TABLE OF CONTENTS
2
3
4
5
6
MEANS OF REPRESENTATION ........................................ 6
1.1
Symbols used ....................................................... 6
1 .2
Formats used .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . 6
SAFETY ADVICE ............................................................... 7
2.1
Repair Manual ....................................................... 7
2.2
Safety advice ........................................................ 7
2.3
Degrees of risk and symbols ................................ 7
2.4
Work rules ............................................................. 7
IMPORTANT NOTES ......................................................... 8
3.1
Manufacturer and implied warranty ...................... 8
3.2
Operating and auxiliary substances ..................... 8
3.3
Spare parts, accessories ...................................... 8
3.4
Figures .................................................................. 8
SERIAL NUMBERS ............................................................ 9
4.1
Chassis number .................................................... 9
4.2
Type label. ............................................................. 9
4.3
Key number (FE EU/AU, FE 350 S US) .................. 9
4.4
Engine number .................................................... 10
4.5
Fork part number ................................................ 10
4.6
Shock absorber article number .......................... 10
MOTORCYCLE ................................................................ 11
5.1
Raising the motorcycle with a lift stand .............. 11
5.2
Removing the motorcycle from the lift stand ...... 11
5.3
Starting ............................................................... 11
5.4
Starting the motorcycle for a check .................... 12
FORK, TRIPLE CLAMP ................................................... 13
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
6.14
6.15
6.16
6.17
6.18
6.19
6.20
6.21
6.22
6.23
6.24
6.25
6.26
6.27
6.28
6.29
Adjusting the compression damping of the
fork ...................................................................... 13
Adjusting the rebound damping of the fork ........ 13
Bleeding the fork legs ......................................... 13
Cleaning the dust boots of the fork legs ............. 14
Loosening the fork protector .............................. 14
Positioning the fork protector ............................. 15
Removing the fork legs ....................................... 15
Installing the fork legs ......................................... 15
Removing the fork protector ............................... 16
Installing the fork protector ................................. 17
Performing a fork service .................................... 17
Disassembling the fork legs ................................ 17
Removing the spring ........................................... 19
Disassembling the cartridge ............................... 20
Disassembling the piston rod ............................. 21
Disassembling the hydrostop unit ...................... 22
Disassembling the seal ring retainer ................... 23
Checking the fork legs........................................ 23
Assembling the seal ring retainer ........................ 24
Assembling the hydrostop unit ........................... 25
Assembling the piston rod .................................. 25
Assembling the cartridge .................................... 27
Assembling the fork legs .................................... 28
Lubricating the steering head bearing ................ 31
Removing the lower triple clamp ........................ 32
Installing the lower triple clamp .......................... 33
Checking the play of the steering head
bearing ................................................................ 35
Changing the steering head bearing ................... 35
Adjusting the play of 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 .................................. 41
8.3
Checking the frame ............................................. 41
SHOCK ABSORBER, SWINGARM .................................. 42
9.1
Adjusting the high-speed compression
damping of the shock absorber .......................... 42
9.2
Adjusting the low-speed compression
damping of the shock absorber. ......................... 42
9.3
Adjusting the rebound damping of the shock
absorber .............................................................. 43
9.4
Measuring rear wheel sag unloaded ................... 43
9.5
Checking the static sag of the shock
absorber .............................................................. 43
9.6
Checking the riding sag of the shock
absorber .............................................................. 44
9.7
Adjusting the spring preload of the shock
absorber .............................................................. 44
9.8
Adjusting the riding sag ...................................... 45
9.9
9.10
9.11
9.12
9.13
9.14
9.15
9.16
9.17
9.18
9.19
9.20
9.21
9.22
9.23
9.24
9.25
9.26
9.27
Removing the shock absorber ............................ 46
Installing the shock absorber .............................. 46
Checking the shock absorber linkage ................ 46
Servicing the shock absorber ............................. 48
Removing the spring ........................................... 49
Disassembling the damper ................................. 49
Disassembling the piston rod ............................. 50
Disassembling the seal ring retainer ................... 51
Changing the pilot bushing ................................. 52
Checking the damper ......................................... 53
Removing the heim joint ..................................... 53
Installing the heim joint ....................................... 54
Assembling the seal ring retainer ........................ 55
Assembling the piston rod .................................. 56
Assembling the damper ...................................... 57
Bleeding and filling the damper .......................... 59
Filling the damper with nitrogen ......................... 61
Installing the spring ............................................. 62
Checking the swingarm ...................................... 63
9.28
Removing the swingarm ..................................... 63
9.29
Installing the swingarm ....................................... 64
9.30
Changing the swingarm bearing ......................... 65
1 0 EXHAUST . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. 68
10.1
Removing the manifold ....................................... 68
10.2
Installing the manifold ......................................... 69
10.3
Removing the main silencer ................................ 71
10.4
Installing the main silencer .................................. 71
10.5
Changing the glass fiber yarn filling in the
main silencer ....................................................... 71
10.6
spark arrestor, cleaning ...................................... 73
11 AIR FILTER ...................................................................... 74
11.1
Removing the air filter box cover ........................ 7 4
11.2
Installing the air filter box cover .......................... 7 4
Summary of Contents for FE 350 2015
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