Husqvarna FS 450 2015 Repair Manual Download Page 22

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FORK, TRIPLE CLAMP

�

Disassemblin

Info

200843-10

200846-10

- Reclamp the cartridge upside down.

Guideline

Use soft jaws.

- Heat the cartridge in area

of pilot bushing

Guideline

1100 °C (212 °F)

- Loosen the screw sleeve and remove the piston rod.

- Remove spring guide

and ring@.

- Remove guide ring@).

- Remove filling screw

and O-ring �-

- Press check valve

against the spring and remove it.

iston rod

The steps are identical for both fork legs.

Preparatory work

- Disassemble the fork legs. (

p. 16)

- Disassemble the cartridge. (

p. 18)

Summary of Contents for FS 450 2015

Page 1: ...PIONEERING SINCE 1903 REPAIR MANUAL2015 FS 450 Art no 3403022en Husqvarna MOTORCYCLES ...

Page 2: ......

Page 3: ...materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice Husqvarna accepts no lia bility for delivery options deviations from illustrations and descriptions as well as misprints and other errors The models portrayed partly contain special equipment that do...

Page 4: ...ering head bearing 39 6 31 Adjusting the steering head bearing play 40 7 8 9 2 HANDLEBAR CONTROLS 42 7 1 7 2 7 3 7 4 7 5 Handlebar position 42 Adjusting the handlebar position 42 Adjusting the basic position of the clutch lever 42 Checking the throttle cable routing 43 Checking the play in the throttle cable 43 7 6 Adjusting the play in the throttle cable 44 FRAME 45 8 1 Checking the frame 45 SHOC...

Page 5: ...3 16 4 Checking the front brake fluid level 113 3 16 5 Adding front brake fluid 113 16 6 Changing the front brake fluid 114 16 7 Checking the rear brake linings 116 16 8 Changing the rear brake linings 116 16 9 Checking the free travel of foot brake lever 117 16 10 Adjusting the basic position of the foot brake lever 118 16 11 Checking the rear brake fluid level 118 16 12 Adding rear brake fluid 1...

Page 6: ...7 5 10 Installing the locking lever 175 17 5 11 Installing the shift drum locating unit 176 17 5 12 Installing the shift shaft 176 17 5 13 Installing the starter idler gear 176 17 5 14 Installing the torque limiter 176 4 17 5 15 Installing the outer clutch hub 176 17 5 16 Installing the clutch discs 177 17 5 17 Installing the clutch cover 178 17 5 18 Installing the water pump cover 179 17 5 19 Ins...

Page 7: ...NG PROTECTIVE TREATMENT 211 25 1 Cleaning themotorcycle 211 26 STORAGE 212 26 1 Storage 212 26 2 Preparing for use after storage 212 27 SERVICE SCHEDULE 213 27 1 Service schedule 213 27 2 Servicework as additional order 214 28 WIRING DIAGRAM 216 28 1 Page1 of3 216 28 2 Page2 of3 218 28 3 Page3 of3 220 29 SUBSTANCES 222 30 AUXILIARY SUBSTANCES 224 31 SPECIAL TOOLS 226 32 STANDARDS 241 INDEX 242 5 ...

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

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

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

Page 11: ...teering head The type label O is fixed to the front of the steering head The engine number O is stamped on the left side of the engine under the engine sprocket The fork part number O is stamped on the inside of the axle clamp The shock absorber article number O is stamped on the top of the shock absorber above the adjusting ring towards the engine side 9 ...

Page 12: ...isoning 402001 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle insert plug in stand O into the left side of the wheel spindle Info Remove the plug in stand before riding 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 extracti...

Page 13: ...r Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Info Press the starter for a maximum of 5 seconds Wait for at least 5 seconds before trying again 400733 01 Shift the trans...

Page 14: ...s I Turn clockwise to increase damping turn counterclockwise to reduce damping Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior Remove protection caps O Turn adjusting screws 8 clockwise all the way Info I Adjusting screws 8 are located at the bottom end of the fork legs Make the same adjustment on both fork legs Turn back counter...

Page 15: ...es Over time dirt can accumulate 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 brak ing effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Clean and oil the dust boots and inner fork tubes of both fork legs I Universal oi...

Page 16: ...oove from the top must be flush with the top edge of the upper triple clamp Tighten screws 8 Guideline I Screw top triple clamp Tighten screws Guideline I Screw bottom triple clamp 11 7 Nm 12 5 lbf ft I 112 Nm 8 9 lbf ft Position the brake line and clamp Mount and tighten screws 8 Finishing work Install the front wheel p 94 Remove screws O on the left fork leg Take off the clamp Remove screws on t...

Page 17: ...both fork legs u 0 200974 01 Condition The fork legs are disassembled Disassemble the fork legs l ll p 16 Disassemble the cartridge J p 18 Disassemble the piston rod J p 20 Disassemble the screw cap with the membrane holder J p 22 Disassemble the screw sleeve J p 23 Check the fork legs J p 23 Change the pilot bushing J p 26 Assemble the screw sleeve J p 27 Assemble the screw cap with the membrane ...

Page 18: ...ntical for both fork legs 201364 10 201363 10 Condition The fork legs are disassembled Remove protection cap 6 Note down the present state of rebound damping O and compression damp ing Fully open the adjusters of the rebound and compression damping Clamp the fork leg in the area of the lower triple clamp I Clamping stand T1403S a p 239 Remove the screw Remove adjuster D of the compression damping ...

Page 19: ...nd adjustment 0 Info I Do not use an impact wrench Place a fluid collector beneath it as usually some oil will drain out The rebound adjustment cannot be removed yet Press the cartridge against the spring and mount special tool D on the piston rod I Support tool T14020 p 238 Hold nut and remove the rebound adjuster Press the cartridge against the spring and remove special tool D Remove the cartrid...

Page 20: ...ing Guideline I so 0 c 122 F Pull the outer tube forcefully off of the inner tube Info The lower sliding bushing Ci must be pulled out of its bearing seat Remove upper sliding bushing 48 Info Without using a tool carefully pull the stack apart by hand Take off the lower sliding bushing Ci Take off support ring 9 Take off seal ring Take off lock ring Take off dust boot C Unclamp the fork leg Disass...

Page 21: ...dge into a vise Info Use soft jaws Remove filling screw D Pierce the membrane with the needle of the special tool I Nitrogen charging tool T14019 a p 238 The pressurized nitrogen is bled off Loosen and remove screw cap C with the membrane holder I Pin wrench T103 p 235 Unclamp the cartridge Empty the cartridge 19 ...

Page 22: ...t bushing 0 Guideline 1100 C 212 F Loosen the screw sleeve and remove the piston rod Remove spring guide D and ring Remove guide ring Remove filling screw 0 and O ring Press check valve 48 against the spring and remove it iston rod The steps are identical for both fork legs Preparatory work Disassemble the fork legs a p 16 Disassemble the cartridge a p 18 20 ...

Page 23: ...e the piston rod Clamp the piston rod with the special tool as far up as possible I Clamping stand T14016S a p 237 Remove nut Remove rebound shim stack C Remove rebound piston Remove the piston ring from the piston Remove compression shim stack D Remove spring Remove tap rebound Q Remove spring with the sleeve 21 ...

Page 24: ...ssemble the cartridge l t I p 18 Main work 22 Clamp the screw cap with the membrane holder and the special tool into a vise Guideline I Use soft jaws I Pin wrench T103 p 235 Info I Only tighten the vise lightly Remove compression holder O Remove membrane Unclamp the special tool Remove 0 ring Clamp the open end wrench in a vise Position compression holder O Remove nut C Remove spring 0 Remove rebo...

Page 25: ...e l t I p 18 Disassemble the piston rod l t J p 20 Main work Remove 0 ring O Remove lockring 8 Remove ring CD Screw the special tool onto the screw sleeve I Threaded bushing T14023 l l p 239 The special tool must have an overhang to protect the thread I Overhang 11 mm 0 04 in Pry out seal ring 8 being sure only to brace the lever against the special tool Condition The forklegs have been disassembl...

Page 26: ...measured value is greater 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 bushing If the bronze colored layer G under the sliding layer Ce is visible or the sur face is rough Replace the sliding bushing Check the spring length Guideline I Spring length with preload spacer s I 482 mm 18 98 in If...

Page 27: ...s have been disassembled Check the inner tube and axle clamp for damage If there is damage Change the inner tube Measure the outside diameter of the inner tube at several locations Outside diameter of the inner tube 47 975 48 005 mm 1 88878 1 88996 in If the measured value is less than the specified value Change the inner tube Measure the run out of the inner tube I Inner tube run out I 0 20 mm 0 ...

Page 28: ...mble the piston rod a p 20 Disassemble the screw sleeve a p 23 Main work Press the pilot bushing out of screw sleeve O using the special tool I Mounting tool T14022B a p 238 Slide the new pilot bushing onto the special tool I Mounting tool T14022B 0 p 238 Ensure that special tool G is mounted and that there is an overhang to protect the thread Guideline I Overhang 11 mm 0 04 in I Threaded bushing ...

Page 29: ...ression holder Mount the compression shim stack 8 with the smaller shims facing downward Grind compression piston 6 on both sides on a surfacing plate using 1200 grit sandpaper Clean the compression piston Mount and grease O ring 8 I Lubricant T158 p 224 Mount the compression piston Guideline Viewf ViewC Mount rebound damping washer C Compression piston from above Compression piston from below Mou...

Page 30: ... special tool 8Nm 5 9 lbf ft Loctite 241 The steps are identical for both fork legs 200862 11 Mount and grease the O rings of tap rebound O and the valve I Lubricant T158 8 p 224 Position the valve with the spring in the tap rebound Degrease the piston rod Clamp the piston rod with the special tool I Clamping stand T14016S p 237 Mount spring with the sleeve Mount and tighten tap rebound O Guidelin...

Page 31: ...low Align triangular plates 9 exactly with the openings of the rebound piston Mount and tighten new nut with the collar facing downward Guideline I Rebound nut Info I Do not twist the triangular plates Secure the nut by locking Take out the piston rod I M6x0 5 I 5 Nm 3 7 lbf ft The steps are identical for both fork legs Preparatory work Check the fork legs a p 23 Assemble the screw cap with the me...

Page 32: ... 239 Grease seal ring and slide onto the piston rod with the open side forward Remove the special tool I Lubricant T511 a p 224 Slide screw sleeve fD onto the piston rod Press the seal ring flush into the screw sleeve Grease the O ring of the screw sleeve I Lubricant T158 a p 224 Tighten the screw sleeve Guideline Screw sleeve on the car M24x1 tridge Mount filling screw with the O ring 40 Nm 29 5 ...

Page 33: ...k legs e 8 8 200669 10 Preparatory work Check the fork legs 1ll p 23 Assemble the screw cap with the membrane holder 1ll p 27 Assemble the piston rod 1ll p 28 Assemble the cartridge I p 29 Main work Clamp in the inner tube with the axle clamp Guideline I Use soft jaws Mount the special tool I Protecting sleeve T1401 1ll p 237 Lubricate and slide on dust boot O I Lubricant T511 I p 224 Info Always ...

Page 34: ... the outer tube in area f of the lower sliding bushing Guideline 1 so 0 c 122 F Hold the lower sliding bushing with the longer shoulder of the special tool I Mounting tool T14040S p 240 Press the outer tube all the way in Position the support ring Hold the seal ring with the shorter shoulder of the special tool I Mounting tool T14040S p 240 Press the outer tube all the way in Mount lock ring Info ...

Page 35: ... it from turning X If the rebound adjuster is not turned all the way to the stop the rebound damping cannot be correctly adjusted Hold onto nut and tighten the rebound adjuster Guideline I Rebound adjuster on the piston rod I M12x1 I 30 Nm 22 1 lbf ft I Press the cartridge against the spring and remove special tool Tighten the rebound adjuster Guideline I Rebound adjuster on the axle clamp I M20x1...

Page 36: ...he 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 recommended range Ride slowly to start with after making adjustments to get the feel of the new handling characteristic Set the adjusting screws to the position determined before removal Mount protection...

Page 37: ...uired value 10 mbar When the vacuum gauge reaches the required value turn control lever Oil reser voir 0 to Equalize pressure Guideline 10 mbar The pressure gauge increases to the required value 0 bar When the pressure gauge reaches the required value turn control lever Damper 8 to Pressure Guideline 0 bar Oil is pumped into the cartridge The pressure gauge increases to the required value 3 bar Wh...

Page 38: ...p 238 Filling gas nitrogen Adjust the pressure regulator of the nitrogen bottle Guideline I Gas pressure 11 2 bar 17 psi Pierce the membrane with the needle of the special tool Open valve O Fill the cartridge for at least 15 seconds Guideline I Gas pressure Info I Watch the pressure regulator dial 11 2 bar 17 psi Ensure that the cartridge is filled to the specified pressure Close the valve Close t...

Page 39: ...e by covering them Do not bend the cables and lines Remove O ring C Remove protective ring 0 Take out the lower triple clamp with the steering stem Take out the upper steering head bearing lnstallin the lower triple clamp 800221 10 Main work Clean the bearing and sealing elements check for damage and grease I High viscosity grease JI p 224 Insert the lower triple clamp with the steering stem Mount...

Page 40: ... Nm 12 5 lbf ft 112 Nm 8 9 lbf ft 12 Nm 8 9 lbf ft Loctite 243 Using a plastic hammer tap lightly on the upper triple clamp to avoid stresses Tighten screws 0 Guideline I Screw top triple clamp 117 Nm 12 5 lbf ft I Position brake line and bracket on fork protector and mount and tighten screws Finishing work Mount the handlebar cushion Install the front fender a p 90 Install the start number plate ...

Page 41: ... play present Adjust the steering head bearing play a p 40 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 bearing play a p 40 Check the steering head bearing and change if necessary Finishing work Remove the moto...

Page 42: ...p 90 Install the front wheel p 94 Check that the wiring harness throttle cables and brake and clutch lines can move freely and are routed correctly Check the steering head bearing play I p 39 Remove the motorcycle from the lift stand I p 10 Adjusting the steering head bearing Qla Preparatory work Raise the motorcycle with a lift stand p 10 Remove the handlebar cushion Main work Loosen screws O Rem...

Page 43: ...P Tighten screws O Guideline I Screw top triple clamp I M8 Check the steering head bearing play I p 39 Finishing work Mount the handlebar cushion Remove the motorcycle from the lift stand I p 10 41 1 1 7 Nm 12 5 lbf ft I ...

Page 44: ... the handlebar supports Place the handlebar supports in the required position Mount and tighten screws 8 Guideline Screw handlebar support M10 Info 40 Nm 29 5 lbf ft Position the left and right handlebar supports evenly Position the handlebar Info Loctite 243 I Make sure the cables and wiring are positioned correctly Position the handlebar clamps Mount and tighten screws O evenly Guideline I Screw...

Page 45: ...t ahead position Turn the throttle grip back and forth slightly and determine the play in throttle cable G I Play in throttle cable 13 5 mm 0 12 0 2 in If the throttle cable play does not meet specifications Adjust the play in the throttle cable p 44 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ven...

Page 46: ...le 44 Loosen nut 8 Turn adjusting screw 0 so that there is play in the throttle cable at the throttle grip Guideline I Play in throttle cable 13 5 mm 0 12 0 2 in Tighten nut 8 Press and hold the throttle grip in the closed setting Turn adjusting screw out until there is no play in the throttle cable 0 Tighten nut Push sleeves O on Check the throttle grip for smooth operation Finishing work Check t...

Page 47: ...deformation If the frame exhibits cracks or deformation due to a mechanical impact Change the frame Info 45 I Always replace a frame that has been damaged due to a mechan ical impact Repair of the frame is not authorized by Husqvarna Motorcycles ...

Page 48: ... clockwise to increase damping turn counterclockwise to reduce damping Adjusting the low speed compression damping of the shock absorber Caution Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Info The low speed setting can be seen during the...

Page 49: ... 4 Measurin rear wheel sa unloaded Preparatory work Raise the motorcycle with a lift stand p 10 Main work Measure the vertical distance between the rear axle and a fixed point such as a marking on the side cover Note down the value as dimension f Finishing work Remove the motorcycle from the lift stand il l p 10 Checkin the static sag of the shock absorber Measure distance f of rear wheel unloaded...

Page 50: ... sag I 75 mm 2 95 in If the riding sag differs from the specified measurement Adjust the riding sag 0 p 49 Adjusting the s ring reload of the shock absorber Caution Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Info Before changing the spri...

Page 51: ...unt the seat p 80 Remove the motorcycle from the lift stand p 10 Preparatory work Raise the motorcycle with a lift stand I p 10 Remove the seat I p 80 Remove the right side cover a p 79 Remove the main silencer a p 75 Remove the manifold a p 74 Remove the shock absorber p 50 After removing the shock absorber clean it thoroughly Main work Choose and mount a suitable spring Guideline Spring rate I 5...

Page 52: ...Remove the seat p 80 Remove the right side cover a p 79 Remove the main silencer a p 75 Remove the manifold a p 74 Main work Remove screw O Remove fitting Press angle lever toward the rear Press linkage lever C downward Raise the swingarm and secure it in the raised position Remove screws 0 on both sides Loosen screws D on both sides Remove screw Raise the rear frame slightly and remove the shock ...

Page 53: ...gle lever and linkage lever Mount and tighten screw cap C Guideline 60 Nm 44 3 lbf ft 30 Nm 22 1 lbf ft 30 Nm 22 1 lbf ft I Nut linkage lever to angle lever I M14x1 5 Mount and tighten screw C Guideline Screw bottom shock absorber Finishing work Install the manifold l ll p 74 M10 Install the main silencer I p 75 Install the right side cover Ii p 80 Mount the seat I p 80 60 Nm 44 3 lbf ft Remove th...

Page 54: ...edle bearing C and 0 for damage and wear If there is damage or wear Change the needle bearing Check spacers D and for damage and wear If there is damage or wear Change the spacers Check the shaft seal rings for damage and wear If there is damage or wear Change the shaft seal rings Check dimension 0 I 54 91 55 00 mm 2 1618 2 1654 in If dimension O is less than the specified value Add the correspond...

Page 55: ... angle lever Info I M14x1 5 I 80 Nm 59 lbf ft I Raise the wheel slightly to make it easier to mount the screw Tighten screws O Guideline Screw bottom shock absorber Tighten fitting Guideline M10 I Nut linkage lever on swingarm Finishing work 60 Nm 44 3 lbf ft I M14x1 5 Remove the motorcycle from the lift stand a p 10 Servicin the shock absorber Caution Risk of injury Parts of the shock absorber wi...

Page 56: ...ing a p 68 Condition The shock absorber has been removed Clamp the shock absorber in the vise using soft jaws for protection 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 Ii p 235 Remove ring Remove spring retainer fD and intermediate washer C Remove the spring 9 14 Disassemblin the damper Pr...

Page 57: ...y The pressurized nitrogen escapes Remove locking cap 0 Press in seal ring retainer D using the special tool Disassembly tool T1216 I p 237 Remove lock ring Info Do not scratch the inner surface Remove the piston rod Remove adjusting ring with the intermediate washer Drain the oil 55 ...

Page 58: ...ston rod with the fork in a vise Guideline I Use soft jaws Remove nut O Remove washer 8 Remove rebound shim stack Info I Place the rebound shim stack onto a screwdriver and set it down as a unit Remove piston C Remove compression shim stack 0 Info I Place the compression shim stack onto a screwdriver and set it down as a unit Remove rebound washer D Remove seal ring retainer Remove locking cap and...

Page 59: ... ring Remove rebound rubber Remove centering disk 8 Remove seal ring 0 Remove washer D for seal ring 0 Remove washer Remove dust boot 9 17 Changing the ilot bushing 8 I 200796 10 Preparatory work Remove the spring I p 54 Disassemble the damper I p 54 Disassemble the piston rod I p 56 Disassemble the seal ring retainer I p 57 Main work Press pilot bushing O out of seal ring retainer 8 with the spec...

Page 60: ...ted Finishing work Assemble the seal ring retainer p 60 Condition The damper has been disassembled Measure the inside diameter on both ends and in the middle of the damper car tridge Damper cartridge Diameter 5 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 t...

Page 61: ... in the vise using soft jaws for protection Remove the collar bushing of the heim joint I Pin T120 I p 236 Turn the shock absorber and remove the second collar bushing 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 I p 236 Remove the second lock ring fj Place special tool f underneath and press out heim joi...

Page 62: ...he heim joint all the way in Press the heim joint against the lock ring using the special tool I Pressing tool T1207S OJ p 236 Mount the second lock ring 8 Mount seal rings on both sides Position both collar bushings C and press them in retainer Mount dust boot O using the special tool I Mounting sleeve T1204 p 236 Lubricate the sealing lip of the dust boot I Lubricant T625 p 224 60 ...

Page 63: ...groove of the O ring I Lubricant T158 p 224 Mount O ring Mount spring Preparatory work Assemble the seal ring retainer p 60 Main work Clamp the piston rod with the fork in a vise Guideline I Use soft jaws Mount rubber buffer O and locking cap 8 Position special tool on the piston rod I Mounting sleeve T1215 p 237 Grease the dust boot and push seal ring retainer Donto the piston rod I Lubricant T62...

Page 64: ... piston Assemble the piston Guideline View6 Piston from above ViewC Piston from below Mount the rebound shim stack with the smaller shims facing upward Mount washer with the collar facing downward Grease the thread of the piston rod I Lubricant T152 p 224 Mount and tighten nut Guideline I Nut piston rod Preparatory work I M16x1 Assemble the seal ring retainer a p 60 Assemble the piston rod a p 61 ...

Page 65: ...fo The adjusting ring cannot be mounted after the piston rod is mounted Fill the damper cartridge about half full I Shock absorber fluid SAE 2 5 50180751S1 p 222 Lubricate O ring 8 of the seal ring retainer I Lubricant T158 p 224 Mount the piston rod carefully Install the seal ring bearer C and push it under the ring groove Mount lock ring 0 Info I Do not scratch the inner surface Pull out the pis...

Page 66: ...10 clicks Alternative 2 Warning Danger of accident Modifications to the suspension setting may seriously alter the handling characteristic Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components Only make adjustments within the recommended range Ride slowly to start with after making adjustments to get the feel of the...

Page 67: ...between the floating piston and reservoir hole with the spe cial tool I Depth micrometer T107S 0 p 235 The floating piston is positioned all the way at the bottom When the vacuum pressure gauge reaches the specified value turn the Oil reser voir control lever 0 to Equalize pressure Guideline 4 mbar The pressure gauge increases to the specified value 0 bar When the pressure gauge reaches the specif...

Page 68: ...ssure gauge increases to the specified value 3 bar When the pressure gauge reaches the specified value turn the Damper C con trol lever to Vacuum Guideline 3 bar The pressure gauge drops to the specified value 0 bar When the pressure gauge reaches the specified value operate the On Off switch Guideline 0 bar The vacuum pump is switched off Slide O ring 0 to the end of the special tool by the speci...

Page 69: ...pecial tool to the pressure regulator of the filling cylinder I Filling gas nitrogen Adjust the pressure regulator Guideline I Gas pressure I 10 bar 145 psi Position the damper in the special tool The hexagonal part of the tap handle f engages in the hexagon socket of the filling port screw Open filler tap Fill the damper for at least 15 seconds Guideline I Gas pressure Info I Watch the pressure r...

Page 70: ...t by turning the adjusting ring Guideline I Spring preload 1 19 mm 0 75 in I Hook wrench T106S I p 235 Alternative 2 Warning Danger of accident Modifications to the suspension setting may seriously alter the handling characteristic Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components Only make adjustments within th...

Page 71: ...ot authorized by Husqvarna Motorcycles Preparatory work Raise the motorcycle with a lift stand p 10 Remove the rear wheel p 96 Main work Take the brake line out of the guide Push the brake caliper forward remove it and hang it to the side Info I Cover the components to protect them against damage Remove screws O and 8 Remove the engine sprocket cover Remove connecting link D of the chain Info I Co...

Page 72: ... and tighten fitting 8 Guideline M16x1 5 100 Nm 73 8 lbf ft I Nut linkage lever on swingarm I M14x1 5 I 80 Nm 59 lbf ft Mount the chain Connect the chain with connecting link D Guideline The closed side of the chain joint lock must face in the direction of travel Position the engine sprocket cover and mount it in the holder Mount and tighten screws 8 and 0 Guideline Screw clutch slave cylinder M6 ...

Page 73: ... wheel ilill p 97 Remove the motorcycle from the lift stand ilill p 10 Changing the swingarm bearing Info These operations are the same on both swingarm bearings G01813 10 Preparatory work Raise the motorcycle with a lift stand ilill p 10 Remove the rear wheel ilill p 96 Remove the swingarm l lll p 69 Main work Remove collar bushings O 71 ...

Page 74: ...14 10 G01814 10 Remove bushing Remove shaft seal rings D using a suitable tool Press out the bearing with a suitable tool Press in the new bearing until it is flush using a suitable tool Press in shaft seal rings D Mount bushing 72 ...

Page 75: ...0 Grease the shaft seal rings I Long life grease a p 224 Position collar bushings O with the shoulder facing inward Finishing work Install the swingarm p 70 Install the rear wheel p 97 Remove the motorcycle from the lift stand a p 10 73 ...

Page 76: ...move screw Take off manifold Position the manifold Mount screw O but do not tighten yet Guideline I Screw manifold holder Attach springs I Spring hook 50305017000 p 228 Tighten screw O Guideline I Screw manifold holder 74 115 Nm 11 1 lbf ft I 115 Nm 11 1 lbf ft I ...

Page 77: ...ighten yet Attach spring 8 I Spring hook 50305017000 p 228 Tighten screws O Guideline I Remaining screws chassis Finishing work Install the right side cover ll p 80 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down before performing any work on the vehicle Info Over ti...

Page 78: ...parts that need to be reinstalled and check for damage Mount new glass fiber yarn filling 0 on inner tube D Slide O ring eand outer tube CD over the glass fiber yarn filling 0 Insert O ring and silencer cap O into outer tube CD Mount and tighten all of the screws Guideline I Screws on the main silencer Finishing work Install the main silencer p 75 Install the right side cover p 80 I 7 Nm 5 2 lbf f...

Page 79: ...filter 11 4 Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations lnstallin the air filter Preparatory work Remove the air filter box lid p 77 Main work Push air filter holder O toward the air filter at position f and detach it at end G Swing the ai...

Page 80: ...ilter with fuel or petroleum since these substances attack the foam Sealin the air filter box 401559 01 Preparatory work Remove the air filter box lid a p 77 Remove the air filter a p 77 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly I Air filter cleaning agent p 224 Info I Only press the air filter to dry it never wring it out Oil the dry air filt...

Page 81: ...f 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 Improper handling of fuel is a d...

Page 82: ... tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avo...

Page 83: ...of the fuel line Info I Remaining fuel may flow out of the fuel hose Mount wash cap set f I Wash cap set 81212016100 Remove screws D with the collar bushings Remove screw C with the rubber bushing Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank The fuel in the fuel tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity o...

Page 84: ...sure that no cables or 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 I Remaining screws chassis Mount and tighten screws 8 with the collar bushings Guideline I Remaining screws chassis Plug in connector 8 for the fuel pump 10 Nm 7 4 lbf ft 10 Nm 7 4 lbf ft Remove the wash cap set and thor...

Page 85: ...s Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children 400926 10 Condition The fuel tank is completely full Ensure that the battery voltage does not drop below 12 5 V The diagnostic tool is disconnected Press on the small metal plate and disconnect fuel hose connection O Info Remaining fuel may flow out of the fuel hose Mo...

Page 86: ...f 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 and consult a doctor...

Page 87: ...ut do not tighten yet Mount and tighten nut O with the gasket Guideline I Nut fuel pump fastener Tighten fuel connection 8 Guideline I Fuel connection on fuel tank Mount and tighten screws Guideline I Screw fuel pump Finishing work Install the fuel tank il1ll p 81 Mount the seat il1ll p 80 I M12x1 75 I M8x1 25 I EJOT 15 Nm 11 1 lbf ft 10 Nm 7 4 lbf ft I 3 Nm 2 2 lbf ft ...

Page 88: ... 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 89: ...hose clamps C Remove fuel filter 0 Press locking mechanism D Pull back fuel pump housing Change fuel screen Mount the fuel pump housing Mount fuel filter 0 Arrow 6 points away from the fuel pump Mount hose clamps C I Hose clamp pliers 60029057000 p 230 87 ...

Page 90: ...el the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a...

Page 91: ...uel hose Pull fuel screen 8 out of the connecting piece Insert the new fuel screen all the way into the connecting piece Lubricate the O ring and connect plug in connection of the fuel line 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 ext...

Page 92: ...ounted in the fender Position the front fender Mount and tighten screws O Guideline I Remaining screws chassis Finishing work I10Nm 7 41bf ft Install the start number plate p 90 late Remove screw O and take off the clamp Remove screw Take off the start number plate late Position the start number plate Mount and tighten screw O Guideline I Remaining screws chassis I10Nm 7 41bf ft The holding lugs e...

Page 93: ...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 motorcycle The tires mounted on the front and rear wheels must have a similar profile Worn tires have a negative effect on handling characteristics especially on wet surfaces Check the front and rear tires for cuts run in objects and other damage If the...

Page 94: ...c Change the rear 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 lat eral and radial run out will form in the wheel Other spokes will become looser as a result Check spoke tension regularly and in part...

Page 95: ...eral and radial run out of the rims Lateral runout Outside the rim joint 1 8 mm 0 071 in Radial runout Outside the rim joint 1 8 mm 0 071 in If the measured value is greater than the specified value Center the rim Info I Center the rim by pulling the spoke nipple on the other side of the rim run out If there is significant deformation change the rim Correct the spoke tension 14 6 1 Removing the fr...

Page 96: ...e front wheel bearing a p 95 Clean and grease the shaft seal rings O and mating surfaces fj of the spacers I Long life grease a p 224 Insert the spacers Clean and grease the thread of the wheel spindle and screw 8 I Long life grease a p 224 Position the front wheel and insert the wheel spindle Mount and tighten screw 8 Guideline I Screw front wheel spindle I M24x1 5 I 45 Nm 33 2 lbf ft I Position ...

Page 97: ...h a lift stand p 10 Remove the front wheel p 93 Main work Remove screws O Take off the brake disc Installing the brake disc of the front brake Main work Clean the contact surface of the brake disc Position the brake disc with the label facing outward Mount and tighten screws O Guideline Screw front brake disc Finishing work M6 Install the front wheel a p 94 14 Nm 10 3 lbf ft Loctite 243 14 6 5 Cha...

Page 98: ...ly press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in Position spacing tube C Press in the new bearing D all the way using a suitable tool Info I Only press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in Grease new shaft seal rings and O and press in until they are flush Finishing work Install the front...

Page 99: ... Always lay the wheel down in such a way that the brake disc is not damaged Holding the rear wheel withdraw the wheel spindle Take the rear wheel out of the swingarm Info I Do not operate the foot brake lever when the rear wheel is removed Remove spacers 8 f f e e H00936 10 14 7 2 Installing the rear wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Alwa...

Page 100: ...be turned by 180 98 Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Finishing work Remove the motorcycle from the lift stand lill p 10 Removing the brake disc of the rear brake Preparatory work Raise the motorcycle with a lift stand lill p 10 Remove the rear wheel p 96 Main work Remove screws O Take off the brake disc...

Page 101: ...ection O must be taut 99 Chain wear is not always even so you should repeat this measurement at different chain positions 14 7 6 Adjusting the chain tension Warning I Chain tension I 55 58 mm 2 17 2 28 in If the chain tension does not meet specifications Adjust the chain tension a p 99 Finishing work Remove the motorcycle from the lift stand p 10 Danger of accidents Incorrect chain tension damages...

Page 102: ... sprocket and chain guide Preparatory work 400227 01 Raise the motorcycle with a lift stand I p 10 Main work Shift the transmission to idle Check the rear sprocket and engine sprocket for wear If the rear sprocket or engine sprocket is worn Change the drivetrain kit il jl p 102 Info I The engine sprocket rear sprocket and chain should always be replaced together Pull at the top part of the chain w...

Page 103: ...n 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 screw on the chain sliding piece Guideline Screw chain sliding piece Check the chain guide for wear Info M8 I Wear can be seen on the front of the chain guide If the light part of the chain guide is worn Change the chain gui...

Page 104: ...e 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 0 p 10 Main work Clean the chain r...

Page 105: ...move engine sprocket Remove fittings Q Take off the rear sprocket Position the new rear sprocket Mount and tighten the fittings Guideline 103 Nut rear sprocket screw M8 35 Nm 25 8 lbf ft Loctite 2701TM Slide new engine sprocket 0 onto the countershaft Mount the new chain Connect the chain with connecting link C Guideline The closed side of the chain joint lock must face in the direction of travel ...

Page 106: ... I Remaining screws chassis Finishing work 60 Nm 44 3 lbf ft Remove the motorcycle from the lift stand p 10 14 7 11 Changing the rear wheel bearing Preparatory work Raise the motorcycle with a lift stand p 10 Remove the rear wheel p 96 Main work Remove shaft seal ring O Remove lock ring 8 Remove shaft seal ring 104 Loctite 2701TM 10 Nm 7 4 lbf ft I 25 Nm 18 4 lbf ft I Using a suitable tool press b...

Page 107: ... bearing will be damaged when it is pressed in Clean grease and mount spacing tube 0 I Long life grease I p 224 Press new bearing C all the way in from the outside to the inside Info I Only press the bearing in via the outer ring otherwise the 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 The lock ring engages audibly G...

Page 108: ...n the starter relay Install a new main fuse I Fuse 58011109110 i I p 208 Check that the electrical equipment is functioning properly Tip I Insert the spare fuse so that it is available if needed Mount the protection caps Finishing work Install the air filter box lid p 77 Risk of injury Battery acid and battery gases cause serious chemical burns Keep batteries out of the reach of children Wear suit...

Page 109: ... negative terminal cover D over the negative terminal Finishing work Mount the seat p 80 Recharging the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Keep sparks and open flames away from the battery Only charge in ...

Page 110: ...ttery charger XCharge professional GB 00029095052 l l p 227 Alternative 4 I Battery charger XCharge professional CH 00029095053 p 227 Info I Follow the instructions of the charger and the manual Disconnect the battery charger after charging the battery Guideline The charging current charging voltage and charging time must not be exceeded Charge the battery regularly when the 1 3 months motorcycle ...

Page 111: ...inishing work Connect the negative cable of the battery Mount the seat I p 80 Condition The battery is disconnected Remove the capacitor Discharge the capacitor by bridging the two contacts Connect the capacitor with a 12 V test lamp on one connector and connect it to the battery as shown in the figure Info I As the charge of the capacitor increases the test lamp becomes dimmer The lamp lights up ...

Page 112: ...elay Pull the starter relay off of the holder Connect the starter relay to a 12 V power supply as shown Measure the resistance between the specified points I Resistance of open circuit I on If the value displayed does not meet specifications Change the starter relay Mount the starter relay onto the holder and lay the cable Clamp cable 8 on the starter relay Position the cover Plug in connector O C...

Page 113: ...ffected 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 and rear brake is changed in accordance ...

Page 114: ...osition the new brake linings D in the guides and press toward the pistons The leaf spring is correctly seated in the brake caliper Fill brake fluid up to the MAX marking I Brake fluid DOT 4 ll p 222 Position cover C with membrane 0 Mount and tighten screws Info I Clean up overflowed or spilled brake fluid immediately with water Position the brake caliper Mount screws O with washers 8 but do not t...

Page 115: ...ront and rear brake is changed in accordance with the service schedule Adding front brake fluid Warning Preparatory work Check the front brake linings p 111 Main work Move the brake fluid reservoir mounted on the handlebar to a horizontal position Check the brake fluid level in the brake fluid reservoir 0 lf the brake fluid level is below the MIN marking Add front brake fluid p 113 Danger of accid...

Page 116: ...king I Brake fluid DOT 4 a p 222 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilled brake fluid immediately with water Changing the front brake fluid Warning Skin irritation Brake fluid 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 con...

Page 117: ...eline I Filling pressure 1 2 2 5 bar 29 36 psi Pull off protection cap 0 of the brake caliper bleeder screw Connect the hose of the bleeder bottle I Bleeding device 00029013100 8 p 226 Open bleeder screw 3 by approx one half turn Info I Drain until the fresh brake fluid emerges from the hose of the bleeder bot tle without bubbles Tighten the bleeder screw Close shut off valve C Open the bleeder sc...

Page 118: ...ome 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 Danger of accident...

Page 119: ...on side brake lining Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Add brake fluid to level 6 I Brake fluid DOT 4 a p 222 Mount and tighten screw cap O with membrane 8 and the O ring Info Clean up overflowed or spilled brake fluid immediately with water Checking the free travel of foot brake lever Warning Danger of ...

Page 120: ...r 13 5 mm 0 12 0 2 in Hold screw fD and tighten nut 8 Guideline I Nut foot brake lever stop I M8 Hold push rod and tighten nut 8 Guideline I Remaining nuts chassis Attach spring O I 20 Nm 14 8 lbf ft I 10 Nm 7 4 lbf ft Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specif...

Page 121: ...ances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly 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 Only use clean brake f...

Page 122: ...e I Bleeding device 00029013100 0 p 226 Open shut off valve 8 Info I Follow the operating instructions of the bleeding device Ensure that the filling pressure is set on pressure gauge E Adjust the filling pressure on pressure regulator 0 if necessary 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 d...

Page 123: ...t the brake fluid up to marking 9 I Brake fluid DOT 4 a p 222 Mount and tighten the screw cap with the membrane and 0 ring Info I Clean up overflowed or spilt brake fluid immediately with water Check the foot brake lever for a firm pressure point 121 ...

Page 124: ...ide cover il ll p 79 Remove the main silencer il ll p 75 Main work Disconnect negative cable O of the battery Remove cable tie s 8 Pull EFI control unit CD from the holder and hang it to one side Disconnect plug in connectors C Remove cable tie s 0 Disconnect plug in connector D Loosen hose clip Pull back the protection cap Unplug connector Remove screws Remove the intake air temperature sensor 12...

Page 125: ...sh back hose clamp 48 Pull off the bleeder hose Pivot up the subframe and secure it Remove screw 49 Pivot the shock absorber toward the rear and twist it slightly Remove springs 4D I Spring hook 50305017000 p 228 Remove screw 48 Take off the manifold Loosen hose clips 41 Pull off the radiator hoses 123 ...

Page 126: ...e off the engine sprocket cover Remove screws Remove the cable tie s Remove cable holder Take off the slave cylinder of the clutch and hang it to one side Info I Do not kink the clutch line Do not activate the clutch lever while the slave cylinder of the clutch is removed Remove the connecting link of the chain Take off the chain 124 ...

Page 127: ...onnect spark plug connector Loosen hose clip 125 Pull the throttle valve body out of the intake flange toward the rear and hang it to one side Remove fittings Take off the engine braces Remove the vent hose Remove spring Remove nut Remove the swingarm pivot Pull the swingarm slightly toward the rear ...

Page 128: ...The help of an assistant is useful in this step Make sure that the engine is sufficiently secured against falling over Protect the frame and attachments against damage Mount screws O but do not tighten yet Guideline 126 I Engine carrying screw I 60 Nm 44 3 lbf ft I Position the swingarm Insert the swingarm pivot Mount and tighten nut 8 Guideline Nut swingarm pivot Tighten screws O Guideline I Engi...

Page 129: ... 24 3 lbf ft Mount and tighten screw with the washers Guideline Screw shift lever M6 Mount the chain Connect the chain with connecting link Guideline 14 Nm 10 3 lbf ft 127 Loctite 2701 TM Loctite 243 The closed side of the chain joint lock must face in the direction of travel Position the clutch slave cylinder with the gasket Mount and tighten screws _ Guideline I Screw clutch slave cylinder M6 10...

Page 130: ...ble on the starter motor Mount and tighten nut 48 Guideline I Remaining nuts chassis Mount the protection cap Mount the radiator hose Position and tighten hose clips 4D Mount the radiator hoses Position and tighten hose clips 48 Feed in the manifold Mount screw 4D but do not tighten yet Guideline I Screw manifold holder M6 M8 128 10 Nm 7 4 lbf ft I 25 Nm 18 4 lbf ft I 10 Nm 7 4 lbf ft 15 Nm 11 1 l...

Page 131: ...nfo I Watch out for the intake flange Mount and tighten screws B Guideline Screw subframe Remove screw Mount and tighten screw Guideline Screw subframe M8 M8 Repeat these steps on the opposite side Position the intake air temperature sensor Mount and tighten screws e Guideline I Screw intake air temperature sensor I M5 Plug in connector c Mount the protection cap 60 Nm 44 3 lbf ft 30 Nm 22 1 lbf f...

Page 132: ... G and add engine oil I Engine oil 11 50 I 1 59 qt I Engine oil SAE 10W 50 p 222 Mount and tighten filler plug G Finishing work Install the main silencer a p 75 Install the right side cover p 80 Install the fuel tank p 81 Mount the seat p 80 Remove the motorcycle from the lift stand l ill p 10 Refill the coolant l ill p 194 Execute the initialization run p 203 Go for a short test ride Read out the...

Page 133: ...pecial tool on the engine assembly stand Engine fixing arm 78029002000 a p 233 Engine assembly stand 61229001000 a p 230 Mount the engine on the special tool Info Have an assistant help you or use a motorized hoist Remove oil drain plug O with the magnet and seal ring Remove screw plug 8 Completely drain the engine oil Remove the long oil screen fD Remove screw plug C with the short oil screen 131...

Page 134: ...ark plug 309417 10 Remove clutch push rod O Remove screws O Remove the oil filter cover 8 with the O ring Pull oil filter out of the oil filter housing I Circlip pliers reverse 51012011000 JI p 228 Remove screws O and take off the starter motor Remove the spark plug using the special tool I Spark plug wrench 77229172000 JI p 233 132 ...

Page 135: ... seal Removing the alternator cover Remove screws O Take off the alternator cover Remove locating pins 8 Take off the alternator cover gasket Positioning the engine at ignition top dead center Turn the crankshaft counterclockwise until the markings 6 are flush with the marking G on the cylinder head Remove screw O 133 ...

Page 136: ...hain tensioner 17 3 11 Removing the camshaft Remove screw O with the washer and spring Remove screws 8 Take off the chain adjuster with the gasket Remove screw O Remove the camshaft support plate Pull the camshaft out of the bearing seats Take the timing chain off the camshaft gear Remove the camshaft ...

Page 137: ... gasket C Push the cylinder upward Info 135 I 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 I If no further work is to be performed on the cylinder and piston the piston can remain in the cylinder Take off dowels 8 and cylinder base gask...

Page 138: ...ing the special tool and pull off the rotor by turning the screw in Remove the woodruff key Remove screw O Take off timing chain guide rail toward the top Remove screw 8 Remove timing chain tensioning rail C toward the top Remove screws 0 Remove the timing chain securing guide Take off the timing chain Info 136 If the timing chain is going to be used again mark the direction of travel ...

Page 139: ...f 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 Take off pin 0 Remove pin D upward Remove O ring 17 3 18 Removing the water pump cover Remove screws O Take off the water pump cover Take off the water pump cover seal 137 ...

Page 140: ...er Remove dowels Take off clutch cover gasket s Clamp the antihopping clutch with special tool O I Assembly screws 75029033000 p 231 Info I Apply the special tool by hand only do not use another tool Loosen screws diagonally and remove them with their spring retainers and clutch springs Remove pressure cap s Remove pressure piece 8 Bend up lock washer 0 Remove special tool Cs I Locking screw 11308...

Page 141: ...ar segment 80029004000 ill p 234 Completely remove clutch disc pack Take off washer O Info The washer usually sticks to the inner clutch hub Lock the outer clutch hub and primary gear using special tool I Gear segment 80029004000 a p 234 Remove nut fD Info Left handed thread Take off C Take off both needle bearings 0 and collar bushing D ...

Page 142: ...arter idler gear O Push sliding plate O away from the shift drum locating unit Remove shift shaft with the washer 17 3 25 Removing the shift drum locating unit Remove screw O 140 Push away locking lever from shift drum locating unit D and remove the shift drum locating unit 17 3 26 Removing the locking lever Relieve tension from the locking lever Unscrew O and remove together with locking lever wa...

Page 143: ... oil pump idler gear 8 Remove lock washer C Take off washer 0 Take off oil pump gear wheel 0 Remove pin Remove screws Take off oil pump cover Remove internal rotor and external rotor 41 Remove the pin Push oil pump shaft 48 inward and take it out of the engine from the ignition side 141 ...

Page 144: ...heel gear Remove woodruff key O Take off freewheel gear 8 17 3 30 Removing the left engine case section Remove screws O Mount special tool 8 with suitable screws I Case separating tool 90129048100 a p 235 Info I Use the drill hole with marking 781 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 te...

Page 145: ...move dowels 8 Remove shift rails O together with upper springs and lower springs Swing shift forks O to one side Info I Do not misplace the shift rollers Remove shift drum Take shift forks O out of the shift grooves Info Do not misplace shift rollers 17 3 34 Removing the transmission shafts Remove O ring 0 143 ...

Page 146: ...eparatory work 309029 10 Remove the oil pressure regulator valve a p 147 Main work Remove all remaining dowels Remove oil nozzles O and Remove the bearing retainer of main shaft bearing D of countershaft bear ing C and of shift drum bearing 0 Remove any sealing mass remnants and clean the engine case section thoroughly Warm the engine case section in an oven Guideline I1so 0 c 302 F Knock the engi...

Page 147: ...ck that the bearings are firmly seated Info I 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 renewed Press in the shaft seal ring from the outside toward the inside with the open side facing outward Position all bearing locks Mount and tighten the screws Guideline Screw bearing retainer M5 Mou...

Page 148: ...tside 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 all the way to the stop or so that it is flush Info I When pressing the bearing in ensure that the engine case section is level to prevent damage Only press the bearings in via the outer be...

Page 149: ...nnels and check that they are clear Removing the oil pressure regulator valve 304671 10 Remove screw plug O with sealing washer 8 Remove pressure spring CD and ball e 17 4 4 Checking spring length of oil pressure regulator valve 306115 10 Preparatory work Remove the oil pressure regulator valve a p 147 Main work Measure the spring length of the oil pressure regulator valve Oil pressure regulator v...

Page 150: ...crankshaft seal ring in the clutch cover 309432 10 17 4 7 Removing the water pump 309435 10 Remove crankshaft seal ring O Press the new crankshaft seal ring into the clutch cover with the open side facing inward until it is flush Grease the sealing lip Remove nut O Remove water pump impeller 8 Info I If the water pump impeller cannot be detached then the water pump shaft can be pressed out toward ...

Page 151: ...t is flush using the appropriate tool Info Support the clutch cover sufficiently when pressing in Press shaft seal ring 8 all the way in Mount special tool 8 on the water pump shaft I Mounting sleeve 90129005000 p 235 Mount balancer shaft 8 Info I Be careful not to damage the shaft seal rings Remove the special tool I Mounting sleeve 90129005000 p 235 Mount water pump impeller C Mount and tighten ...

Page 152: ... the timing chain sprocket In such a case the crank webs will be distorted rendering the crankshaft unserviceable Warm up the new timing chain sprocket and immediately push it onto the crankshaft Guideline I1ao 0 c 356 F 17 4 11 Changing the connecting rod conrod bearing and crank pin 306595 10 Main work Position the crankshaft with special tool O in the press I Separator plate 78929009000 p 234 P...

Page 153: ...nsert for crankshaft pressing tool 78929008000 0 p 234 Place the crank web in with the connecting rod and the bearing Position the sec ond crank web Position special tool 8 with the heel at the bottom I Insert for crankshaft pressing tool 78929008000 I p 234 Press the upper crank web in as far as possible Info I The press mandrel must be applied above the crank pin Take the crankshaft out of the s...

Page 154: ...ng are very good heat conduc tivity resulting in much improved performance low wear and a lightweight cylinder 17 4 14 Checking measuring the cylinder 306590 10 304696 10 Check the cylinder bearing surface for damage If the cylinder bearing surface is damaged Change the cylinder and piston Measure the cylinder diameter at several locations on the 0 and 0 axes using a micrometer to identify oval we...

Page 155: ... seating has excessive play Replace the connecting rod and piston pin 153 Measure the piston at the piston skirt parallel to the gudgeon pin at a distance ofG Guideline Distance G Piston diameter Size I Size II Info 7 mm 0 28 in 94 93 94 96 mm 3 7374 3 7386 in 94 94 94 97 mm 3 7378 3 739 in I Piston dimensions O are marked on the piston head 17 4 16 Checking the piston ring end gap 304694 10 Remov...

Page 156: ...5 in Wear limit 0 120 mm 0 00472 in The following steps apply to both oil pumps Use special tool O to measure the play between the external rotor and the engine case I Feeler gauge 59029041100 p 229 Oil pump External rotor engine case clear ance I 0 20 mm 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 ...

Page 157: ...or 304674 11 304673 11 Insert long flange O of the autodecompression spring in the hole push the autodecompression spring over bearing bolt and hook it into autodecompression weight 8 Mount autodecompression shaft C in the camshaft Mount new lock ring 3 Perform a function check The autodecompression spring does not turn the autodecompression shaft back to the stop Pre tension the autodecompression...

Page 158: ... 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 rail for damage and wear If there is damage or wear Replace the timing chain tensioning rail Check the timing chain guide rail fD for damage and wear If there is damage or wear Replace the timing chain guide rail Check the timing chain securing guide C...

Page 159: ...retainers and lay them to one side accord ing to their normal built in position Pretension the valve springs using the special tool Valve spring mounter 59029019000 Ii p 229 Insert for valve spring lever 77029041200 ll p 232 Remove valve keys O and relax the valve springs Remove valve spring retainer 8 and the valve spring Pull the valve out of the valve guide from below and remove valve stem seal...

Page 160: ...17000 a p 227 Internal bearing puller 15112018100 p 227 Press the small camshaft bearing in until flush using the special tool I Push in drift 75029044020 p 231 Press the large camshaft bearing in until flush using special tool D I Push in drift 75029044010 a p 231 The valve shaft is hard chrome plated wear generally appears at the valve guide 200193 10 Check the run out at the valve plate Valve R...

Page 161: ... 1 602 in If the measured value does not meet specifications Change the valve spring Check the valve spring seat for breakage and wear visual check If the valve spring seat is broken or worn Change the valve spring seat Measure the thickness of the valve spring seat Valve spring Valve spring seat 1 8 mm 0 071 in If the measured value does not meet specifications Change the valve spring seat Check ...

Page 162: ...in If the measured value does not meet specifications Rework the valve seat Blow compressed air through all oil channels and check that they are clear 17 4 30 Checking the rocker arm shafts 306609 10 17 4 31 Installing the valves Check the rocker arm shafts for damage and wear If there is damage or wear Change the rocker arm shafts Position valve spring seats O Mount the new valve stem seals Mount...

Page 163: ...cylin der head Use special tool 0 to set the distance of the intake rocker arm Guideline I Rocker arm axial play I 0 10 mm 0 0039 in I Feeler gauge 59029041100 p 229 Press the rocker arm shaft of the intake side all the way into the cylinder head Mount and tighten screw 0 Guideline I Screw rocker arm bearing Remove special tool 0 I Feeler gauge 59029041100 lll p 229 15 Nm 11 1 lbf ft Repeat these ...

Page 164: ... 163 17 4 34 Preassembling the antihopping clutch 306630 10 306631 10 Thoroughly oil the clutch facing discs Mount the sleeves Recess O engages in edge Cs Beginning with an intermediate clutch disc alternately position all other clutch facing discs and intermediate clutch discs Position release springs 8 in the inside inner clutch hub Slide on the outside inner clutch hub watching out for the mark...

Page 165: ...ngth I 45 60 46 80 mm 1 7953 1 8425 in If the clutch spring length is less than the specified value Change all clutch springs Check the thrust face of pressure cap 8 for damage and wear If there is damage or wear Change the pressure cap Check inner clutch hub 0 for damage and wear If there is damage or wear Change the inner clutch hub Check sleeves D for damage and wear If there is damage or wear ...

Page 166: ...cs 41 for damage and wear If the intermediate clutch discs are not level and have pittings Change all intermediate clutch discs 17 4 36 Checking the shift mechanism e o _ Check shift forks O at leaf 6 for wear Shift fork 304687 10 Thickness at leaf 4 85 4 95 mm 0 1909 0 1949 in If the measured value does not meet specifications Change the shift fork Check shift grooves C of shift drum for wear If ...

Page 167: ...nge 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 ll p 165 Check clearance O between the sliding plate and the shift quadrant 165 Shift shaft play in sliding plate shift quadrant 0 40 0 80 mm 0 0157 0 0315 in 304682 10 17 4 37 Preassembling the shift shaft 304683 10 If the measured value does ...

Page 168: ... and 2nd gear fixed gear 8 Remove lockring fD Remove needle bearing 8 and distance sleeve Remove 3rd 4th gear sliding gear D Remove lockring and stop disk Remove 5th gear idler gear Remove needle bearing C 17 4 39 Disassembling the countershaft Fix the countershaft in the vice with the toothed end facing downward Guideline Use soft jaws 166 306610 10 306612 10 ...

Page 169: ...bearings Check the pivot points of main shaft 8 and countershaft CD for damage and wear If there is damage or wear Change the main shaft and or countershaft Check the tooth profiles of main shaft 8 and countershaft CD for damage and wear If there is damage or wear Change the main shaft and or countershaft Checkthe pivot points of idler gears 8 for damage and wear If there is damage or wear Change ...

Page 170: ...f there is damage or wear Change the stop disks Use new lock rings C with every repair Check distance sleeves Gi for damage and wear If there is damage or wear Change the distance sleeves 17 4 41 Assembling the main shaft Info I Use new lock rings with every repair Preparatory work Carefully grease all parts before assembling Check the transmission a p 167 Main work Secure the main shaft with the ...

Page 171: ...aring O and 2nd gear idler gear 8 onto the countershaft with the protruding collar facing downward Mount stop disk D and lock ring 8 Mount 2nd 4th gear shift collar 0 with the shift groove facing up Mount lock ring D and stop disk Mount needle bearing CD and the 4th gear idler gear with the collar facing up Mount needle bearing and the 3rd gear idler gear G with the collar facing down Mount stop d...

Page 172: ...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 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 with connector of the starter motor If the starter motor does not turn when the circuit is closed Change...

Page 173: ... together with suitable pliers and take off Take the freewheel out of the primary gear Thoroughly oil all parts Push the freewheel O into the primary gear Info Note the direction of rotation Mount spreader ring 171 Ensure that all lugs of the spreader ring pass through slots 6 of the freewheel and engage in groove C of the primary gear ...

Page 174: ...e right section of the engine case Remove the special tool 17 5 2 Installing the transmission shafts 17 5 3 Installing the shift forks 0 Lubricate all bearings Slide both transmission shafts into the bearing seats Info Make sure not to misplace the washers Mount lock ring O Lubricate all parts thoroughly Mount shift fork O in the upper shift groove of the main shaft Mount shift fork in the lower s...

Page 175: ...e Grease the sealing surfaces Apply the sealing compound to the left section of the engine case I Loctite 5910 Info I To prevent sealing compound from entering into the oil channels dow els O must be mounted first Mount the left engine casing If necessary strike it lightly with a rubber mallet Info I Do not use the screws to pull the two sections of the engine case together Mount screws 8 but do n...

Page 176: ...ttern Guideline I Screw engine case I M6x85 Mount the O ring on the countershaft Lightly grease and mount spacer Mount freewheel gear O Mount woodruff key O Degrease the cone and thinly apply thread locker to it I Loctite 648 Mount primary gear 8 Info Turn the freewheel gear to ease engagement 10 Nm 7 4 lbf ft Oil the oil pump shaft internal rotor and external rotor before assembly Mount oil pump ...

Page 177: ...D M6 Position oil pump gear wheel Position washers fD Mount lock washer Mount oil pump idler gear Gi Mount washer a and lock ring 48 10 Nm 7 4 lbf ft Loctite 243 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 8 Guideline Screw locking lever M5 6Nm 4 4 lbf ft Loctite 243 175 ...

Page 178: ...ctite 243 176 Push sliding plate 8 away from the shift drum locating unit and insert the shift shaft all the way Let the sliding plate engage in the shift drum locating unit 8 17 5 13 Installing the starter idler gear Shift through the transmission Slide on starter idler gear O with the collar facing the engine case 17 5 14 Installing the torque limiter Position the washer and mount the lock ring ...

Page 179: ... M20LHx1 5 100 Nm 73 8 lbf ft Insert the clutch package O in the clutch basket Info Loctite 648 I If necessary turn the main shaft a little to ease engagement Make sure that the upper clutch facing disc is offset by one notch Position the new lock washer and mount nut Lock the clutch basket and primary gear using special tool CD and tighten the nut Guideline 177 I Nut inner clutch hub I M18x1 5 I ...

Page 180: ...lutch spring retainer Remove special tool D I Assembly screws 75029033000 Ip 231 Position the balancer shaft with special tool O I Fixing drift 78129032000 p 234 Marking O and the special tool are aligned Mount dowels and position the clutch cover gasket Mount the clutch cover Mount screws 8 but do not tighten them yet Guideline I Screw clutch cover I M6x25 Mount screw Ci but do not tighten yet Gu...

Page 181: ...ter pump cover I M6x25 Mount screw but do not tighten yet Guideline I Screw water pump cover I M6x25 Mount screw fD and tighten all screws in a crisscross pattern Guideline I Screw water pump cover I M6x55 Oil the internal rotor and external rotor before mounting Insert O ring O Position pin into the oil pump shaft from above Position pin C Mount internal rotor C and external rotor G 10Nm 7 4 lbf ...

Page 182: ... before ensure it is running in the correct direction Position the timing chain securing guide Mount and tighten screws 0 Guideline Screw timing chain securing guide M6 10Nm 7 4 lbf ft Thread in the timing chain tensioning rail 8 from above Mount and tighten screw Guideline Screw timing chain ten M6 10Nm sioning rail 7 4 lbf ft Slip in the timing chain guide rail C from above Mount and tighten scr...

Page 183: ...hat 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 the hammer The piston rings should not catch or they will be damaged Mount dowels O and put cylinder base gasket 8 in place Ensure that piston mark D faces toward the exhaust side Cover the engine housing o...

Page 184: ...counterclockwise thereby pushing the piston pin retainer into the groove I Insertion tool for piston ring lock 77329030100 a p 233 Ensure that the piston pin retainer is seated properly on both sides Remove the cloth Keep the timing chain taut Carefully push the cylinder downward letting the dowels engage Mount dowels O and put cylinder base gasket 8 in place 182 ...

Page 185: ...7 4 lbf ft 17 5 25 Installing the camshaft Place the timing chain over the camshaft gear Push the camshaft into the bearing seats The camshaft f and cylinder head G markings are lined up with each other Info Ensure that the crankshaft is at top dead center TDC Position the camshaft support plate Mount and tighten screw O Guideline Screw camshaft support M6 plate 10 Nm 7 4 lbf ft Loctite 243 17 5 2...

Page 186: ...nition top dead center a p 133 Check the valve clearance at all valves between the valve and rocker arm Guideline Valve clearance Intake at 20 C 68 F I 0 10 0 15 mm 0 0039 0 0059 in Exhaust at 20 C 68 F I 0 12 0 17 mm 0 0047 0 0067 in I Feeler gauge 59029041100 Ill p 229 If the valve clearance does not meet specifications Adjust the valve clearance Ill p 184 Remove the special tool I Locking screw...

Page 187: ...lling the spark plug 308929 10 Mount locating pins O Position alternator cover gasket 8 Position the alternator cover Mount screw fD with washer b ut do not tighten it yet Guideline I Screw alternator cover I M6x25 10Nm 7 4 lbfft Mount screws C and tighten all screws in a crisscross pattern Guideline I Screw alternator cover Position the valve cover seal Position the valve cover Mount and tighten ...

Page 188: ... 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 5 Guideline I Screw oil filter cover Mount clutch push rod O I 6 Nm 4 4 lbf ft Mount and tighten screw plug O with the short oil screen and the O ring...

Page 189: ... ring Guideline I Screw plug oil screen I M20x1 5 I1s Nm 11 1 lbf ft I Mount and tighten the oil drain plug D with the magnet and the new seal ring Guideline I Oil drain plug with magnet I M12x1 5 I 20 Nm 14 8 lbf ft I 17 5 36 Removing the engine from the engine assembly stand Remove the screw connection from the special tool I Engine fixing arm 78029002000 IOJ p 233 Remove the engine from the eng...

Page 190: ...r rim 14 mm 0 16 in If the fluid level does not meet specifications Correct the fluid level of the hydraulic clutch I Brake fluid DOT 4 a p 222 Position the cover with the membrane Mount and tighten the screws Changing the h draulic clutch 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 i...

Page 191: ... it emerges from drill hole D of the mas ter cylinder without bubbles Now and then extract fluid from the master cylinder reservoir to prevent overflow Tighten the bleeder screw and remove the bleeding syringe with the hose Correct the fluid level of the hydraulic clutch Guideline I Fluid level below container rim 14 mm 0 16 in Position the cover with the membrane Mount and tighten the screws Info...

Page 192: ...er is thus lower In case of a high level of engine braking effect short term slip of the clutch occurs This prevents rear wheel hopping 18 4 Adjusting the antihopping clutch 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 characterist...

Page 193: ...t screws 8 b ut do not tighten yet Guideline 191 I Screw clutch cover I M6x25 10Nm 7 4 lbfft Mount screw 8 b ut do not tighten yet Guideline I Screw clutch cover I M6x55 Mount screw 8 b ut do not tighten yet Guideline I Screw clutch cover I M6x60 Tighten all screws in a crisscross pattern Guideline I Screw clutch cover Attach spring 0 Finishing work Stand the motorcycle upright Danger 10Nm 7 4 lbf...

Page 194: ...po nents of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of...

Page 195: ...cle upright on a horizontal surface Remove the radiator cap Check the coolant level in the radiator Coolant level f above the radiator fins 10 mm 0 39 in If the coolant level does not match the specified value 400243 10 Draining the coolant Warning Correct the coolant level I Coolant p 222 Mount the radiator cap Danger of scalding During motorcycle operation the coolant gets very hot and is under ...

Page 196: ...eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing Make sure that screw O is tightened Position the motorcycle upright Pour coolant in u...

Page 197: ...annel transmission lubrication ine oil level Condition The engine is at operating temperature Preparatory work Stand the motorcycle upright on a horizontal surface Main work Check the engine oil level Info I After switching off the engine wait one minute before checking the level The engine oil level is between f and C If the engine oil level is below marking G Add engine oil a p 198 If the engine...

Page 198: ...c correctly and in compliance with the applicable regulations Info Drain the engine oil only when the engine is warm Preparatory work 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 short oil screen and the O rings Info Do not remove screw f Remove screw plug with the lon...

Page 199: ...out of the oil filter housing I Circlip pliers reverse 51012011000 a p 228 Completely drain the engine oil Thoroughly clean the parts and sealing area Lay the motorcycle on its side and fill the oil filter housing to about full with engine oil Insert the oil filter into the oil filter housing Lubricate the O ring of the oil filter cover and mount it with the oil filter cover Mount and tighten the ...

Page 200: ... not mix different types of engine oil If appropriate change the engine oil Install and tighten the oil filler plug with 0 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 extraction system when starting or running the engine in an enclo...

Page 201: ... Engine oil temperature 80 c 176 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 pump 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 immedi...

Page 202: ...en removed Measure the resistance between the specified points Measuring point 1 Measuring point 2 Spark plug connector Resistance at 20 c 68 F If the specification is not reached Change the spark plug connector 3 75 6 25 kn Alternator checking stator winding Condition The alternator is disconnected Stator winding checking the resistance Measure the resistance between the specified points 0 Altern...

Page 203: ...ve 8 from the alternator case Remove screws 8 Take the stator out of the alternator cover Position the stator in the alternator cover Mount and tighten screws O Guideline I Screw stator I M4 I 4 Nm 3 lbf ft I Loctite 648 Position cable support sleeve 8 in the alternator case Position the cable holder Mount and tighten screw 8 Guideline Screw cable holder in alternator cover M4 4 Nm 3 lbf ft Loctit...

Page 204: ...otor 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 with connector 0 of the starter motor If the starter motor does not turn when the circuit is closed Change the starter motor ...

Page 205: ...he idle speed Turning clockwise raises the idle speed Condition The diagnostic tool is connected and running Execute Engine electronics Functions Deleting adaptation values The adaptation values are deleted Select Engine electronics Measured values Engine coolant tempera ture sensor TW1 The coolant temperature is displayed during the initialization run mDanger Danger of poisoning Exhaust gases are...

Page 206: ...ALVE BODY As soon as the specified temperature is reached switch off the ignition Info I If the initialization is not completed or the initialization process is inter rupted the entire process must be restarted 204 ...

Page 207: ...aulically operated Gearbox 5 gear claw shifted Transmission ratio 1st gear 16 32 2nd gear 18 30 3rd gear 20 28 4th gear 22 26 5th gear 24 24 Alternator 12 V 75 W Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment Spark plug NGK LKAR8Al 9 Spark plug electrode gap 0 9 mm 0 035 in Cooling Water cooling permanent circulation of coolant by water pump Starting ai...

Page 208: ...ft Screw crankshaft position sensor M5 6 Nm 4 4 lbf ft Loctite 243 Screw locking lever M5 6 Nm 4 4 lbf ft Loctite 243 Screw oil filter cover M5 6 Nm 4 4 lbf ft Screw suction pump cover M5 6 Nm 4 4 lbf ft Loctite 243 Nut water pump wheel M6 8 Nm 5 9 lbf ft Loctite 243 Screw alternator cover M6 10 Nm 7 4 lbf ft Screw bearing bolt for starter idler M6 10 Nm 7 4 lbf ft Loctite 243 gear Screw bearing b...

Page 209: ... 50 I 1 59 qt 11 20 I 1 27 qt 7 5 I 1 98 US gal 4 Nm 3 lbf ft 9 Nm 6 6 lbf ft 15 Nm 11 1 lbf ft 8 Nm 5 9 lbf ft 10 Nm 7 4 lbf ft 15 Nm 11 1 lbf ft 60 Nm 44 3 lbf ft Loctite 243 Loctite 243 Loctite 2701 TM 207 Step 1 Lubricated with engine oil 10 Nm 7 4 lbf ft Step 2 30 Nm 22 1 lbf ft Step 3 50 Nm 36 9 lbf ft 60 Nm 44 3 lbf ft Thread oiled with engine oil cone degreased 15 20 Nm 11 1 14 8 lbf ft 12...

Page 210: ... 335 kg 739 lb 24 6 Electrical s stem Battery YTX5L BS Battery voltage 12 V Nominal capacity 4 Ah Maintenance free Fuse 58011109110 10 A I Fl warning lamp 24 7 Tires Front tires Rear tires 125 80 R 420 TL 165 55 R 17 M C TL Metzeler Racetec SM 16 5 125 80 R 420 NHS TL K1 Metzeler Racetec SM 17 165 55 R 17 M C NHS TL K1 The tires specified represent one of the possible series production tires Addit...

Page 211: ...justing ring Remaining nuts chassis Remaining screws chassis Screw ball joint of push rod on foot brake cylinder Screw chain sliding guard Screw electric starter cable connec tion Screw front brake disc Screw rear brake disc EJOT PT K60x25 Z M4 5 M4 5 M5 M5 M5 M5 M5 M6 M6 M6 M6 M6 M6 M6 209 1 2 bar 17 psi 920 mm 36 22 in Fork oil SAE 4 48601166S1 p 222 Fork oil SAE 4 48601166S1 p 222 18 18 7M 08 W...

Page 212: ... M14x1 5 Nut linkage lever to angle lever M14x1 5 Nut swingarm pivot M16x1 5 Screw top steering head M20x1 5 Screw in nozzles cooling system M20x1 5 Screw front wheel spindle M24x1 5 Nut rear wheel spindle M25x1 5 5 Nm 3 7 lbf ft 10 Nm 7 4 lbf ft 20 Nm 14 8 lbf ft 35 Nm 25 8 lbf ft 12 Nm 8 9 lbf ft 25 Nm 18 4 lbf ft 25 Nm 18 4 lbf ft 12 Nm 8 9 lbf ft 15 Nm 11 1 lbf ft 33 Nm 24 3 lbf ft 15 Nm 11 1 ...

Page 213: ...exhaust system to prevent water from entering First remove coarse dirt particles with a gentle spray of water Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush Info I Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to the dry vehicle always rinse with water first After rinsing the motorcycle with a gentle s...

Page 214: ...e motorcycle out of service add fuel additive Refuel Clean the motorcycle I p 211 Change the engine oil and oil filter and clean the oil screens I p 196 Check the antifreeze and coolant level I p 192 Check the tire air pressure 0 p 91 Remove the battery 0 p 106 26 2 401058 01 Charge the battery Guideline Storage temperature of battery with out direct sunshine 0 35 C 32 95 F Store the vehicle in a ...

Page 215: ...poke tension p 92 0 I Check the chain rear sprocket engine sprocket and chain guide l ll p 100 I I I Check the chain tension p 99 I o I I Grease all moving parts e g hand lever chain and check for smooth operation I I I Check correct the fluid level of the hydraulic clutch p 188 I I I Check the front brake fluid level l ll p 113 I I I Check the free travel of the hand brake lever I Check the steer...

Page 216: ...ange 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 pressure regulator valve Change the suction pump Check the pressure pump and lubricati...

Page 217: ...215 ...

Page 218: ...ID CII E cc C C C z cc C0 C I I f J I T DT 36 1FC 2 X7 I 1 X16 1 col LJ FS 450 2015 II II 0 0 0 X302 l i j 1 l I l x1 i iEB 4 B EB 4 I 1 i 0 5 ...

Page 219: ...Components A11 EFI control unit C10 Capacitor G10 Battery G20 Alternator K10 Starter relay with main fuse K30 Power relay M10 Starter motor T20 Voltage regulator S21 Electric starter button X295 Diagnostics connector 217 ...

Page 220: ...t 5 i 1 DD 1 0 B B I I I I I cc t l u 1 0 ii C j xs X2 C BF 1 I NCX 2 i N AT 2 j NDQ 2 M GA 3 BA 1 30 NCW 2 ru S20 P25 X295 t X301 E 1 N AP 6 r 7 0 n CW 2 i D W r G M D CX 2 X3 XS D X2 0 5 5 0 DDD X300 l C E E C C I z 0 1 FB a cc G 1 FB b g 0 F F C0 C I df f I FS 450 2015 I 2 3 1 2 I 3 I 4 5 I 6 I 7 I 8 ...

Page 221: ...28 WIRING DIAGRAM Components A11 EFI control unit M13 Fuel pump M51 Injection valve cylinder 1 P25 Fl warning lamp MIL R30 CAN bus terminating resistor S20 Kill switch X295 Diagnostics connector 219 ...

Page 222: ...V 2 X15 X12 CR 1 N A L 2 X14 X9 e A M 3 SS1 _ EL 2 NDX 3 m A X 2 r fff1 r 2 AP 6 NCM 2 J a LtiJ _ r r A M 3 6 N r EL 2 rr DX 3 i A X 2 1 1 AP 6 i CM 2 D X6 N DV 2 X15 X12 X14 X9 D X13 E c c E c c c E c c E E E _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _ _ _ _ _ _ _ _ ___ _ _ _ _ _ _ _ _ _ _ ___ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _ _ _ _ _ _ _ _ _ _ _ _ ...

Page 223: ...e sensor cylinder 1 826 Rollover sensor 837 Crankshaft position sensor 841 Manifold absolute pressure sensor cylinder 1 R51 Ignition coil cylinder 1 S51 Map Select switch for ride mode optional S55 Map Select switch 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 221 ...

Page 224: ...se distilled water if the coolant needs to be diluted The use of premixed coolant is recommended Observe the coolant manufacturer specifications for antifreeze protection dilution and miscibility compatibility with other coolants Recommended supplier Bel Ray Moto Chill Racing Coolant Engine oil SAE 10W 50 Standard classification JASO T903 MA p 241 SAE p 241 SAE 10W 50 Guideline Use only engine oil...

Page 225: ...OZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100 223 ...

Page 226: ... Recommended supplier Lubcon Turmogrease PP 300 Lubricant T511 Recommended supplier Lubcon Turmsilon GTI 300 P Lubricant T625 Recommended supplier Molykote 33 Medium Lubricant I152 Recommended supplier Bel Ray Molylube Anti Seize Lubricant I159 Recommended supplier Bel Ray MC 11 Offroad chain s ra Guideline Recommended supplier Bel Ray Blue Tac Chain Lube Oil for foam air filter Recommended suppli...

Page 227: ...30 AUXILIARY SUBSTANCES Preserving materials for aints metal and rubber Recommended supplier Bel Ray Silicone Detailer Protectant Spray Universal oil s ray Recommended supplier Bel Ray 6 in 1 225 ...

Page 228: ...2 H00501 01 Bleeder cover Art no 00029013006 00029013006 H00505 01 Bleedin device Art no 00029013100 00029013100 H00518 01 Battery charger XCharge professional EU Art no 00029095050 H01065 01 Batte charger XCharge rofessional US Art no 00029095051 H01065 01 226 ...

Page 229: ...ring puller 15112017000 Internal bearing uller 15112018100 Art no 00029095052 H01065 01 rofessional CH H01065 01 H00944 01 H00520 01 H00522 01 Art no 00029095053 Art no 113080802 Art no 15112017000 Art no 15112018100 Feature 118 23 mm 0 71 0 91 in 227 ...

Page 230: ...9075000 45129075000 H00525 01 hook Art no 50305017000 50305017000 H00973 01 Bleed syrin e Art no 50329050000 50329050000 H00565 01 Circlip pliers reverse Art no 51012011000 51012011000 H00572 01 Extractor Art no 58012009000 58012009000 H00592 01 ...

Page 231: ...Art no 58429094000 flt 58429094000 H00606 01 Valve s Art no 59029019000 2x 59029019000 H00610 01 Limit plu Art no 59029026006 59029026006 H00612 01 Feeler gauge Art no 59029041100 59029041100 H00616 01 Piston ring mounting tool Art no 60029015000 60029015000 H00628 01 ...

Page 232: ...liers 60029057000 Testin hose 61029093000 Pressure tester 4x D 61029094000 Engine assembly stand 61229001000 Art no 60029033000 H00633 01 Art no 60029057000 H00650 01 Art no 61029093000 H00659 01 Art no 61029094000 H00660 01 Art no 61229001000 H00662 01 230 ...

Page 233: ...00 H00707 01 Assembl screws Art no 75029033000 4x 75029033000 H00708 01 Push in drift Art no 75029044010 75029044010 H00712 01 Push in drift Art no 75029044020 75029044020 H00713 01 Pressing tool for crankshaft com lete Art no 75029047000 75029047000 H00714 01 ...

Page 234: ...0000 H00719 01 Push out drift Art no 75029051000 75029051000 H00721 01 Protection cap Art no 75029090000 75029090000 H00726 01 Oil pressure adapter Art no 75029094000 75029094000 H00728 01 Insert for valve s ring lever Art no 77029041200 77029041200 H00746 01 ...

Page 235: ...00 77229172000 H00761 01 Insertion tool for Art no 77329030100 77329030100 H00768 01 En arm Art no 78029002000 2x 78029002000 H00783 01 Mounting sleeve Art no 78029005100 78029005100 H00785 01 Removal tool Art no 78029049100 2x 78029049100 H00794 01 ...

Page 236: ...78129032000 78129032000 H00796 01 tool Art no 78929008000 78929008000 H01016 01 Separator plate Art no 78929009000 78929009000 H00799 01 Gear segment Art no 80029004000 80029004000 H00813 01 Lift stand Art no 81329955000 81329955000 H01015 01 ...

Page 237: ...ng sleeve Art no 90129005000 90129005000 H00816 01 Case se tool Art no 90129048100 90129048100 H00828 01 Pin wrench Art no T103 T103 H00838 01 Hook wrench Art no T106S T106S H00841 01 De th micrometer Art no T107S T107S H00842 01 ...

Page 238: ...OLS 236 Pin Art no T120 T120 H00844 01 Mountin sleeve Art no T1204 T1204 H00878 01 Calibration pin Art no T1205 T1205 H00879 01 Pressing tool Art no T1206 T1206 H00880 01 Pressing tool Art no T1207S T1207S H00881 01 ...

Page 239: ...g sleeve Art no T1215 T1215 H00886 01 Disassembl tool Art no T1216 CJ T1216 H00887 01 Vacuum pump Art no T1240S T1240S H00890 01 Protecting sleeve Art no T1401 6Y T1401 H00894 01 Clam ing stand Art no T14016S ml T14016S H01036 01 ...

Page 240: ...Rin wrench Art no T14017 T14017 H00904 01 Nitro tool Art no T14019 T14019 H00906 01 Support tool Art no T14020 T14020 H00907 01 Calibrating unit Art no T14021 T14021 H00908 01 Mounting tool Art no T14022B T14022B H00910 01 ...

Page 241: ...eaded bushing Art no T14023 T14023 H00911 01 Mountin sleeve Art no T14029 T14029 H00917 01 Fillin adapter Art no T14030 T14030 H00918 01 Tweezers Art no T14033 T14033 H00921 01 Clam ing stand Art no T1403S 2x T1403S H00896 01 ...

Page 242: ...CIAL TOOLS 240 Mounting tool Art no T14040S T14040S H00922 01 Press drift Art no T1504 T1504 H00899 01 Assembly tool Art no T150S o T150S H00852 01 Nitrogen filling tool 2x 3x Art no T170S1 i T170S1 H00855 01 ...

Page 243: ...ong service intervals are demanded for automobile engines the focus for motorcycle engines is on high performance at high engine speeds In most motorcycle engines the transmission and the clutch are lubricated with the same oil The JASO MA standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils ac...

Page 244: ...embling 18 Chain checking cleaning 100 102 Chain guide checking 100 Chain tension adjusting 99 checking 99 Charging voltage checking 108 Chassis number 9 Clutch 189 adjusting 190 fluid level checking correcting 188 fluid changing 188 Clutch lever basic position adjusting 42 Compression damping fork adjusting 12 Compression damping high speed shock absorber adjusting 46 Compression damping low spee...

Page 245: ...lutch hub installing 176 piston installing 181 primary gear installing 174 rotor installing 180 shift drum locating unit installing 176 shift drum installing 173 shift forks installing 172 shift rails installing 173 shift shaft installing 176 spark plug installing starter idler gear installing 243 185 176 starter motor installing 186 suction pump installing 179 timing chain tensioner installing 18...

Page 246: ... 45 Front fender installing 90 removing 90 Front wheel installing removing Fuel filter changing 94 93 86 Fuel pressure checking 83 Fuel pump changing 84 Fuel screen changing 88 Fuel tank installing 81 removing 80 244 Fuse main fuse changing 106 H Hand brake lever basic position adjusting 113 Handlebar position 42 adjusting 42 Idle speed adjusting 203 Ignition coil secondary winding checking 200 Im...

Page 247: ...g adjusting 47 removing 50 riding sag checking 48 seal ring retainer assembling 60 seal ring retainer disassembling 57 shock absorber servicing 53 spring preload adjusting 48 spring installing 68 spring removing 54 static sag checking 47 Shock absorber article number 9 245 Shock absorber linkage checking 51 Spare parts 8 Spark plug connector checking 200 Spoke tension checking 92 Start number plat...

Page 248: ...INDEX w Warranty 8 Wheel bearing of the front wheel changing 95 of the rear wheel changing 104 Wiring diagram 216 221 page 1 of 3 216 page 2 of 3 page 3 of 3 218 220 Work rules 7 246 ...

Page 249: ...11111111111111111111IIIIIIIIIIII 3403022en 07 2016 Husqvarna MOTORCYCLES Husqvarna Motorcycles GmbH fiiiHiAvl StallhofnerstraBe 3 5230 Mattighofen Austria llmi LZZa O www husqvarna motorcycles com __ __ Photo Mitterbauer Husqvarna Motorcycles GmbH ...

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Husqvarna FS 450 2015, Repair Manual

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