighten yet Position the clutch line in the guide above the voltage regulator Position the fork legs Bleeder screws 0 are positioned toward the front Info I The compression damping is located in the left fork leg COMP white adjusting screw The rebound damping is located in the right fork leg REB red adjusting screw Grooves are milled into the side of the upper end of the fork legs The sec ond...

Page 36: ... screws Ci Guideline Screw front brake caliper M8 Mount the cable tie s 25 Nm 18 4 lbf ft 112 Nm 8 9 lbf ft Loctite 243 17 Nm 12 5 lbf ft 17 Nm 12 5 lbf ft Loctite 243 34 Position the brake line wiring harness and clamp Mount and tighten screws G Finishing work Install the front fender a p 87 Install the front wheel a p 94 Install the headlight mask with the headlight p 89 Check that the wiring ha...

Page 37: ...steering head bearing a p 36 Move the handlebar to and fro over the entire steering range It must be possible to move the handlebar easily over the entire steering range There should be no detectable detent positions If detent positions are detected Adjust the play of the steering head bearing a p 36 Check the steering head bearing and replace if necessary Finishing work Remove the motorcycle from...

Page 38: ...harness throttle cables and brake and clutch lines can move freely and are routed correctly Check the play of the steering head bearing p 35 Remove the motorcycle from the lift stand ll l p 11 Check the headlight setting ll l p 127 Adjusting the la of the steering head bearing Preparatory work Raise the motorcycle with a lift stand p 11 Main work FE EU AU US Release screws O Remove screw 8 Loosen ...

Page 39: ... ft Using a plastic hammer tap lightly on the upper triple clamp to avoid strains Tighten screws O Guideline Screw top triple clamp Mount and tighten screw Guideline Screw top steering stem M8 Finishing work M8 17 Nm 12 5 lbf ft Check the play of the steering head bearing p 35 Remove the motorcycle from the lift stand p 11 17 Nm 12 5 lbf ft Loctite 243 ...

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

Page 41: ...e routing Both throttle cables must be routed to the throttle valve body side by side behind the handlebars and above the fuel tank bearing If the throttle cable is not routed as specified Correct the throttle cable routing Finishing work Install the fuel tank p 79 Mount the seat p 77 in the throttle cable Check the throttle grip for smooth operation Move the handlebar to the straight ahead positi...

Page 42: ...le cable Preparatory work Remove the seat Ill p 77 Remove the fuel tank Ill p 77 Check the routing of the throttle cable p 39 Main work Move the handlebar to the straight ahead position Push back sleeves O Loosen nut Turn adjusting screw fD in as far as possible Loosen nut 8 Turn adjusting screw 0 so that there is play 6 in the throttle cable at the throttle grip Guideline I Play in throttle cable...

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

Page 45: ...in rear wheel sa unloaded Preparatory work Raise the motorcycle with a lift stand p 11 Main work Measure the distance as vertically as possible between the rear axle and a fixed point such as a mark on the side cover Make note of the value as measurement f Finishing work Remove the motorcycle from the lift stand il l p 11 Checkin the static sag of the shock absorber Measure distance f of rear whee...

Page 46: ...ding sag 1100 mm 3 94 in If the riding sag differs from the specified measurement Adjust the riding sag 0 p 45 Adjusting the s ring reload of the shock absorber Caution Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Info Before changing the ...

Page 47: ...he right side cover a p 77 Remove the motorcycle from the lift stand a p 11 Preparatory work Raise the motorcycle with a lift stand I p 11 Remove the right side cover a p 76 Remove the main silencer a p 71 Remove the seat a p 77 Remove the manifold a p 68 Remove shock absorber a p 46 After removing the shock absorber clean it thoroughly Main work Choose and mount a suitable spring Guideline Spring...

Page 48: ...move the seat a p 77 Remove the manifold I p 68 Main work Carefully take the shock absorber out of the vehicle toward the top Main work Carefully position the shock absorber into the vehicle from above Finishing work Install the manifold i ll p 69 Mount the seat i ll p 77 Install the main silencer a p 71 Install the right side cover I p 77 Remove the motorcycle from the lift stand I p 11 Checkin t...

Page 49: ... there is damage or wear Change the spacers Check the shaft seal rings for damage and wear If there is damage or wear Change the shaft seal rings Check dimension 6 303096 10 I 54 91 55 00 mm 2 1618 2 1654 in If dimension 6 is below the specified value Add the necessary spacing washers Position angle lever Mount fitting D but do not tighten yet Guideline I Nut angle lever on swingarm I M14x1 5 47 I...

Page 50: ...3 lbf ft I Nut angle lever on swingarm I M14x1 5 Servicing the shock absorber Caution Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided 201457 01 Condition The shock absorber has been removed Remove the spring a p 49 Disassemble the damper I p ...

Page 51: ...no longer under tension I Hook wrench T106S p 296 Remove ring 8 Remove spring retainer and intermediate washer C Remove the spring Disassembling the dam er 0 Preparatory work Remove the spring p 49 Main work Note down the current state of rebound damping O and compression damp ing 8 Completely open the adjusters of the rebound and compression damping Remove rubber cap of the reservoir Open screw C...

Page 52: ...mbly tool T1216 a p 297 Remove lock ring Info Do not scratch the inner surface Remove the piston rod Remove adjusting ring with the intermediate washer Drain the oil Remove compression adjuster Remove the spring and piston iston rod Preparatory work Remove the spring a p 49 Disassemble the damper a p 49 50 ...

Page 53: ...n as a unit Remove piston 8 Remove compression shim stack 0 Info I Place the compression shim stack onto a screwdriver and set it down as a unit Remove rebound washer D Remove seal ring retainer Remove locking cap and rubber buffer Disassembling the seal ring retainer 201405 10 Preparatory work Remove the spring p 49 Disassemble the damper p 49 Disassemble the piston rod p 50 Main work Remove spri...

Page 54: ...ing O onto the special tool I Press drift T1504 l t J p 299 Position the pilot bushing in the seal ring retainer using the special tool I Press drift T1504 p 299 Support seal ring retainer 8 with sleeve f of the special tool Press the pilot bushing all the way in I Assembly tool T150S 0 p 299 Lubricate the special tool Shock absorber fluid SAE 2 5 50180751S1 a p 284 Calibration pin T1205 I p 297 S...

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

Page 56: ... tool f underneath and press out heim joint D with special tool I Pressing tool T1207S il l p 297 Position the new heim joint O and the special tool into a vise as shown Guideline I Use soft jaws I Pressing tool T1206 il l p 297 Press the heim joint all the way in Press the heim joint against the lock ring using the special tool I Pressing tool T1207S il l p 297 Mount the second lock ring 8 Mount ...

Page 57: ...ing sleeve T1204 a p 296 Lubricate the sealing lip of the dust boot I Lubricant T625 l ll p 286 Mount washer Position washer Don seal ring e Grease seal ring 8 and mount with the washer facing downward I Lubricant T511 l t I p 286 Mount centering disk Mount rebound rubber 0 Lubricate the groove of the O ring I Lubricant T158 I p 286 Mount O ring Mount spring 55 ...

Page 58: ...unting sleeve T1215 a p 297 Grease the dust boot and push seal ring retainer onto the piston rod I Lubricant T625 a p 286 Remove the special tool Mount rebound washer 8 with the cut out facing downward Mount the compression shim stack 0 with the smaller shims facing downward Sand both sides of piston D on a surface plate using 1200 grit sandpaper Clean the piston Assemble the piston Guideline View...

Page 59: ...icate the threads I Lubricant T159 a p 286 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...

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: ...10 Remove the screw of the filling port Install adapter O on the damper Info I Tighten only hand tight without the use of tools Connect the adapter O to connector of the vacuum pump I Vacuum pump T1240S l ll p 298 Clamp the damper with soft jaws or hold it as shown in the figure Info I Clamp the damper only lightly The filling port must be at the highest point The piston rod slides in and out duri...

Page 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: ...ight of rider 75 85 kg 165 54 N mm 308 lb in 187 lb Weight of rider 85 95 kg 187 57 N mm 325 lb in 209 lb Mount intermediate washer 8 and spring retainer C Mount ring C Alternative 1 Tension the spring to the prescribed amount by turning the adjusting ring Guideline I Spring preload I Hook wrench T106S p 296 Alternative 2 Warning 113 mm 0 51 in Danger of accident Modifications to the suspension se...

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 0 p 11 Remove the rear wheel p 96 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: ...vot Remove the swingarm Main work Position the swingarm Mount the swingarm pivot Mount and tighten nut O Guideline Nut swingarm pivot Lift the swingarm Mount and tighten fitting Guideline Nut angle lever on swingarm Mount the chain M16x1 5 M14x1 5 Connect the chain with connecting link CD Guideline 100 Nm 73 8 lbf ft I 80 Nm 59 lbf ft The closed side of the chain joint lock must face in the direct...

Page 67: ...screws chassis I 25 Nm 18 4 lbf ft I Position the brake caliper and pull it back Position the brake line in the guide Finishing work Install the rear wheel a p 97 Remove the motorcycle from the lift stand a p 11 Changing the swingarm bearing Info These operations are the same on both swingarm bearings Preparatory work Raise the motorcycle with a lift stand li l p 11 Remove the rear wheel ta p 96 R...

Page 68: ...01813 10 G01814 10 Main work Remove collar bushings 0 Remove bushing 8 Remove shaft seal rings D using a suitable tool Press out the bearing with a suitable tool Press in the new bearing until it is flush using a suitable tool 66 ...

Page 69: ...ings CD Mount bushing Grease the shaft seal rings I Long life grease 0 p 286 Position collar bushings O with the shoulder facing inward Finishing work Install the swingarm l l l p 64 Install the rear wheel l l l p 97 Remove the motorcycle from the lift stand l i p 11 67 ...

Page 70: ...nd JI p 11 Remove the seat JI p 77 Remove the right side cover JI p 76 Remove the main silencer JI 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: ... EU Remove the fuel tank I p 77 69 Disconnect plug in connector fD of the lambda sensor and remove the cable binder Remove springs I Spring hook 50305017000 I p 289 Remove screw and take off the manifold Main work Position the manifold and mount springs O I Spring hook 50305017000 p 289 ...

Page 72: ...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 screw...

Page 73: ...e main silencer Mount screws O but do not tighten yet Reconnect spring I Spring hook 50305017000 p 289 Tighten screws O Guideline I Remaining screws chassis Finishing work Install the right side cover la p 77 Changing the glass fiber arn filling in the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down before perf...

Page 74: ... 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 ring D...

Page 75: ...p 71 e Main work CG Remove screws O and take off silencer cap with O ring Warning Danger to health Soot particles irritate the eyes and mucuous membranes Wear suitable breathing and eye protection when cleaning the main silencer and carbon screen Clean main silencer housing C and screen 0 of the spark arrestor with compressed air Mount a new 0 ring on silencer cap Position silencer cap Mount and t...

Page 76: ... filter 11 4 Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Preparatory work Remove the air filter box cover l J p 74 Main work Push air filter holding bracket O toward the air filter at position f and detach it at end G Swivel the air filter...

Page 77: ...er with fuel or petroleum since these substances attack the foam Sealin the air filter box 401559 01 Preparatory work Remove the air filter box cover a p 74 Remove the air filter a p 74 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly I Air filter cleaning agent p 286 Info I Only press the air filter to dry it never wring it out Oil the dry air filte...

Page 78: ...fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Warning Environmental hazard Improper handling of fuel is a danger to the e...

Page 79: ...e fuel in the fuel tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a...

Page 80: ...stances 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 EU AU Disconnect the connector of the horn Remove screws 8 with the collar bushings and horn FE US Remove screws 8 with the collar bushings Remove screw C with the rubber bushing 78 Pull both...

Page 81: ...ase of fuel contact with the eyes Change your clothing in case of fuel spills on them Main work Check the routing of the throttle cable p 39 79 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 I 10Nm ...

Page 82: ... plug in connection O of the fuel line thoroughly with compressed air Info 80 I Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Disconnect the plug in connection of the fuel line Info I Remaining fuel may flow out of the fuel hose Pull fuel screen 8 out of the connecting piece Insert the new fuel screen all the way into the connecting pie...

Page 83: ...ls on them Keep fuels correctly in a suitable canister and out of the reach of children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system 305313 10 305314 10 305315 10 305317 10 Preparatory work Drain the fuel from the fuel tank into a suitable container Remove the seat a p 77 Remove the fu...

Page 84: ...deline I Fuel connection on fuel pump Mount and tighten screws Guideline I Screw fuel pump Finishing work Install the fuel tank a p 79 Mount the seat a p 77 I EJOT PT 10 Nm 7 4 lbf ft 15 Nm 11 1 lbf ft 10 Nm 7 4 lbf ft I 3 Nm 2 2 lbf ft 12 11 Changing the fuel pump mDanger Fire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not refuel th...

Page 85: ...environment Do not allow fuel to enter the groundwater the soil or the sewage system 305313 10 305314 10 Preparatory work Drain the fuel from the fuel tank into a suitable container Remove the seat a p 77 Remove the fuel tank a p 77 Main work Remove nut O with the gasket Remove fuel connection 8 with the gasket Remove screws 8 Pull out the fuel pump Position the fuel pump Mount fuel connection 8 w...

Page 86: ...ister and out of the reach of children Condition The fuel tank is full Ensure that the battery voltage does not drop below 12 5 V The diagnostics tool is disconnected Thoroughly clean the plug in connection of the fuel line using compressed air Info I Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Press on the small metal plate and disco...

Page 87: ... the Function test of fuel pump control actuator test by pressing the Quit button Remove the special tools Join the fuel hose connection Removin the activated charcoal filter FE 350S US Preparatory work Remove the seat p 77 Remove the fuel tank p 77 Main work Detach rubber strap O Hang the activated charcoal filter to the side Detach hoses 8 and CD Remove the activated charcoal filter Push back ho...

Page 88: ... and tighten fittings O Guideline Screw engine brace Mount the hose Position hose clamp 8 Mount hoses fD and 8 M8 Position the activated charcoal filter Mount rubber band 0 Finishing work Install the fuel tank p 79 Mount the seat p 77 33 Nm 24 3 lbf ft Loctite 2701 TM 86 ...

Page 89: ...ove the headlight mask with the headlight p 88 Main work Remove screws O and Remove the front fender Main work Position the front fender Mount and tighten screws O and Guideline I Remaining screws chassis Finishing work Install the headlight mask with the headlight p 89 Check the headlight setting p 127 I10Nm 7 41bf ft 87 ...

Page 90: ...light mask up and swing it forward Detach plug in connectors C and take off the headlight mask with the head light FE 350 US Detach brake line O and wiring harness 8 Release rubber straps Slide the headlight mask up and swing it forward Detach plug in connector C and take off the headlight mask with the head light FE 350S US Detach brake line O and wiring harness 8 Release rubber straps 8 Slide th...

Page 91: ...ct plug in connectors O Position the headlight mask and secure it with rubber bands 8 The holding lugs engage in the fender Position brake line CD and wiring harness e in the brake line guide FE 350 US Connect plug in connector O Position the headlight mask and secure it with rubber bands 8 The holding lugs engage in the fender ...

Page 92: ... line guide FE 350S US Connect plug in connectors O Position the headlight mask and secure it with rubber bands 8 The holding lugs engage in the fender Position brake line CD and wiring harness e in the brake line guide Finishing work Check the headlight setting I p 127 90 ...

Page 93: ...mpact 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 re...

Page 94: ...er of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary damage The spokes break due to being overloaded if they are too tightly tensioned If the tension in the spokes is too low then lat eral and radial run out will form in the wheel Other spokes will become looser as a result Check spoke tension regularly and in particular on a new vehicle Strike ea...

Page 95: ...orcycle 400998 01 Front wheel Check for lateral and radial run out of the rims Lateral runout Outside the rim joint 1 8 mm 0 071 in Radial runout Outside the rim joint 1 8 mm 0 071 in If the measured value is greater than the specified value Center the rim Info I Center the rim by pulling the spoke nipple on the other side of the rim run out If there is significant deformation change the rim Corre...

Page 96: ... wheel bearing is damaged or worn Change the front wheel bearing p 95 Clean and grease the shaft seal rings O and bearing surface f of the spacers I Long life grease p 286 Insert the spacers Lift the front wheel into the fork position it and insert the wheel spindle The brake linings are positioned Mount and tighten screw 8 Guideline I Screw front wheel spindle I M24x1 5 I 45 Nm 33 2 lbf ft I Acti...

Page 97: ...10 3 lbf ft Loctite 243 14 6 5 Changing the front wheel bearing Preparatory work Raise the motorcycle with a lift stand I p 11 Remove the front wheel I p 93 Main work Remove shaft seal rings O and 8 Press out bearing 8 using a suitable tool Info I Spacing tube e can be pushed aside Remove the spacing tube Press out bearing 0 using a suitable tool Press in the new bearing 0 all the way using a suit...

Page 98: ...ush back the brake piston Info 96 I Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove nut O Remove chain adjuster Withdraw wheel spindle D only enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Remove the chain from the rear sprocket Info Cover the components to protect them against damage...

Page 99: ...eel into the swingarm position it and insert wheel spindle Mount the chain The brake linings are correctly positioned Position chain adjuster Mount nut 8 but do not tighten it yet Make sure that chain adjusters are fitted correctly on adjusting screws 0 Check the chain tension l p 98 Tighten nut 8 Guideline I Nut rear wheel spindle Info I M20x1 5 I 80 Nm 59 lbf ft I The wide adjustment range of th...

Page 100: ...d too much the chain engine sprocket rear sprocket transmission and rear wheel bearings wear more quickly Some components may break if overloaded If the chain is too loose the chain may fall off the engine sprocket or the rear sprocket As a result the rear wheel locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the specification Preparat...

Page 101: ...n Turn adjusting screws D on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks f The rear wheel is then correctly aligned Tighten nuts Make sure that the chain adjusters C are fitted correctly on the adjusting screws D Tighten nut 0 Guideline I Nut rear wheel spindle Info I M20x1 5 I 80 Nm 59 lbf ft I The wide adjustm...

Page 102: ...ngine sprocket should also be changed New chains wear out faster on old worn sprockets Check the chain sliding guard for wear If the lower edge of the chain pin is at the level of or below the chain sliding guard Change the chain sliding guard Check that the chain sliding guard is firmly seated If the chain sliding guard is loose Tighten the chain sliding guard Guideline Screw chain sliding guard ...

Page 103: ...ery dirty Clean the chain p 101 14 7 9 Cleaning the chain A Warning Danger of accidents Oil or grease on the tires reduces the road grip Remove the lubricant from the tires using a suitable cleaning agent Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary ...

Page 104: ...om the lift stand il p 11 Preparatory work Raise the motorcycle with a lift stand Ii p 11 Main work Remove screws O and 8 Remove the engine sprocket cover Have an assistant operate the rear brake Remove screw with washer Remove the rear wheel l J p 96 Remove connecting link C of the chain Info I Cover the components to protect them against damage Take off the chain Remove engine sprocket 0 102 ...

Page 105: ...f travel Install the rear wheel 1ll p 97 Have an assistant operate the rear brake Mount and tighten screw 8 with washer Guideline Screw engine sprocket M10 Position the engine sprocket cover Mount and tighten screw O Guideline I Screw clutch slave cylinder Mount and tighten screw Guideline I Remaining screws chassis Finishing work 60 Nm 44 3 lbf ft Remove the motorcycle from the lift stand a p 11 ...

Page 106: ...to the outside Press new bearing C all the way in from the outside to the inside Info 104 I Only press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in Clean grease and mount spacing tube 0 I Long life grease ilill p 286 Press new bearing C all the way in from the outside to the inside Info I Only press the bearing in via the outer ring otherwise the be...

Page 107: ...press it in until it is flush Mount lock ring The lock ring engages audibly Grease new shaft seal ring O and press it in until it is flush Finishing work Install the rear wheel ilill p 97 Remove the motorcycle from the lift stand ilill p 11 105 ...

Page 108: ...e the faulty main fuse Info I A defective fuse can be identified by the burned out fuse wire e A reserve fuse 8 is located in the starter relay Install a new main fuse I Fuse 58011109120 i l p 215 Check that the electrical equipment is functioning properly Tip I Insert the spare fuse so that it is available if needed Mount the protection caps Finishing work Install the air filter box cover i l p 7...

Page 109: ... 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 FE 3505 US Open fuse box cover O Remove the defective fuse Guideline Fuse 1 10 A EFI control unit Fuse 2 10 A fuel pump Fuse 3 10 A ignition Fuse 4 10 A high beam low beam parking light tail light license plate lamp horn brake light turn signal radiator fan Fuses r...

Page 110: ...ions Change the starter relay 108 601201 10 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Keep sparks and open flames away from the battery Only charge in well ventilated rooms In the event of skin cont...

Page 111: ...tact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Warning Environmental hazard Batteries contain environmentally hazardous materials Do not dispose of batteries as household waste Dispose of batteries at a collection point for used batteries Warning Environmental hazard Hazardous substances cause environmental d...

Page 112: ...cedure a p 11 Measure the voltage between the specified points Measuring point Plus Measuring point Ground I Charging voltage 5 000 rpm 1 13 5 15 0 V Checking the quiescent current If the displayed value is less than the specified value Check the plug in connections from the alternator to the voltage regulator Check the plug in connectors from the voltage regulator to the wiring har ness Check the...

Page 113: ... doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the ...

Page 114: ...lly 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 C pull out pin 0 and remove the brake linings Clean the brake caliper and brake calip...

Page 115: ...r Checking free travel of hand brake lever Warning Danger of accidents The brake system fails in the event of overheating If there is no free travel on the hand brake lever pressure builds up on the front brake circuit Set the free travel on the hand brake lever in accordance with the specification FE EU AU FE 350S US Push the hand brake to the handlebar and check free travel fj I Free travel of h...

Page 116: ...e pressure point moves towards the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding Checkin the front brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified valu...

Page 117: ...thing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Never ...

Page 118: ...in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the appl...

Page 119: ...f the brake fluid reservoir is prevented Tighten the bleeder screw Remove the bleeder bottle hose Mount the pro tection cap Disconnect the bleeding device Remove the bleeder cover Correct the brake fluid to level Q Guideline I Level Q I Brake fluid DOT 4 p 284 I 5 mm 0 2 in Position the cover with the membrane Mount and tighten the screws Info I Clean up overflowed or spilled brake fluid immediate...

Page 120: ...id reservoir is prevented Tighten the bleeder screw Remove the bleeder bottle hose Mount the pro tection cap Disconnect the bleeding device Remove the bleeder cover Correct the brake fluid to level Q Guideline I Level Q I Brake fluid DOT 4 p 284 I 5 mm 0 2 in Position the cover with the membrane Mount and tighten the screws Info I Clean up overflowed or spilled brake fluid immediately with water C...

Page 121: ... discs free of oil and grease Clean the brake discs with brake cleaner when necessary Warning Danger of accidents Brake linings which have not been approved alter the braking efficiency 119 Not all brake linings are tested and approved for Husqvarna motorcycles The structure and friction coefficient of the brake linings and thus their brake power may vary greatly from that of original brake lining...

Page 122: ...tion of the brake disc Insert the new brake linings insert pin C and mount cotter pins s Info I Always change the brake linings in pairs Make sure that decoupling plate is mounted on the piston side brake lining Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Add brake fluid to level 6 I Brake fluid DOT 4 a p 284 Moun...

Page 123: ...the foot brake lever individually loosen nut and turn screw CD accordingly Info I The range of adjustment is limited Turn push rod 0 accordingly until you have free travel 6 If necessary adjust the basic position of the foot brake lever Guideline I Free travel at foot brake lever Hold screw CD and tighten nut Guideline I Nut foot brake lever stop Hold push rod 0 and tighten nut 8 Guideline I Remai...

Page 124: ...rake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front...

Page 125: ...cted area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly ...

Page 126: ...100 a p 288 Open bleeder screw 0 by approx one half turn Info I Bleed until new brake fluid emerges from the bleeder bottle hose without bubbles Tighten the bleeder screw Close shut off valve D Open the bleeder screw again until no more brake fluid emerges Info I This prevents overfilling of the brake fluid reservoir Tighten the bleeder screw Remove the hose of the bleeder bottle Mount the pro tec...

Page 127: ...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 128: ...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 129: ...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 130: ...n the lower mark for a motorcycle with driver instructions on how to apply the mark Checking the headlight setting Info I If you have a payload you may have to correct the headlight range Tighten screw O FE 3505 US Loosen screw O Adjust the headlight range by pivoting the headlight Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with driver instruct...

Page 131: ... Remove the main silencer ll p 71 FE EU AU US Remove the seat p 77 Remove the fuel tank ll p 77 FE 350S US Remove the seat p 77 Remove the fuel tank p 77 Remove the activated charcoal filter 0 p 85 Main work Remove screw O Disconnect the negative cable of the battery Loosen hose clip 8 Pull back the protection cap Unplug connector fs Push back hose clamp C Pull off the vent hose 129 ...

Page 132: ...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 289 Remove screw Take off the manifold Push back the cover Remove nut Gi Take off the cable 130 ...

Page 133: ...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 131 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 134: ...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 132 ...

Page 135: ...ghten 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 5 133 I 60 Nm 44 3 lbf ft I 100 Nm 73 8 lbf ft Loctite 2701TM 60 Nm 44 3 lbf ft 100 Nm 73 8 lbf ft...

Page 136: ... and tighten screws Guideline I Screw clutch slave cylinder M6 Mount the chain Connect the chain with connecting link Guideline 134 110Nm 7 41bf ft The closed side of the chain joint lock must face in the direction of travel Position the engine sprocket cover Mount and tighten screw 48 Guideline I Screw clutch slave cylinder Mount and tighten screw 41 Guideline I Remaining screws chassis Mount spr...

Page 137: ...Position the cover Position the manifold and mount springs 4D I Spring hook 50305017000 l p 289 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 135 I 25 Nm 18 4 lbf ft I Loctite 2701 TM ...

Page 138: ...s Guideline Screw subframe Remove screw Mount and tighten screw Guideline Screw subframe M8 M8 Repeat these steps on the opposite side Mount the vent hose Position hose clamp G Plug in connector Position the protection cap Position and tighten hose clip 35 Nm 25 8 lbf ft 35 Nm 25 8 lbf ft 136 Loctite 2701 TM Loctite 2701 TM ...

Page 139: ... fitting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Start the engine and check that it is oil tight Switch off the engine Check the engine oil level p 202 Check ...

Page 140: ...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 138 ...

Page 141: ...lter housing I Circlip pliers reverse 51012011000 l l p 289 Remove the spark plug using special tool O I Spark plug wrench 77229172000 p 295 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 139 ...

Page 142: ...140 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 143: ... 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 141 ...

Page 144: ...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 292 Attach special tool CD to the rotor Hold it tight using the special tool and pull off the rotor by turning the sc...

Page 145: ...143 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 146: ...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 144 ...

Page 147: ...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 0 145 ...

Page 148: ... special tool Loosen nut O I Clutch holder 51129003000 i J p 290 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 14...

Page 149: ...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 150: ... 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 151: ...292 Mount special tool 8 with the appropriate screws I Puller 77229048000 l t I p 295 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...

Page 152: ...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 150 ...

Page 153: ...e 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 th...

Page 154: ...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 155: ...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 156: ...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 157: ...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 158: ...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 I p 290 Repeat the operation on the opposite side Ensure that the new crankshaft bearing inner race is flush Info 156 I After replacing the crankshaft bearings the crankshaft end p...

Page 159: ... 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 a p 293 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 ax...

Page 160: ...f 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 I p 156 Calculate the thickness of the compensating disks Add or remove compensating disks equally on both sides Info...

Page 161: ... improved performance low wear and a lightweight cylinder 18 4 14 Checking measuring the cylinder 305004 10 Check the cylinder bearing surface for damage If the cylinder bearing surface is damaged Change the cylinder and piston Measure the cylinder diameter at several locations on the 0 and 0 axes using a micrometer to identify oval wear Guideline Cylinder drill hole diameter Size I Size II Info 8...

Page 162: ...ston ring with the marking facing upward Check the piston pins for discoloration or signs of wear If the piston pin shows severe discoloration signs of wear Change the piston pin Place the piston pin in the connecting rod and check the seating for play If the piston pin seating has excessive play Change the connecting rod and piston pin Measure the piston at the piston skirt at right angles to the...

Page 163: ...e the cylinder 0 p 159 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 0 p 295 Mount the camshaft on the special tool Remove screw 8 Pull camshaft gear D off of the camshaft I...

Page 164: ...amshafts 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 p 291 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 oi...

Page 165: ...ide accord ing to their normal built in position Pre tension the valve spring using the special tool Valve spring mounter 59029019000 lllll p 290 Insert for valve spring lever 77229060000 p 295 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 va...

Page 166: ... 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 167: ...der 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 ch...

Page 168: ...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 169: ...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 167 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 170: ...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 171: ...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 172: ...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 173: ...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 174: ...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 172 Check clearance O between the sliding plat...

Page 175: ...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 10 173 ...

Page 176: ...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 177: ...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 178: ...ershaft Info Use new lockrings with every repair Preparatory work Carefully lubricate all parts before assembling Checkthe transmission i I p 174 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 lo...

Page 179: ...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 177 ...

Page 180: ... 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 181: ...n 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 182: ... 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 183: ...oil pump idler gear with the washer Mount washers 41 Mount lock ring G Insert needle roller O Position suction pump 8 The rounded sides of the external rotor face the engine case Crank the oil pump gear wheel and ensure that it can move easily Mount O ring Position the oil pump cover C Mount and tighten screws 0 Guideline Screw oil pump cover M5 6Nm 4 4 lbf ft Loctite 243 181 ...

Page 184: ... 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 185: ...hub M18x1 5 I Clutch holder 51129003000 p 290 Secure the nut with the lock washer Thoroughly oil the clutch facing discs 100 Nm 73 8 lbf ft Loctite 243 183 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 186: ...or distortion I Feeler gauge 59029041100 a p 291 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 i ll p 291 I Spring washer distortion I 0 0 10 mm 0 0 0039 in If the specified value is not rea...

Page 187: ...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 188: ...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 186 I 6 Nm 4 4 lbf ft 10 Nm 7 4 lbf ft Thread oiled with engine oil cone degreased ...

Page 189: ... the 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 187 Cover the engine case opening with a cloth Thread the timing chain through the cha...

Page 190: ...s 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 a...

Page 191: ...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 192: ...al tool I Adjustment bush bridge 77229050044 0 p 295 The valves are not activated 190 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 193: ...r installation p 169 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 292 The timing chain tensioner u...

Page 194: ... 68 F I 0 13 0 18 mm 0 0051 0 0071 in I Feeler gauge 59029041100 a p 291 If the valve clearance does not meet specifications Adjust the valve clearance a p 192 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 a p 140 Remove the camshaft a p 141 Raise cam levers O 110 Nm 7 4 lbf ft ...

Page 195: ... 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 196: ... wrench 77229172000 I p 295 194 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 wit...

Page 197: ...e 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 a p 293 Remove...

Page 198: ...d and purple in color Oil seals and clutch lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container FE EU AU US Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi tion Remove screws O Remove cover with membrane 8 Check the fluid level I Fluid level below c...

Page 199: ... compliance with the applicable regulations FE EU AU US 197 Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi tion Remove screws O Remove cover with membrane D FE 350S US Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi tion Remove screws O Remove cover with membrane D Fill bleeding syringe 8 with the appropriate hydraulic fluid Bleed syring...

Page 200: ...bbles Now and then extract fluid from the master cylinder reservoir to prevent over flow Remove the bleeding syringe Mount and tighten screws bleeder screw Correct the fluid level of the hydraulic clutch Guideline I Fluid level below container rim 14 mm 0 16 in Position the cover with the membrane Mount and tighten the screws ...

Page 201: ...the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature Allow the cooling system and the engine to cool down before you open the radiator the radiator hoses or other compo nents of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a healt...

Page 202: ...cle upright on a horizontal surface Remove the radiator cap Check the coolant level in the radiator Coolant level f above the radiator fins 10 mm 0 39 in If the coolant level does not match the specified value 400243 10 Draining the coolant Warning Correct the coolant level I Coolant p 284 Mount the radiator cap Danger of scalding During motorcycle operation the coolant gets very hot and is under ...

Page 203: ...is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change ...

Page 204: ...tory work Stand the motorcycle upright on a horizontal surface Condition The engine is cold Check the engine oil level The engine oil reaches the lower edge of level viewer f Condition If the engine oil does not reach the lower edge of the level viewer Add engine oil l t p 205 The engine is at operating temperature Check the engine oil level Info I After switching off the engine wait one minute be...

Page 205: ...n a level surface Remove the engine guard il J 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 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 203 Insert the ...

Page 206: ... cover Stand the motorcycle upright 10 Nm 7 4 lbf ft Remove the oil filler plug with the 0 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 l l p 284 Info I Too little engine oil or poor quality engine oil results in premature wear to the engine Install and tighten the oil filler plug with 0 ring mDanger Danger of poisoning Exhaust gases a...

Page 207: ...in an enclosed space Start the engine and check that it is oil tight Finishing work Check the engine oil level l ll p 202 ressure Check the engine oil level l ll p 202 Remove the release screw of the chain adjuster Mount and tighten special tool O Guideline I Oil pressure adapter I M10x1 I Oil pressure adapter 77329006000 Ip 295 10 Nm 7 4 lbf ft Connect pressure tester 8 to the special tool withou...

Page 208: ... Warning Danger of burns Some vehicle components get very hot when the machine is driven Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water Remove the special tools Mount and tighten the release screw of the chain adjuster Guideline Screw unlocking of timing chain ten sioner M10x1 8 Nm 5 9 lbf ft 206 ...

Page 209: ...ring point1 Measuring point 2 Spark plug connector Resistance at 20 c 68 F If the specification is not reached Change the spark plug connector 3 75 6 25 kn Alternator checking the stator winding EZ 601211 10 Condition The stator is disconnected Preparatory work Remove the seat l t I p 77 Main work Stator winding measurement I check the resistance 0 Measure the resistance between the specified poin...

Page 210: ...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 211: ... 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 212: ...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 213: ...cted and running Execute Engine electronics Functions Delete adaptation values The adaptation values are deleted Select Engine electronics Measured values Coolant temperature sensor TW1 The coolant temperature is displayed during the initialization run Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient v...

Page 214: ...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 215: ... 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 lubricat...

Page 216: ...t 25 4 3 Fuel Totalfuel tank capacity 9 5 I 2 51 US gal approx FE EU AU Totalfuel tank capacity 8 5 I 2 25 US gal approx FE US I Fuel reserve approx 214 10 Nm 7 4 lbfft Loctite 243 10 Nm 7 4 lbfft Loctite 243 8 Nm 5 9 lbfft 10 Nm 7 4 lbfft 10 Nm 7 4 lbfft 14 Nm 10 3 lbfft Lub ricated with engine oil 10 Nm 7 4 lbfft 25 Nm 18 4 lbfft 15 Nm 11 1 lbfft 60 Nm 44 3 lbfft 15 Nm 11 1 lbfft 70 Nm 51 6 lbff...

Page 217: ... 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 overall weight 335 kg 739 lb 25 ...

Page 218: ...e Weight of rider 65 75 kg 143 165 lb Weight of rider 75 85 kg 165 187 lb Weight of rider 85 95 kg 187 209 lb 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 Sp...

Page 219: ... steering stem M8 Screw top triple clamp M8 Engine attachment bolt M10 Remaining nuts chassis M10 Remaining screws chassis M10 Screw bottom shock absorber M10 Screw handlebar holder M10 Screw top shock absorber M10 Nut fuel pump fixation M12 54 N mm 308 lb in 57 N mm 325 lb in 260 mm 10 24 in 10 bar 145 psi 30 mm 1 18 in 100 mm 3 94 in 490 mm 19 29 in I Shock absorber fluid SAE 2 5 50180751S1 0 p ...

Page 220: ... ft Nut linkage lever on angle lever M14x1 5 80 Nm 59 lbf ft Nut swingarm pivot M16x1 5 100 Nm 73 8 lbf ft Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Screw in nozzles cooling system M20x1 5 12 Nm 8 9 lbf ft Loctite 243 Screw front wheel spindle M24x1 5 45 Nm 33 2 lbf ft ...

Page 221: ...gentle water jet Spray dirty parts with a normal commercial engine cleaner and then brush off with a soft brush Info I Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to a dry vehicle always rinse the vehicle with water first After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the closure of the exhaust sy...

Page 222: ...e a p 219 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 223: ...otorcycle out of service add fuel additive Refuel Clean the motorcycle I p 219 Change the engine oil and oil filter clean the oil screen I p 203 Check the antifreeze and coolant level I p 199 Check the tire air pressure 0 p 91 Remove the battery 0 p 108 27 2 401058 01 Charge the battery Guideline Storage temperature of battery with out direct sunshine 0 35 C 32 95 F Store the vehicle in a dry loca...

Page 224: ...smooth operation I I Check correct the fluid level of the hydraulic clutch p 196 I I I Check the front brake fluid level a p 114 I I I Check the free travel of the hand brake lever I p 113 I Check the play of the steering head bearing 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 scre...

Page 225: ...heck camshaft and cam lever Change the connecting rod conrod bearing and crank pin Check the transmission and shift mechanism Check the oil pressure regulator valve Change the suction pump Check the force pump and lubrication system Change the timing chain Check the timing assembly Change all engine bearings Change the freewheel o One time interval Periodic interval 223 Annually Every 135 operatin...

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Page 227: ...29 WIRING DIAGRAM Components G10 Battery K10 Starter relay with main fuse M10 Starter motor S21 Electric starter button 225 ...

Page 228: ... 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 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 229: ...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 227 ...

Page 230: ... 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 231: ...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 229 ...

Page 232: ... AH 2 BY 4 D1 2 AK 2 AK 2 CV 4 00 X11 B76 B77 X17 P36 CV 4 BY 4 t 0 BY 4 NM CV 4 X17 X11 N N AK 2 N AK 2 CV 4 i D l H 2 l AH 2 n B Y 4 X14 D X18 X19 X13 i i I j cf j j I I I I C w C w 3 EB 1 ye bu E 3 EB bC br E C co z 0 cc G g 0 F F 0 C I gj FE 350 EU 2014 2015 I Hu5 Mlrna I 4 8 1 2 I 3 I 4 5 I 6 I 7 I 8 ...

Page 233: ...29 WIRING DIAGRAM Components B76 Brake light switch front B77 Brake light switch rear E60 License plate lamp P36 Brake tail light 231 ...

Page 234: ...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 w C w E E C co z 0 It cc G g 0 F F 0 It C I FE 350 EU 2014 2015 I I Hu5 Mlrna I 5 8 1 2 I 3 I 4 5 6 I 7 I 8 ...

Page 235: ...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 233 ...

Page 236: ...a 1 2 I 3 I 4 5 I 7 A4 l X15 5 5 FE 350 EU 2014 2015 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 237: ...29 WIRING DIAGRAM Components A11 EFI control unit 832 Fuel level indicator 851 Lambda sensor cylinder 1 F1 Fuse P13 Speedometer 235 ...

Page 238: ... 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 239: ...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 237 ...

Page 240: ... 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 241: ...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 239 ...

Page 242: ...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 243: ...29 WIRING DIAGRAM Components G10 Battery K10 Starter relay with main fuse M10 Starter motor S23 Emergency OFF switch electric starter button 241 ...

Page 244: ...E 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 245: ...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 243 ...

Page 246: ... 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 247: ...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 245 ...

Page 248: ...2 AH 2 BY 4 D1 2 AK 2 AK 2 CV 4 00 X11 B76 B77 X17 P36 CV 4 BY 4 t 0 BY 4 NM CV 4 X17 X11 N N AK 2 N AK 2 CV 4 i D l H 2 l AH 2 n B Y 4 X14 D X18 X19 X13 i i I j cf j j I I I I C J C 3 EB 1 ye bu E 3 EB bC br E C co z 0 cc G g 0 F F I 0 Ii C I 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 249: ...29 WIRING DIAGRAM Components B76 Brake light switch front B77 Brake light switch rear E60 License plate lamp P36 Brake tail light 247 ...

Page 250: ... X25 X41 X28 C m NMAJ 3 u x CX 2 CX 2 CX 2 CX 2 AH 2 NF0 2 j NMBG 3 CW 2 CW 2 CW 2 CW 2 S25 P42 P46 P41 P45 LR 2 w hr BG 3 NCW 2 NCW 2 NCW 2 l D X45 iAm NCX 2 NCX 2 NCX 2 i D X42 X23 X25 X41 X28 I I I I J C E E C co z 0 It cc G g 0 F F I 0 Ii C I FE 350 AU 2014 2015 I I Hu5 Mlrna I 5 8 1 2 I 3 I 4 5 6 I 7 I 8 ...

Page 251: ...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 249 ...

Page 252: ...o z 0 co cc G 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 253: ...29 WIRING DIAGRAM Components A11 EFI control unit 832 Fuel level indicator F1 Fuse P13 Speedometer 251 ...

Page 254: ...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 255: ...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 253 ...

Page 256: ... 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 AU 2014 2015 1 T T T T T 8 0 J I J IA I Is T r 8 8 ...

Page 257: ...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 255 ...

Page 258: ... 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 259: ...29 WIRING DIAGRAM Components G10 Battery K10 Starter relay with main fuse M10 Starter motor S21 Electric starter button 257 ...

Page 260: ...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 261: ...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 259 ...

Page 262: ...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 263: ...29 WIRING DIAGRAM Components A11 EFI control unit E11 Low beam P35 Parking light P37 Tail light S20 Kill switch S30 Light switch 261 ...

Page 264: ... 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 265: ...29 WIRING DIAGRAM Components A11 EFI control unit 832 Fuel tank sensor F1 Fuse P13 Speedometer 263 ...

Page 266: ...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 267: ...29 WIRING DIAGRAM Components A11 EFI control unit 870 Front wheel speed sensor M13 Fuel pump M51 Injector cylinder 1 P13 Speedometer R30 CAN bus terminating resistor 1 X295 Diagnostics connector 265 ...

Page 268: ... 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 269: ...cylinder 1 826 Rollover sensor 837 Crankshaft position sensor 841 Manifold absolute pressure sensor cylinder 1 R51 Ignition coil cylinder 1 S51 Map Select switch for ride mode optional S55 Map Select switch 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 267 ...

Page 270: ...F 4 FJ 2 M10 JL G10 J M BK 4 CV 4 rn K10 S23 S10 It i tr X56 N r ffvt l E v M GT 6 I 7J NBK 4 NM CV 4 i1 l t D X2 1 ru4 i BY 4 X7 D X4 X55 l 1 0 i l j X300 l s i I I rd a 2 E1 wh rd c b 2 E1 E E ye br c c 2 E1 C co z 0 cc G m br d 2 F1 F F I 0 I C I gJ ml FE 350 SUS 2015 I I Husqvama I 1 8 1 2 I 3 I 4 5 I 6 I 7 8 ...

Page 271: ...29 WIRING DIAGRAM Components F3 Fuse G10 Battery K10 Starter relay with main fuse M10 Starter motor S10 Ignition lock S23 Emergency OFF switch electric starter button 269 ...

Page 272: ...I I 1 FB dC br 0 l f I I gJ is X56 N GT 6 N GS 6 X20 c c c w 1 I 1 5 1 5 5 U co 0 C ye rd 1 e 6 B1 T20 n X9 0 FE 350 SUS 2015 j i l xo 1 x FJ 2 N MEB 4 B X295 AP 6 X6 X3 i 1 i rn l i B33 l X285 5 I I I I I I IC l x N FJ 2 M14 l 111 X 40 N MBG 3 lt J X39 Il i X8 1 1 ff_a r w ye bu 1 1 3 E1 br d 3 E1 IE br 1 d 7 F1 I 2 8 ...

Page 273: ...G DIAGRAM Components A11 EFI control unit 833 Radiator fan temperature switch F2 Fuse F4 Fuse G20 Alternator K12 Light relay K30 Power relay M14 Radiator fan T20 Voltage regulator X295 Diagnostics connector 271 ...

Page 274: ... I r I JJJ t 1_ s t cR 1 it 1 lil lf P 1 1 2 0 2 P15 a B i S29 M w BC 6 X22 E13 uE P35 X46 X53 P23 X50 I 5 C2 o N BP 4 M DG 4 N CW 2 CX 2 BA 1 BA 1 E v 0 X44 X47 N DG 4 M BP 4 N CX 2 CW 2 1 7 __ _ t l i ii i _ i _ 1 LJ 1P 1 i 1 E 1 1 2 EB f ye i 2 EB 11 ye bu t ye bu 1 1 4 E1 E 2 EB dC br br 1 d 4 E1 E F t tF Hu ma FE 350 SUS 2015 I 318 1 2 I 3 I 4 s I 6 I 1 I s ...

Page 275: ...29 WIRING DIAGRAM Components A11 EFI control unit E13 Low beam high beam P15 Horn P23 High beam indicator lamp P35 Parking light S29 Light switch horn button turn signal switch 273 ...

Page 276: ... C 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 BY 4 NM CV 4 X17 X11 N N AK 2 N AK 2 CV 4 i D fAH 2 fAH 2 n B Y 4 X14 D X18 X19 X13 i i I j cf j j I I I I 3 EB 11 ye bu E 3 EB dC br E C co z 0 cc G g 0 F F C0 0 I C I gJ FE 350 SUS 2015 I HuSQ lama I 4 8 1 2 I 3 I 4 5 I 6 I 7 I 8 ...

Page 277: ...29 WIRING DIAGRAM Components B76 Front brake light switch B77 Rear brake light switch E60 License plate lamp P36 Brake tail light 275 ...

Page 278: ...ama 1 2 I 3 I I I I 11 5 c a c u m NMAJ 3 H x NF0 2 NMBG 3 S29 3 C3 LR hr BG 3 i Am X42 I FE 350 SUS 2015 I 3 I 4 5 6 I 7 I 8 A B l I I 0 0 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 279: ...M Components K20 Turn signal relay P21 Turn signal switch P41 Front left turn signal P42 Front right turn signal P45 Rear left turn signal P46 Rear right turn signal S29 Light switch horn button turn signal switch 277 ...

Page 280: ...5 NfJ 2 ffi i J D XS 0 0 cc u C I C C co z 0 co cc G g 0 F co 0 I C I gJ teJ FE 350 SUS 2015 HUS IYl ma 1 2 I 3 I 4 5 I 6 I I l X15 i I i X51 N CZ 3 CY 3 P31 3 1 X51 0 I 6 I 7 GA 3 _ 7 D7 R ff DI 7 I I 8 A B C D or h 7 E1 E F I I I 6 8 8 ...

Page 281: ...29 WIRING DIAGRAM Components A11 EFI control unit 832 Fuel level sensor F1 Fuse P31 Fl warning lamp and low fuel warning lamp 279 ...

Page 282: ... l ih I C S36 1 1 p13 1 _ B 7 0 M51 R30 M20 M13 d I rr Mode 2 _J f X295 6 D7 I Up 3 3 S V N M w AP 6 X301 r 7 M r Dowe 4 4 1 _ 2 r n 6D7 T T N N co Ml IJZ 3 X o o ttt o o 0012 oF 2 iG N3 D M l I N l y i 1 X26 1 X5 7 1 X29 D ODD O O O D DD 6 E8 hC or jC E E 2 F8 dC br t __ 1 ____ _ Ft F Hu rna FE 350 S US 2015 I S 1 2 I 3 I 4 s 6 I 1 I s ...

Page 283: ...nents A11 EFI control unit 870 Front wheel speed sensor M13 Fuel pump M20 Fuel evaporation valve M51 Injector cylinder 1 P13 Speedometer S36 Tripmaster switch R30 CAN bus terminating resistor 1 X295 Diagnostics connector 281 ...

Page 284: ... 0 I C I gJ HuSQ11arna 1 2 I 3 I l I i X15 X15 I I t 0 AX 2 FL 1 I r X35 0 FE 350 SUS 2015 I 3 I B37 4 ll X15 1 I 1 I j X37 NAU2 m e 4 5 I 6 I 7 I 8 I A tj 4 1 4 iii i i i i i X15 X15 X15 X15 X15 il 9 it B t it C i i EX 3 AP 6 NDX 3 NCM 2 S O e 0 i n W m i l ii m t X30 X33 X32 X38 D il _s c 0 il _5 c 0 E F I I I 8 8 5 I 6 I 7 I 8 ...

Page 285: ...cylinder 1 826 Rollover sensor 837 Crankshaft position sensor 841 Manifold absolute pressure sensor cylinder 1 R51 Ignition coil cylinder 1 S51 Map Select switch for ride mode optional S55 Map Select switch 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 283 ...

Page 286: ...Use distilled water if the coolant needs to be diluted The use of premixed coolant is recommended Observe the coolant manufacturer specifications for antifreeze protection dilution and miscibility compatibility with other coolants Recommended supplier Bel Ray Moto Chill Racing Coolant Engine oil SAE 10W 50 Standard classification JASO T903 MA p 300 SAE p 300 SAE10W 50 Guideline Use only engine oil...

Page 287: ...OZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100 285 ...

Page 288: ... 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 289: ...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 1 287 ...

Page 290: ...5 H00504 01 Bleeder cover Art no 00029013006 00029013006 H00505 01 Bleedin device Art no 00029013100 00029013100 H00518 01 Battery charger XCharge professional EU Art no 00029095050 H01065 01 Batte charger XCharge rofessional US Art no 00029095051 H01065 01 288 ...

Page 291: ...095052 H01065 01 Batte rofessional CH Art no 00029095053 H01065 01 Sprin hook Art no 50305017000 50305017000 H00973 01 Bleed syringe Art no 50329050000 50329050000 H00565 01 Circli liers reverse Art no 51012011000 51012011000 H00572 01 ...

Page 292: ...000 H00592 01 Tool for inner bearin race 58429037037 H00596 01 Art no 51129003000 Art no 58012009000 Art no 58429037037 Torque wrench with various accessories in set Art no 58429094000 58429094000 H00606 01 Valve s ring mounter Art no 59029019000 59029019000 H00610 01 290 ...

Page 293: ...041100 59029041100 H00616 01 Plasti e clearance Art no 60029012000 60029012000 H00627 01 tool Art no 60029015000 60029015000 H00628 01 Hose clamp pliers Art no 60029057000 60029057000 H00650 01 Testing hose Art no 61029093000 61029093000 H00659 01 ...

Page 294: ...n ine assembl stand Art no 61229001000 61229001000 H00662 01 Release device for timin chain tensioner Art no 61229021000 61229021000 H00675 01 Pressing tool for crankshaft complete Art no 75029047000 75029047000 H00714 01 Protection ca Art no 75029090000 75029090000 H00726 01 292 ...

Page 295: ...1044 H00747 01 En arm Art no 77229002000 2x 77229002000 H00748 01 Insert for crankshaft pressin tool Art no 77229008000 B 77229008000 H00750 01 Extrude plate base Art no 77229009000 77229009000 H00751 01 Pliers for valve stem seals Art no 77229010000 77229010000 H00752 01 ...

Page 296: ...26000 H00753 01 Insertion for lock Art no 77229030000 77229030000 H00754 01 Protection cap Art no 77229031000 77229031000 H00755 01 Separator plate Art no 77229032000 77229032000 H00756 01 Insert timing chain tensioner Art no 77229035000 77229035000 H00757 01 ...

Page 297: ...h brid e 2x 77229050044 H00759 01 Insert for valve sprin lever 77229060000 H00760 01 Spark plug wrench 77229172000 H00761 01 Oil ressure ada ter 77329006000 H00764 01 Art no 77229048000 Art no 77229050044 Art no 77229060000 Art no 77229172000 Art no 77329006000 295 ...

Page 298: ...296 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 Mounting sleeve Art no T1204 T1204 H00878 01 ...

Page 299: ... Calibration in Art no T1205 T1205 H00879 01 Pressin tool Art no T1206 T1206 H00880 01 Pressin tool Art no T1207S T1207S H00881 01 Mounting sleeve Art no T1215 T1215 H00886 01 Disassembly tool Art no T1216 T1216 H00887 01 ...

Page 300: ...cuum Art no T1240S T1240S H00890 01 Protectin sleeve Art no T1401 cs T1401 H00894 01 Clampin stand Art no T1403S 2x T1403S H00896 01 Mounting tool Art no T14040S T14040S H00922 01 S ecial socket Art no T14047 T14047 H00923 01 ...

Page 301: ...tand Art no T14049S 2x T14049S H00924 01 Press out tool Art no T14051 T14051 H00926 01 Press drift Art no T1504 T1504 H00899 01 Assembly tool Art no T150S 0 Q T150S H00852 01 Nitrogen filling tool Art no T170S1 2x 3x T170S1 H00855 01 ...

Page 302: ...ong service intervals are demanded for automobile engines the focus for motorcycle engines is on high performance at high engine speeds In most motorcycle engines the transmission and the clutch are lubricated with the same oil The JASO MA standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils ac...

Page 303: ...e 101 checking 99 Chain tension adjusting 99 checking 98 Charging voltage checking 110 Chassis number 9 Closed current checking 110 Clutch fluid level checking correcting 196 fluid changing 197 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 an...

Page 304: ...g unit installing 182 shift drum installing 178 shift forks installing 178 shift rails installing 178 shift shaft installing 182 spacer installing 179 195 spark plug installing 194 starter drive installing 185 suction pump installing 181 timing chain tensioner installing 191 timing chain installing 179 torque limiter installing 193 302 transmission shafts installing 177 valve clearance adjusting 1...

Page 305: ...ual power consumers changing 106 main fuse changing 106 Hand brake lever basic position adjusting free travel adjusting 114 114 free travel checking 113 Handlebar position 38 adjusting 38 303 Headlight light range adjusting 128 Headlight adjustment checking 127 Headlight mask with headlight installing 89 removing 88 Hydrostop unit fork legs assembling 25 fork legs disassembling 22 Idle speed adjus...

Page 306: ...er servicing 48 spring preload adjusting 44 spring installing 62 spring removing 49 static sag checking 43 Shock absorber linkage checking 46 Spare parts 8 Spark plug connector checking 207 Speedometer clock setting kilometers or miles setting service display setting setting wheel circumference setting Spoke tension 304 126 126 127 125 126 checking 92 Spring fork legs removing 19 Starter motor che...

Page 307: ...256 page 1 of 8 224 240 268 page 2 of 6 258 page 2 of 8 226 242 270 page 3 of 6 260 page 3 of 8 228 244 272 page 4 of 6 262 page 4 of 8 230 246 274 page 5 of 6 264 page 5 of 8 232 248 276 page 6 of 6 266 page 6 of 8 page 7 of 8 page 8 of 8 234 250 278 236 252 280 238 254 282 Work rules 7 305 ...

Page 308: ...11111111111111111111111111111111 3403018en 07 2016 Husqvarna MOTORCYCLES Husqvarna Motorcycles GmbH fiiiHiAvl StallhofnerstraBe 3 5230 Mattighofen Austria llmi LZZa O www husqvarna motorcycles com __ __ Photo Mitterbauer Husqvarna Motorcycles GmbH ...

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Husqvarna FE 350 2015, Repair Manual

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Summary of Contents for FE 350 2015

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