Husqvarna FE 450 2016 Owner'S Manual Download Page 61

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12 SERVICE WORK ON THE CHASSIS

12.34

Removing the fuel tank

Danger

Fire hazard

Fuel is highly flammable.

–

Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no

fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

–

The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.

Warning

Danger of poisoning

Fuel is poisonous and a health hazard.

–

Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with

the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with

soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that has been contaminated with

fuel. Store fuel properly in a suitable canister and keep away from children.

Preparatory work

–

Remove the seat. (

p. 49)

H00187-10

Main work

–

Unplug connector



of the fuel pump.

–

Pull the hose off the fuel tank breather on the tank lid.

M00392-10

–

Thoroughly clean the plug-in connection of the fuel line using compressed air.

Info

Under no circumstances should dirt enter into the fuel line. Dirt in the fuel

line clogs the injection valve!

–

Disconnect the plug-in connection of the fuel line.

Info

Remaining fuel may flow out of the fuel hose.

–

Mount the wash cap set



Wash cap set (81212016100)

H00188-10

(FE EU/AU)

–

Disconnect the connector of the horn.

–

Remove screws



with the collar bushings and horn.

S00906-10

(FE US)

–

Remove screws



with the collar bushings.

Summary of Contents for FE 450 2016

Page 1: ...OWNER S MANUAL 2016 FE 450 FE 501 Art no 3402066en ...

Page 2: ......

Page 3: ...ces 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 Motorcy cles accepts no liability for delivery options deviations from illustrations and descriptions as well as misprints and other errors The models portrayed partly contain special equipment that does ...

Page 4: ... 7 6 Setting the clock 23 7 7 Setting the service display 23 7 8 Speed time and DST distance 1 24 7 9 Speed time and DST2 distance 2 24 7 10 AVG average speed ART operating hours and ODO total distance covered 24 8 PREPARING FOR USE 25 8 1 Advice on first use 25 8 2 Running in the engine 26 8 3 Preparing the vehicle for difficult riding conditions 26 8 4 Preparing for rides on dry sand 27 8 5 Prep...

Page 5: ...ting free travel of hand brake lever FE EU AU 68 13 3 Adjusting the basic position of the hand brake lever FE US 68 13 4 Checking the brake discs 69 13 5 Checking the front brake fluid level 69 13 6 Adding front brake fluid 69 13 7 Checking the front brake linings 70 13 8 Changing the front brake linings 71 13 9 Checking the free travel of foot brake lever 72 13 10 Adjusting the basic position of ...

Page 6: ... 3 2 Coolant 109 23 3 3 Fuel 109 23 4 Chassis 109 23 5 Electrical system 110 23 6 Tires 110 23 7 Fork 110 23 8 Shock absorber 111 23 9 Chassis tightening torques 111 24 SUBSTANCES 113 25 AUXILIARY SUBSTANCES 114 26 STANDARDS 115 27 LIST OF ABBREVIATIONS 116 28 LISY OF SYMBOLS 117 28 1 Yellow and orange symbols 117 28 2 Green and blue symbols 117 INDEX 118 ...

Page 7: ...shop There your motorcycle will be optimally cared for by specially trained experts using the specialist tools required Indicates a page reference more information is provided on the specified page Indicates information with more details or tips Indicates the result of a testing step 1 2 Formats used The typographical formats used in this document are explained below Proprietary name Indicates a p...

Page 8: ...d to at the relevant passages Info The vehicle has various information and warning labels at prominent locations Do not remove information warning labels If they are missing you or others may not recognize dangers and may therefore be injured 2 3 Degrees of risk and symbols Danger Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate m...

Page 9: ...g Warning Risk of injury Missing or poor protective clothing presents an increased safety risk Wear protective clothing helmet boots gloves pants and jacket with protectors every time you ride the vehicle Always wear protective clothing that is in good condition and meets the legal requirements In the interest of your own safety Husqvarna Motorcycles recommends that you only operate the vehicle wh...

Page 10: ... you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury Keep the Owner s Manual in an accessible place to enable you to refer to it as needed If you would like to know more about the vehicle or have questions on the material you read please contact an authorized Husq varna Motorcycles dealer The Owner s Manual is an important component of th...

Page 11: ...sories for your vehicle can be found on the Husqvarna Motorcycles website International Husqvarna Motorcycles website www husqvarna motorcycles com 3 4 Service A prerequisite for perfect operation and prevention of premature wear is that the service care and tuning work on the engine and chassis is properly carried out as described in the Owner s Manual Incorrect adjustment and tuning of the engin...

Page 12: ...4 VIEW OF VEHICLE 10 4 1 View of vehicle front left example H00210 10 1 Filler cap 2 Air filter box lid 3 Side stand p 19 4 Engine number p 12 5 Shift lever p 18 ...

Page 13: ... button p 15 2 Light switch p 15 2 Turn signal switch p 15 3 Emergency OFF switch p 15 3 Electric starter button p 16 4 Throttle grip p 14 5 Fork rebound adjustment 6 Foot brake lever p 18 7 Level viewer engine oil 8 Shock absorber rebound adjustment 9 Level viewer for brake fluid rear 10 Shock absorber compression adjustment ...

Page 14: ...l is fixed to the front of the steering head 5 3 Key number FE EU AU 402247 10 The key number for the steering lock is stamped onto the key connector 5 4 Engine number 401949 10 The engine number is stamped on the left side of the engine under the engine sprocket 5 5 Fork part number 401947 10 The fork part number is stamped on the inner side of the fork stub ...

Page 15: ...5 SERIAL NUMBERS 13 5 6 Shock absorber article number 0 0 1 1 401948 10 The shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side ...

Page 16: ...is fitted on the left side of the handlebar Possible states Kill switch in basic position the ignition circuit is closed in this position and the engine can be started Kill switch pressed the ignition circuit is open in this position the engine goes out if it was running or does not start if it was off 6 5 Kill switch FE US S00889 10 Kill switch is fitted on the left side of the handlebar Possible...

Page 17: ...ght switch is pressed in up to the stop In this position the light is switched off Light on Light switch is pulled out to the stop In this position the low beam and tail light are switched on 6 9 Turn signal switch FE EU AU H00169 10 Turn signal switch is fitted on the left side of the handlebar Possible states Turn signal light off Turn signal switch is in the central position Turn signal light l...

Page 18: ... MIL lights up flashes orange The OBD has detected an emission or safety critical fault The low fuel warning lamp lights up orange The fuel level has reached the reserve mark Turn signal indicator light flashes green The turn signal is switched on 6 14 Overview of indicator lamps FE US M00355 12 Possible states FI warning lamp MIL lights up flashes orange The OBD has detected an emission or safety...

Page 19: ...ay from children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system H00170 10 FE EU Press release button turn the filler cap counterclockwise and lift it off S00909 10 FE AU US Press release button turn the filler cap counterclockwise and lift it off 6 16 Closing the filler cap H00170 ...

Page 20: ...M increase activated Idle speed adjusting screw is pulled out all the way RPM increase deactivated Idle speed adjusting screw is pushed in all the way 6 18 Shift lever 401950 10 Shift lever is mounted on the left side of the engine 401950 11 The gear positions can be seen in the photograph The neutral or idle position is between the first and second gears 6 19 Foot brake lever 401956 10 The foot b...

Page 21: ...is used to lock the steering Steering and therefore riding is no longer possible 6 22 Locking the steering FE EU AU Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 400732 01 Park the vehicle Turn the handlebar as far as possible to the right Grease the steering lock regularly Universal oil spray p 114 Insert the key in the ste...

Page 22: ...ing the steering FE EU AU 400731 01 Insert the key in the steering lock p 19 turn it to the left pull it out and turn it to the right Remove the key You can now steer the bike again Info Never leave the key in the steering lock ...

Page 23: ...meter Battery voltage of the speedometer is too low Change the battery Service A service is due Contact an authorized Husqvarna Motorcy cles workshop 7 4 Setting the speedometer Condition The motorcycle is stationary 401909 01 Press both buttons for 3 5 seconds The Setup menu is displayed The UNIT display flashes Press one of the buttons to select UNIT for the speed in kilometers KM H or miles M H...

Page 24: ...h Shortening the service interval Press the left button The value decreases Extending the service interval Press the right button The value increases 401914 01 Switching off the service interval display Press and hold the left button off appears on the display 7 5 Setting the kilometers or miles Info If the unit is changed the value ODO is retained and converted accordingly Condition The motorcycl...

Page 25: ...value decreases Advancing the time Press the right button The value increases 7 7 Setting the service display Condition The motorcycle is stationary 401913 01 Press 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 Set the service Guideline One time service after 1 h Service every 15 h Shortening the service interval...

Page 26: ... since the last reset such as between two refueling stops Info If the value of 39999 9 is exceeded DST2 is automatically reset to 0 0 Press the left but ton briefly Next display mode Press the left but ton for 3 5 sec onds DST2 can be preset to a value between 0 0 and 39999 9 by pressing the buttons Press the right button briefly Next display mode Press the right button for 3 5 seconds DST2 is res...

Page 27: ...ag continuously The rear brake may fail due to overheating Take your foot off the foot brake lever when you are not braking Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permissible weight and axle loads Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine is running Secure the vehicle against use by unauthorized p...

Page 28: ...perating hour 7 000 rpm Maximum engine performance During the first 3 operating hours 75 Avoid fully opening the throttle 8 3 Preparing the vehicle for difficult riding conditions Info Use of the vehicle under difficult conditions such as on sand or on wet and muddy surfaces can lead to considerably more rapid wear of components such as the drive train brake system or suspension components For thi...

Page 29: ...rna Motorcycles accessories fitting instructions 600868 01 Clean the chain Fit the steel sprocket Tip Do not grease the chain Clean the radiator fins Straighten bent radiator fins carefully 8 5 Preparing for rides on wet sand M01001 01 Fit a waterproofing device on the air filter Waterproofing device for air filter 77206921100 Info See the Husqvarna Motorcycles accessories fitting instructions 600...

Page 30: ... for rides at high temperature and slow speed 600868 01 Adjust the secondary drive to the road conditions Info The engine oil heats up quickly when the clutch is operated frequently due to an excessively high secondary drive Clean the chain Clean the radiator fins Straighten bent radiator fins carefully Check the coolant level p 91 8 8 Preparing for rides at low temperature or in snow M01001 01 Fi...

Page 31: ...e that they can be operated smoothly Check all screws nuts and hose clamps regularly for tightness Check the fuel supply 9 2 Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exha...

Page 32: ...ses fuel consumption To shift down apply the brakes and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and either open the throttle or shift again Switch off the engine if you expect to be standing for a long time Guideline 2 min Avoid frequent and longer slipping of the clutch This heats the engine oil the engine and the cooli...

Page 33: ...e hazard Some vehicle components become very hot when the vehicle is operated Do not park the vehicle near flammable or explosive substances Do not place objects on the vehicle while it is still warm from being run Always let the vehicle cool first Apply the brakes on the motorcycle Shift transmission to neutral FE EU AU Press and hold the kill switch while the engine is idling until the engine st...

Page 34: ...ontact a physician immediately Change clothing that is contaminated with fuel Note Material damage Premature clogging of the fuel filter In some countries and regions the available fuel quality and cleanliness may not be sufficient This will result in problems with the fuel system Your authorized Husqvarna Motorcycles workshop will be glad to help Only refuel with clean fuel that meets the specifi...

Page 35: ...heck for smooth operation Check rectify the fluid level of the hydraulic clutch p 66 Check the front brake fluid level p 69 Check the free travel of the hand brake lever p 68 Check the steering head bearing play p 47 Check the valve clearance Check the clutch Change the engine oil and oil filter and clean the oil screens p 97 Check all hoses e g fuel cooling bleeding drainage and sleeves for crack...

Page 36: ...rvice Service the shock absorber Change the spark plug and spark plug connector Change the piston Check measure the cylinder Check the cylinder head Change the valves valve springs and valve spring seats Check the camshaft and rocker arm Change the connecting rod conrod bearing and crank pin Change the shaft seal rings of the water pump Check the transmission and shift mechanism Check the oil pres...

Page 37: ...el suspension and not to the vehicle speed The high speed setting for example has an effect on the landing after a jump the rear wheel suspension compresses more quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses more slowly These two ranges can be adjusted separately although the transition between high speed and low sp...

Page 38: ...number of turns corresponding to the shock absorber type Guideline Compression damping high speed Comfort 2 5 turns Standard 2 turns Sport 1 5 turns Info Turn clockwise to increase damping turn counterclockwise to reduce damping 11 5 Adjusting the rebound damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with ...

Page 39: ...c sag is the difference between measurements and Check the static sag Static sag 30 mm 1 18 in If the static sag is less or more than the specified value Adjust the spring preload of the shock absorber p 38 11 8 Checking the riding sag of the shock absorber 400990 10 Measure distance of rear wheel unloaded p 37 With another person holding the motorcycle the rider wearing full protective clothing s...

Page 40: ...e the manifold p 52 Remove shock absorber p 49 After removing the shock absorber clean it thoroughly 401025 10 Main work Loosen screw Turn adjusting ring until the spring is no longer under tension Hook wrench T106S Measure the overall spring length while the spring is not under tension Tighten the spring by turning adjusting ring to measurement Guideline Spring preload 15 mm 0 59 in Info Dependin...

Page 41: ...ng Smaller weight differences can be compensated by changing the spring preload Finishing work Install the shock absorber p 49 Install the manifold p 54 Install the fuel tank p 60 Mount the seat p 50 Install the main silencer p 57 Install the right side cover p 58 Remove the motorcycle from the lift stand p 42 Check the static sag of the shock absorber p 37 Check the riding sag of the shock absorb...

Page 42: ... the fork Info The hydraulic rebound damping determines the fork suspension behavior H00212 11 Turn the red adjusting screw all the way clockwise Info The adjusting screw is located at the upper end of the right fork leg The rebound damping is located in the right fork leg REB red adjusting screw The compression damping is located in the left fork leg COMP white adjusting screw Turn counterclockwi...

Page 43: ...onents to protect them against damage Do not bend the cables and lines Remove screws Take off the handlebar supports Place the handlebar supports in the required position Mount and tighten screws Guideline Screw handlebar holder M10 40 Nm 29 5 lbf ft Loctite 243 Info Position the left and right handlebar holders evenly Position the handlebar Info Make sure the cables and wiring are positioned corr...

Page 44: ...ss side stand to 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 12 3 Bleeding the fork legs Preparatory work Raise the motorcycle with a lift stand p 42 402556 10 Main work Release bleeder screws Any excess pressure escapes from the interior of the fork Tighten the bleeder screws Finishing work Remo...

Page 45: ...n the right fork leg Take off the fork protector 12 6 Installing the fork protector S00899 11 Position the fork protector on the left fork leg Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake line wiring harness and clamp Mount and tighten screws Position the fork protector on the right fork leg Mount and tighten screws Guideline Remaining screws c...

Page 46: ... Tighten screws Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Tighten screws Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft H00178 10 Position the brake caliper and mount and tighten screws 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 Finishing work Install the ...

Page 47: ... the lower triple clamp with the steering stem Remove the upper steering head bearing 12 10 Installing the lower triple clamp M00420 10 Main work Clean the bearing and sealing elements check for damage and grease High viscosity grease p 114 Position the lower triple clamp with the steering stem Mount the upper steering head bearing Check whether the upper steering head seal is correctly positioned...

Page 48: ...0 Tighten screws Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft H00218 10 Tighten screw Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft H00234 10 Mount and tighten screw Guideline Screw top steering stem M8 17 Nm 12 5 lbf ft Loctite 243 H00180 11 Tighten screws Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Secure the wiring harness with cable holder H00178 11 Position ...

Page 49: ...in the direction of travel No play should be noticeable in the steering head bearing If there is noticeable play present Adjust the steering head bearing play p 47 Move the handlebar to and fro over the entire steering range The handlebar must be able to move easily over the entire steering range No resting locations should be noticeable If click positions are noticeable Adjust the steering head b...

Page 50: ... work Switch off all power consumers and switch off the engine Remove the headlight mask with the headlight p 85 H00235 10 Main work Remove screws and Remove the front fender 12 15 Installing the front fender H00181 10 Main work Position the front fender Mount and tighten screws and Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the headlight mask with the headlight ...

Page 51: ...ve the manifold p 52 H00222 01 Main work Carefully take the shock absorber out of the vehicle toward the top 12 17 Installing the shock absorber H00222 01 Main work Carefully position the shock absorber into the vehicle from above Finishing work Install the manifold p 54 Install the fuel tank p 60 Mount the seat p 50 Install the main silencer p 57 Install the right side cover p 58 Remove the motor...

Page 52: ...usly push the seat forward The seat is correctly engaged H00182 10 Mount and tighten the seat fixing screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 12 20 Removing the air filter box lid H00213 10 Release catch pull off the air filter box lid sideways in areas and and remove toward the rear 12 21 Installing the air filter box lid H00213 10 Position the air filter box lid and tab Enga...

Page 53: ...ort Remove the air filter from the air filter support 12 23 Installing the air filter L00943 10 Main work Mount the clean air filter on the air filter support Grease the air filter in area Long life grease p 114 H00184 11 Insert both parts together position them and fasten them using air filter holder in area The arrow of marking UP faces up Info If the air filter is not correctly mounted dust and...

Page 54: ...nishing work Install the air filter p 51 Install the air filter box lid p 50 12 25 Sealing the air filter box Preparatory work Remove the air filter box lid p 50 401559 01 Main work Seal the air filter box in the marked area Finishing work Install the air filter box lid p 50 12 26 Removing the manifold Preparatory work Raise the motorcycle with a lift stand p 42 Remove the seat p 49 Remove the rig...

Page 55: ...S 53 H00224 10 Lift the swingarm M00389 10 Remove screws on both sides Loosen screws on both sides S00892 10 Remove screw Raise the rear frame slightly and lower the shock absorber S00910 10 Remove springs Spring hooks 50305017000 ...

Page 56: ...manifold 12 27 Installing the manifold M00423 11 Main work Position the manifold and mount springs Spring hooks 50305017000 M00424 11 Mount and tighten screw Guideline Remaining screws chassis M8 25 Nm 18 4 lbf ft S00913 10 Lift the rear frame slightly and position the shock absorber Mount and tighten screw Guideline Screw top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 Position the rear fra...

Page 57: ...59 lbf ft Mount and tighten screw Guideline Screw bottom shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 H00225 11 FE EU Route cable avoiding stress connect plug in connector on lambda sensor and secure with a new cable binder Finishing work Install the fuel tank p 60 Install the main silencer p 57 Install the right side cover p 58 Mount the seat p 50 Remove the motorcycle from the lift stand p ...

Page 58: ...em to cool down Do not touch hot components Info Soot particles accumulate on the screen of the spark arrestor over time This changes the performance characteristics Preparatory work Remove the right side cover p 58 Remove the main silencer p 55 402269 10 Main work Remove screws and take off silencer cap with O ring Warning Danger to health Soot particles irritate the eyes and mucuous membranes We...

Page 59: ...n the vehicle is driven Allow the exhaust system to cool down Do not touch hot components Info Over time the fibers of the glass fiber yarn escape and the damper burns out Not only is the noise level higher the performance characteristic changes Preparatory work Remove the right side cover p 58 Remove the main silencer p 55 M00435 10 Main work FE EU AU Remove all screws on the main silencer Take o...

Page 60: ...ss fiber yarn filling on the perforated pipe Mount 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 Guideline Screws on the main silencer M5 7 Nm 5 2 lbf ft Mount O ring on the silencer cap Position the silencer cap with O ring in the outer tube Mount and tighten screws Gui...

Page 61: ...n contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that has been contaminated with fuel Store fuel properly in a suitable canister and keep away from children Preparatory work Remove the seat p 49 H00187 10 Main work Unplug connector of the fuel pump Pull the hose off the fuel tank breather on the tank lid M00392 10 Thoroughly ...

Page 62: ...contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Main work Check the routing of the throttle cable p 65 H00189 11 Position...

Page 63: ... 12 36 Checking for chain dirt accumulation 400678 01 Check the chain for coarse dirt accumulation If the chain is very dirty Clean the chain p 61 12 37 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Alw...

Page 64: ...e chain at the end of the chain sliding component upwards to measure chain tension Info The lower chain section must be taut Chain wear is not always even so you should repeat this measurement at different chain positions Chain tension 55 58 mm 2 17 2 28 in If the chain tension does not meet specifications Adjust the chain tension p 62 Finishing work Remove the motorcycle from the lift stand p 42 ...

Page 65: ... 42 12 40 Checking the chain rear sprocket engine sprocket and chain guide Preparatory work Raise the motorcycle with a lift stand p 42 400227 01 Main work Shift gear to neutral Check the rear sprocket and engine sprocket for wear If the rear sprocket or engine sprocket is worn Change the drivetrain kit Info The engine sprocket rear sprocket and chain should always be replaced together 400987 10 P...

Page 66: ... line with or below the chain sliding piece Change the chain sliding piece Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten the chain sliding piece Guideline Screw chain sliding piece M8 15 Nm 11 1 lbf ft 400985 01 Check the chain guide for wear Info Wear is visible on the front of the chain guide If the light part of the chain guide is worn Change th...

Page 67: ...ion If the swingarm shows signs of damage cracking or deformation Change the swingarm Info Always change a damaged swingarm Repair of the swingarm is not authorized by Husqvarna Motorcycles 12 43 Checking the routing of the throttle cable Preparatory work Remove the seat p 49 Remove the fuel tank p 59 H00227 01 Main work Check the throttle cable routing Both throttle cables must be routed to the t...

Page 68: ...sting screw clockwise to increase the distance between the clutch lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the clutch 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 12 47 Checking rectifying the fluid level of the hydraulic ...

Page 69: ... bleeder screw and mount bleeding syringe H00229 10 Inject the liquid into the system until it escapes from openings of the master cylinder without bubbles To prevent overflow drain fluid occasionally from the master cylinder reservoir Remove the bleeding syringe Mount and tighten screws bleeder screw Correct the fluid level of the hydraulic clutch Guideline Fluid level below container rim 4 mm 0 ...

Page 70: ...ravel of the hand brake lever p 68 Adjust the free travel of the hand brake lever with adjusting screw Info Turn the adjusting screw clockwise to reduce free travel The pressure point moves away from the handlebar Turn the adjusting screw counterclockwise to increase free travel The pressure point moves towards the handlebar The range of adjustment is limited Turn the adjusting screw by hand only ...

Page 71: ...n Check the brake system and do not continue riding Your authorized Husqvarna Motorcycles workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized Husqvarna Motor cycles workshop will be glad to help H00214 10 Move the brake fluid reservoir mounted...

Page 72: ...front brake linings p 70 H00230 10 Main work Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane Add brake fluid to level Guideline Level brake fluid level below con tainer rim 5 mm 0 2 in Brake fluid DOT 4 p 113 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilled brake fluid imm...

Page 73: ...e and friction coefficient of the brake linings and thus their brake power may vary greatly from that of original Husqvarna Motorcycles bake linings If brake linings that differ from the original equipment are used it cannot be guaranteed that these are in keeping with the original homologation In this case the vehicle will not correspond to its condition at delivery and the warranty shall be void...

Page 74: ...ne Mount and tighten screws Info Clean up overflowed or spilled brake fluid immediately with water 13 9 Checking the free travel of foot brake lever Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to overheating Adjust the free travel on foot brake lever according to specifi...

Page 75: ...d screw and tighten nut Guideline Nut foot brake lever stop M8 20 Nm 14 8 lbf ft Hold push rod and tighten nut Guideline Remaining nuts chassis M6 10 Nm 7 4 lbf ft Reconnect spring 13 11 Checking the rear brake fluid level Warning Danger of accidents Brake system failure If the brake fluid level drops below the specified marking or the specified value this is an indication that the brake sys tem i...

Page 76: ...ing efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized Husqvarna Motor cycles workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5...

Page 77: ...ake according to the service schedule Your authorized Husqvarna Motor cycles workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accident Reduced braking efficiency due to the use of non approved brake linings...

Page 78: ...caliper support M01232 10 Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated properly The arrow on the leaf spring points in the rotation direction of the brake disc M01231 10 Insert the new brake linings insert pin and mount cotter pins Info Always change the brake linings in pairs Make sure that decoupling plate is mounted on the piston side of ...

Page 79: ...remove the wheel spindle Take the front wheel out of the fork Info Do not pull the hand brake lever when the front wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged H00934 10 Remove spacers 14 2 Installing the front wheel Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil ...

Page 80: ...ise the motorcycle with a lift stand p 42 H00204 10 Main work Press the brake caliper by hand on to the brake disc in order to press back the brake piston Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove nut Remove chain adjuster Withdraw wheel spindle only enough to allow the rear wheel to be pushed forward Push the rear wheel for...

Page 81: ...fitted correctly on adjusting screws Check the chain tension p 62 Tighten nut Guideline Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm 1 26 in enables different secondary ratios with the same chain length Chain adjusters can be turned by 180 Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc...

Page 82: ...ange the tires 14 6 Checking the tire air pressure Info Low tire air pressure leads to abnormal wear and overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life 400695 01 Remove the protection cap Check the tire air pressure when the tires are cold Tire air pressure off road Front 1 0 bar 15 psi Rear 1 0 bar 15 psi Road tire pressure FE EU AU ...

Page 83: ...und frequencies in spokes with the same length and thickness this indicates different spoke tensions You should hear a high note If the spoke tension varies Correct the spoke tension Check the spoke torque Guideline Spoke nipple front wheel M4 5 6 Nm 4 4 lbf ft Spoke nipple rear wheel M4 5 6 Nm 4 4 lbf ft Torque wrench with various accessories in set 58429094000 ...

Page 84: ...erminal cover and disconnect the negative cable from the battery Pull back the positive terminal cover and disconnect the positive cable from the battery Detach rubber band at the bottom Lift the battery up and out 15 2 Installing the battery H00233 10 Main work Insert battery into the battery compartment with the terminals facing to the front Battery YTX5L BS p 110 Reconnect rubber band Info Cont...

Page 85: ...tens the battery s service life If the charging current charging voltage and charging time are exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted from starting the vehicle repeatedly the battery must be charged immediately If the battery is left in a discharged state for an extended period it will become over discharged and sulfate d...

Page 86: ...protection caps Remove the faulty main fuse Info A defective fuse can be identified by the burned out fuse wire A reserve fuse is located in the starter relay Install a new main fuse Fuse 58011109120 p 110 Check that the electrical equipment is functioning properly Tip Insert the spare fuse so that it is available if needed Mount the protection caps Finishing work Install the air filter box lid p ...

Page 87: ...with the correct rating only Fuse 75011088010 p 110 Tip Replace the spare fuse in the fuse box so that it is available if needed Check that the power consumer is functioning properly Close the fuse box cover Finishing work Mount the seat p 50 15 6 Removing the headlight mask with the headlight Preparatory work Switch off all power consumers and switch off the engine S00513 10 Main work FE EU AU De...

Page 88: ...Main work FE EU AU Connect plug in connectors H00221 10 Position the headlight mask and secure it with rubber bands The holding lugs engage in the fender H00208 10 Position brake line and wiring harness in the brake line guide S00893 11 FE US Connect plug in connector S00509 11 Position the headlight mask and secure it with rubber bands The holding lugs engage in the fender ...

Page 89: ...tion cap together with the underlying bulb socket counter clockwise all the way and remove it Pull bulb socket of the parking light out of the reflector M00433 10 FE US Turn protection cap together with the underlying bulb socket counter clockwise all the way and remove it Pull bulb socket of the parking light out of the reflector S00508 10 Pull out headlight bulb Insert the new headlight bulb Hea...

Page 90: ...Turn signal R10W socket BA15s p 110 Mount the orange cap Position the diffuser Insert the screw and first turn counterclockwise until it engages in the thread with a small jerk Tighten the screw lightly Finishing work Check that the turn signal system is functioning properly 15 10 Checking the headlight setting 400726 10 Position the vehicle upright on a horizontal surface in front of a light wall...

Page 91: ... and switch off the engine Remove the headlight mask with the headlight p 85 S00505 10 Main work Remove screws Pull the speedometer upward out of the holder B01644 10 Using a coin turn protection cap all the way counterclockwise and remove it Remove speedometer battery Insert the new battery with the label facing outward Speedometer battery CR 2032 p 110 Check the O ring of the protection cap for ...

Page 92: ...Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If f...

Page 93: ...10 mm 0 39 in If the coolant level does not match the specified value Correct the coolant level Coolant p 113 Mount the radiator cap 16 4 Draining the coolant Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling syste...

Page 94: ... contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children C00604 10 Main work Make sure that the screw is tightened Stand the vehicle upright Pour coolant in up to measurement above the radiator fins Guideline 10 mm 0 39 in Coolant 1 2 l 1 3 qt Coolant p 113 Refit ...

Page 95: ... idle Move the handlebar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust the play in the throttle cable p 93 17 2 Adjusting the play in the throttle cable Preparatory work Remove the seat p 49 Remove the fuel tank p 59 Check the routing of the throttle cable p 65 C00606 10 Main work Move the handlebar to the straight ahead position Push bac...

Page 96: ...ed adjusting screw Guideline Idle speed 1 800 1 900 rpm Info Turn counterclockwise to increase the idle speed Turn clockwise to decrease the idle speed 17 4 Checking the basic position of the shift lever Info When driving the shift lever must not touch the driver s boot when in the basic position When the shift lever keeps touching the boot the transmission will be subject to an excessive load 400...

Page 97: ...on the shift shaft in the required position and engage the gearing Info The range of adjustment is limited The shift lever must not come into contact with any other vehicle compo nents during the shift procedure Locate and tighten screw with washers Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 ...

Page 98: ...ction of the fuel line thoroughly with compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Disconnect the plug in connection of the fuel line Info Remaining fuel may flow out of the fuel hose Pull fuel screen out of the connecting piece Slide the new fuel screen all the way into the connecting piece Lubricate the O ring an...

Page 99: ...lated in applicable regulations Info Drain the engine oil only when the engine is warm Preparatory work Remove the engine guard p 67 Park the motorcycle on a level surface B01758 10 Main work Place a suitable container under the engine Remove oil drain plug with the magnet and seal ring B01759 10 Remove screw plug with the gear oil screen and the O rings Info Do not remove screw B01760 10 Remove s...

Page 100: ...l oil filter out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing area B01763 11 Lay the motorcycle on its side and fill the oil filter housing to about full with engine oil Insert the new oil filter into the oil filter housing Oil the O ring of the oil filter cover and mount it with oil filter cover Mount and tight...

Page 101: ...e wear to the engine S00499 10 Main work Remove the oil filler plug with the O ring from the clutch cover Fill engine oil to the middle of the level viewer Engine oil SAE 10W 50 p 113 Info For optimal performance of the engine oil do not mix different types of engine oil If appropriate change the engine oil Install and tighten the oil filler plug with O ring Danger Danger of poisoning Exhaust gase...

Page 102: ...pray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to a dry vehicle always rinse the vehicle with water first After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the closure of the exhaust system Warning Danger of acc...

Page 103: ...torcycle p 100 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 vehicle with cold water and dry it well Treat the engine swingarm and all other bright and zinc plated parts except for the brake discs with a wax ba...

Page 104: ...last time before taking the motorcycle out of service add fuel additive Refuel p 32 Clean the motorcycle p 100 Change the engine oil and oil filter and clean the oil screens p 97 Check the antifreeze and coolant level p 90 Check the tire air pressure p 80 Remove the battery p 82 Charge the battery p 83 Guideline Storage temperature of battery with out direct sunshine 0 35 C 32 95 F Store the vehic...

Page 105: ...t in fuel injection system Read out the fault memory using the Husq varna Motorcycles diagnostics tool Engine does not speed up Defect in fuel injection system Read out the fault memory using the Husq varna Motorcycles diagnostics tool Ignition system defective Ignition coil check the secondary winding Check the spark plug connector Check the stator winding of the alternator Engine has too little ...

Page 106: ...iagnostics tool High oil consumption Engine vent hose bent Route the vent hose without bends or replace it if necessary Engine oil level too high Check the engine oil level p 96 Engine oil too thin low viscosity Change the engine oil and oil filter and clean the oil screens p 97 Piston and cylinder worn Measure the piston cylinder mounting clear ance Battery discharged Battery is not being charged...

Page 107: ... warning lamp MIL 13 FI warning lamp MIL flashes 1x long 3x short Error level condition Intake air temperature sensor input signal too low Intake air temperature sensor input signal too high Blink code FI warning lamp MIL 15 FI warning lamp MIL flashes 1x long 5x short Error level condition Rollover sensor A D type input signal too low Rollover sensor A D type input signal too high Blink code FI w...

Page 108: ...ing lamp MIL 45 FI warning lamp MIL flashes 4x long 5x short Error level condition FE EU Lambda sensor heater cylinder 1 sensor 1 short circuit to ground or open circuit FE EU Lambda sensor heater cylinder 1 sensor 1 input signal too high ...

Page 109: ...ission 32 76 Clutch Multidisc clutch in oil bath hydraulically activated Transmission ratio 1st gear 14 36 2nd gear 17 32 3rd gear 19 28 4th gear 22 26 5th gear 24 23 6th gear 26 21 Alternator 12 V 200 W Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment type Kokusan Spark plug NGK LKAR 9AI 10 Spark plug electrode gap 1 0 mm 0 039 in Cooling Water permanent...

Page 110: ... 4 lbf ft Loctite 243 Screw timing chain securing guide M6 10 Nm 7 4 lbf ft Loctite 243 Screw timing chain tensioner M6 10 Nm 7 4 lbf ft Screw timing chain tensioning rail M6 10 Nm 7 4 lbf ft Loctite 243 Screw torque governor M6 10 Nm 7 4 lbf ft Loctite 243 Screw valve cover M6 10 Nm 7 4 lbf ft Screw water pump cover M6x25 10 Nm 7 4 lbf ft Screw water pump cover M6x55 10 Nm 7 4 lbf ft Oil jet for ...

Page 111: ...per unleaded ROZ 95 RON 95 PON 91 p 113 Fuel reserve approx 1 5 l 1 6 qt 23 4 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork WP Performance Systems Up Side Down 4860 MXMA 4CS Suspension travel Front 300 mm 11 81 in Suspension travel Rear 330 mm 12 99 in Fork offset 22 mm 0 87 in Shock absorber WP Performance Systems 5018 DCC Brake system Disc brakes brake calipers on ...

Page 112: ...R 2032 Battery voltage 3 V Fuse 75011088010 10 A Fuse 58011109120 20 A Headlight HS1 Sockel PX43t 12 V 35 35 W Parking light W5W socket W2 1x9 5d 12 V 5 W Indicator lamps W2 3W socket W2x4 6d 12 V 2 3 W Turn signal FE EU AU R10W socket BA15s 12 V 10 W Brake tail light LED License plate lamp FE EU AU W5W socket W2 1x9 5d 12 V 5 W 23 6 Tires Validity Front tires Rear tires FE EU AU 90 90 21 M C 54R ...

Page 113: ...g 143 165 lb 54 N mm 308 lb in Weight of rider 75 85 kg 165 187 lb 57 N mm 325 lb in Weight of rider 85 95 kg 187 209 lb 60 N mm 343 lb in Spring length 260 mm 10 24 in Gas pressure 10 bar 145 psi Static sag 30 mm 1 18 in Riding sag 100 mm 3 94 in Fitted length 490 mm 19 29 in Shock absorber oil Shock absorber fluid SAE 2 5 50180751S1 p 113 23 9 Chassis tightening torques Screw pressure regulator ...

Page 114: ...stand attachment M8 45 Nm 33 2 lbf ft Loctite 2701 Screw subframe M8x20 30 Nm 22 1 lbf ft Loctite 2701 Screw subframe M8x30 30 Nm 22 1 lbf ft Loctite 2701 Screw top steering stem M8 17 Nm 12 5 lbf ft Loctite 243 Screw top triple clamp M8 17 Nm 12 5 lbf ft Engine attachment bolt M10 60 Nm 44 3 lbf ft Remaining nuts chassis M10 45 Nm 33 2 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Screw b...

Page 115: ...rds see specifications on the container and that possess the corre sponding properties Synthetic engine oil Recommended supplier Bel Ray Works Thumper Racing Synthetic Ester 4T Fork oil SAE 4 48601166S1 Standard classification SAE p 115 SAE 4 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding properties Shock abso...

Page 116: ...ended supplier SKF LGHB 2 Long life grease Recommended supplier Bel Ray Waterproof Grease Offroad chain spray Guideline Recommended supplier Bel Ray Blue Tac Chain Lube Oil for foam air filter Recommended supplier Bel Ray Foam Filter Oil Preserving materials for paints metal and rubber Recommended supplier Bel Ray Silicone Detailer Protectant Spray Universal oil spray Recommended supplier Bel Ray ...

Page 117: ...rvice intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils ...

Page 118: ...27 LIST OF ABBREVIATIONS 116 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 119: ...ls FI warning lamp MIL lights up flashes orange The OBD has detected an emission or safety critical fault The low fuel warning lamp lights up orange The fuel level has reached the reserve mark 28 2 Green and blue symbols Green and blue symbols reflect information The high beam indicator light lights up blue The high beam is switched on Turn signal indicator light flashes green The turn signal is s...

Page 120: ...ing 63 Chain tension adjusting 62 checking 62 Chassis number 12 Clutch fluid level checking rectifying 66 fluid changing 67 Clutch lever 14 basic position adjusting 66 Combination instrument overview 21 Compression damping fork adjusting 40 Compression damping high speed shock absorber adjusting 36 Compression damping low speed shock absorber adjusting 35 Coolant draining 91 refilling 92 Coolant l...

Page 121: ...Horn button 15 I Idle speed adjusting 94 Idle speed adjusting screw 18 Implied warranty 9 Intended use 6 K Key number 12 Kill switch 14 L Light switch 15 Lower triple clamp installing 45 removing 44 M Main fuse changing 84 Main silencer glass fiber yarn filling changing 57 installing 57 removing 55 spark arrestor cleaning 56 Manifold installing 54 removing 52 Motorcycle cleaning 100 lift stand rai...

Page 122: ...g 19 unlocking 20 Steering head bearing lubricating 48 Steering head bearing play adjusting 47 checking 47 Storage 102 Swingarm checking 65 T Technical data capacities 109 chassis 109 chassis tightening torques 111 electrical system 110 engine 107 engine tightening torques 107 fork 110 shock absorber 111 tires 110 Throttle cable play adjusting 93 Throttle cable routing checking 65 Throttle grip 14...

Page 123: ... 3402066en 3402066en 07 2015 Husqvarna Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen Austria www husqvarna motorcycles com Photo Mitterbauer Husqvarna Motorcycles GmbH ...

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