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Husqvarna FE 450 2014, Repair Manual

The Husqvarna FE 450 2014 Repair Manual is an essential resource for all owners of this powerful off-road motorcycle. With detailed instructions and expert tips, this comprehensive manual aids in maintaining and repairing the FE 450. Download it for free from manualshive.com and keep your bike running smoothly.

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'A 

Accessories 

. . . . . . . . . . . . . . . . . . . . . . . . . .  9 

Air filter 

cleaning  . . . . . . . . . . . . . . . . . . . . . . . . . .  88 
installing  ..........................  88 
removing  . . . . . . . . . . . . . . . . . . . . . . . . .  87 

Air filter box 

cleaning  . . . . . . . . . . . . . . . . . . . . . . . . . .  88 
sealing  ...........................  89 

Air filter box cover 

installing  . . . . . . . . . . . . . . . . . . . . . . . . . .  87 
removing  . . . . . . . . . . . . . . . . . . . . . . . . .  87 

Alternator 

stator winding,  checking 

240 

Antifreeze 

checking  . . . . . . . . . . . . . . . . . . . . . . . . .  230 

Assembling the engine 

crankshaft,  installing . . . . . . . . . . . . . . . . .  207 

Auxiliary substances 

. . . . . . . . . . . . . . . . . . . .  9 

B 

Battery 

installing 
recharging 
removing 

Brake disc 

front brake,  installing 
front brake,  removing 

126 
126 
125 

110 
109 

rear brake,  installing  . . . . . . . . . . . . . . . . .  113 
rear brake,  removing 

Brake discs 

113 

checking  . . . . . . . . . . . . . . . . . . . . . . . . .  1 06 

Brake fluid 

front brake,  changing 
of front brake,  adding 
of rear brake,  adding 
rear brake,  changing 

134 
133 
141 
142 

Brake fluid level 

front brake,  checking 

133 

rear brake,  checking  . . . . . . . . . . . . . . . . .  140 

Brake linings 

C 

front brake,  changing  . . . . . . . . . . . . . . . .  129 
front brake,  checking  . . . . . . . . . . . . . . . .  129 
of rear brake,  changing  . . . . . . . . . . . . . . .  136 
rear brake,  checking  . . . . . . . . . . . . . . . . .  136 

Capacity 

coolant  ....................... 233,  250 

engine oil  . . . . . . . . . . . . . . . . .  158,  237,  250 

Cartridge 

of fork legs,  disassembling  . . . . . . . . . . . . .  22 
of the fork legs, assembling . . . . . . . . . . . . .  30 

Chain 

checking 
cleaning 

Chain guide 

checking 

Chain tension 

115 
118 

115 

adjusting  . . . . . . . . . . . . . . . . . . . . . . . . .  114 
checking  . . . . . . . . . . . . . . . . . . . . . . . . .  114 

Charging voltage 

checking  . . . . . . . . . . . . . . . . . . . . . . . . .  128 

Chassis number 

. . . . . . . . . . . . . . . . . . . . . .  1 0 

Clutch 

fluid level,  checking/correcting  . . . . . . . . .  228 
fluid,  changing  . . . . . . . . . . . . . . . . . . . . .  229 

Clutch lever 

basic position,  adjusting  . . . . . . . . . . . . . . .  44 

Combination instrument 

adjusting  ........................ .  145 
adjusting the clock  ................. .  146 
adjusting the kilometers or miles  . . . . . . . .  146 
service display,  adjusting 

147 

Compression damping 

fork,  adjusting  . . . . . . . . . . . . . . . . . . . . . .  14 

Compression damping,  high-speed 

shock absorber,  adjusting  . . . . . . . . . . . . . .  48 

Compression damping, low-speed 

shock absorber,  adjusting  ..............  48 

Coolant 

antifreeze and coolant level,  checking 
draining  ........................ . 
level,  checking .................... . 
refilling  ......................... . 

230 
232 
231 
232 

Cooling system 

. . . . . . . . . . . . . . . . . . . . . .  230 

Cylinder - Nikasil

® 

coating 

. . . . . . . . . . . . . .  185 

D 

Disassembling the engine 

clutch cover,  removing  . . . . . . . . . . . . . . .  167 
oil filter,  removing 

160 

torque limiter,  removing  . . . . . . . . . . . . . .  170 
transmission shafts,  removing 

Drivetrain kit 

changing 

174 

118 

329 

INDEX 

Summary of Contents for FE 450 2014

Page 1: ...PIONEERING SINCE 1903 REPAIR MANUAL2014 FE 450 FE 501 Art no 3403003en Husqvarna MOTORCYCLES ...

Page 2: ......

Page 3: ...H specifically reserves the right to modify or delete technical specifications prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice Husqvarna accepts no liability for delivery options deviations from figures and descriptions as well...

Page 4: ...5 Disassembling the piston rod 24 6 16 Disassembling the hydrostop unit 25 7 8 6 17 Disassembling the seal ring retainer 26 6 18 Checking the fork legs 26 6 19 Assembling the seal ring retainer 28 6 20 Assembling the hydrostop unit 28 6 21 Assembling the piston rod 29 6 22 Assembling the cartridge 30 6 23 Assembling the fork legs 32 6 24 Lubricating the steering head bearing 36 6 25 Removing the l...

Page 5: ...e right side cover 91 12 5 Removing the seat 91 12 6 Mounting the seat 91 TABLE OF CONTENTS 12 7 Removing the fuel tank 92 12 8 Installing the fuel tank 93 12 9 Changing the fuel screen 95 12 10 Changing the fuel filter 96 12 11 Changing the fuel pump 98 12 12 Checking the fuel pressure 100 13 MASK FENDER 102 13 1 Removing front fender 102 13 2 Installing front fender 102 13 3 Removing the headlig...

Page 6: ...oving the alternator cover 162 Positioning the engine at ignition top dead center 162 Removing the timing chain tensioner 163 18 3 11 Removing the camshaft 163 18 3 12 Removing the cylinder head 164 18 3 13 Removing the piston 164 18 3 14 Removing the rotor 164 18 3 15 Removing the timing chain guide rail 165 18 3 16 Removing the timing chain tensioning rail 165 18 3 17 Removing the timing chain s...

Page 7: ...ewheel 206 TABLE OF CONTENTS 18 5 Engine assembly 207 18 5 1 Installing the crankshaft 207 18 5 2 Installing the transmission shafts 207 18 5 3 Installing the shift forks 208 18 5 4 Installing the shift drum 208 18 5 5 Installing the shift rails 209 18 5 6 Installing the left engine case 209 18 5 7 Installing the freewheel gear 210 18 5 8 Installing the primary gear 210 18 5 9 Installing the force...

Page 8: ...ues 248 25 4 Capacities 250 25 4 1 Engine oil 250 25 4 2 Coolant 250 25 4 3 Fuel 250 25 5 Chassis 250 25 6 Electrical system 251 25 7 Tires 251 25 8 Fork 252 25 9 Shock absorber 252 25 10 Chassis tightening torques 253 26 CLEANING CARE 255 26 1 Cleaning the motorcycle 255 26 2 Checks and maintenance steps for winter operation 256 27 STORAGE 257 27 1 Storage 257 27 2 Preparing for use after storage...

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

Page 10: ...ermanent injury if the appropriate 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 Wa...

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

Page 12: ...number o 402247 10 401949 10 The chassis number O is stamped on the steering head on the right The type label O is fixed to the front of the steering head The key number O for the steering lock is stamped onto the key connector The engine number O is stamped on the left side of the engine under the engine sprocket ...

Page 13: ... NUMBERS The fork part number O is stamped on the inner side of the fork stub 4 6 Shock absorber article number Shock absorber article number O is stamped on the top of the shock absorber above the adjusting ring towards the engine side 11 ...

Page 14: ...rface 401943 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle press side stand Oto the ground with your foot and lean the motorcycle on it Info When you are riding the side stand must be folded up and secured with the rubber band 5 3 Startin Note Danger Danger of poisoning death Exhaust gases are toxic and inhaling them may result in unconsciousness and Alw...

Page 15: ...Fl lights up briefly as a functional con trol when starting 5 4 400733 01 Starting the motorc cle for a check Danger Danger of poisoning death Exhaust gases are toxic and inhaling them may result in unconsciousness and 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 Pre...

Page 16: ...amping Comfort Standard Sport Info 15 clicks 13 clicks 11 clicks I Turn clockwise to increase damping turn counter clockwise to reduce damping Ad usting the rebound dam ing of the fork Info The hydraulic rebound damping determines the fork suspension behavior r_ µ W 1 e 1i 1 ii_ iEm mlr I 14 Turn the red adjusting screw O all the way clockwise Info Adjusting screw O is located at the upper end of ...

Page 17: ...ift stand a p 12 Loosen the fork protector a p 16 Main work Push dust boots O of both fork legs downward Info The dust boots remove dust and coarse dirt particles from the inside fork tubes Over time dirt can pene trate behind the 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 braking effect Alw...

Page 18: ...screws O Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake line wiring harness and clamp Mount and tighten screws 8 Position the fork protector on the right fork leg Mount and tighten the screws Guideline Remaining screws chassis Preparatory work M6 10 Nm 7 4 lbf ft Switch off all the power consumers and the engine Remove the headlight mask with the headlight p 103 Raise th...

Page 19: ...egs The second milled groove from the top must be flush with the upper edge of the upper triple clamp Tighten screws 8 Guideline Screw top triple clamp Tighten screws 5 Guideline M8 Screw bottom triple M8 clamp 17 Nm 12 5 lbf ft 15 Nm 11 1 lbf ft Position the brake caliper and mount and tighten screws C Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Mount the cable tie s Posi...

Page 20: ... on the right fork leg Remove the fork protector upwards Installing the fork protector C00565 10 Performing a fork service Main work Position the fork protector on the left fork leg Mount and tighten screws O Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the fork protector on the right fork leg Mount and tighten the screws Guideline Remaining screws chassis Finishing work M6 Inst...

Page 21: ...e cartridge 0 p 30 0 fiB Assemble the fork legs a p 32 I Ii c o 0 201926 01 Disassemblin the fork le s Info The operations are the same on both fork legs 201700 10 Condition The fork legs have been removed Note down the current state of rebound damping O REB red adjuster on the right fork leg Note down the current state of compression damping 8 COMP white adjuster on the left fork leg Open the adj...

Page 22: ... Release hydrostop unit 0 and remove it Info Do not use an impact wrench Place a pan underneath since oil will run out Remove the cartridge from the fork leg Pressing tool T14051 p 325 Info I Removing the O ring seat from the cartridge usually requires the application of considerable force Remove dust boot D Remove fork protector ring 6 Info I The fork protector ring does not necessarily need to b...

Page 23: ...ter tube from the inner tube with a jerk Info Lower sliding bushing must be pulled from its bearing seat Remove upper sliding bushing D Info Without using a tool pull the stack slightly apart by hand Take off lower sliding bushing Take off support ring 4l Take off seal ring G Take off lock ring Take off dust boot C Unclamp the fork leg The operations are the same on both fork legs Preparatory work...

Page 24: ...324 Pull the spring downward Remove the open end wrench Remove the screw cap Remove the spring with the preload spacer s Disassembling the cartridge Info The operations are the same on both fork legs 202480 10 Preparatory work Disassemble the fork legs 0 p 19 Remove the spring 0 p 21 Main work Degrease piston rod O and clamp using the special tool I Clamping stand T14049S 0 p 325 Remove adjusting ...

Page 25: ...dge Degrease the cartridge and clamp it with the special tool I Clamping stand T14049S p 325 Release seal ring retainer 0 and remove with the washer Remove lock ring D Pull reservoir out of the cartridge Pull sleeve out of the reservoir Remove spring Remove seal rings Ci and O ring 48 Remove pilot bushings 48 23 ...

Page 26: ...d Clamp the piston rod with the special tool as far up as possi ble I Clamping stand T14049S p 325 Release hydrostop needle O and remove it from the piston rod Valve 8 usually remains in the hydrostop needle Info 6 silver hydrostop needle on compression damp ing side G red hydrostop needle on rebound damping side Turn piston rod degrease and clamp using the special tool I Clamping stand T14049S I ...

Page 27: ...tube can be used for this unit The steps are identical for both fork legs Preparatory work Disassemble the fork legs p 19 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 fD Remove hub C with washers 3 Info It is possible that only one washer or no washer is present Remove the O ring from the hub 25 ...

Page 28: ...rk legs Checkin the fork le s 200728 10 Preparatory work Disassemble the fork legs I p 19 Remove the spring I p 21 Disassemble the cartridge I p 22 Main work Remove pilot bushing support 0 Remove O ring 8 and seal ring D Condition The fork legs have been disassembled Check the inner tube and axle clamp for damage If there is damage Change the inner tube ...

Page 29: ...f the outer tube Inside diameter of outer tube 49 20 mm 1 937 in If the measured value is larger than the specified value Change the outer tube Check the outer tube for damage If there is damage Change the outer tube Check the surface of the sliding bushings If the bronze colored layer f under sliding layer G is visible or the surface is rough Change the sliding bushings Check the spring length Gu...

Page 30: ...identical for both fork legs Mount and grease O ring 0 1 Lubricant T158 a p 308 Mount washer 8 Mount shim stack 8 with the smaller washers facing down ward Mount the new O ring on hub C Mount the hub with washers 0 Info It is possible that only one or no washer is present Mount and tighten adapter D Guideline Hydrostop unit adapter M6x0 5 7 Nm 5 2 lbf ft Mount shim stack with the smaller washers f...

Page 31: ...l for both fork legs except for the hydrostop needle and valve 201790 10 201791 10 0 201730 10 Degrease the piston rod Clamp the piston rod with the special tool I Clamping stand T14049S a p 325 Grease the O ring Mount valve needle O in the piston rod I Lubricant T158 a p 308 Mount spring Mount and tighten adapter CD with spring e and washer Guideline Adapter of piston rod Position the spring M6x0...

Page 32: ...cing upward Press the piston downward against the spring Make sure the pistons do not squeeze the shims Position valve in hydrostop needle fD Mount and tighten the hydrostop needle Guideline Hydrostop needle on M6x0 5 piston rod Info 7 Nm 5 2 lbf ft I e silver hydrostop needle on compression damp ing side G red hydrostop needle on rebound damping side Unclamp the piston rod The operations are the ...

Page 33: ...s 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 p 325 Slide reservoir 0 onto the cartridge Info Hold the sleeve in the reservoir to prevent it from slid ing out Mount lock ring C Mount seal ring retainer with the washer and tighten Guideline Seal ring retainer M23 5x0 75 46 Nm 33...

Page 34: ...de screw cap with mark COMP brake caliper holder white adjuster Rebound damping side screw cap with mark REB no brake caliper holder red adjuster e 8 8 201714 10 Preparatory work Assemble the hydrostop unit I p 28 Main work Clamp the inner tube with the axle clamp Guideline I Use soft jaws Mount the special tool I Protecting sleeve T1401 p 324 Grease and push on dust boot O I Lubricant T14034 0 p ...

Page 35: ...n area f of the lower sliding bush ing Guideline I so 0 c 122 F Slide the outer tube onto the inner tube Hold the lower sliding bushing with the longer side of the special tool I Mounting tool T14040S llill p 324 Press the sliding bushing all the way into the outer tube Position the support ring Hold the seal ring with the shorter side of the special tool I Mounting tool T14040S llill p 324 Press ...

Page 36: ...he entire filling quantity of fork oil avail able Oil capacity per fork 635 ml Fork oil SAE 4 leg 21 47 fl oz 48601166S1 a p 306 Add some of the fork oil while pulling out and pushing in the piston rod numerous times Guideline I Fork oil quantity 1510 ml 17 24 fl oz Mount and tighten hydrostop unit Guideline I Hydrostop unit I M30x1 Clamp the fork vertically Add the remaining quantity of fork oil ...

Page 37: ...tly mounted according to the hydrostop needles Rebound damping side red hydrostop needle screw cap with mark REB Compression damping side silver hydrostop needle screw cap with mark COMP Mount the open end wrench on the hexagonal part Hold the open end wrench Tighten screw cap Guideline Screw cap on piston M8x0 75 rod I Mounting tool T14047 Ip 324 Push the outer tube upward 18 Nm 13 3 lbf ft Clamp...

Page 38: ...rnative 2 Warning Danger of accident Modifications to the sus pension setting may seriously alter the handling characteristic Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components Only make adjustments within the recom mended range Ride slowly to start with after making adjustments to get the feel of the new handlin...

Page 39: ...he fork legs I p 16 Remove front fender I p 102 Main work Open cable holder O in front of the right radiator and detach the wiring harness Remove screw Remove screw take off the upper triple clamp with the handlebar and set it aside Info I Cover the components to protect them against dam age Do not kink the cables and lines Remove 0 ring C Remove protective ring G Take off the lower triple clamp w...

Page 40: ...rotective ring 8 and O ring 8 Position the upper triple clamp with the handlebar Mount screw C but do not tighten yet Position the clutch line next to the voltage regulator Position the fork legs Bleeder screws 0 face forwards Info The compression damping is located in left fork leg COMP white adjusting screw The rebound damping is located in right fork leg REB red adjusting screw Grooves are mill...

Page 41: ...ten screws Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Secure the wiring harness with cable holder Position the brake caliper Mount and tighten screws 61 Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Mount the cable tie s Position the brake line wiring harness and clamp Mount and tighten screws 4i Finishing work Install front fender I p 102 Install the front wheel ...

Page 42: ...Move the handlebar to the straight ahead position Move the fork legs to and fro in the direction of travel Play should not be detectable on the steering head bear ing If there is detectable play Adjust the steering head bearing play p 42 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 de...

Page 43: ...per bearing race fj using a suitable tool Press in the new bearing race all the way using a suitable tool Pull off bearing CD Remove seal ring retainer Remove O ring Grease the new O ring and mount with seal ring retainer Press on the new bearing with a suitable tube as far as it will go Finishing work Install the lower triple clamp ll p 38 Install front fender ll p 102 41 ...

Page 44: ...the steering head bearing la Preparatory work Raise the motorcycle with a lift stand p 12 Main work Loosen screws O Remove screw 8 Loosen and retighten screw 8 Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid stresses Tighten screws 0 Guideline Screw top triple M8 clamp Mount and tighten screw 8 Guideline 17 Nm 12 5 lb...

Page 45: ... The handlebar may break as a result Change the handlebar if the handlebar is damaged or bent 101860 10 Remove screws O Take off the handlebar clamps Take off the handlebar and lay it to one side Info Cover the components to protect them against dam age Do not bend the cables and lines Remove screws 8 Take off the handlebar supports Place the handlebar supports in the required position Mount and t...

Page 46: ... 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 Checking the routing of the throttle cable Preparatory work Remove the seat il l p 91 Remove the fuel tank il l p 92 Main work Check the routing of the throttle cable Both throttle cables must be routed to the throttle valve body side by side b...

Page 47: ...ning 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 let it run idle Move the handlebar to and fro over the entire steering range I The idle speed must not change If the id...

Page 48: ...e throttle cable at the throttle grip Guideline I Play in throttle cable I 3 5 mm 0 12 0 2 in Tighten nut C Press and hold the throttle grip in the closed setting Turn adjusting screw out until there is no play in throttle cable 3 Tighten nut Push sleeves O on Check the throttle grip for smooth oper ation Finishing work Install the fuel tank l ll p 93 Mount the seat l ll p 91 Check the play in the...

Page 49: ...uard on the 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 Always replace a frame that has been damaged due to a mechanical impact Repair of the frame is not authorized by Husqvarna Motorcycles 47 ...

Page 50: ...nfo I Do not loosen nut Turn counterclockwise by the number of turns corresponding to the shock absorber type Guideline Compression damping high speed Comfort Standard Sport Info 2 5 turns 2 turns 1 5 turns I Turn clockwise to increase damping turn counter clockwise to reduce damping 9 2 Adjusting the low speed compression damping of the shock absorber A 48 Caution Risk of injury rectly Parts of t...

Page 51: ...damping Ad usting the rebound dam ing of the shock absorber Caution Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incor rectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Turn adjusting screw O clockwise up to the last perceptible click Turn counterclockwise by the number of clicks correspond in...

Page 52: ...the motorcycle from the lift stand p 12 Checkin the static sa of the shock absorber Measure distance t of rear wheel unloaded p 50 Hold the motorcycle upright with the aid of an assistant Measure the distance between the rear axle and the fixed point again Note down the value as dimension G Info The static sag is the difference between measure ments t and G Check the static sag I Static sag I 35 m...

Page 53: ...I Riding sag 1105 mm 4 13 in If the riding sag differs from the specified measurement Adjust the riding sag a p 52 41 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 incor rectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Info Before chang...

Page 54: ...it may be necessary to increase or decrease the spring preload Tighten screw O Guideline Screw shock MS absorber adjusting ring Finishing work Install the shock absorber p 54 Install the manifold p 83 Mount the seat p 91 Install the main silencer a p 85 Install the right side cover a p 91 5 Nm 3 7 lbf ft Remove the motorcycle from the lift stand 0 p 12 Preparatory work Raise the motorcycle with a ...

Page 55: ...ber p 54 Install the manifold p 83 Mount the seat i p 91 Install the main silencer i p 85 Install the right side cover i p 91 Remove the motorcycle from the lift stand i p 12 Check the static sag of the shock absorber l l p 50 Check the riding sag of the shock absorber l l p 51 Adjust the rebound damping of the shock absorber l l p 49 41 9 9 Removin the shock absorber Preparatory work Raise the mo...

Page 56: ...Install the main silencer p 85 Install the right side cover lll p 91 Remove the motorcycle from the lift stand lll p 12 Checking the shock absorber linkage Preparatory work Raise the motorcycle with a lift stand p 12 Main work Remove screw O Remove fitting 8 Info Raise the wheel slightly to be able to remove the screws more easily Remove fitting Take off the angle lever ...

Page 57: ...r 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 f 303096 10 I 54 91 55 00 mm 2 1618 2 1654 in If dimension f is below the specified value Add the necessary spacing washers Position angle lever Mount fitting D but do not tighten yet Guideline Nut angle lever on swingarm M14x1 5 80 Nm 59 lbf ft 55 ...

Page 58: ...9 lbf ft Raise the wheel slightly to be able to mount the screw more easily Tighten screws O Guideline Screw bottom M10 shock absorber Tighten screw cap CD Guideline Nut angle lever on swingarm M14x1 5 60 Nm 44 3 lbf ft Loctite 2701 TM 80 Nm 59 lbf ft Servicing the shock absorber Caution Risk of injury rectly Parts of the shock absorber will fly off if the shock absorber is disassembled incor The ...

Page 59: ...the seal ring retainer p 64 Assemble the piston rod p 65 Assemble the damper p 67 Install the spring p 73 Condition The shock absorber has been removed Clamp the shock absorber in the vise using soft jaws for pro tection Measure and note spring length in its preloaded state Loosen screw O Turn adjusting ring until the spring is no longer under tension I Hook wrench T106S p 321 Remove ring Remove s...

Page 60: ...mping O and compression damping 8 Completely open the adjusters of the rebound and compres sion damping Remove rubber cap 8 of the reservoir Open screw 8 slowly The pressurized nitrogen escapes Remove locking cap 0 Press in seal ring retainer 3 using the special tool I Pressing tool T1216 lll l p 323 Remove lock ring Info Do not scratch the inner surface ...

Page 61: ...ate washer Drain the oil Remove compression adjuster Remove the spring and piston Disassembling the piston rod Preparatory work Remove the spring a p 57 Disassemble the damper a p 58 Main work Clamp the piston rod with the fork in a vise Guideline I Use soft jaws Remove nut O Remove washer 8 59 ...

Page 62: ...fo I Place the compression shim stack onto a screwdriver and set it down as a unit Remove rebound washer CD Remove seal ring retainer Remove locking cap fD and rubber buffer Disassembling the seal ring retainer 201405 10 Preparatory work Remove the spring 0 p 57 Disassemble the damper 0 p 58 Disassemble the piston rod 0 p 59 Main work Remove spring O Remove O ring 8 Remove rebound rubber ...

Page 63: ... 59 Disassemble the seal ring retainer l JI p 60 Main work Press pilot bushing O out of seal ring retainer 8 with the special tool I Pressing tool T1504 l JI p 325 Slide the new pilot bushing O onto the special tool I Pressing tool T1504 p 325 Position the pilot bushing in the seal ring retainer using the special tool I Pressing tool T1504 p 325 Support seal ring retainer 8 with sleeve f of the sp...

Page 64: ...the damper cartridge Damper cartridge Diameter s 50 08 mm 5 1 9716 in If the measured value is greater than the specified value Change the damper cartridge Check the damper cartridge for damage and wear If there is damage or wear Change the damper cartridge Check the heim joint for damage and wear If there is damage or wear Change the heim joint Measure the diameter of the piston rod Piston rod Di...

Page 65: ...ise using soft jaws for pro tection Remove the collar bushing of the heim joint I Drift f120 i l p 322 Turn the shock absorber and remove the second collar bush ing of the heim joint Remove seal rings O on both sides Press the heim joint against a lock ring using the special tool I Pressing tool T1207S a p 323 Remove the second lock ring Place special tool f underneath and press out heim joint D w...

Page 66: ...6 a p 322 Press the heim joint all the way in Press the heim joint against the lock ring using the special tool I Pressing tool T1207S a p 323 Mount the second lock ring Mount seal rings D on both sides Position both collar bushings C and press them in Mount dust boot O with the special tool I Mounting sleeve T1204 a p 322 Grease the sealing lip of the dust boot I Lubricant T625 a p 308 ...

Page 67: ...bound rubber D Grease the 0 ring groove I Lubricant T158 0 p 308 Mount 0 ring Mount spring Preparatory work Assemble the seal ring retainer 0 p 64 Main work Clamp the piston rod with the fork in a vise Guideline I Use soft jaws Mount rubber buffer O and locking cap Position special tool on the piston rod I Mounting sleeve T1215 0 p 323 Grease the dust boot and push seal ring retainer Donto the pis...

Page 68: ... stack 0 with the smaller shims facing downward Sand both sides of piston 3 on a surface plate using 1200 grit sandpaper Clean the piston Assemble the piston Guideline View6 Piston from above View Piston from below Mount the rebound shim stack with the smaller shims facing upward Mount washer fD with the collar facing downward ...

Page 69: ... 308 Lubricate the threads I Lubricant T159 l t J p 308 Mount the piston with the spring Mount and tighten the compression adjuster 0 Guideline Compression adjuster M31x1 Clamp the damper in a bench vise Guideline I Use soft jaws 45 Nm 33 2 lbf ft Mount adjusting ring 8 with the intermediate washer Info The adjusting ring cannot be mounted after the piston rod is mounted Fill the damper cartridge ...

Page 70: ...rnative 1 Turn adjusting screw fD clockwise with a screwdriver up to the last perceptible click Turn counterclockwise by the number of clicks corre sponding 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 corre sponding...

Page 71: ...s to get the feel of the new handling characteristic Turn adjusting screws and G to the position determined during disassembly Bleeding and filling the dam er Info Before working with the vacuum pump be sure to read the operating instructions carefully Completely open the adjusters of the rebound and compression damping Remove the screw of the filling port Install adapter O on the damper Info Tigh...

Page 72: ...crometer T107S a p 321 The floating piston is positioned all the way at the bot tom When the vacuum pressure gauge reaches the specified value turn the Oil reservoir control lever 0 to Equalize pressure Guideline 14 mbar The pressure gauge increases to the specified value 0 bar When the pressure gauge reaches the specified value turn the Damper control lever C to Pressure Guideline 0 bar Oil is pu...

Page 73: ...ol lever 8 to Pressure Guideline 0bar Oil is pumped into the damper The pressure gauge increases to the specified value 3 bar When the pressure gauge reaches the specified value turn the Damper 8 control lever to Vacuum Guideline 3 bar The pressure gauge drops to the specified value 0bar When the pressure gauge reaches the specified value oper ate the On Off switch Guideline 0bar The vacuum pump i...

Page 74: ...illing port I M10x1 114 Nm 10 3 lbf ft 411 Mount screw O with the O ring and screw it in approx 2 full turns but do not tighten it fully yet Info The piston rod is fully extended Fix the special tool in the vise I Filling tool T170S1 ilill p 326 Connect the special tool to the pressure regulator of the filling cylinder I Filling gas nitrogen Adjust the pressure regulator Guideline I Gas pressure 1...

Page 75: ...adjusting ring O is screwed on with the interme diate washer Measure the overall spring length while the spring is not under tension Position spring Guideline Spring rate Weight of rider 65 54 N mm 308 lb in 75 kg 143 165 lb Weight of rider 75 57 N mm 325 lb in 85 kg 165 187 lb Weight of rider 85 60 N mm 343 lb in 95 kg 187 209 lb Mount intermediate washer 8 and spring retainer 8 Mount ring C Alte...

Page 76: ...the new handling characteristic Tension the spring to the amount measured during dis mantling by turning the adjusting ring I Hook wrench T106S p 321 Tighten screw 0 Guideline Screw shock M5 5 Nm 3 7 lbf ft absorber adjusting ring Check the swingarm for damage cracking and deformation If the swingarm shows signs of damage cracking or deformation Change the swingarm Info I Always change a damaged s...

Page 77: ...lay Change the swingarm bearing p 78 Finishing work Remove the motorcycle from the lift stand a p 12 Preparatory work Raise the motorcycle with a lift stand a p 12 Remove the rear wheel a p 111 Main work Take the brake line out of the guide Push the brake caliper forward slip it out and hang it to the side Info Cover the components to protect them against dam age Remove screws O and 8 Take off the...

Page 78: ...Remove fitting C Lower the swingarm Remove nut 0 Remove the swingarm pivot Take off the swingarm Main work Position the swingarm Mount the swingarm pivot Mount and tighten nut O Guideline I Nut swingarm pivot I M16x1 5 Lift the swingarm Mount and tighten fitting Guideline Nut angle lever on swingarm M14x1 5 I 100 Nm 73 8 lbf ft I 80 Nm 59 lbf ft ...

Page 79: ... sprocket cover and mount in the holder Mount and tighten screws 8 Guideline Screw clutch slave cylinder M6 Mount and tighten screws 0 Guideline Remaining screws chassis M8 10 Nm 7 4 lbf ft 25 Nm 18 4 lbf ft Position the brake caliper and pull it back Position the brake line in the guide Finishing work Install the rear wheel ll ll p 112 Remove the motorcycle from the lift stand 8 p 12 77 ...

Page 80: ...ons are the same on both swingarm bearings G01813 10 J G01814 10 Preparatory work Raise the motorcycle with a lift stand p 12 Remove the rear wheel p 111 Remove the swingarm p 75 Main work Remove collar bushings O Remove bushing 8 Remove shaft seal rings 8 using a suitable tool ...

Page 81: ...ntil it is flush using a suitable tool Press in shaft seal rings Ci Mount bushing G01814 10 Grease the shaft seal rings I Long life grease lll I p 308 Position collar bushings O with the shoulder facing inward 801819 10 Finishing work Install the swingarm I p 76 Install the rear wheel I p 112 79 ...

Page 82: ...9 SHOCK ABSORBER SWINGARM 80 Remove the motorcycle from the lift stand p 12 ...

Page 83: ...Remove the seat a p 91 Remove the right side cover JI p 91 Remove the main silencer i I p 84 Main work Remove fitting O Remove screw Press angle lever 8 toward the rear Press linkage lever C downward Raise the swingarm Remove screws 0 on both sides Loosen screws D on both sides 10 EXHAUST 81 ...

Page 84: ... frame slightly and lower the shock absorber FE EU Remove the fuel tank p 92 Disconnect plug in connector of the lambda sensor and remove the cable binder Remove springs I Spring hook 50305017000 p 312 Remove screw GD and take off the manifold ...

Page 85: ...with a new cable binder Install the fuel tank 0 p 93 Lift the rear frame slightly and position the shock absorber Mount and tighten screw 8 Guideline Screw top M10 shock absorber 60 Nm 44 3 lbf ft Loctite 2701 TM Position the rear frame Mount and tighten screws 0 on both sides Guideline Screw sub frame M8 Remove screws CD on both sides 35 Nm 25 8 lbf ft Loctite 2701 TM Mount and tighten screws CD ...

Page 86: ...k Install the main silencer p 85 Install the right side cover p 91 Mount the seat p 91 Remove the motorcycle from the lift stand p 12 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down before performing any work on the vehicle Preparatory work Remove the right side cover p 91 Main work Disconnect spri...

Page 87: ... out Not only is the noise level higher the performance characteristic changes M00435 10 Preparatory work Remove the right side cover p 91 Remove the main silencer p 84 Main work FE EU AU Remove all screws on the main silencer Take off silencer cap O and 0 ring 8 Take off outer tube 6 and 0 ring e Remove glass fiber yarn filling 0 from inner tube D Clean the parts that need to be reinstalled and c...

Page 88: ...uter tube a Mount and tighten screws Guideline Screws on the main silencer M5 Mount O ring CD on the silencer cap 7 Nm 5 2 lbf ft Fit the new glass fiber yarn filling onto the perforated pipe Fit the connecting cap with the glass fiber yarn filling in the outer tube Info Press the glass fiber yarn filling into the outer tube using a blunt tool Mount and tighten screws 0 Guideline Screws on the mai...

Page 89: ...without an air filter Never start to use the vehicle without an air filter 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 a p 87 Main work Push air filter holding bracket O toward the air filte...

Page 90: ...tal 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 Do not clean the air filter with fuel or petroleum since these substances attack the foam Preparatory work Remove the air filter box cover a p 87 Remove the air filter p 87 Main work Wash the air filter thoro...

Page 91: ...rk Install the air filter p 88 Install the air filter box cover 1ll p 87 Preparatory work Remove the air filter box cover 1ll p 87 Main work Seal the air filter box in the marked area f Finishing work Install the air filter box cover p 87 11 AIR FILTER 89 ...

Page 92: ... Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Warning Environmental hazard I...

Page 93: ...nd tighten screw O Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Remove screws O in the recessed grips on the left and right Lift the seat at the rear pull it back and take it off toward the top Mount the front of the seat on the collar bushing of the fuel tank lower the seat at the rear while pushing it forward The seat is correctly engaged Mount and tighten the screws for securing the s...

Page 94: ...o 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 Preparatory work Remove the seat I p 91 Main work Unplug connector O of the fuel ...

Page 95: ...ator bracket and lift off the fuel tank Installing the fuel tank Danger Fire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe ...

Page 96: ... throttle cables are trapped or damaged Attach the hose to the fuel tank breather on the tank lid Mount and tighten screw O with the rubber bushing Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the collar bushings and horn and mount and tighten screws Guideline Remaining screws chassis M6 Connect the connector of the horn Plug in connector fs for the fuel pump Remove the wash cap...

Page 97: ... 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 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 Clean plug in connection O of t...

Page 98: ...rts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water ...

Page 99: ... TRIM Main work Remove nut O with the gasket Remove fuel connection with the gasket Remove screws 8 Pull out the fuel pump Remove hose clamps e Remove fuel filter 0 Press lock 0 Pull back fuel pump housing Change fuel screen fD Mount the fuel pump housing 97 ...

Page 100: ...l connection on fuel pump M8 Mount and tighten screws D Guideline I Screw fuel pump I EJOT PT Finishing work Install the fuel tank p 93 Mount the seat ll J p 91 15 Nm 11 1 lbf ft 10 Nm 7 4 lbf ft I 3 Nm 2 2 lbf ft 12 11 Changing the fuel um 98 Danger Fire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicini...

Page 101: ...ren 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 Preparatory work Drain the fuel from the fuel tank into a suitable container Remove the seat Ip 91 Remove the fuel tank Ip 92 Main work Remove nut O with the gasket Remove fuel connection 8 with the gasket Remove scre...

Page 102: ...el is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact 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 ...

Page 103: ...ion of the actuator test 3 min Check the fuel pressure with the filler cap closed Fuel pressure When the fuel pump is active 1 3 35 3 65 bar 48 6 52 9 psi If the specification is not reached Open the filler cap p 90 Check the tank air vent system Check the fuel pressure with the filler cap open Fuel pressure When the fuel pump is active 1 3 35 3 65 bar 48 6 52 9 psi If the specification is not rea...

Page 104: ... harness out of the brake line guide Remove screws s Take off the fender Main work Position front fender Mount and tighten screws 0 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake line and wiring harness in the brake line guide Mount and tighten screws 8 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Connect plug in connectors s of the turn signals Finishing work ...

Page 105: ...nnector fD Take off the headlight mask with headlight 13 4 Installing the headlight mask with the headlight Main work Plug in connector 0 Check that the lighting is functioning properly Attach headlight holder 8 at catch fD and position the headlight mask Position rubber bands 8 around the fork legs and close them The wiring harness and brake line 0 are routed in front of the headlight mask Finish...

Page 106: ...ondition Info Only mount tires approved and or recommended by Husqvarna Motorcycles Other tires could have a negative effect on handling characteristics The type condition and air pressure of the tires all have a major impact on the handling of the motorcy cle The tires mounted on the front and rear wheels must have a similar profile Worn tires have a negative effect on handling characteristics es...

Page 107: ... the tires Checking the wheel bearing for la Preparatory work Raise the motorcycle with a lift stand I p 12 Place a load on the rear of the vehicle The front wheel is not in contact with the ground Main work Move the front wheel from side to side Info Hold the fork leg to check it If there is detectable play Change front wheel bearing a p 110 Place a load on the front of the vehicle The rear wheel...

Page 108: ...the brake disc exhibits damage cracking or deforma tion Change the brake disc Danger 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 lateral and radial run out will form in the wheel Other spokes will become looser as a ...

Page 109: ...s a result Check spoke tension regularly and in particular on a new vehicle Info A loose spoke can unbalance the wheel and other spokes may loosen within a short period If the spokes are too tight they can break due to local overload Check the spoke tension regularly especially on a new motorcycle Check for lateral and radial run out of the rims Lateral runout Outside the rim joint 1 8 mm 0 071 in...

Page 110: ...spokes when pushing back the brake pis tons Loosen screw O by several rotations Loosen screws 8 Press on screw O to push the wheel spindle out of the axle clamp Remove screw O Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Holding the front wheel withdraw the wheel spindle Take the front wheel out...

Page 111: ...cers 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 Screw front wheel spindle M24x1 5 45 Nm 33 2 lbf ft Activate the hand brake lever multiple times until the brake linings are in contact with the brake disc Remove the motorcycle from the lift stand p 12 Pull the front brake and compress the fork forc...

Page 112: ... ft Loctite 243 Changing front wheel bearing Preparatory work Raise the motorcycle with a lift stand p 12 Remove the front wheel p 108 Main work Remove shaft seal rings O and 8 Press out bearing 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 new bearing 0 all the way using a suitable tool Info Only press th...

Page 113: ...2 Main work Press the brake caliper onto the brake disc by hand in order to push back the brake piston Info 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 8 Pull out wheel spindle 8 far enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Remove the chain from...

Page 114: ...king effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Main work Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change the rear wheel bearing a p 120 Clean and grease shaft seal rings O and bearing surface f of the spacers I Long life grease p 308 Insert the spacers Lift the rear wheel into the swi...

Page 115: ...peatedly until the brake lin ings are in contact with the brake disc and there is a pressure point Finishing work Remove the motorcycle from the lift stand i ll p 12 Removing the rear brake disc Installing the rear brake disc Preparatory work Raise the motorcycle with a lift stand a p 12 Remove the rear wheel a p 111 Main work Remove screws 0 Take off the brake disc Main work Clean the contact sur...

Page 116: ...tion O must be taut Chain wear is not always even so you should repeat this measurement at different chain positions I Chain tension 1 55 58 mm 2 17 2 28 in If the chain tension does not meet specifications Adjust the chain tension 0 p 114 Finishing work Remove the motorcycle from the lift stand 0 p 12 14 8 6 Adjusting the chain tension 114 Warning Danger of accidents Incorrect chain tension damag...

Page 117: ... Guideline Nut rear wheel spin M20x1 5 die Info 80 Nm 59 lbf ft I The wide adjustment range of the chain adjusters 32 mm 1 26 in enables different secondary ratios with the same chain length Chain adjusters C can be turned by 180 Finishing work Remove the motorcycle from the lift stand p 12 Checking the chain rear sprocket motor sprocket and chain guide Preparatory work 400227 01 Raise the motorcy...

Page 118: ...on 272 mm 10 71 in If distance D is greater than the specified measurement Change the drivetrain kit p 118 Info I When the chain is replaced the rear sprocket and engine 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 slidin...

Page 119: ...piece Guideline Screw chain slid M8 ing piece Check the chain guide for wear Info 15 Nm 11 1 lbf ft Wear can be seen on the front of the chain guide If the light part of the chain guide is worn Change the chain guide Check that the chain guide is firmly seated If the chain guide is loose Tighten the chain guide Guideline Remaining M6 10 Nm 7 4 lbf ft screws chassis Remaining nuts M6 10 Nm 7 4 lbf ...

Page 120: ...e brake discs with brake cleaner when necessary 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 The service life of the chain depends largely on its maintenance 400725 01 Preparatory work Raise the motorcycle with a lift stand a p 12 Main...

Page 121: ...Remove the rear wheel a p 111 Remove connecting link C of the chain Info Cover the components to protect them against dam age Take off the chain Remove engine sprocket 0 Remove fittings D Take off the rear sprocket Position the new rear sprocket Mount and tighten the fit tings Guideline Nut rear MB sprocket screw 35 Nm 25 8 lbf ft Loctite 2701TM 119 ...

Page 122: ...ten screw D with the washer Guideline Screw engine sprocket M10 Position the engine sprocket cover Mount and tighten screw O Guideline Screw clutch slave cylinder M6 Mount and tighten screw 8 Guideline Remaining screws chassis Finishing work M8 60 Nm 44 3 lbf ft Loctite 2701TM 10 Nm 7 4 lbf ft 25 Nm 18 4 lbf ft Remove the motorcycle from the lift stand p 12 14 8 11 Changing the rear wheel bearing ...

Page 123: ...earing 8 out from the inside to the outside Remove spacing tube 0 Using a suitable tool press bearing Q out from the inside to the outside Press new bearing Q all the way in from the outside to the inside Info Only press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in 121 ...

Page 124: ... the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in Grease new shaft seal ring 8 and press it in until it is flush Mount lock ring 8 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 0 p 112 Remove the motorcycle from the lift stand p 12 ...

Page 125: ... low beam parking light tail light license plate lamp Fuse 4 10 A horn brake light turn signal radiator fan Fuses res 10 A spare fuses Info I A defective fuse is indicated by a burned out fuse wireG Warning Fire hazard Incorrect fuses overload the electrical system Only use fuses with the required ampere value Do not bypass or repair fuses Use spare fuses with the correct rating only I Fuse 750110...

Page 126: ...ch off the engine Remove the air filter box cover p 87 Main work Remove protection caps O Remove the faulty main fuse 8 Info 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 p 251 Check that the electrical equipment is functioning properly Tip I Insert the spare fuse so that it is available ...

Page 127: ...Wear suitable protective clothing and safety glasses Avoid contact with battery acid and battery gases Keep sparks or open flames away from the battery Only charge batteries in well ventilated rooms Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes with water for at least 15 minutes and consult a doctor immediately if battery acid and battery...

Page 128: ...tive terminal Finishing work Mount the seat 0 p 91 Recharging the batte 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 safety glasses Avoid contact with battery acid and battery gases Keep sparks or open flames away from the battery Only charge batteries in well ventilated rooms Ri...

Page 129: ...n a discharged state for an extended period it will become over discharged and sul fated destroying the battery The battery is maintenance free i e the acid level does not have to be checked 311910 10 Preparatory work Remove the seat ill p 91 Main work Connect the battery charger to the battery Adjust the battery charger EU battery charger XCharge professional 00029095050 p 310 Alternative 1 US ba...

Page 130: ...ltage regu lator to the wiring harness Check the stator winding of the alternator a p 240 If the displayed value is greater than the specified value Change the voltage regulator Checking the o en circuit current Preparatory work Switch off all power consumers and switch off the engine Remove the seat a p 91 Main work Disconnect the negative cable of the battery Measure the current between battery ...

Page 131: ...d causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid 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 ...

Page 132: ...rectly and in compliance with the applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container 100397 01 Move the brake fluid reservoir mounted on the handlebar to a hori...

Page 133: ...e Mount and tighten screws 0 Info Clean up overflowed or spilt brake fluid immediately with water Checking the free travel of the 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 specificat...

Page 134: ...sting screw counterclockwise to decrease the distance between the hand brake lever and 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 Adjusting free travel of hand brake lever FE EU AU B01638 10 Check the free travel of the hand brake lever Ip 131 Adjust the free travel of the hand brake lev...

Page 135: ...sufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the brake system is leaking or the brake linings are worn down Check the brake system and do not continue riding until the problem is eliminated Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wea...

Page 136: ...Brake fluid DOT 4 llill p 306 5 mm 0 2 in Position the cover with the membrane Mount and tighten the screws Chan in the front brake fluid Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Info Clean up overflowed or spilled brake fluid immediately with water Wear suitable protective clothing and safety glasses Do not allow brake fluid to come ...

Page 137: ... 0 p 310 Connect the bleeding device I Bleeding device 00029013100 p 310 Open shut off valve 8 Info Follow the operating instructions of the bleeding device Ensure that the filling pressure is correctly set at pressure gauge f If necessary adjust the filling pressure at pressure regulator C Guideline I Filling pressure I 2 2 5 bar 29 36 psi Pull off protection cap 0 of the brake caliper bleeder sc...

Page 138: ...and brake lever for a firm pressure point Checking the rear brake linings Warning Danger of accidents Worn out brake linings reduce the braking effect Ensure that worn out brake linings are replaced immediately Chan in Warning Check the brake linings for minimum thickness fj I Minimum thickness fj I 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings l l p 13...

Page 139: ...th brake cleaner when necessary Warning Danger of accidents Brake linings which have not been approved alter the braking efficiency 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 linings If brake linings are used that differ from the original ...

Page 140: ...ter pins pull out pin C and remove the brake linings Clean the brake caliper and brake caliper support Check that leaf spring 0 in the brake caliper and sliding plate D in the brake caliper support are seated correctly The arrow on the leaf spring points in the rotation direc tion of the brake disc Insert the new brake linings insert pin C and mount cotter pins Info I Always change the brake linin...

Page 141: ...ee travel on the foot brake lever pressure builds up in the brake system on the rear brake Set the free travel on the foot brake lever in accordance with the specification 402026 10 Disconnect spring O Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel f Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in I...

Page 142: ...sary adjust the basic position of the foot brake lever Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in M00410 10 Hold screw 8 and tighten nut fj Guideline Nut foot brake lever MS stop Hold push rod 3 and tighten nut C Guideline Remaining nuts chassis Reconnect spring O M6 Checking the rear brake fluid level Warning 20 Nm 14 8 lbf ft 10 Nm 7 4 lbf ft Danger of accidents An insufficient...

Page 143: ...ake 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 144: ... into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Environmental hazard ...

Page 145: ...essure gauge f If necessary adjust the filling pressure at pressure regulator C Guideline I Filling pressure I 2 2 5 bar 29 36 psi Pull off protection cap C of the bleeder screw Connect the hose of the bleeder bottle I Bleeding device 00029013100 p 310 Open bleeder screw by approx one half turn Info I Bleed until new brake fluid emerges from the bleeder bottle hose without bubbles Tighten the blee...

Page 146: ...pright Correct the brake fluid up to marking I Brake fluid DOT 4 p 306 Fit and tighten plug with oil screen and O ring Info Clean up overflowed or spilt brake fluid immediately with water Check the foot brake lever for a firm pressure point ...

Page 147: ...item The 0 symbol flashes Press one of the buttons to select the 24h or 12h display of the clock Wait for 5 seconds Combination instrument 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 Combination instrument changes to the next menu item The symbol flas...

Page 148: ...3 5 seconds The Setup menu is displayed The UNIT display flashes Press one of the buttons to select UNIT for the speed in kilo meters KM H or miles M H Condition The motorcycle is stationary Press and hold 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...

Page 149: ...creases Enlarging the wheel circumference Press the right button The value increases Finishing work Disconnect speedometer connector CZ 17 5 Ad usting the service dis la 1 15 nn ART I I LIU 401913 01 Condition The motorcycle is stationary Press and hold both buttons for 3 5 seconds The Setup menu is displayed The UNIT display flashes Wait for the menu of the service display to flash Adjust the ser...

Page 150: ...down on the motorcycle Switch on the low beam Check the headlight setting The boundary between light and dark must be exactly on the lower mark for a motorcycle with rider If the light dark border does not meet specifications Adjust the headlight range 0 p 148 Preparatory work Check the headlight setting 0 p 148 Main work Adjust the headlight range of the headlight by turning adjust ing screw O Gu...

Page 151: ...de cover Ii p 91 Remove the main silencer Ii p 84 Remove the seat Ii p 91 Remove the fuel tank Ii p 92 Main work Remove screw O Disconnect the negative cable of the battery Loosen hose clip 8 Pull back the protection cap Unplug connector 5 Remove screws C Take off the intake air temperature sensor Push back hose clamp 0 Pull off the air release hose 18 ENGINE 149 ...

Page 152: ... 150 Remove screws D Loosen screw Repeat these steps on the opposite side Pivot up the subframe and secure it Remove screw Swing the shock absorber to the rear Remove springs C I Spring hook 50305017000 a p 312 ...

Page 153: ... the manifold Push back the cover Remove nut D Take off the cable Loosen hose clips Pull off the radiator hoses Detach spring 48 Pull back the protection cap Unplug connector e Disconnect the spark plug connector 18 ENGINE 151 ...

Page 154: ...in Remove the cable ties Remove screws 48 Take off the slave cylinder of the clutch and hang it to one side Info Do not kink the clutch line Do not activate the clutch lever while the slave cylin der of the clutch is removed Loosen hose clip 4E Pull off the throttle valve body to the rear Loosen hose clip G Pull off the radiator hose ...

Page 155: ...move the swingarm pivot Pull the swingarm slightly toward the rear Remove screws Lift out the engine sideways Info The help of an assistant is useful in this step Make sure that the engine is sufficiently secured against falling over 18 ENGINE Protect the frame and attachments against damage 153 ...

Page 156: ...gine attachment bolt Position the swingarm M10 Mount the swingarm pivot 60 Nm 44 3 lbf ft Mount nut 8 but do not tighten it yet Guideline I Nut swingarm pivot I M16x1 5 Plug in connector CD Plug in connector 8 Position the engine braces Mount and tighten fittings 0 Guideline Screw engine brace MB Tighten screws O and nut 8 Guideline Engine attachment M10 bolt Nut swingarm pivot M16x1 5 1100 Nm 73 ...

Page 157: ...Guideline Screw clutch slave cylinder Mount the chain M6 10 Nm 7 4 lbf ft Connect the chain with connecting link Guideline The closed side of the chain joint lock must face in the direction of travel Position the engine sprocket cover Mount and tighten screw Ci Guideline Screw clutch slave cylinder M6 Mount and tighten screw 48 Guideline 10 Nm 7 4 lbf ft Remaining screws chassis M8 25 Nm 18 4 lbf ...

Page 158: ...ection cap Plug in the spark plug connectors Mount spring G Mount the radiator hoses Position and tighten hose clips 4D Position the cable Mount and tighten nut 48 Position the cover Position the manifold and mount springs I Spring hook 50305017000 p 312 ...

Page 159: ...4 3 lbf ft Loctite 2701 TM Remove the locking piece and position the subframe Info Watch out for the intake flange Mount and tighten screws G Guideline Screw sub frame Remove screw fl MB Mount and tighten screw fl Guideline Screw sub frame M8 35 Nm 25 8 lbf ft Loctite 2701 TM 35 Nm 25 8 lbf ft Loctite 2701 TM Repeat these steps on the opposite side Mount the vent hose Position hose clamp G 157 ...

Page 160: ... Screw battery termi M5 nal Info 2 5 Nm 1 84 lbf ft I The contact disk f must be mounted between the battery terminal and the cable lug with the claws fac ing upward Refill the coolant p 232 Install the main silencer p 85 Remove the motorcycle from the lift stand p 12 Install the fuel tank p 93 Mount the seat p 91 Remove oil filler plug i on the clutch cover and fill up with engine oil Engine oil ...

Page 161: ...eck the engine oil level l I p 234 Check the coolant level l I p 231 Execute the initialization run l I p 244 Finishing work Take a test ride Read out the fault memory using the Husqvarna Motorcycles diagnostics tool Check the engine for leak tightness Check the engine oil level l I p 234 Check the coolant level 0 p 231 Install the engine guard 0 p 47 Mount the special tool on the engine assembly ...

Page 162: ...e oil screen plug Completely drain the engine oil Remove engine oil screen Remove engine oil screen plug 8 Removing the clutch push rod Removing the oil filter Remove clutch push rod 0 Remove screws 0 Remove oil filter cover 8 with the O ring ...

Page 163: ... Pull oil filter D out of the oil filter housing I Lock ring plier 51012011000 i l p 313 Remove screws O and take off the starter motor Remove the spark plug using the special tool I Spark plug wrench with link 77229172000 p 318 18 ENGINE Remove screws O Remove the valve cover with the valve cover seal 161 ...

Page 164: ...over Remove centering pins 8 Take off the alternator cover gas ket Positioning the engine at ignition top dead center Turn the crankshaft counterclockwise until the markings G are flush with the marking 0 on the cylinder head Remove screw O Screw in special tool 8 Locking screw 113080802 ill p 311 ...

Page 165: ...e screw O Remove screw 8 Take off the chain adjuster with the gasket 18 3 11 Removing the camshaft Remove screw O Remove the camshaft support plate 8 Pull the camshaft out of the bearing seats Take the timing chain off the camshaft gear Remove the camshaft 163 ...

Page 166: ...linder head gasket Push the cylinder upward Info Only push the cylinder as far up as necessary to take the piston pin out Remove the piston pin retainer O Remove the piston pin Take off the cylinder and piston Push the piston upward out of the cylinder Info If no further work is to be performed on the cylinder and piston the piston can remain in the cylinder Take off dowels and cylinder base gaske...

Page 167: ...Remove the woodruff key 18 3 15 Removing the timing chain guide rail Remove screw O Take off timing chain guide rail 4i toward the top 18 3 16 Removing the timing chain tensioning rail Remove screw O Remove the timing chain tensioning rail from above 18 3 17 Removing the timing chain securing guide Remove screws O Take off the timing chain securing guide 41 165 ...

Page 168: ...travel 18 3 19 Removing the ignition pulse generator 18 3 20 Removing the suction pump 166 Remove screws O Pull the cable support sleeve from the engine case Take off the crankshaft position sensor Remove screws O Take off oil pump cover 8 of the suction pump Remove external rotor and internal rotor C ...

Page 169: ...ing the clutch cover Remove screws O Take off the water pump cover Take off the water pump cover seal Remove screws O Take off the clutch cover Info I If work is to be performed on the water pump unscrew the nut of the water pump impeller Take out dowels Take off clutch cover gasket 8 18 ENGINE 167 ...

Page 170: ...3 23 Removing the clutch discs 168 Remove screws O Take off spring retainer Take off spring washer Take off pretension ring C Take off pressure cap 0 Completely remove clutch disc pack D Remove clutch pressure piece ...

Page 171: ...o I LH thread Remove nut 18 3 25 Removing the outer clutch hub Bend up the lock washer Hold the inner clutch hub with the special tool Loosen nut O I Holding wrench 51129003000 p 313 Remove the nut with the lock washer Dispose of the lock washer Take off inner clutch hub and washer Info The washer usually sticks to the inner clutch hub Take off 8 Take off both needle bearings 0 and collar bushing ...

Page 172: ...he shift shaft Remove the lock ring Take off the washer Take off starter idler gear O Push sliding plate O away from the shift drum locating unit Remove shift shaft with the washer 18 3 29 Removing the shift drum locating unit 170 Remove screw O Push away locking lever from shift drum locating unit D and remove the shift drum locating unit Relieve tension from the locking lever ...

Page 173: ...ve together with locking lever washer sleeve and spring 18 3 31 Removing the oil pump gear wheels Remove lock ring O Take off washer Remove oil pump idler gear s Remove lock washer 8 Take off washer Take off oil pump gear wheel C Remove pin 18 ENGINE 171 ...

Page 174: ...shaft 0 inward and take it out of the engine from the ignition side Insert special tool O in the crankshaft I Protection cap 75029090000 a p 317 Install special tool 8 I Puller 75029021000 a p 316 Hold it using the special tool and pull off the primary gear by turning the screw in Remove the special tools 18 3 34 Removing the freewheel gear 172 Remove woodruff key O Take off freewheel gear ...

Page 175: ...o I Use the drill hole with marking 781 18 ENGINE Tilt the left section of the engine case upward and remove the fitting of the engine fixing arm Pull off the section of the engine case Info I Do not tension the section of the engine case Remove the special tool Take off the left section of the engine case Remove spacer Remove dowels 8 173 ...

Page 176: ...rks Remove shift rails O together with upper springs 8 and the lower springs Tilt shift forks O to the side Info Do not misplace the shift rollers Remove shift drum Take shift forks O out of the shift grooves Info Do not misplace shift rollers 8 18 3 39 Removing the transmission shafts Remove O ring O 174 ...

Page 177: ...ial tool to the crankshaft I Protection cap 75029090000 p 317 Mount special tool O onto the engine case with suitable screws I Puller 90129048100 p 321 Press the crankshaft out of the bearing seat Take out crankshaft Remove the special tools Take off the right section of the engine case Working on individual parts Work on the right section of the engine case Preparatory work Remove the oil pressur...

Page 178: ... collar on the inside Press in the shaft seal ring from the outside toward the inside with the open side facing outward Warm the engine case section again Guideline 1150 C 302 F 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 from the inside to the outside all the way to the stop or so it is flush In...

Page 179: ... all remaining dowels Remove screw O Remove oil spray tube 8 Remove screws Remove membrane support plate C and the membrane Remove countershaft shaft seal ring 0 and shift shaft C Info The shaft seal ring of crankshaft can only be removed after the crankshaft bearing has been taken out because of a small external collar Remove screws 8 Remove membrane support plate 0 and the membrane Remove any re...

Page 180: ...s flat in order prevent damage Only press the bearings in using the outer bearing race otherwise the bearings will be damaged when they are pressed in After the section of the engine case has cooled check that the bearings are firmly seated Info If the bearings are not firmly seated after cooling it is likely that they will rotate in the engine case when warm In this case the engine case must be r...

Page 181: ...r 8 Remove pressure spring CD and ball e 18 4 4 Checking spring length of oil pressure regulator valve 200155 10 Preparatory work Remove the oil pressure regulator valve l p 179 Main work Measure the spring length of the oil pressure regulator valve Oil pressure regulator valve Minimum length of preload spring 1 23 5 mm 0 925 in If the measured value does not meet specifications Change the spring ...

Page 182: ...n the clutch cover 18 4 7 18 4 8 180 309242 10 Remove the crankshaft seal ring in clutch cover O Installing the crankshaft seal ring in the clutch cover 309242 10 Removing the water pump 309243 10 Press crankshaft seal ring O into the clutch cover with the open side flush toward the inside Grease the sealing lip Remove nut O Remove water pump impeller Info If the water pump impeller cannot be deta...

Page 183: ...water pump shaft bearing 0 toward the inside with an appropriate tool Info Suitably support the clutch cover while pressing it out Press water pump shaft bearing O in until it is flush using the appropriate tool Info Support the clutch cover sufficiently when pressing in Press shaft seal ring 8 all the way in 181 ...

Page 184: ...243 309243 11 18 4 10 Removing the timing chain sprocket Warm up the timing chain sprocket O with a blow dryer Pull off the timing chain sprocket with the special tool I Puller 60029033000 I p 315 Info I The timing chain sprocket is usually damaged by the disassembly and must be replaced 304702 10 I E 18 4 11 Installing the timing chain sprocket Info I Never clamp the crankshaft with a crankshaft ...

Page 185: ...bearing and crank pin 304715 10 Main work Position the crankshaft with special tool O in the press I Separator plate 78029009100 ll l p 319 Press the crank pin out of the upper crankweb with special tool I Crankshaft pressing tool 75029047000 p 316 Info I Hold the lower crankweb Take off the connecting rod and bearing Press crank pin fD out of the lower crankweb 41 183 ...

Page 186: ...ls to check that they are clear Mount new connecting rod CD Info Lubricate bearing thoroughly Position special tools and 0 on the press Crankshaft pressing tool 75029047000 p 316 Crankshaft pressing tool insert 78029008000 l I p 319 Insert the crankweb with the connecting rod and bearing Position the second crankweb Position special tool C with the heel pointing down I Crankshaft pressing tool ins...

Page 187: ...rankshaft run out at the bearing pin is larger than the specification Align the crankshaft Nikasil is a surface protection layer for a coating procedure developed by Mahle The name is derived from the two materials used in this procedure a layer of nickel into which is embedded the particularly hard silicone carbide The most important advantages of the Nikasil coating are very good heat conductivi...

Page 188: ...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 I Mount the piston ring with the marking facing upward Chec...

Page 189: ...ton ring end gap Compression ring I S 1 00 mm S 0 0394 in Oil scraper ring I S 1 20 mm S 0 0472 in I Feeler gauge 59029041100 il ll p 314 If the end gap is greater than the specified value Check measure the cylinder il l p 185 If cylinder wear lies within the specified tolerance Change the piston ring Mount the piston ring with the marking facing upward 18 4 18 Measuring the piston cylinder mounti...

Page 190: ...8 p 314 Oil pump External rotor engine case clearance I s 0 20 mm S 0 0079 in If the measured value does not meet specifications Change the oil pump and if necessary the engine case Use special tool O to measure the play between the exter nal rotor and the internal rotor I Feeler gauge 59029041100 p 314 Oil pump External rotor internal rotor clearance I s 0 20 mm s 0 0079 in If the measured value ...

Page 191: ...1 304674 11 304673 11 Insert long flange O of the autodecompression spring in the hole push the autodecompression spring over bearing bolt 8 and hook it into autodecompression weight fD Mount autodecompression shaft 8 in the camshaft Mount new lock ring Perform a function check The autodecompression spring does not turn the autode compression shaft back to the stop Pre tension the autodecompressio...

Page 192: ... 3346 1 3425 in Camshaft cam height all 501 models Intake 1 34 40 34 60 mm 1 3543 1 3622 in If the measured value does not meet specifications Change the camshaft 18 4 23 Checking the timing assembly 8 JI Clean all parts well Check the timing chain gear timing chain sprocket O for damage and wear If there is damage or wear Change the camshaft timing chain sprocket Check the timing chain tensioning...

Page 193: ... straight line Replace the timing chain 18 4 24 Removing the rocker arm 308885 10 308886 10 18 4 25 Removing the valves Remove screws O and 8 of the rocker arm shafts Remove plugs with the O rings Screw appropriate screw C into the rocker arm shafts Pull out rocker arm shafts 0 Take off rocker arm 0 Take the shims out of the valve spring retainers and lay them to one side according to their normal...

Page 194: ...tion position and label them 200189 10 18 4 26 Changing the camshaft bearing Condition 192 Valves are removed Mount the cylinder head I Clamping plate 75029050000 l l p 317 Remove the large camshaft bearing using the special tool I Pressing tool 75029051000 p 317 Remove small camshaft bearing O using the special tool Bearing puller 15112017000 p 312 Internal bearing puller 15112018100 p 312 Press ...

Page 195: ...asured value does not meet specifications Change the valve Check sealing seat 6 on the valve Valve Intake sealing seat width 2 00 mm 0 0787 in Valve Exhaust sealing seat width 1 2 00 mm 0 0787 in If the sealing area is not in the center of the valve seat or deviates from the specified value Rework the valve seat Check the valve springs for breakage and wear visual check If the valve spring is brok...

Page 196: ...st valve guides O using the special tool I Limit plug gauge 77029026000 ill p 318 If the special tool is easy to insert in the valve guide Change the valve guide and valve Check intake valve guides 8 using the special tool I Limit plug gauge 59029026006 ill p 314 If the special tool is easy to insert in the valve guide Change the valve guide and valve Check the sealing area of the spark plug threa...

Page 197: ...8 4 31 Checking the rocker arm shafts 301119 10 18 4 32 Installing the valves 304686 11 308887 10 Check the rocker arm shafts for damage and wear If there is damage or wear Change the rocker arm shafts Position valve spring seats 0 Mount the new valve stem seals Mount the valves according to their normal built in position Mount the springs and spring retainers CD Pretension the valve springs using...

Page 198: ...tallation position Position rocker arm O and push in rocker arm shafts Markings f face upward Info Make sure that the tapped hole of the rocker arm shaft is facing outward Align drill holes D in the rocker arm shafts with drill holes C in the cylinder head Install and tighten screws and D of the rocker arm shafts Guideline Screw rocker arm bearing M7x1 15 Nm 11 1 lbf ft Install and tighten screw p...

Page 199: ...ing Check spring washer 0 for damage and wear If there is damage or wear Change the spring washer Check the contact surface of pressure cap D for damage and wear If there is damage or wear Change the pressure cap Check clutch center for damage and wear If there is damage or wear Change the clutch center Check damping rubber pieces fD for damage and wear If there is damage or wear Change the dampin...

Page 200: ...ge all clutch facing discs Check the thickness of clutch facing discs CD I Clutch facing disc thickness I 1 9 mm 0 075 in If the clutch facing disc does not meet specifications Change all clutch facing discs 18 4 35 Checking the shift mechanism e Check shift forks O at leaf G for wear Shift fork J0 304687 10 Thickness at leaf 4 85 4 95 mm 0 1909 0 1949 in If the measured value does not meet specif...

Page 201: ...liding plate is worn Change the sliding plate Check return surface 0 on the sliding plate for wear If there is severe grooving Change the sliding plate Check guide bolts for firm seating and wear If the guide bolts are loose or worn Change the sliding plate Preassemble the shift shaft l JJ p 199 Check clearance 4 between the sliding plate and the shift 304682 10 18 4 36 Preassembling the shift sha...

Page 202: ...6th gear idler gear D Remove the split needle bearing 8 and stop disk t Remove lock ring D Remove 3rd 4th gear sliding gear Remove lock ring fD Remove stop disk 0 and 5th gear idler gear Remove split needle bearing 48 18 4 38 Assembling the main shaft Info Use new lock rings with every repair Preparatory work Lubricate all parts carefully before assembling Check the transmission p 203 200 304684 1...

Page 203: ...ith the shift dogs facing up Mount stop disk and lockring e Push on the third fourth gear sliding gear 0 with the small gear wheel facing downward and mount lock ring i Push on stop disk and split needle bearing Attach sixth gear idler gear with the shift dog facing downward Attach second gear fixed gear Ci with the collar facing downward and stop disk 48 Finally check all the gear wheels for smoo...

Page 204: ... sliding gear 0 and lock ring D Remove stop disk and third gear idler gear fD Remove needle bearing CD and fourth gear idler gear Remove needle bearing 48 and stop disk 48 Remove lock ring G and sixth gear sliding gear 4D Remove lock ring e and stop disk 40 Remove second gear idler gear 48 and needle bearing G i 18 4 40 Assembling the countershaft Info Use new lock rings with every repair Preparat...

Page 205: ...oove facing up Mount lockring D and stop disk Mount needle bearing C and the fourth gear idler gear with the collar facing up Mount needle bearing Ci and the third gear idler gear 48 with the collar facing down Mount stop disk 48 and lockring G Mount the fifth gear sliding gear 4D with the shift groove facing down and stop disk e Mount needle bearing Gs first gear idler gear 49 with the recess fac...

Page 206: ...s 8 and sliding gears 0 for damage and wear If there is damage or wear Change the gear wheel pair Check the tooth faces of idler gears e sliding gears 0 and fixed gear CD for damage and wear If there is damage or wear Change the gear wheel pair Check the tooth profiles of sliding gears 0 for damage and wear If there is damage or wear Change the gear wheel pair Check sliding gear 0 for smooth opera...

Page 207: ...ear If there is damage or wear Change the freewheel gear or bearing Check freewheel 8 for damage and wear when it is disassembled If there is damage or wear Change the freewheel Check the gear mesh of starter motor 0 for damage and wear If there is damage or wear Change the starter motor Change the O ring D of the starter motor 18 ENGINE Connect the negative cable of a 12 volt power supply to the ...

Page 208: ...heel 8 out of the primary gear Insert freewheel gear O into primary gear turning the primary gear clockwise do not wedge Check the locking action of freewheel gear O If the primary gear does not turn clockwise or if it does not lock counterclockwise Remove the freewheel ll J p 206 Turn the freewheel 180 Install the freewheel p 206 Thoroughly oil all parts Push the freewheel O into the primary gear...

Page 209: ...ine assembly stand Heat the crankshaft bearing Guideline 1 ao 0 c 176 F Info I Do not damage the seal ring Mount the special tool on the clutch end of the crankshaft I Protection cap 78029005000 a p 319 Push the crankshaft all the way into the bearing seat of the right section of the engine case Remove the special tool Installing the transmission shafts Lubricate all bearings Slide both transmissi...

Page 210: ...mount this in the shift groove of the main shaft Mount shift fork 8 in the lower shift groove of the counter shaft Mount shift fork 8 in the upper shift groove of the counter shaft Slide on shift rollers 8 Info Fix the shift rollers to the shift forks with grease Push shift drum O into the bearing seat Put shift forks 8 in the shift drum Info Do not misplace the shift rollers ...

Page 211: ...t Mount the left engine casing If necessary strike it lightly with a rubber mallet Info Do not use the screws to pull the two sections of the engine case together Mount screws but do not tighten them yet Guideline I Screw engine case I M6x40 I10 Nm 7 4 lbf ft Mount screws D but do not tighten them yet Guideline I Screw engine case I M6x60 110 Nm 7 4 lbf ft Mount screws C but do not tighten them ye...

Page 212: ... the cone and thinly apply thread locker to it I Loctite 648 Mount primary gear 8 Info Turn the freewheel gear to ease engagement Oil the oil pump shaft internal rotor and external rotor before assembly I Engine oil SAE 1 0W 50 l p 306 Mount oil pump shaft O Mount pin 8 Slide on the internal rotor with the marking facing outward Mount external rotor 8 with the marking facing inward Info The markin...

Page 213: ...nstalling the locking lever Insert pin O Position oil pump gear wheel Position washers D Mount lock washer C Mount oil pump idler gear 0 Mount washer D and lock ring Crank the oil pump gear wheels and ensure that they can move easily Mount locking lever O with the washer sleeve and spring Mount and tighten screw Guideline 41 Screw locking lever M5 6 Nm 4 4 lbf ft Loctite 243 41 211 ...

Page 214: ...e 243 Slide shift shaft O with the washer into the bearing seat Push sliding plate 8 away from the shift drum locating unit Insert the shift shaft all the way Let sliding plate 8 engage in the shift drum locating unit Shift through the transmission 18 5 14 Installing the starter idler gear 18 5 15 Installing the torque limiter 212 Slide on starter idler gear O with the collar facing the engine cas...

Page 215: ...tion the new lock washer and mount nut Tighten the nut holding the inner clutch hub with a special tool Guideline I Nut inner clutch hub I M18x1 5 I 80 Nm 59 lbf ft I Holding wrench 51129003000 a p 313 Secure the nut with the lock washer 18 5 17 Installing the primary gear nut Lock the outer clutch hub and primary gear using special tool O I Gear segment 80029004000 Ii p 320 Mount and tighten nut ...

Page 216: ...ng screw 113080802 llill p 311 Thoroughly oil the clutch facing discs Beginning with an intermediate clutch disc alternately insert all other clutch facing discs and intermediate clutch discs into the clutch basket Mount clutch throw out O Position pressure cap 8 Mount pretension ring D with marking Top facing up Position spring washer C ...

Page 217: ... Remove screws D and mount the spring retainer with marking II Using a straightedge and the special tool check the spring washer for distortion I Feeler gauge 59029041100 I p 314 Spring washer distortion 0 0 10 mm 0 0 0039 in If the specified value is not reached Remove screws D and mount the spring retainer with marking Ill Using a straightedge and the special tool check the spring washer for dis...

Page 218: ... lbf ft Mount screw 0 and tighten once all of the clutch cover screws have been mounted Guideline I Screw clutch cover I M6x55 110 Nm 7 4 lbf ft Mount screw D and tighten all screws in a crisscross pat tern Guideline I Screw clutch cover I M6x30 Remove the special tool 110 Nm 7 4 lbf ft I Marking mandrel 78129032000 p 320 18 5 20 Installing the water pump cover 216 Put the water pump cover seal in...

Page 219: ...ion pin into the oil pump shaft from above Position pin fD Mount internal rotor 8 and external rotor G The rounded sides of the external rotor face the engine case Position oil pump cover 0 Mount and tighten screws Guideline Screw oil pump M5 cover 6 Nm 4 4 lbf ft Loctite 243 18 5 22 Installing the ignition pulse generator Position the ignition pulse generator Info I Use the outer drill hole pair ...

Page 220: ...timing chain securing guide Mount and tighten screws O Guideline Screw timing M6 10 Nm 7 4 lbf ft chain securing Loctite 243 guide 18 5 25 Installing the timing chain tensioning rail Thread in the timing chain tensioning rail from the top Mount and tighten screw O Guideline Screw timing M6 10 Nm 7 4 lbf ft chain tension Loctite 243 ing rail 18 5 26 Installing the timing chain guide rail 218 Slip i...

Page 221: ...led piston on the cylinder Compress the piston rings using the special tool I Piston ring mounting tool 60029015000 a p 314 Tap lightly on the piston ring mounting tool from above with a plastic hammer so that it lies flush with the cylinder The special tool must press the piston rings together properly and lie flush with the cylinder Carefully tap the piston into the cylinder using the handle of ...

Page 222: ... toward the exhaust side Cover the engine case opening with a cloth Thread the tim ing chain through the chain shaft Mount the piston pin Info I In order to present them more clearly the following steps are shown with a removed piston Position the piston pin retainer ...

Page 223: ...Keep the timing chain taut Carefully push the cylinder downward letting the dowels engage Mount the dowels Put the new cylinder head gasket in place Put the cylinder head in place Put on the cylinder head bolt washers Mount cylinder head bolts O and tighten in a crisscross pat tern Guideline Screw cylinder M10x1 25 head Mount and tighten screw 8 Tightening sequence Tighten diagonally beginning wit...

Page 224: ...ach other Info Make sure that the crankshaft is at top dead center Position the camshaft support plate Mount and tighten screw O Guideline Screw M6 10 Nm 7 4 lbf ft camshaft Loctite 243 bearing support 18 5 31 Installing the timing chain tensioner 222 Activate release f and push the timing chain tensioner all the way back Position the timing chain tensioner with the gasket Mount and tighten screws...

Page 225: ...een the valve and rocker arm Guideline Valve clearance Exhaust at 20 C 68 F 0 12 0 17 mm 0 0047 0 0067 in Intake at 20 C 68 F 0 10 0 15 mm 0 0039 0 0059 in I Feeler gauge 59029041100 llill p 314 If the valve clearance does not meet specifications Adjust the valve clearance llill p 223 Remove the special tool I Locking screw 113080802 llill p 311 Mount and tighten screw with washer 18 5 33 Adjustin...

Page 226: ... alternator cover 18 5 35 Installing the valve cover 224 Mount locating pins Q Position alternator cover gasket Position the alternator cover Mount screws CD with washer and tighten after all of the alternator cover screws have been mounted Guideline Screw alternator cover M6x25 10 Nm 7 4 lbf ft Mount screws C and tighten all screws in a crisscross pat tern Guideline Screw alternator cover M6x25 P...

Page 227: ...nch with link 77229172000 p 318 Grease the O ring Position the starter motor Mount and tighten screws O Guideline I Screw starter motor I M6 110 Nm 7 4 lbf ft Tilt the motorcycle to one side and fill the oil filter housing to about 1 3 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 8 Mount and tighten screws Guidel...

Page 228: ...een with O rings onto a pin wrench Push the pin wrench through the opening into the drill hole of the opposite engine case wall and push the oil screen as far as possible into the engine case Mount and tighten engine oil screen plug with the O ring Guideline Screw plug engine oil screen M20x1 5 15 Nm 11 1 lbf ft Mount and tighten the oil drain plug 8 with the magnet and the new seal ring Guideline...

Page 229: ...the engine assembly stand Remove the fitting from the special tool 18 ENGINE I Holder and fitting for work stand 78029002000 p 319 Remove the engine from the engine assembly stand Info I Work with an assistant or a motorized hoist 227 ...

Page 230: ... of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info The fluid level rises with increasing wear of the clutch facing discs Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and clutch lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attac...

Page 231: ...C with the appropriate hydraulic fluid Syringe 50329050000 l p 312 Brake fluid DOT 4 l p 306 On the clutch slave cylinder remove bleeder screw 0 and mount bleeding syringe C Inject the liquid into the system until it escapes from open ings D of the master cylinder without bubbles To prevent overflow drain fluid occasionally from the master cylinder reservoir Remove the bleeding syringe Mount and t...

Page 232: ...n provides extra cooling It is controlled by a ther moswitch Checking the antifreeze and coolant level Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not open the radiator 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 do...

Page 233: ...gine to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediate...

Page 234: ...ately with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing Condition The engine is cold Position the motorcycle upright Place a suitable container under the water pump cover Remove screw O Take off radiator cap Completely drain the coolant Mount...

Page 235: ...w O is tightened Stand the vehicle upright Pour coolant in up to measurement 6 above the radiator fins Guideline I 10 mm 0 39 in I Coolant 11 2 I 1 3 qt I Coolant p 306 Refit the radiator cap Finishing work Take a short test ride Check the coolant level p 231 233 ...

Page 236: ...e engine is at operating temperature Preparatory work Stand the motorcycle upright on a horizontal surface Main work Check the engine oil level Info After switching off the engine wait one minute before checking the level I The engine oil level is between e and es When the engine oil level is below the 6 marking Add engine oil p 237 When the engine oil level is at or above the 0 marking Correct th...

Page 237: ...of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Drain the engine oil only when the engine is warm Preparatory work Remove the engine guard 0 p 47 Park the motorcycle on a level surface Main work Place a suitable container under the engine Remove oil drain plug O with the magnet and seal ring Remove screw plug 8 with the g...

Page 238: ... Push the oil screen all the way into the engine case Mount and tighten screw plug D with the O ring Guideline Screw plug engine oil screen M20x1 5 15 Nm 11 1 lbf ft Mount and tighten the oil drain plug O with the magnet and a new seal ring Guideline Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Remove screws Remove the oil filter cover with the O ring Pull oil filter D out of the oil filte...

Page 239: ... 1 50 I 1 59 qt Engine oil SAE 1OW 50 l p 306 I Too little engine oil or poor quality engine oil results in premature wear to the engine Install and tighten the oil filler plug with O ring 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 extr...

Page 240: ...ent 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 Finishing work Check the engine oil level Ip 234 Main work Place a suitable container under the engine Remove screws O Remove the oil filter cover with the O ring Remove the oil filter I Lock ring plier 510120110...

Page 241: ... F Engine speed 6 000 rpm 0 9 bar 13 psi 2 5 bar 36 psi If the measured value is less than the specification Check the oil pumps for wear Check all oil channels for free flow Switch off the engine 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 Remov...

Page 242: ...spark plug connector 1 601170 10 Condition Spark plug connector cylinder 1 has been removed 0 Measure the resistance between the specified points Measuring point 1 Measuring point 2 Spark plug connector Resistance at 20 C 68 F 1 3 75 6 25 kn If the specification is not reached Change the spark plug connector Alternator checkin the stator windin EZ 601211 10 Condition The stator is disconnected Pre...

Page 243: ... Change the stator Stator winding check for a short circuit to ground terminal 31 Measure the resistance between the specified points Stator connector EZ pin 1 Measuring point Ground I Resistance I oo Q If the value displayed does not meet specifications Change the stator 22 4 Removing the stator Condition The alternator cover has been removed Remove screw O and take off the cable holder Remove ca...

Page 244: ...alternator cover Mount and tighten screws O Guideline Screw stator M5 6 Nm 4 4 lbf ft Loctite 243 Position cable support sleeve 8 in the alternator case Position the cable holder Mount and tighten screw fD Guideline Screw cable M4 4 Nm 3 lbf ft holder in alter Loctite 243 nator cover ...

Page 245: ...r 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 243 ...

Page 246: ...ning the idle speed adjusting screw Guideline Idle speed I 1 soo 1 900 rpm Executing the initialization run Condition Info Turn counterclockwise to increase the idle speed Turn clockwise to decrease the idle speed The diagnostics tool is connected and running Execute Engine electronics Functions Delete adaptation values The adaptation values are deleted Select Engine electronics Measured values Co...

Page 247: ... the specified temperature Guideline I Coolant temperature Info I so 90 c 176 194 F I Do not operate the throttle grip during the initialization process As soon as the specified temperature is reached switch off the ignition Info I If the initialization is not completed or the initializa tion process is interrupted the entire process must be restarted 245 ...

Page 248: ...0039 0 0059 in Crankshaft bearing 2 grooved ball bearings Conrod bearing Slide bearing Piston pin bearing No bearing bushes DLC plated piston pins Pistons Forged light alloy Piston rings 1 compression ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with two rotary pumps Primary transmission 32 76 Clutch Multidisc clutch in oil bath hydraulically activated Transmission r...

Page 249: ...e I 95 000 95 012 mm 3 74015 3 74062 in Size II 95 013 95 025 mm 3 74066 3 74113 in Piston cylinder mounting clearance Size I 0 040 0 082 mm 0 00157 0 00323 in Size II 0 043 0 085 mm 0 00169 0 00335 in Wear limit 0 120 mm 0 00472 in Piston ring end gap Compression ring 5 1 00 mm 5 0 0394 in Oil scraper ring 5 1 20 mm 5 0 0472 in Conrod bearing axial clearance 0 20 0 45 mm 0 0079 0 0177 in Cranksha...

Page 250: ...austflange M6 Screw idler M6 Screw kick starter spring hanger M6 Screw kick starter stop M6 Screw oil pump cover M6 Screw shi ft drum locating M6 Screw shi ft lever M6 248 2 Nm 1 5 lbfft 4 Nm 3 lbfft 2 Nm 1 5 lbfft 2 Nm 1 5 lbfft 6 Nm 4 4 lbfft 6 Nm 4 4 lbfft 6 Nm 4 4 lbfft 6 Nm 4 4 lbfft 6 Nm 4 4 lbfft 6 Nm 4 4 lbfft 6 Nm 4 4 lbfft 8 Nm 5 9 lbfft 2 5 Nm 1 84 lbfft 10 Nm 7 4 lbfft 10 Nm 7 4 lbfft ...

Page 251: ...x0 75 M6x0 75 M7 M7x1 M8 M8 M8 M8x1 M10 M10 M10x1 25 M12x1 M12x1 25 M12x1 5 M12x1 5 M12x1 5 M12x1 5 M14x1 25 M18x1 5 25 TECHNICAL DATA 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 4 Nm 3 lbf ft 4 Nm 3 lbf ft 9 Nm 6 6 lbf ft 15 Nm 11 1 lbf ft 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft 25 Nm 18 4 lbf f...

Page 252: ...sion travel front Suspension travel rear Fork offset Shock absorber Brake system Brake discs diameter front rear Brake discs wear limit front rear Tire air pressure off road front rear Road tire pressure FE EU AU front rear Final drive FE EU AU Final drive FE 501 US Chain Rear sprockets available 250 Central tube frame made of chrome molybdenum steel tubing WP Suspension Up Side Down 4860 4CS 300 ...

Page 253: ...use 75011088010 10A Fuse 58011109120 20A Headlight S2 I socket B A20d 12 V 35 35 W Parking light W5W socket W2 1x9 5d 12 V 5 W Indicator lamp W2 3W I socket W2x4 6d 12 V 2 3 W Turn signal FE EU AU R1OW socket B A15s 12 V 10 W Brake tail light LED License plate lamp FE EU AU W5W socket W2 1x9 5d 12 V 5 W 25 7 Tires Validity Front tire Rear tire FE EU AU 90 90 21 M C 54R TT 140 80 18 M C 70R TT Mich...

Page 254: ...100 mm 3 94 in Oil capacity per fork leg 635 ml 21 47 fl oz Fork oil SAE 4 48601166S1 a p 306 25 9 Shock absorber Shock absorber part number Shock absorber Compression damping low speed Comfort Standard Sport Compression damping high speed Comfort Standard Sport Rebound damping Comfort Standard Sport Spring preload Spring rate Weight of rider 65 75 kg 143 165 lb Weight of rider 75 85 kg 165 187 lb...

Page 255: ...ce MS Screw fork stub MS Screw front brake caliper MS Screw handlebar clamp MS Screw side stand attachment MS Screw subframe MS Screw top steering stem MS Screw top triple clamp MS 105 mm 4 13 in 490 mm 19 29 in 25 TECHNICAL DATA Shock absorber fluid SAE 2 5 50180751S1 p 307 6 Nm 4 4 lbf ft 6 Nm 4 4 lbf ft 2 5 Nm 1 84 lbf ft 2 Nm 1 5 lbf ft 5 Nm 3 7 lbf ft 1 5 Nm 1 11 lbf ft 10 Nm 7 4 lbf ft 10 Nm...

Page 256: ... Screw top steering head Screw in nozzles cooling system Screw front wheel spindle 254 M10 M10 M10 M10 M10 M10 M12 M12x1 M16x1 5 M20x1 5 M20x1 5 M20x1 5 M24x1 5 60 Nm 44 3 lbf ft 45 Nm 33 2 lbf ft 45 Nm 33 2 lbf ft 60 Nm 44 3 lbf ft 40 Nm 29 5 lbf ft 60 Nm 44 3 lbf ft 15 Nm 11 1 lbf ft 20 Nm 14 8 lbf ft 100 Nm 73 8 lbf ft 80 Nm 59 lbf ft 12 Nm 8 9 lbf ft 12 Nm 8 9 lbf ft 45 Nm 33 2 lbf ft Loctite ...

Page 257: ...gularly Avoid direct sunshine when cleaning the motorcycle 1 111111111111111 401061 01 Close off the exhaust system to keep water from entering Remove coarse dirt particles with a gentle water jet Spray dirty parts with a normal commercial engine cleaner and then brush off with a soft brush Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to...

Page 258: ... was operated in road salt clean it with cold water after riding Warm water would enhance the corrosive effects of salt 401060 01 Clean the motorcycle l p 255 Clean the brake system Info 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 vehi ...

Page 259: ...aiting times at the start of the new season 1111 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Refuel Clean the motorcycle p 255 Change the engine oil and oil filter and clean the oil screens p 235 Check the antifreeze and coolant level p 230 Check the tire air pressure a p 104 Remove the battery a p 125 Charge the battery Guideline Storag...

Page 260: ...RAGE 27 2 258 Pre aring for use after storage 401059 01 Remove the motorcycle from the lift stand p 12 Install the battery p 126 Perform checks and maintenance measures when preparing for use Take a test ride ...

Page 261: ...e spoke tension I p 106 0 I Check the chain rear sprocket motor sprocket and chain guide p 115 I Check the chain tension a p 114 0 I Grease all moving parts e g side stand hand lever chain and check for smooth operation I I Check correct the fluid level of the hydraulic clutch I p 228 I I Check the front brake fluid level p 133 I I I Check the free travel of the hand brake lever a p 131 I Check th...

Page 262: ...l p 134 I I I Change the rear brake fluid I p 142 I I I I I Change the hydraulic clutch fluid a p 229 I I I I I I Lubricate the steering head bearing p 36 Clean the spark arrestor FE 501 US Perform a fork service I p 18 Service the shock absorber a p 56 Change the spark plug and spark plug connector Change the piston Check measure the cylinder Check the cylinder head Change the valves valve spring...

Page 263: ...28 SERVICE SCHEDULE 261 ...

Page 264: ...10 J K10 G10 f A I n D X2 l 1 1 X300 l 1 w w E E C0 F a C nr tel FE 450 501 EU 2014 2015 HuS ll ma 1 2 I 3 I c I I z a 4 521 4 n 5 BR 4 l x4 l K 4 I i R 4 X4 1 s 5 I 6 I 6 I 7 I 8 A f B C f D f w rd a 2 E1 E f lW t b 2 F1 F I ha I 7 I 8 ...

Page 265: ...Components G10 Battery K10 Starter relay with main fuse M10 Starter motor S21 Electric starter button 29 WIRING DIAGRAM 263 ...

Page 266: ...f I X 10 f s1 4 ij f EB 4 I 0 1 1 rrDY 4 I 1 X 9 1 5 t6 1 t3 J12 1 1EBl4 F2 rn K30 rfil tJ 5 l JJ J 2 f EB 4 1 X6 I 1 X 3 1 1 1 1 EB aC wlHdl e 1 t L j __ B33 Ca C t J 2 J 2 i iFJ 2 rFJ 2 111 8S12 XS X7 X 285 f 1 I 1 L_JI n c b 3 E1 1 FB bC tr tr t b 7 F1 Hu5 l i ma FE 450 501 EU 2014 2015 2 8 re ...

Page 267: ...11 EFI control unit B33 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 29 WIRING DIAGRAM 265 ...

Page 268: ... 2 X50 B I l wh c f 4 B1 1 l I pj5 8 cru i r JJJ BP 4 M j DG 4 1 X44 1 1 l DG 4 I BP 4 X46 X22 AC 6 BA 1 iAC 6 f f i i 1 1 1 I 1 X48 1 X47 X48 I I I I s i I i 111 r 1 I I l j w 2 EB dC E l 2 EB bC 0 c 4 E1 IE 0 I I C I ll ll M i HuS ll ma FE 450 501 EU 2014 2015 I l I 1 I I I ...

Page 269: ...Components A11 EFI control unit E13 Low beam high beam P13 Speedometer P15 Horn P35 Parking light S22 Light switch horn button kill switch 29 WIRING DIAGRAM 267 ...

Page 270: ...X18 X19 L 1 X 1 3 C AH 2 AH 2 BY 4 D1 2 r X11 B76 B77 P36 CV 4 f 7 f r l X17 AK 2 K 2 X11 V 4 I D f H 2 f H 2 ii Y 4 X14 D X18 X19 X13 l sl 1 I i II I f w w 3 EB et ye OO E C0 a v C nr E 3 EB b C O E f F F C c I 1 l z tel FE 450 501 EU 2014 2015 hm HuS ll ma 1 2 I 3 I 4 5 I 6 I 7 I 8 re a ...

Page 271: ...Components B76 Front brake light switch B77 Rear brake light switch E60 License plate lamp P36 Brake tail light 29 WIRING DIAGRAM 269 ...

Page 272: ...i D X45 f J 3 X42 i i w w E C0 a It C nr E F C c I IU l z tel FE 450 501 EU 2014 2015 HuS ll ma 1 2 I 3 I a 4 5 I l l I j X23 j X25 j X41 CX 2 CX 2 CX 2 P46 P41 W 2 W 2 W 2 i CX 2 l X 2 l X 2 X23 X25 X41 I I 4 5 I 6 I l X28 CX 2 P45 W 2 i CX 2 X28 I 6 I 7 I 8 I I 7 I 8 A f B C f D f E f F hm 0 r 11 ...

Page 273: ...ts K20 Turn signal relay P21 Turn signal indicator light P41 Left front turn signal P42 Right front turn signal P45 Left rear turn signal P46 Right rear turn signal S25 Turn signal switch 29 WIRING DIAGRAM 271 ...

Page 274: ...E F c I I l tel FE 450 501 EU 2014 2015 HuSQYi ma I 2 I 3 I 4 5 a 1ITTrn n X15 X15 ca 1 U CU 4 B51 L t M DY 4 il U 4 X20 ca ca 6 I I P13 3 A6 7 A2 X15 i 6 I 7 I S ll Y 3 lY 3 l rn 3 l 3 X51 X51 jl I GA 3 7 07 R ll D7 I 7 I 8 or t g 7 E1 bl t h 8 F1 hm 8 A f B C f D f E f F C II r C II ...

Page 275: ...Components A11 EFI control unit B32 Fuel level sensor B51 Lambda sensor cylinder 1 F1 Fuse P13 Speedometer 29 WIRING DIAGRAM 273 ...

Page 276: ... X26 5 l5 l5 w w E C0 a C nr E 6 EB g C er 2 FS b C t F c I Ir l tel FE 450 501 EU 2014 2015 HuS ll ma 1 2 I 3 I 4 a 5 6 I m ITT X15 l X15 j i f I I 9 9 9 9 r f f l 1 NAT 2 f X295 X 3 01 r 7 AP 6 n 5 6 I 7 I l X15 il il J GA 3 6 D7 M 16 Dl t X29 I 7 I 8 I TI ITT X15 1515 1515 hm 8 A f B C f D f E f F j r 11 ...

Page 277: ...mponents A11 EFI control unit B70 Front wheel speed sensor M13 Fuel pump M51 Injection valve cylinder 1 R30 CAN bus terminating resistor 1 P13 Speedometer X295 Diagnostics connector 29 WIRING DIAGRAM 275 ...

Page 278: ...X 2 FU1 B37 f fv e 1 t D X35 X34 w w E 00 a 00 C nr E 6 FB h C bl F c I 1 l tel FE 450 501 EU 2014 2015 HuS ll ma 1 2 I 3 I 4 a 5 I 6 1 1 1 X15 X15 X15 B f t i 9 EX 3 AP 6 n n n w X30 X33 il il 5 I 6 I 7 I 1 X15 1 NDX 3 M El 0 n m X32 I 7 I 1 X15 J CM 2 t X38 I 8 I hm 8 A f B C f D f E f F 0 r 11 ...

Page 279: ...r sensor B37 Crankshaft position sensor B41 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 29 WIRING DIAGRAM 277 ...

Page 280: ... n D X2 l 1 1 a X300 l 1 w E E C0 F a C nr tel FE 450 501 AU 2014 2015 HuS ll ma 1 2 I 3 I c I IO l z a 4 523 3 C2 4 n 5 l x4 BR 4 I BK 4 J E 1 fv j 1 D2 I BK 4 1I X4 1 s 5 I I 6 I 7 I I 6 I 7 I 8 w rd a 2 E1 lW t b 2 F1 ha 8 A f B C f D f E f F C0 r 11 ...

Page 281: ...Components G10 Battery K10 Starter relay with main fuse M10 Starter motor S23 Emergency OFF switch electric starter button 29 WIRING DIAGRAM 279 ...

Page 282: ...10 f s1 4 ij f EB 4 I 0 1 1 rrDY 4 I 1 X9 1 5 t6 1 t3 J12 1 1EBl4 F2 rn K30 rfil tJ 5 l JJ J 2 f EB 4 1 X 6 I 1 X3 1 1 1 1 EB aC wlHdl e 1 t L j __ B33 Ca C t J 2 J 2 i iFJ 2 rFJ 2 111 8S12 XS X7 X285 f 1 I 1 L_JI n l b 3 E1 1 FB bC tr tr t b 7 F1 Hu5 l i ma FE 450 501 AU 2014 2015 2 8 re ...

Page 283: ...11 EFI control unit B33 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 29 WIRING DIAGRAM 281 ...

Page 284: ...X 1 5 t I 0 I tfcw12 J N CX 2 X50 B I l wh c f 4 B1 1 l I pj5 8 cru i _ _ _ r JJJ BP 4 M j DG 4 1 X44 l DG 4 I BP 4 X46 X22 1 1 _ 1 t l l 1 I l 1 j i 1n r 1 j j E l 2 EB bC 0 c 4 E1 IE 0 I I C I ll ll i HuS ll ma FE 450 501 AU 2014 2015 I l I 1 I I I ...

Page 285: ...onents 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 29 WIRING DIAGRAM 283 ...

Page 286: ...c C X18 X19 L 1 X 1 3 C AH 2 AH 2 BY 4 D1 2 r X11 B76 B77 P36 CV 4 f 7 f r l X17 AK 2 K 2 X11 V 4 I D f H 2 f H 2 ii Y 4 X14 D X18 X19 X13 l sl 1 I i II I f w 3 EB et ye OO E C0 a v C nr E 3 EB b C O E f F F I I z tel FE 450 501 AU 2014 2015 hm HuS ll ma 1 2 I 3 I 4 5 I 6 I 7 I 8 re a ...

Page 287: ...Components B76 Front brake light switch B77 Rear brake light switch E60 License plate lamp P36 Brake tail light 29 WIRING DIAGRAM 285 ...

Page 288: ...42 j X23 j X25 j X41 X28 C m N AJ 3 a CX 2 CX 2 CX 2 CX 2 AH 2 NF0 2 525 P42 P46 P41 P45 R f 13 W 2 W 2 W 2 W 2 i D X45 f J 3 i CX 2 l X 2 l X 2 i CX 2 D X42 X23 X25 X41 X28 i i I I I I f w E C0 a It C nr E E f F F I I z tel FE 450 501 AU 2014 2015 I hm HuS ll ma 1 2 I 3 I 4 5 I 6 I 7 I 8 a ...

Page 289: ...ts K20 Turn signal relay P21 Turn signal indicator light P41 Left front turn signal P42 Right front turn signal P45 Left rear turn signal P46 Right rear turn signal S25 Turn signal switch 29 WIRING DIAGRAM 287 ...

Page 290: ...0 a co C nr E F I I tel FE 450 501 AU 2014 2015 HuS ll ma 1 2 I 3 I 4 5 a l TI X15 X15 c i 7 1 1 rrrn CU 4 6 I I P13 3 A6 7 A2 X15 i 6 I 7 I S 1lY 3 lY 3 N lrn 3 lli3 X51 X51 p i GA 3 Jm Tl T 07 R rr D7 I 7 I 8 A f B C f D f O t g 7 E1 E f bl t h 8 F1 F hm 8 re ...

Page 291: ...Components A11 EFI control unit B32 Fuel level sensor F1 Fuse P13 Speedometer 29 WIRING DIAGRAM 289 ...

Page 292: ...15 X15 X15 X15 f X52 B70 5 l5 l5 e r j i f 1515 il 8 B I I 9 9 9 9 r f f l 1 il C C 1 J NDQ 2 NAT 2 GA 3 f f X295 X 3 01 r 7 6 D7 M f AP 6 n 16 Dl 1 0 0 t D X26 X29 D 5 l5 l5 1515 f w E C0 a C nr E 6 EB g C er E f 2 FS b C t F F I I tel FE 450 501 AU 2014 2015 I hm HuS ll ma 1 2 I 3 I 4 5 6 I 7 I 8 a ...

Page 293: ...mponents A11 EFI control unit B70 Front wheel speed sensor M13 Fuel pump M51 Injection valve cylinder 1 R30 CAN bus terminating resistor 1 P13 Speedometer X295 Diagnostics connector 29 WIRING DIAGRAM 291 ...

Page 294: ...5 X15 X15 I t 1 B f t B B l sl 9 i 9 C x34 I I X37 C DV 2 NAU2 1 J S51 u2 AX 2 FU1 EX 3 AP 6 NDX 3 CM 2 B37 M f n El f fv e 0 1 t n n w n m t D X35 X30 X33 X32 X38 D X34 il il f w E C0 a C0 C nr E E f 6 FB h C bl F F I 1 tel FE 450 501 AU 2014 2015 I hm HuS ll ma 1 2 I 3 I 4 5 I 6 I 7 I 8 a ...

Page 295: ...r sensor B37 Crankshaft position sensor B41 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 29 WIRING DIAGRAM 293 ...

Page 296: ... DIAGRAM 29 17 Page 1 of 6 FE 501 US I m m J1 0 C J N 0 N 0 J1 I m 294 I 0 I 0 I l l p J oo ro 4 wh ro IJd 1 20A wh rd 0 3 9 1 i i i 111 iP J wh rd wh rd I i oo d c 2 J b bl A A _i A 0 I 0 I ro I ro I 202862 01 ...

Page 297: ...Components G10 Battery K10 Starter relay with main fuse M10 Starter motor S21 Electric starter button 29 WIRING DIAGRAM 295 ...

Page 298: ...EB 4 I 0 1 1 i t6 1 t3 J 2 i iEB 4 F 2 rll K J O ri Jl ti 5 l JJ FJ 2 f EB 4 1 X6 I 1 XJ 1 1 1 1 ES aC wh rdl e t L _j_ _ B33 l M 1 4 N BV 20 J C l BS 2 1 X285 1 i xs t7 j j J 2 J 2 F4 rn FJ ffi X 19 BG 3 111A J 3 FJ 2 r f J 2 X23 1 xs x1 t Ljll I 1 FS bC br br t b 5 F1 tel HUSQ llma FE 501 US 2014 2015 2 6 ...

Page 299: ...ntrol unit B33 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 29 WIRING DIAGRAM 297 ...

Page 300: ... l BI I 1 rn s X15 I f_X18 iBF 1 fsA 1 520 11 E 2 3 4 5 6 I l 11 t i l 11 t t n p37 CV 4 x22 E11 P35 j X1E i BP 4 MDG 4 J v l DG 4 I BP 4 1 r V 4 x1s x22 l l c ii l l 1 l I 111 1 I 1 1 FE 501 US 2014 2015 HuS ll ma I l I 7 8 IA f Is I I 1 I I ...

Page 301: ...Components A11 EFI control unit E11 Low beam P35 Parking light P37 Tail light S20 Kill switch S30 Light switch 29 WIRING DIAGRAM 299 ...

Page 302: ...D X5 w E 0 a v C nr E F I I tel FE 501 US 2014 2015 HuS ll ma 1 2 I 3 I 4 5 a l TI X15 X15 c i 7 1 1 rrrn CU 4 6 I I P13 5 A2 X15 i 6 I 7 I S 1lY 3 lY 3 N lrn3 l li3 X14 X14 p GA 3 Jm Tl 15 07 R r i D7 I 7 I 8 A f B C f D f O t e 5 E1 E f bl f 6 F1 F 8 ...

Page 303: ...Components A11 EFI control unit B32 Fuel tank sensor F1 Fuse P13 Speedometer 29 WIRING DIAGRAM 301 ...

Page 304: ...X15 X15 X15 X15 f X13 B70 5 l5 l5 e r j i f 1515 il B B I I 9 9 9 9 r f f l 1 il C C 1 J NDQ 2 NAT 2 GA 3 f f X295 X301 r 7 4 D7 M f AP 6 n 14 D7 1 0 0 t D X26 X29 D 5 l5 l5 1515 f w E 0 a It C nr 4 EB e C er E E f 2 FS b C t F F I 1 l tel FE 501 US 2014 2015 I HuS ll ma 1 2 I 3 I 4 5 6 I 7 I 8 a ...

Page 305: ...mponents A11 EFI control unit B70 Front wheel speed sensor M13 Fuel pump M51 Injection valve cylinder 1 P13 Speedometer R30 CAN bus terminating resistor 1 X295 Diagnostics connector 29 WIRING DIAGRAM 303 ...

Page 306: ...5 X15 X15 X15 I t 1 B f t B B l sl 9 i 9 C x34 I I X28 C DV 2 NAU2 1 l S51 u2 AX 2 FU1 EX 3 AP 6 NDX 3 CM 2 B37 M f n El f fv e 0 1 t n n w n m t D X35 X30 X33 X32 X25 D X34 il il f w E 0 a 0 C nr E E f 4 FB IC bl F F I I tel FE 501 US 2014 2015 I HuS ll ma 1 2 I 3 I 4 5 I 6 I 7 I 8 g a ...

Page 307: ...r sensor B37 Crankshaft position sensor B41 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 29 WIRING DIAGRAM 305 ...

Page 308: ...protection to at least I 25 C 13 F The mixture ratio must be adjusted to the necessary antifreeze protection Use distilled water if the coolant needs to be diluted The use of premixed coolant is recommended Observe the coolant manufacturer specifications for antifreeze protection dilution and miscibility compatibility with other coolants Recommended supplier Bel Ray Moto Chill Racing Coolant En in...

Page 309: ...that exhibit the corresponding properties Super unleaded ROZ 95 RON 95 PON 91 Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info I Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100...

Page 310: ...Waterproof Grease Lubricant I158 Recommended supplier Lubcon Turmogrease PP 300 Lubricant 14034 Recommended supplier WP Performance Systems WP Racing Grease IPR 2 Lubricant 625 Recommended supplier Molykote 33 Medium Lubricant T152 Recommended supplier Bel Ray Molylube Anti Seize Lubricant T159 Recommended supplier Bel Ray MC 11 Offroad chain spray Guideline Recommended supplier Bel Ray Blue Tac C...

Page 311: ...nded supplier Bel Ray Foam Filter Oil Preserving materials for aints metal and rubber Recommended supplier Bel Ray Silicone Detailer Protectant Spray Universal oil s ra Recommended supplier Bel Ray 6 in 1 31 AUXILIARY SUBSTANCES 309 ...

Page 312: ...0029013006 I 00029013006 H00505 01 Bleeding device Art no 00029013100 00029013100 H00518 01 EU batte charger XCharge rofessional Art no 00029095050 Feature EU safety plug Nominal voltage 230 V Mains fuse 16A Power cable length 5 m 16 ft approx Charger cable 5 m 16 ft H01065 01 length approx 310 ...

Page 313: ...al H01065 01 Art no 00029095052 Feature UK safety plug Nominal voltage Mains fuse Power cable length approx Charger cable length approx rofessional H01065 01 H00944 01 Art no 00029095053 Feature CH plug Nominal voltage Mains fuse Power cable length approx Charger cable length approx Art no 113080802 32 SPECIAL TOOLS 120V 32 A 5 m 16 ft 5 m 16 ft 230V 16 A 5 m 16 ft 5 m 16 ft 230V 16 A 5 m 16 ft 5 ...

Page 314: ...2017000 Internal bearing uller 15112018100 S ring hook 50305017000 s ringe 50329050000 312 H00520 01 H00522 01 H00973 01 H00565 01 Art no 15112017000 Art no 15112018100 Feature 118 23 mm 0 71 0 91 in Art no 50305017000 Art no 50329050000 ...

Page 315: ...h set 58429094000 H00606 01 Art no 51012011000 Art no 51129003000 Art no 58012009000 Art no 58429094000 Feature Torque Open ended bit Open ended bit Open ended bit Open ended bit Bit diameter 32 SPECIAL TOOLS 3 15 Nm 2 2 11 1 lbf ft 3 9 mm 0 154 in 4 9 mm 0 193 in 5 5 mm 0 217 in 6 8 mm 0 268 in 5 9 mm 0 232 in 313 ...

Page 316: ... gauge 59029041100 H00616 01 Piston ring mountin tool 60029015000 H00628 01 314 Art no 59029019000 Art no 59029026006 Feature I Diameter Art no 59029041100 Feature 1 s piece Art no 60029015000 Feature Height Diameter I 6 05 mm 0 2382 in I 0 10 0 25 mm 0 0039 0 0098 in 80 mm 3 15 in 57 125 mm 2 24 4 92 in ...

Page 317: ...2x Art no 60029033000 60029033000 H00633 01 Hose clamR Rlier Art no 60029057000 60029057000 H00650 01 Testing hose Art no 61029093000 61029093000 H00659 01 Pressure testin tool Art no 61029094000 4x D 61029094000 H00660 01 315 ...

Page 318: ...er Art no 75029021000 75029021000 H00707 01 Pressing tool Art no 75029044010 75029044010 H00712 01 Pressing tool Art no 75029044020 75029044020 H00713 01 Crankshaft ressing tool Art no 75029047000 75029047000 H00714 01 316 ...

Page 319: ...ing late Art no 75029050000 75029050000 H00719 01 Pressing tool Art no 75029051000 75029051000 H00721 01 Protection ca Art no 75029090000 75029090000 H00726 01 Oil ressure ada ter Art no 75029094000 75029094000 H00728 01 317 ...

Page 320: ...00746 01 S ark lug wrench with link 77229172000 H00761 01 Insertion for iston ring lock 77329030100 H00768 01 318 Art no 77029026000 Feature I Diameter Art no 77029041200 Art no 77229172000 Feature Drive Hexagonal part Length Art no 77329030100 I 5 05 mm 0 1988 in 3 8 in 14 mm 0 55 in 130 mm 5 12 in ...

Page 321: ...ing for work stand Art no 78029002000 78029002000 H00783 01 Protection ca Art no 78029005000 78029005000 H00784 01 Crankshaft ressing tool insert Art no 78029008000 78029008000 H00786 01 Se Art no 78029009100 78029009100 H01174 01 319 ...

Page 322: ...segment 80029004000 Engine work stand 80329001000 Lift stand 81329955100 320 H00796 01 H00813 01 H01047 01 H00985 01 Art no 78129032000 Art no 80029004000 Art no 80329001000 Art no 81329955100 Feature Height Load 315 425 mm 12 4 16 73 in 150 kg 331 lb ...

Page 323: ...H00816 01 Puller 90129048100 H00828 01 Hook wrench T106S H00841 01 De th micrometer T107S H00842 01 Art no 90129005000 Art no 90129048100 Art no T106S Feature I Diameter Art no T107S 32 SPECIAL TOOLS I 68 75 mm 2 68 2 95 in 321 ...

Page 324: ... Pressing tool T1206 322 H00844 01 H00878 01 H00879 01 H00880 01 Art no T120 Feature I Diameter Art no T1204 Feature I Diameter Art no T1205 Feature I Diameter Art no T1206 Feature I Diameter I 8 mm 0 31 in I25 5 30 5 mm 1 004 1 201 in 118 mm 0 71 in 115 30 mm 0 59 1 18 in ...

Page 325: ...eeve T1215 Pressing tool T1216 Vacuum T1240S H00881 01 H00886 01 H00887 01 H00890 01 Art no T1207S Art no T1215 Feature I Diameter Art no T1216 Feature I Diameter Art no T1240S 32 SPECIAL TOOLS 118 mm 0 71 in 138 49 mm 1 5 1 93 in 323 ...

Page 326: ...T14047 324 H00894 01 H00896 01 H00922 01 H00923 01 Art no T1401 Feature I Diameter Art no T1403S Feature Diameter Diameter Art no T14040S Feature I Diameter Art no T14047 Feature Drive Narrow diameter Wide diameter I 48 mm 1 89 in 48 mm 1 89 in 60 mm 2 36 in I 48 mm 1 89 in 1 2 in 34 mm 1 34 in 42 7 mm 1 681 in ...

Page 327: ...01 Pressing tool T1504 H00899 01 Mounting tool T150S H00852 01 Art no T14049S Feature Diameter Diameter Art no T14051 Feature I Diameter Art no T1504 Feature I Diameter Art no T150S 32 SPECIAL TOOLS 8 mm 0 31 in 24 8 mm 0 976 in I 50 mm 1 97 in 118 mm 0 71 in 325 ...

Page 328: ...32 SPECIAL TOOLS Filling tool 2x 3x Art no T170S1 T170S1 H00855 01 326 ...

Page 329: ... intervals are demanded for automobile engines the focus for motorcycle engines is on high performance at high engine speeds In most motorcycle engines the transmission and clutch are lubricated with the same oil The JASO 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 according to thei...

Page 330: ...34 LIST OF ABBREVIATIONS Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly 328 ...

Page 331: ... Capacity coolant 233 250 engine oil 158 237 250 Cartridge of fork legs disassembling 22 of the fork legs assembling 30 Chain checking cleaning Chain guide checking Chain tension 115 118 115 adjusting 114 checking 114 Charging voltage checking 128 Chassis number 10 Clutch fluid level checking correcting 228 fluid changing 229 Clutch lever basic position adjusting 44 Combination instrument adjustin...

Page 332: ...188 186 187 175 195 191 198 199 179 205 190 182 182 203 194 193 193 181 187 192 197 183 202 202 177 main shaft assembling rocker arm installing valves installing 200 196 195 valves removing 191 water pump removing 180 Engine assembly alternator cover installing 224 camshaft installing 222 clutch cover installing 216 clutch discs installing 214 clutch push rod installing 226 cylinder head installin...

Page 333: ...g 166 valve cover removing 161 water pump cover removing Engine guard 167 installing 47 removing 47 Engine number 10 Engine oil adding 237 changing 235 Engine oil level checking 234 Engine oil pressure checking 238 F Figures 9 Filler cap closing 90 opening 90 Foot brake lever basic position adjusting free travel checking Fork legs 140 139 assembling 32 bleeding 15 cartridge assembling 30 cartridge...

Page 334: ...old installing 83 removing 81 Motor sprocket checking Motorcycle 115 cleaning 255 lift stand raising with 12 332 0 removing from lift stand 12 Oil circuit Oil filter changing 234 235 Oil pressure regulator valve installing 180 removing 179 spring length checking 179 Oil screens cleaning 235 Open circuit current checking 128 Operating substances 9 p Piston rod of fork legs assembling 29 of fork leg...

Page 335: ...tarting 12 13 Stator installing removing Steering head bearing 242 241 changing lubricating 40 36 Steering head bearing play adjusting 42 checking 40 Storage 257 Swingarm checking 74 installing 76 removing 75 Swingarm bearing changing 78 checking 74 Technical data capacities 250 chassis 250 chassis tightening torques 253 electrical system 251 engine 246 engine tolerance wear limits 247 engine tigh...

Page 336: ...INDEX Page 6 of 8 272 288 Page 7 of 8 274 290 Page 8 of 8 276 292 Work rules 8 334 ...

Page 337: ...1111111111111111111111111111111111111111IIIIII 3403003en 07 2017 Husqvarna MOTORCYCLES Husqvarna Motorcycles GmbH StallhofnerstraBe 3 5230 Mattighofen Austria www husqvarna motorcycles com Photo Mitterbauer Husqvarna Motorcycles GmbH ...

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