Husqvarna FE 350 2015 Repair Manual
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Husqvarna FE 350 2015 Repair Manual

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PIONEERING SINCE 1903
REPAIR MANUAL2015
leJ
FE 350 EU
FE 350 AU
FE 350 US
FE 350S US
®
Husqvarna
Art. no. 340301 Sen
MOTORCYCLES

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Summary of Contents for Husqvarna FE 350 2015

  • Page 1 PIONEERING SINCE 1903 REPAIR MANUAL2015 FE 350 EU FE 350 AU FE 350 US FE 350S US ® Husqvarna Art. no. 340301 Sen MOTORCYCLES...
  • Page 3 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 does not belong to the regular scope of supply.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS HANDLEBAR, CONTROLS ..........38 MEANS OF REPRESENTATION ........6 Handlebar position ..........38 Symbols used ............6 Adjusting the handlebar position ......38 1 .2 Formats used ............6 Adjusting the basic position of the clutch SAFETY ADVICE ...............
  • Page 5 TABLE OF CONTENTS 11.3 Removing the air filter ......... 7 4 15.6 Recharging the battery ........109 11.4 Installing the air filter ........... 7 4 15. 7 Checking the charging voltage ......110 11.5 Cleaning the air filter and air filter box ....75 15.8 Checking the quiescent current..

  • Page 6: Removing The Air Filter Box Cover

    TABLE OF CONTENTS 18.3.26 Removing the timing chain ......148 18.4.41 Assembling the countershaft ......176 18.3.27 Removing the spacer ........148 18.5 Engine assembly ..........177 18.3.28 Removing the left section of the engine 18.5.1 Installing the crankshaft ....... 177 case ..............
  • Page 7 TABLE OF CONTENTS 22.3 Alternator - checking the stator winding ... 207 29.26 Page 4 of 8 (FE 350S US) ......... 27 4 29.27 Page 5 of 8 (FE 350S US) ......... 276 22.4 Removing the stator and ignition pulse generator ............

  • Page 8: Means Of Representation

    MEANS OF REPRESENTATION S mbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). Indicates a page reference (more information is provided on the specified page). Indicates information with more details or tips .

  • Page 9: Safety Advice

    Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you repair and maintain your vehicle. This manual assumes that the necessary special Husqvarna tools and Husqvarna workplace and workshop equipment are avail­ able.

  • Page 10: Important Notes

    IMPORTANT NOTES Manufacturer and im lied warran The work prescribed in the service schedule must be carried out by an authorized Husqvarna Motorcycles workshop only and con­ firmed both in the customer's Service & Warranty Booklet and in the Husqvarna Motorcycles Dealer.net;...

  • Page 11: Serial Numbers

    SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right. 401945-10 (FE EU/AU) The type label is fixed to the front of the steering head. 401946-10 (FE 350S US) The type label is fixed to the front of the steering head. The additional type label for Canada @ is fixed to the front of the front pipe.

  • Page 12: Engine Number

    SERIAL NUMBERS (FE 350S US) Key number for the ignition and steering lock is indicated on KEYCODECARD. �� � • Info KEYCODECARD You need the key number to order a spare key. Keep 1234 11 1 1 1 1 1 1 1 1 111 1 1 1 1 1 1 1 11 1 1 1 KEYCODECARD in a safe place.

  • Page 13: Motorcycle

    MOTORCYCLE Raising the motorc cle with a lift stand Note Danger of damage The parked vehicle can roll away or fall over. Park the vehicle on a firm and level surface. Raise the motorcycle at the frame underneath the engine. Lift stand (81329955000) (�...

  • Page 14: Starting The Motorcycle For A Check

    MOTORCYCLE Press the electric starter button. • Info Press the electric starter button for at most 5 seconds. Wait for a least 5 seconds before trying again. Warning lamp Fl lights up briefly as a functional control when starting. 400733-01 Starting the motorc cle for a check Danger Danger of poisoning...

  • Page 15: Fork, Triple Clamp

    FORK, TRIPLE CLAMP Ad"ustin in of the fork Info The hydraulic compression damping determines the fork suspension behavior. Turn the white adjusting screw all the way clockwise. • Info Adjusting screw is located at the upper end of the left fork leg. The compression damping is located in the left fork leg COMP (white...

  • Page 16: Cleaning The Dust Boots Of The Fork Legs

    FORK, TRIPLE CLAMP Main work Release bleeder screws ✓ Any excess pressure escapes from the interior of the fork. Tighten the bleeder screws. 402556-10 Finishing work Remove the motorcycle from the lift stand. (il!) p. 11) Cleaning the dust boots of the fork legs Preparatory work Raise the motorcycle with a lift stand.

  • Page 17: Positioning The Fork Protector

    FORK, TRIPLE CLAMP rotector Position the fork protector on the left fork leg. Mount and tighten screws Guideline Remaining screws, chassis 110 Nm (7.4 lbf ft) Position the brake line, wiring harness, and clamp. Mount and tighten screws @. Position the fork protector on the right fork leg. Mount and tighten the screws. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft)

  • Page 18: Removing The Fork Protector

    FORK, TRIPLE CLAMP (FE EU/ AU/US) Tighten screws Guideline Screw, top triple clamp 17 Nm (12 .5 lbf ft) Tighten screws (D. Guideline Screw, bottom triple clamp 15 Nm (11 .1 lbf ft) (FE 350S US) Tighten screws Guideline Screw, top triple clamp 17 Nm (12 .5 lbf ft) Tighten screws (D.

  • Page 19: Installing The Fork Protector

    FORK, TRIPLE CLAMP 6.10 Installing the fork rotector Main work Position the fork protector on the left fork leg. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) Position the fork protector on the right fork leg. Mount and tighten the screws. Guideline Remaining screws, chassis 110 Nm (7.4 lbf ft)
  • Page 20 FORK, TRIPLE CLAMP Clamp the fork leg in the area of the lower triple clamp. Clamping stand (T1403S) (lit!I p. 298) Remove the screw. Remove adjuster@). 201700-10 Release screw cap Special socket (T14047) (!ill p. 298) • Info The cartridge cannot be taken off yet. 201701-10 Unclamp the fork leg.

  • Page 21: Removing The Spring

    FORK, TRIPLE CLAMP Remove lock ring • Info The lock ring has a ground end against which a screwdriver can be posi­ tioned. Warm the outer tube in area G) of the lower sliding bushing. Guideline (122 °F) Pull the outer tube forcefully off of the inner tube. •...

  • Page 22: Disassembling The Cartridge

    FORK, TRIPLE CLAMP Clamp the open end wrench in the vise. Release screw cap but do not remove it yet. Special socket (T14047) (!ill p. 298) Pull the spring down. Remove the open end wrench. Remove the screw cap. Remove the spring with the preload spacer(s). 201724-11 Disassemblin the cartrid e...

  • Page 23: Disassembling The Piston Rod

    FORK, TRIPLE CLAMP CD . Remove lock ring Pull reservoir @ off of the tube. Pull sleeve out of the reservoir. Remove spring 201795-10 4I . Remove seal rings 6!) and O-ring Remove pilot bushings Disassembling the piston rod Info The steps are identical for both fork legs, except for the hydrostop needle and valve.

  • Page 24: Disassembling The Hydrostop Unit

    FORK, TRIPLE CLAMP Remove the compression shim stack Remove spring. • 201730-10 Remove adapter with spring @ and washer . Remove spring 201788-10 Remove valve needle from the piston rod. Info The adjusting tube can be used for this. Disassembling the hydrostop unit Info The steps are identical for both fork legs.

  • Page 25: Disassembling The Seal Ring Retainer

    FORK, TRIPLE CLAMP Remove shim stack (3. Remove washer Remove 0-ring Disassembling the seal ring retainer Info The steps are identical for both fork legs. Preparatory work Disassemble the fork legs. (� p. 17) Remove the spring. (� p. 19) Disassemble the cartridge.

  • Page 26: Assembling The Seal Ring Retainer

    FORK, TRIPLE CLAMP Measure the run-out of the inner tube. Inner tube run-out $ 0.20 mm ($ 0.0079 in) the measured value is larger than the specified value: Change the inner tube. 200685-10 Measure the inside diameter at multiple locations of the outer tube. Inside diameter of outer tube $ 49.20 mm ($ 1.937 in) the measured value is larger than the specified value:...

  • Page 27: Assembling The Hydrostop Unit

    FORK, TRIPLE CLAMP Assembling the h Info The steps are identical for both fork legs. Mount and grease O-ring Lubricant (T158) (� p. 286) Mount washer Mount shim stack with the smaller washers facing downward. Mount the new O-ring on hub Mount the hub with washers •...
  • Page 28 FORK, TRIPLE CLAMP Mount spring Mount and tighten adapter with spring and washer. Guideline Adapter of piston rod M6x0.5 12 Nm (8.9 lbf ft) Position the spring. Mount the compression shim stack with the smaller washers facing down- ward. 201730-10 Grind the piston on both sides on a surfacing plate using 1200 grit sandpaper.

  • Page 29: Assembling The Cartridge

    FORK, TRIPLE CLAMP Assembling the cartridge Info The steps are identical for both fork legs. Preparatory work Assemble the seal ring retainer. (!!;!l p. 24) Assemble the piston rod. (!!;!l p. 25) Main work Mount and grease seal rings and O-ring @. Lubricant (T158) (�...

  • Page 30: Assembling The Fork Legs

    FORK, TRIPLE CLAMP Degrease piston rod and clamp in the vise. Clamping stand (T14049S) (@}J p. 299) Screw spring guide Ci) all the way on. Info • The nut must be firmly tightened against the stop by hand. Do not use a tool.
  • Page 31 FORK, TRIPLE CLAMP Slide on the lower sliding bushing Mount the upper sliding bushing (D. Info Do not use a tool; pull the ends apart slightly by hand. Warm the outer tube in area of the lower sliding bushing. Guideline (122 °F) Slide the outer tube onto the inner tube.
  • Page 32 FORK, TRIPLE CLAMP Turn the fork. Have the entire filling quantity of fork oil available. Oil capacity per 635 ml Fork oil (SAE 4) (48601166S1) fork leg (21.47 fl. oz.) p. 284) Add some of the fork oil while pulling out and pushing in the piston rod numerous times.

  • Page 33: Lubricating The Steering Head Bearing

    FORK, TRIPLE CLAMP Push the outer tube up. Clamp the outer tube in the area of the lower triple clamp. Clamping stand (T1403S) (� p. 298) Tighten screw cap@). Guideline Cartridge on outer tube M51x1.5 40 Nm (29.5 lbf ft) Special socket (T14047) (!!l p.

  • Page 34: Removing The Lower Triple Clamp

    FORK, TRIPLE CLAMP 6.25 Removin the lower tri Preparatory work Switch off all power consumers and switch off the engine. Remove the headlight mask with the headlight. (� p. 88) Raise the motorcycle with a lift stand.(� p. 11) Remove the front wheel. p.

  • Page 35: Installing The Lower Triple Clamp

    FORK, TRIPLE CLAMP 6.26 Installing the lower tri Main work Clean the bearing and sealing elements, check for damage, and grease. � I...: High viscosity grease (il!.!J p. 286) - t t , 1... t ;:;:;,; Position the lower triple clamp with the steering stem. Mount the upper steering head bearing.
  • Page 36 FORK, TRIPLE CLAMP Tighten screw Guideline Screw, top steering head M20x1.5 112 Nm (8.9 lbf ft) Mount and tighten screw@. Guideline Screw, top steering stem 17 Nm Loctite ® ™ (12.5 lbf ft) (FE EU/ AU/US) Tighten screws @. Guideline Screw, top triple clamp 17 Nm (12 .5 lbf ft)

  • Page 37: Checking The Play Of The Steering Head 10.5 Bearing

    FORK, TRIPLE CLAMP Checkin Warning Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components. Correct incorrect steering head bearing play immediately. Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time.

  • Page 38: Adjusting The Play Of The Steering Head Bearing

    FORK, TRIPLE CLAMP Remove the upper bearing race @ using a suitable tool. Press in the new bearing race all the way using a suitable tool. Pull off bearing Remove seal ring retainer. Remove O-ring. Grease the new O-ring and mount with seal ring retainer. Press on the new bearing with a suitable tube as far as it will go.
  • Page 39 FORK, TRIPLE CLAMP (FE 350S US) Release screws Remove screw @. Loosen and retighten screw Guideline Screw, top steering head M20x1.5 112 Nm (8.9 lbf ft) Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains. Tighten screws Guideline Screw, top triple clamp...

  • Page 40: Handlebar,Controls

    HANDLEBAR,CONTROLS Handlebar osition On the upper triple clamp, there are two holes at a distance of to each other. 1 15 mm (0.59 in) I Hole distance The holes on the handlebar supports are placed at a distance of from the center. I 3.5 mm (0.138 in) I Hole distance The handlebar supports can be mounted in four different positions.

  • Page 41: Checking The Routing Of The Throttle Cable

    HANDLEBAR,CONTROLS Checkin the routing of the throttle cable Preparatory work Remove the seat. (� p. 77) Remove the fuel tank. (� p. 77) Main work (FE EU/ AU/US) Check the throttle cable routing. Both throttle cables must be routed to the throttle valve body side by side behind the handlebars and above the fuel tank bearing.

  • Page 42: Adjusting The Play In The Throttle Cable

    HANDLEBAR,CONTROLS Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. Always make sure there is sufficient ventilation when running the engine. Use an effective exhaust extraction system when starting or running the engine in an enclosed space. Start the engine and let it run idle.

  • Page 43: Frame

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

  • Page 44: Shock Absorber, Swingarm

    SHOCK ABSORBER, SWINGARM Ad"ustin Caution Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly. The shock absorber is filled with highly compressed nitrogen. Please follow the description provided. Info The effect of the high-speed setting can be seen in fast compression of the shock absorber. Turn adjusting screw all the way clockwise with a socket wrench.

  • Page 45: Adjusting The Rebound Damping Of The Shock Absorber

    SHOCK ABSORBER, SWINGARM Ad"ustin the rebound dam in of the shock absorber Caution Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly. Risk of injury The shock absorber is filled with highly compressed nitrogen. Please follow the description provided.

  • Page 46: Checking The Riding Sag Of The Shock Absorber

    SHOCK ABSORBER, SWINGARM sag of the shock absorber Measure distance of rear wheel unloaded. p. 43) With another person holding the motorcycle, the rider, wearing protective full clothing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down a few times.

  • Page 47: Adjusting The Riding Sag

    SHOCK ABSORBER, SWINGARM Main work Loosen screw Turn adjusting ring @ until the spring is no longer under tension. Hook wrench (T1 06S) (I!!:! p. 296) Measure the overall spring length while the spring is not under tension. Tighten the spring by turning adjusting ring @ to measurement f). Guideline Spring preload 13 mm (0.51 in)

  • Page 48: Removing The Shock Absorber

    SHOCK ABSORBER, SWINGARM Remove the motorcycle from the lift stand. p. 11) Check the static sag of the shock absorber. p. 43) Check the riding sag of the shock absorber. (� p. 44) Adjust the rebound damping of the shock absorber. p.
  • Page 49 SHOCK ABSORBER, SWINGARM Remove fitting (D. Take off the angle lever. 303096-10 @» Check needle bearings for damage and wear. If there is damage or wear: Change the needle bearings. Check spacers and @ for damage and wear. If there is damage or wear: Change the spacers.

  • Page 50: Servicing The Shock Absorber

    SHOCK ABSORBER, SWINGARM Mount screw but do not tighten yet. Guideline Screw, bottom shock 60 Nm Loctite 2701 ™ ® absorber (44.3 lbf ft) • Info Raise the wheel slightly to be able to mount the screw more easily. Position the linkage lever. Mount and tighten fitting @.

  • Page 51: Removing The Spring

    SHOCK ABSORBER, SWINGARM 9.13 ring 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 Turn adjusting ring until the spring is no longer under tension. Hook wrench (T106S) (�...

  • Page 52: Disassembling The Piston Rod

    SHOCK ABSORBER, SWINGARM Press in seal ring retainer (3 using the special tool. Disassembly tool (T1216) p. 297) Remove lock ring @. Info Do not scratch the inner surface. Remove the piston rod. Remove adjusting ring (;) with the intermediate washer. Drain the oil.

  • Page 53: Disassembling The Seal Ring Retainer

    SHOCK ABSORBER, SWINGARM Main work Clamp the piston rod with the fork in a vise. Guideline Use soft jaws. Remove nut Remove washer Remove rebound shim stack • Info Place the rebound shim stack onto a screwdriver and set it down as a unit. Remove piston Remove compression shim stack •...

  • Page 54: Changing The Pilot Bushing

    SHOCK ABSORBER, SWINGARM Remove centering disk Remove seal ring 201406-10 Remove washer for seal ring Remove washer @. Remove dust boot. 201407-10 9.17 Chan ilot bushin Preparatory work Remove the spring. p. 49) Disassemble the damper. p. 49) Disassemble the piston rod. p.

  • Page 55: Checking The Damper

    SHOCK ABSORBER, SWINGARM 9.18 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 s 50.08 mm (S 1.9716 in) If the measured value is greater than the specified value: Change the damper cartridge.

  • Page 56: Installing The Heim Joint

    SHOCK ABSORBER, SWINGARM Remove seal rings on both sides. Press the heim joint against a lock ring using the special tool. Pressing tool (T1207S) (il!l p. 297) Remove the second lock ring Place special tool underneath and press out heim joint with special tool@).

  • Page 57: Assembling The Seal Ring Retainer

    SHOCK ABSORBER, SWINGARM Position both collar bushings and press them in. 9.21 Mount dust boot using the special tool. Mounting sleeve (T1204) p. 296) Lubricate the sealing lip of the dust boot. Lubricant (T625) (l!ll p. 286) Mount washer@}. Position washer (Don seal ring 201409-10 Grease seal ring and mount with the washer facing downward.

  • Page 58: Assembling The Piston Rod

    SHOCK ABSORBER, SWINGARM 9.22 Assembling the iston rod Preparatory work Assemble the seal ring retainer. (ll!;!l p. 55) Main work Clamp the piston rod with the fork in a vise. Guideline Use soft jaws. Mount rubber buffer and locking cap Position special tool on the piston rod.

  • Page 59: Assembling The Damper

    SHOCK ABSORBER, SWINGARM Mount washer with the collar facing downward. Grease the thread of the piston rod. Lubricant (T152) p. 286) Mount and tighten nut Guideline Nut, piston rod M16x1 45 Nm (33.2 lbf ft) 9.23 Assemblin Preparatory work Assemble the seal ring retainer. p.
  • Page 60 SHOCK ABSORBER, SWINGARM Install the seal ring bearer and push it under the ring groove. Mount lock ring • Info Do not scratch the inner surface. Pull out the piston rod so that the seal ring retainer rests against the lock ring. Mount locking cap (3 of the damper cartridge.

  • Page 61: Bleeding And Filling The Damper

    SHOCK ABSORBER, SWINGARM 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 new handling characteristic.
  • Page 62 SHOCK ABSORBER, SWINGARM When the vacuum pressure gauge reaches the specified value, turn the Oil reser­ voir control lever to Equalize pressure. Guideline 4 mbar ✓ The pressure gauge increases to the specified value. 0 bar When the pressure gauge reaches the specified value, turn the Damper control lever...

  • Page 63: Filling The Damper With Nitrogen

    SHOCK ABSORBER, SWINGARM When the pressure gauge reaches the specified value, turn the con­ Damper 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 switch.

  • Page 64: Installing The Spring

    SHOCK ABSORBER, SWINGARM Open filler tap G). Fill the damper for at least 15 seconds. Guideline Gas pressure 1 1 0 bar (145 psi) • Info Watch the pressure regulator dial. Make sure that the damper is filled to the specified pressure. Close the filling port screw using tap handle f).

  • Page 65: Checking The Swingarm

    If the swingarm shows signs of damage, cracking, or deformation: Change the swingarm. • Info Always change a damaged swingarm. Repair of the swingarm is not authorized by Husqvarna M otorcycles. 9.28 Removing the swingarm Preparatory work Raise the motorcycle with a lift stand.

  • Page 66: Installing The Swingarm

    SHOCK ABSORBER, SWINGARM Remove connecting link of the chain. • Info Cover the components to protect them against damage. Take off the chain. Remove fitting Lower the swingarm. Remove nut Remove the swingarm pivot. Remove the swingarm. Main work Position the swingarm. Mount the swingarm pivot. Mount and tighten nut Guideline Nut, swingarm pivot...

  • Page 67: Changing The Swingarm Bearing

    SHOCK ABSORBER, SWINGARM Position the engine sprocket cover and mount it in the holder. Mount and tighten screws Guideline Screw, clutch slave cylinder 10 Nm (7.4 lbf ft) Mount and tighten screws Guideline Remaining screws, chassis 25 Nm (18.4 lbf ft) Position the brake caliper and pull it back.
  • Page 68 SHOCK ABSORBER, SWINGARM Main work Remove collar bushings G01813-10 Remove bushing G01814-10 Remove shaft seal rings 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.
  • Page 69 SHOCK ABSORBER, SWINGARM Press in shaft seal rings Mount bushing(!}. G01814-10 Grease the shaft seal rings. Long-life grease p. 286) •- Position collar bushings with the shoulder facing inward. G01819-10 Finishing work Install the swingarm. (l!l,,!l p. 64) Install the rear wheel. (l!l,,!l p.

  • Page 70: Exhaust

    EXHAUST 10.1 Removin the manifold Preparatory work Raise the motorcycle with a lift stand. (!:JI p. 11) Remove the seat. (!:JI p. 77) Remove the right side cover. (!:JI p. 76) Remove the main silencer. (!:JI p. 71) Main work Remove fitting Remove screw Press angle lever...

  • Page 71: Installing The Manifold

    EXHAUST Remove screw Raise the rear frame slightly and lower the shock absorber. (FE EU) Remove the fuel tank. (I!!:! p. 77) Disconnect plug-in connector of the lambda sensor and remove the cable binder. Remove springs@). Spring hook (50305017000) (I!!:! p.
  • Page 72 EXHAUST Mount and tighten screw Guideline Remaining screws, chassis 25 Nm (18.4 lbf ft) (FE EU) Connect plug-in connector of the lambda sensor, route the cable without tension, and secure with a new cable tie. Install the fuel tank. (� p.

  • Page 73: Removing The Main Silencer

    EXHAUST Install the right side cover. (la,! p. 77) Mount the seat. p. 77) Remove the motorcycle from the lift stand. p. 11) Removin 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.
  • Page 74 EXHAUST Main work (FE EU/AU) Remove all screws on the main silencer. Take off silencer cap and 0-ring @. Take off outer tube (D and 0-ring Remove glass fiber yarn filling from inner tube (D. Clean the parts that need to be reinstalled and check for damage. Fit the new glass fiber yarn filling onto the inner tube.

  • Page 75: Spark Arrestor, Cleaning

    EXHAUST 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 Soot particles accumulate on the screen of the spark arrestor over time. This changes the performance characteristics.

  • Page 76: Air Filter

    AIR FILTER Release catch pull off the air filter box lid sideways in areas f) and G), and remove toward the rear. Position the air filter box cover and catch Engage the air filter box cover in areas f) and G). Engage catch 11.3 Removin the air filter...

  • Page 77: Cleaning The Air Filter And Air Filter Box

    AIR FILTER Insert both parts together, position them, and secure them using air filter holder in area ✓ The arrow of marking faces up. • Info If the air filter is not mounted correctly, dust and dirt may enter the engine and result in damage.

  • Page 78: Fuel Tank, Seat, Trim

    FUEL TANK, SEAT, TRIM 12.1 0 ening filler ca Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. Switch off the engine for refueling.

  • Page 79: Installing The Right Side Cover

    FUEL TANK, SEAT, TRIM Position the side cover and engage in area f). Mount and tighten screw Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) Removin the seat Remove screws in the recessed grips on the left and right. Lift the seat at the rear, pull it back, and take it off toward the top.
  • Page 80 FUEL TANK, SEAT, TRIM Main work Unplug connector of the fuel pump. Pull the hose off the fuel tank breather on the tank lid. Thoroughly clean the plug-in connection of the fuel line with an air line. • Info Dirt should not be allowed to get into the fuel line under any circumstances.

  • Page 81: Installing The Fuel Tank

    FUEL TANK, SEAT, TRIM 12.8 Installing the fuel tank Danger Fuel is highly flammable. Fire hazard The fuel in the fuel tank expands when warm and can escape if overfilled. Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. Switch off the engine for refueling.

  • Page 82: Changing The Fuel Screen

    FUEL TANK, SEAT, TRIM 12.9 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. Switch off the engine for refueling.
  • Page 83 FUEL TANK, SEAT, TRIM Warning Fuel is poisonous and a health hazard. Danger of poisoning Avoid skin, eye and clothing contact with fuel. Immediately consult a doctor if you swallow fuel. Do not inhale fuel vapors. In case of skin contact, rinse the affected area with plenty of water. Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.

  • Page 84: Changing The Fuel Pump

    FUEL TANK, SEAT, TRIM Change fuel screen Mount the fuel pump housing. Mount fuel filter ✓ Arrow points away from the fuel pump. Mount hose clamps Hose clamp pliers (60029057000) p. 291) 305316-10 Position the fuel pump. Mount fuel connection @ with the gasket but do not tighten yet. Guideline Fuel connection on fuel pump 10 Nm (7.4 lbf ft)
  • Page 85 FUEL TANK, SEAT, TRIM Warning Fuel is poisonous and a health hazard. Danger of poisoning Avoid skin, eye and clothing contact with fuel. Immediately consult a doctor if you swallow fuel. Do not inhale fuel vapors. In case of skin contact, rinse the affected area with plenty of water. Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.

  • Page 86: Checking The Fuel Pressure

    FUEL TANK, SEAT, TRIM 12.12 Checkin ressure Danger Fuel is highly flammable. Fire hazard The fuel in the fuel tank expands when warm and can escape if overfilled. Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. Switch off the engine for refueling.

  • Page 87: Removing The Activated Charcoal Filter (Fe 350S Us)

    FUEL TANK, SEAT, TRIM Check the fuel pressure with the filler cap open. Fuel pressure When the fuel pump is active 3.35 ... 3.65 bar (48.6 ... 52.9 psi) If the specification is not reached: Check that the fuel line is clear. Change the fuel filter.

  • Page 88: Installing The Activated Charcoal Filter (Fe 350S Us)

    FUEL TANK, SEAT, TRIM Main work Position the retaining bracket. Mount and tighten fittings Guideline Screw, engine brace 33 Nm Loctite 2701 ® (24.3 lbf ft) Mount the hose. Position hose clamp Mount hoses Position the activated charcoal filter. Mount rubber band Finishing work Install the fuel tank.

  • Page 89: Mask, Fender

    MASK, FENDER 13.1 Removin the front fender Preparatory work Switch off all power consumers and switch off the engine. Remove the headlight mask with the headlight. (� p. 88) Main work Remove screws Remove the front fender. Main work Position the front fender. Mount and tighten screws and @.

  • Page 90: Removing The Headlight Mask With The Headlight

    MASK, FENDER 13.3 Removin the headlight mask with the headlight Preparatory work Switch off all power consumers and switch off the engine. Main work (FE EU/AU) Detach brake line and wiring harness Release rubber straps @ . Slide the headlight mask up and swing it forward. Detach plug-in connectors and take off the headlight mask with the head­...

  • Page 91: Installing The Headlight Mask With The 17.4 Headlight

    MASK, FENDER Detach plug-in connectors and take off the headlight mask with the head­ light. 13.4 Main work (FE EU/AU) Connect plug-in connectors Position the headlight mask and secure it with rubber bands ✓ The holding lugs engage in the fender. Position brake line and wiring harness in the brake line guide.
  • Page 92 MASK, FENDER Position brake line and wiring harness in the brake line guide. (FE 350S US) Connect plug-in connectors Position the headlight mask and secure it with rubber bands ✓ The holding lugs engage in the fender. Position brake line and wiring harness in the brake line guide.

  • Page 93: Wheels

    Husqvarna Motorcycles recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear. the tires are more than 5 years old:...

  • Page 94: Checking The Brake Discs

    WHEELS Checkin the brake discs Warning Danger of accidents Worn-out brake discs reduce the braking effect. Make sure that worn-out brake discs are replaced immediately. Check the thickness of the front and rear brake discs at several places on the disk to see if it conforms to measurement t).

  • Page 95: Checking The Rim Run-Out

    WHEELS Checkin the rim run-out Warning 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.

  • Page 96: Installing The Front Wheel

    WHEELS Warning Damaged brake discs reduce the braking effect. Danger of accidents Always lay the wheel down in such a way that the brake disc is not damaged. Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork.

  • Page 97: Installing The Front Brake Disc

    WHEELS Main work Remove screws Take off the brake disc. 14.6.4 Installing the front brake disc Main work Clean the contact surface of the brake disc. Position the brake disc with the label facing outward. Mount and tighten screws Guideline Screw, front brake disc 14 Nm Loctite...

  • Page 98: Rear Wheel

    WHEELS Position spacing tube Press in the new bearing all the way using a suitable tool. Info • 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 and press in until they are flush.

  • Page 99: Installing The Rear Wheel

    WHEELS Remove spacers 14.7.2 Installing the rear wheel Warning Oil or grease on the brake discs reduces the braking effect. Danger of accidents Always keep the brake discs free of oil and grease. Clean the brake discs with brake cleaner when necessary. Main work Check the wheel bearing for damage and wear.

  • Page 100: Removing The Rear Brake Disc

    WHEELS 14.7.3 Removing the rear brake disc Preparatory work Raise the motorcycle with a lift stand. p. 11) Remove the rear wheel. p. 96) Main work Remove screws Take off the brake disc. 14.7.4 Installing the rear brake disc Main work Clean the contact surface of the brake disc.

  • Page 101: Adjusting The Chain Tension

    WHEELS 14.7.6 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.
  • Page 102 WHEELS Pull at the top part of the chain with the specified weight 6). Guideline 110 ... 15 kg (2 2 ... 33 lb.) Weight of chain wear measurement Measure the distance G) of 18 chain links in the lower chain section. Info •...

  • Page 103: Checking For Chain Dirt Accumulation

    WHEELS Check the chain guide for wear. • Info Wear can be seen on the front of the chain guide. If the light part of the chain guide is worn: Change the chain guide. Check that the chain guide is firmly seated. If the chain guide is loose: Tighten the chain guide.

  • Page 104: Changing The Drivetrain Kit

    WHEELS Main work Clean the chain regularly and then treat with chain spray. Offroad chain spray (l!!,!J p. 286) 400725-01 Finishing work Remove the motorcycle from the lift stand. (il!) p. 11) 14.7.10 Changing the drivetrain kit Preparatory work Raise the motorcycle with a lift stand. (Ii!:,!! p.

  • Page 105: Changing The Rear Wheel Bearing

    WHEELS Remove fittings (D. Take off the rear sprocket. Position the new rear sprocket. Mount and tighten the fittings. Guideline Nut, rear sprocket screw 35 Nm Loctite ® 2701 (25.8 lbf ft) Slide new engine sprocket onto the countershaft. Mount the new chain. Connect the chain with connecting link Guideline The closed side of the chain joint lock must face in the direction of travel.
  • Page 106 WHEELS Main work Remove shaft seal ring Remove lock ring Remove shaft seal ring (5). Using a suitable tool, press bearing out from the inside to the outside. Remove spacing tube Using a suitable tool, press bearing out from the inside to the outside. Press new bearing all the way in from the outside to the inside.
  • Page 107 WHEELS Grease new shaft seal ring and press it in until it is flush. Mount lock ring@. ✓ The lock ring engages audibly. Grease new shaft seal ring and press it in until it is flush. Finishing work Install the rear wheel. (ilill p.

  • Page 108: Wiring Harness, Battery

    WIRING HARNESS, BATTERY Changing the main fuse Warning Fire hazard Incorrect fuses overload the electrical system. Only use fuses with the required ampere value. Do not bypass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the air filter box lid. Preparatory work Switch off all power consumers and switch off the engine.
  • Page 109 WIRING HARNESS, BATTERY Remove the defective fuse. Guideline Fuse 1 - 10 A - EFI control unit Fuse 2 - 10 A - fuel pump Fuse 3 - 10 A - high beam, low beam, parking light, tail light, license plate lamp Fuse - 10 A - horn, brake light, turn signal, radiator fan...

  • Page 110: Checking The Starter Relay

    WIRING HARNESS, BATTERY Check that the power consumer is functioning properly. Close the fuse box cover. Finishing work Mount the seat. (lit!l p. 77) 15.3 Checkin the starter relay Preparatory work Switch off all power consumers and switch off the engine. Remove the seat.

  • Page 111: Installing The Battery

    WIRING HARNESS, BATTERY Main work Insert the battery into the battery compartment with the terminals facing forward. Battery (YTX5L-BS) (� p. 215) Reconnect rubber band • Info Contact disks must be mounted under screws and cable sock­ with the claws toward the battery terminal. Position the positive cable and mount and tighten the screw.

  • Page 112: Checking The Charging Voltage

    WIRING HARNESS, BATTERY Main work Connect the battery charger to the battery. Set the battery charger. Alternative 1 Battery charger EU (00029095050) (� p. 288) XCharge-professional Alternative 2 Battery charger US (00029095051) (� p. 288) XCharge-professional Alternative 3 Battery charger GB (00029095052) p.

  • Page 113: Brake System

    Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 114 BRAKE SYSTEM Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container.

  • Page 115: Checking Free Travel Of Hand Brake Lever

    BRAKE SYSTEM (FE EU/ AU/US) Correct the brake fluid to level fj . Guideline Level fj (brake fluid level below 5 mm (0.2 in) container rim) Brake fluid DOT 4 (� p. 284) (D . Position cover @ with membrane Mount and tighten screws Info Clean up overflowed or spilled brake fluid immediately with water.

  • Page 116: Brake Lever (Fe 350 Us)

    BRAKE SYSTEM osition of the hand brake lever FE 350 US Check the free travel of the hand brake lever. (il!l p. 113) Adjust the basic setting of the hand brake lever to your hand size by turning adjusting screw •...

  • Page 117: Adding Front Brake Fluid

    BRAKE SYSTEM Adding front brake fluid Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail. If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.

  • Page 118: Changing The Front Brake Fluid

    BRAKE SYSTEM (FE 350S US) Move the brake fluid reservoir mounted on the handlebar to a horizontal posi- tion. Remove screws Remove cover with membrane Add brake fluid to level 6). Guideline 5 mm (0.2 in) Level 6) (brake fluid level below reservoir rim) Brake fluid DOT 4 (�...
  • Page 119 BRAKE SYSTEM Open shut-off valve • Info Follow the operating instructions of the bleeding device. Ensure that the filling pressure is set on pressure gauge t). Correct the filling pressure on pressure regulator if necessary. Guideline Filling pressure 2 ... 2.5 bar (29 ... 36 psi) Pull off protection cap of the brake caliper bleeder screw.

  • Page 120: Checking The Rear Brake Linings

    BRAKE SYSTEM Open shut-off valve Info • Follow the operating instructions of the bleeding device. Ensure that the filling pressure is set on pressure gauge t). Correct the filling pressure on pressure regulator if necessary. Guideline Filling pressure 2 ... 2.5 bar (29 ... 36 psi) Pull off protection cap of the brake caliper bleeder screw.

  • Page 121: Changing The Rear Brake Linings

    Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.

  • Page 122: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM Press the brake caliper onto the brake disc by hand in order to push back the brake piston and ensure that brake fluid does not flow out of the brake fluid reser­ voir, extracting it by suction if it does. •...

  • Page 123: Adjusting The Basic Position Of The Foot Brake Lever

    BRAKE SYSTEM Disconnect spring Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Guideline 13 ... Free travel at foot brake lever 5 mm (0.12 ... 0.2 in) If the free travel does not meet specifications: Adjust the basic position of the foot brake lever.

  • Page 124: Adding Rear Brake Fluid

    BRAKE SYSTEM Stand the vehicle upright. Check the brake fluid level in level viewer If the brake fluid level has dropped below marking Add rear brake fluid. (� p. 122) Adding rear brake fluid Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail. If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.

  • Page 125: Changing The Rear Brake Fluid

    BRAKE SYSTEM Main work Stand the vehicle upright. Remove screw cap with membrane and the O-ring. Add brake fluid to level 6). Brake fluid DOT 4 p. 284) Mount the screw cap with the membrane and the O-ring. Info Clean up overflowed or spilled brake fluid immediately with water. Changing the rear brake fluid Warning Skin irritation...
  • Page 126 BRAKE SYSTEM Mount bleeder cover Bleeder cover (00029013006) p. 288) Connect the bleeding device. Bleeding device (00029013100) p. 288) Open shut-off valve (D. • Info Follow the operating instructions of the bleeding device. Ensure that the filling pressure is correctly set at pressure gauge 6). If neces­ sary, adjust the filling pressure at pressure regulator Guideline Filling pressure...

  • Page 127: Lighting System, Instruments

    LIGHTING SYSTEM, INSTRUMENTS 17.1 Setting the s eedometer Condition The motorcycle is stationary. Press both buttons for 3 - 5 seconds. ✓ The Setup menu is displayed. The UNIT display flashes. ____ ,�_ I _L, Press one of the buttons to select UNIT for the speed in kilometers KM/H or -um�- ✓...

  • Page 128: Setting The Kilometers Or Miles

    LIGHTING SYSTEM, INSTRUMENTS Setting the kilometers or miles Info If the unit is changed, the value ODO is retained and converted accordingly. Condition The motorcycle is stationary. Press both buttons for 3 - 5 seconds. ✓ The Setup menu is displayed. The UNIT display flashes.

  • Page 129: Setting The Service Display

    LIGHTING SYSTEM, INSTRUMENTS Wait for the menu TIRE to flash. Reducing the wheel circumference ----,�-1 - �-- Press the left button. -�: fE- ✓ The value decreases. ,,,,,, / I ' � ' "" Enlarging the wheel circumference Press the right button. ✓...

  • Page 130: Adjusting The Headlight Range

    LIGHTING SYSTEM, INSTRUMENTS If the light-dark border does not meet specifications: Adjust the headlight range. (� p. 128) 17.7 Ad"usting the headlight range Preparatory work Check the headlight setting. (I!!:! p. 127) Main work (FE EU/ AU/US) Loosen screw Adjust the headlight range by pivoting the headlight. Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with driver (instructions on how to apply the mark: Checking...

  • Page 131: Engine

    ENGINE 18.1 Removin the engine Preparatory work Remove the engine guard.(� p. 41) Drain the coolant. (� p. 200) Raise the motorcycle with a lift stand.(� p. 11) Remove the right side cover. (!!ll p. 76) Remove the main silencer. (!!ll p.
  • Page 132 ENGINE Remove screws Loosen screw (D. Repeat these steps on the opposite side. Swing up the subframe and secure it. Remove screw Swing back the shock absorber. Remove springs@). Spring hook (50305017000) (� p. 289) Remove screw Take off the manifold. Push back the cover.
  • Page 133 ENGINE G, . Loosen hose clip Pull off the radiator hose. 48 . Disconnect spring Remove screw Remove screw Take off the engine sprocket cover. Remove the connecting link of the chain. Take off the chain. Remove screws Take off the clutch slave cylinder and hang it to one side. •...
  • Page 134 ENGINE Loosen hose clip G). Pull off the throttle valve body toward the rear. Loosen hose clip�­ Pull off the radiator hose. Remove fittings Take off the engine braces. Remove nut�- Remove the swingarm pivot. Pull the swingarm toward the rear slightly. Remove screws Lift out the engine sideways.

  • Page 135: Installing The Engine

    ENGINE Main work Position the engine in the frame. Mount screws but do not tighten yet. Guideline Engine attachment bolt 60 Nm (44.3 lbf ft) Position the swingarm. Mount the swingarm pivot. Mount nut but do not tighten it yet. Guideline Nut, swingarm pivot M16x1.5...
  • Page 136 ENGINE Mount the throttle valve body. Position and tighten hose clip Ci) . Plug in connector (D . Position the protection cap. Plug in connector @ . Plug in connector @) . Mount the spark plug connector. Position the clutch slave cylinder with the gasket. Mount and tighten screws Guideline 1 10Nm(7.41bf ft)
  • Page 137 ENGINE Mount the radiator hose. Position and tighten hose clip Position the cable. Mount and tighten nut Position the cover. Position the manifold and mount springs Spring hook (50305017000) (!!l p. 289) Mount and tighten screw Guideline Remaining screws, chassis 25 Nm (18.4 lbf ft) Position the shock absorber.
  • Page 138 ENGINE Remove the locking piece and position the subframe. • Info Watch out for the intake flange. Mount and tighten screws �. Guideline Screw, subframe 35 Nm Loctite 2701 ® (25.8 lbf ft) Remove screw �. Mount and tighten screw �. Guideline 35 Nm Screw, subframe...

  • Page 139: Engine Disassembly

    Execute the initialization run. (� p. 211) Finishing work Take a test ride. Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. Check the engine for leak tightness. Check the engine oil level. p. 202) Check the coolant level.

  • Page 140: Removing The Clutch Push Rod

    ENGINE 18.3.2 Removing the clutch push rod Remove clutch push rod 18.3.3 Removing the spacer Remove spacer of the countershaft. Remove O-ring. 18.3.4 Draining the engine oil Remove plug with oil screen and the O-rings. Remove oil drain plug @ with the magnet. Completely drain the engine oil.

  • Page 141: Removing The Spark Plug

    ENGINE Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) (!l;!l p. 289) 18.3.6 Removing the spark plug Remove the spark plug using special tool Spark plug wrench (77229172000) (� p. 295) 18.3.7 Removing the valve cover Remove screws Remove the valve cover with the valve cover seal.

  • Page 142: Removing The Torque Limiter

    ENGINE Take off the alternator cover gasket ✓ Dowels @ remain in the engine case. 18.3.9 Removing the torque limiter Remove torque limiter 18.3.10 Positioning the engine at ignition top dead center Turn the crankshaft counterclockwise until markings on the cylinder head are located flush above the flat areas G) of the camshafts.

  • Page 143: Removing The Camshaft

    ENGINE Pull out timing chain tensioner Remove O-ring 18.3.12 Removing the camshaft Loosen screws from the outside to the inside and remove. Take off guide rail fj . Take off the camshaft bearing bridge. Take the timing chain off the camshaft gear. Remove the camshafts.

  • Page 144: Removing The Piston

    ENGINE Remove cylinder head gasket 18.3.14 Removing the piston Push the cylinder upward. • Info Only push the cylinder as far up as necessary to take the piston pin out. Remove the piston pin retainer Remove the piston pin. Take off the cylinder and piston. Push the piston upward out of the cylinder.

  • Page 145: Removing The Suction Pump

    ENGINE Remove lock ring Take off the starter idler gear with the washer. Remove freewheel gear CD . Remove screws Remove the inside alternator cover. Take off gasket@. Remove screws @. Take off the starter motor. 18.3.16 Removing the suction pump Remove screws Take off oil pump cover...

  • Page 146: Removing The Water Pump Wheel

    ENGINE Remove O-ring Remove suction pump Remove needle roller@). 18.3.17 Removing the water pump wheel Remove screws Take off the water pump cover. Remove nut Take off the two-part water pump impeller...

  • Page 147: Removing The Clutch Cover

    ENGINE 18.3.18 Removing the clutch cover Remove screws Take off the clutch cover. Remove the clutch cover seal. 18.3.19 Removing the clutch discs Remove screws Take off spring retainer@. Take off spring washer@). Take off pretension ring Take off pressure cap...

  • Page 148: Removing The Clutch Basket

    ENGINE Completely remove clutch disc pack (D . Remove clutch pressure piece 18.3.20 Removing the clutch basket Bend open lock washer. Hold the inner clutch hub with the special tool. Loosen nut Clutch holder (51129003000) (i!!J p. 290) Remove the nut with the lock washer. Dispose of the lock washer. Take off inner clutch hub and washer •...

  • Page 149: Removing The Shift Drum Locating Unit

    ENGINE 18.3.22 Removing the shift drum locating unit Remove screw Push away locking lever from shift drum locating unit and remove the shift drum locating unit. Relieve tension from the locking lever. 18.3.23 Removing the locking lever Unscrew and remove together with locking lever@, washer, sleeve and spring.

  • Page 150: Removing The Primary Gear

    ENGINE Remove pin@). Push oil pump shaft Gi) inward and take it out of the engine from the alternator side. Remove force pump 18.3.25 Removing the primary gear Remove nut • Info Left-handed thread! Take off primary gear(!}. 18.3.26 Removing the timing chain Remove screws Remove the timing chain tensioning rail(!}.

  • Page 151: Removing The Left Section Of The Engine Case

    ENGINE 18.3.28 Removing the left section of the engine case Remove screws Tilt the left section of the engine case upward and remove the screw connections of the engine fixing arm. Insert the special tool into the crankshaft. Protection cap (75029090000) p.

  • Page 152: Removing The Shift Drum

    ENGINE 18.3.30 Removing the shift drum Tilt shift forks to the side. • Info Do not misplace the shift rollers. Remove shift drum@. 18.3.31 Removing the shift forks Remove shift forks Info Do not misplace shift rollers 18.3.32 Removing the transmission shafts Remove lock ring Pull both transmission shafts out of the bearing seats together.

  • Page 153: Working On Individual Parts

    ENGINE arts 18.4 Working on individual 18.4.1 Work on the right section of the engine case Remove all dowels. Remove shaft seal ring of the crankshaft. Remove nozzle Remove oil nozzle for conrod bearing lubrication. Remove screw Remove the oil nozzle for piston cooling. Remove screws@).

  • Page 154: Work On The Left Section Of The Engine Case

    ENGINE Guideline Screw, oil nozzle for pis­ Loctite ® ™ ton cooling (1 .5 lbf ft) Position all bearing locks. Mount and tighten screws Guideline Loctite Locking screw for bearing ® ™ (4.4 lbf ft) Blow out the oil channel with compressed air and check that it is clear. 18.4.2 Work on the left section of the engine case Remove all dowels.

  • Page 155: Work On The Clutch Cover

    ENGINE Press in shaft seal ring of the countershaft so it is flush with the open side facing in. Mount and tighten oil nozzle Guideline Oil nozzle for clutch lubri- Loctite ® ™ cation (4.4 lbf ft) Mount and tighten oil nozzle Guideline Oil nozzle, piston cooling 2 Nm...
  • Page 156 ENGINE Mount lock ring Press the shaft seal ring all the way in from the inside to the outside with the open side facing in. Press the new bearing all the way in from the inside to the outside using a suitable tool.

  • Page 157: Checking The Oil Pressure Regulator Valve

    ENGINE 18.4.4 Checking the oil pressure regulator valve with sealing washer @ . Remove screw plug Remove pressure spring fs) and ball o- 8 305033-10 Measure the spring length of the oil pressure regulator valve. Oil pressure regulator valve Minimum length of pressure spring 23.5 mm (0.925 in) If the measured value does not meet specifications: Change the spring.

  • Page 158: Removing The Crankshaft Bearing Inner Race

    ENGINE Change the oil pump shaft. Check the oil pump cover for damage and wear. If there is damage or wear: Change the oil pump cover. 18.4.6 Removing the crankshaft bearing inner race Fix the crankshaft in the vise. • Info Use soft jaws.
  • Page 159 ENGINE Press the crank pin out of the lower crank web. Press in the new crank pin as far as possible. ✓ Oil hole is aligned with oil hole@). X If the oil holes are not correctly aligned, the conrod bearing will not be sup­ plied with oil.

  • Page 160: Checking The Crankshaft Run-Out At The Bearing Pin

    ENGINE 18.4.9 Checking the crankshaft run-out at the bearing pin Position the crankshaft on a roller block. Turn the crankshaft slowly. Check the crankshaft run-out on both bearing pins. Crankshaft - run-out at bearing pin :5 0.03 mm (:5 0.0012 in) If the crankshaft run-out at the bearing pin is larger than the specification: Align the crankshaft.

  • Page 161: Installing The Drive Wheel Of The Balancer Shaft

    ENGINE 18.4.12 Installing the drive wheel of the balancer shaft Ensure that woodruff key is seated properly. Warm drive wheel @ of the balancer shaft and push it onto the balancer shaft. Guideline 1100 °C (212 °F) 303077-10 18.4.13 Cylinder - Nikasil ®...

  • Page 162: Checking/Measuring The Piston

    ENGINE 18.4.15 Checking/measuring the piston Use the special tool to measure clearance of the piston rings in the piston ring groove. e -• ­ Guideline Piston ring - groove clearance $ 0.08 mm ($ 0.0031 in) Feeler gauge (59029041100) (� p.

  • Page 163: Checking The Piston Ring End Gap

    ENGINE Guideline Piston/cylinder - mounting clearance Size I 0.025 ... 0.047 mm (0.00098 ... 0.00185 in) Size II 0.027 ... 0.049 mm (0.00106 ... 0.00193 in) Wear limit 0.070 mm (0.00276 in) 18.4.17 Checking the piston ring end gap Remove the piston ring from the piston. Place the piston ring in the cylinder and align with the piston.

  • Page 164: Checking The Camshafts

    ENGINE 18.4.19 Checking the camshafts Check the camshaft for damage and wear. If there is damage or wear: Change the camshaft. If the surface of the cams is damaged, check the oil supply to the camshaft and cam lever. Check the autodecompressor for damage and wear. If there is damage or wear: Change the exhaust camshaft.

  • Page 165: Removing The Valves

    ENGINE Take off the camshafts and clean the parts. 18.4.21 Removing the valves Remove screw plugs with the O-ring. Screw appropriate screw into the cam lever shaft. Hold cam levers and remove the cam lever shaft. • Info If the cam levers will continue to be used, note down their installation posi­ tion.

  • Page 166: Checking The Valves

    ENGINE 18.4.22 Checking the valves Check the valve plate for run-out. Valve - run-out At the valve plate s; 0.05 mm (s; 0.002 in) If the measured value does not meet specifications: Change the valve. 200193-10 Check sealing seat on the valve. Valve - sealing seat width Intake 1 .40 mm (0.0551 in)

  • Page 167: Checking The Cylinder Head

    ENGINE 18.4.26 Checking the cylinder head Check valve guides using the special tool. Limit plug gauge (77229026000) p. 294) If the special tool is easy to insert in the valve guide: Change the valve guide and valve. Check the sealing area of the spark plug thread and the valve seats from damage and cracking.

  • Page 168: Checking The Freewheel

    ENGINE Mount valve keys Info • When mounting the valve keys, ensure that they are seated properly; it is recommended to adhere the valve keys to the valves with a small amount of grease. Position cam levers in the positions they had before they were removed. Mount the cam lever shafts.

  • Page 169: Installing The Freewheel

    ENGINE Press expansion ring @ together with suitable pliers and take off. Take freewheel (D out of the primary gear. 18.4.30 Installing the freewheel Thoroughly oil all parts. Slide freewheel into the primary gear. Info Note the direction of rotation. Mount spreader ring@.

  • Page 170: Checking The Electric Starter Drive

    ENGINE 18.4.31 Checking the electric starter drive ·-• 305006-10 Check the gear mesh and bearing of starter idler gear for damage and wear. If there is damage or wear: Change the starter idler gear. Check the gear mesh and bearing of torque limiter for damage and wear.

  • Page 171: Checking The Timing Assembly

    ENGINE 18.4.32 Checking the timing assembly 305007-10 Check timing chain sprocket for damage and wear. If there is damage or wear: Change the 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.

  • Page 172: Checking The Clutch

    ENGINE Place two compensating disks or similar aids next to the timing chain tensioner piston. This ensures that, when pressed in, the piston cannot go in all the way. Guideline Thickness of the compensating disks 2 ... 2.5 mm (0.08 ... 0.098 in) Release the timing chain tensioner.

  • Page 173: Checking The Shift Mechanism

    ENGINE Change the pressure cap. Check clutch center @ for damage and wear. If there is damage or wear: Change the clutch center. Check damping rubber for damage and wear. If there is damage or wear: Change the damping rubbers. Check the inner clutch hub for damage and wear.

  • Page 174: Preassembling The Shift Shaft

    ENGINE Change the shift drum. Check the seating of the shift drum in the grooved ball bearings@). If the shift drum is not correctly seated: Change the shift drum and/or the grooved ball bearing. Check grooved ball bearing @) for smooth operation and wear. If the grooved ball bearings are stiff or worn: Change the grooved ball bearing.

  • Page 175: Disassembling The Main Shaft

    ENGINE 18.4.37 Disassembling the main shaft 305011-10 Secure the main shaft with the toothed end facing downward in the vise. Guideline Use soft jaws. Remove stop disk and 2nd-gear fixed gear Remove 5th-gear idler gear Ci) and needle bearing Remove stop disk Remove lock ring (3.
  • Page 176 ENGINE Guideline Use soft jaws Remove stop disk and 1st-gear idler gear @. Remove needle bearing (D. Remove stop disk Remove 6th-gear sliding gear Remove stop disk Cs). Remove lock ring @. Remove 3rd-gear idler gear@. Remove needle bearing Remove 4th-gear idler gear Gi). Remove needle bearing Remove stop disk and lock ring G).

  • Page 177: Assembling The Main Shaft

    ENGINE If there is damage or wear: Change the gear wheel pair. Check the shift dogs of idler gears and sliding gears @) for damage and wear. If there is damage or wear: Change the gear wheel pair. Check the tooth faces of idler gears sliding gears @), and fixed gear (3 for damage and wear.

  • Page 178: Assembling The Countershaft

    ENGINE Mount needle bearing Mount 6th-gear idler gear @. Mount stop disk and lock ring Mount 3rd/4th-gear sliding gear with the small gear wheel facing downward. Mount lock ring (3. Mount stop disk@. Mount needle bearing (D. Mount 5th-gear idler gear Mount 2nd-gear fixed gear and stop disk Finally, check all gear wheels for smooth operation.

  • Page 179: Engine Assembly

    ENGINE Mount 6th-gear sliding gear with the shift groove facing downward. Mount stop disk Gt). Mount needle bearing Ci}. Mount 1st-gear idler gear Mount stop disk Gi). Finally, check all gear wheels for smooth operation. 18.5 Engine assembl� 18.5.1 Installing the crankshaft Position the right section of the engine case in the engine work stand.

  • Page 180: Installing The Shift Forks

    ENGINE 18.5.3 Installing the shift forks Shift fork has a smaller inside diameter; mount this in the shift groove of the main shaft. •- Mount shift fork @ in the lower shift groove of the countershaft. Mount shift fork (D in the upper shift groove of the countershaft. Slide on shift rollers Fix the shift rollers in the shift forks with grease.

  • Page 181: Installing The Left Engine Case

    ENGINE 18.5.6 Installing the left engine case Mount the dowels. Degrease the sealing area. Apply sealing compound to the left section of the engine case. Loctite 591 O ® Mount the left section of the engine case. If necessary, strike it lightly with a rub­ ber mallet and turn the transmission shafts.

  • Page 182: Installing The Primary Gear

    ENGINE Position timing chain guide rail (D. Mount and tighten screw Guideline Screw, timing chain guide 10 Nm Loctite ® ™ rail (7.4 lbf ft) Position timing chain tensioning rail Mount and tighten screw 0). Guideline Screw, timing chain ten­ 15 Nm Loctite ®...

  • Page 183: Installing The Suction Pump

    ENGINE Position oil pump gear wheel (D. Mount washer@. Mount lock ring Crank the oil pump gear wheel and ensure that it can move easily. Mount oil pump idler gear with the washer. Mount washers 41). G, . Mount lock ring 18.5.11 Installing the suction pump Insert needle roller...

  • Page 184: Installing The Locking Lever

    ENGINE 18.5.12 Installing the locking lever Mount locking lever with the washer, sleeve and spring. Mount and tighten screw Guideline Screw, locking lever Loctite ® ™ (4.4 lbf ft) 18.5.13 Installing the shift drum locating unit Push away locking lever from the shift drum locating unit and position the shift drum locating unit •...

  • Page 185: Installing The Clutch Discs

    ENGINE Slide on washer and inner clutch hub Position the new lock washer and mount nut (s). Tighten the nut, holding the inner clutch hub with a special tool. Guideline Nut, inner clutch hub M18x1 .5 100 Nm Loctite ® ™...

  • Page 186: Installing The Clutch Cover

    ENGINE Position spring retainer with the I marking. Install the screws and tighten them diagonally. Guideline Screw, clutch spring I 6 Nm (4.4 lbf ft} Using a straightedge and the special tool, check the spring washer for distortion. Feeler gauge (59029041100) (i!!ll p.

  • Page 187: Installing The Water Pump Cover

    ENGINE Position the clutch cover. • Info Ensure that the shaft seal rings of the water pump and the crankshaft are not damaged. Remove screw Mount screw @ with the washer but do not tighten yet. Guideline Screw, clutch cover M6x25 110 Nm (7.4 lbf ft) Mount screws...
  • Page 188 ENGINE Mount gasket Position the inside alternator cover. Mount and tighten screws (5). Guideline Screw, inside alternator cover I 6 Nm (4.4 lbf ft) Tighten screws Guideline Screw, starter motor 10 Nm (7.4 lbf ft) Position freewheel gear Mount the starter idler gear with the washer. Mount lock ring Position the rotor.

  • Page 189: Installing The Piston

    ENGINE 18.5.20 Installing the piston ° Shift the joint of the piston rings by 120 Place the special tool on the oiled piston. Compress the piston rings using the special tool. Piston ring mounting tool (60029015000) (E.,!1 p. 291) ✓ The piston rings are pushed together all the way. 302642-10 Position the piston on the cylinder using the special tool.

  • Page 190: Installing The Cylinder Head

    ENGINE Insert the special tool and press it forcefully to the piston. Turn the special tool clockwise, thereby pushing the piston pin retainer into the groove. Insertion for piston ring lock (77229030000) p. 294) Ensure that the piston pin retainer is seated properly on both sides. Remove the cloth.

  • Page 191: Installing The Camshafts

    ENGINE Mount and tighten nut with the washer. Guideline Nut, cylinder head 10 Nm Lubricated with (7.4 lbf ft) engine oil 18.5.22 Installing the camshafts Pull up the timing chain and insert intake camshaft Place the timing chain over the camshaft gear of the intake camshaft. ✓...

  • Page 192: Adjusting The Valve Timing

    ENGINE Remove the special tool. Adjustment bush bridge (77229050044) p. 295) Insert, timing chain tensioner (77229035000) p. 294) 18.5.24 Adjusting the valve timing Condition Camshaft gears were loosened. Mount special tool and tension the timing chain. Insert, timing chain tensioner (77229035000) p.

  • Page 193: Installing The Timing Chain Tensioner

    ENGINE Mount and tighten screws Guideline Screw, camshaft bearing M7x1 14 Nm Lubricated with bridge (10.3 lbf ft) engine oil Remove special tool Insert, timing chain tensioner (77229035000) (!.::!I p. 294) 18.5.25 Installing the timing chain tensioner Preparatory work Prepare the timing chain tensioner for installation. (�...

  • Page 194: Checking The Valve Clearance

    ENGINE 18.5.26 Checking the valve clearance Remove screw Crank over the engine repeatedly. Position the engine at ignition top dead center. ✓ Markings on the cylinder head are flush above the flat areas of the camshafts. Check the valve clearance at all valves between the camshaft and cam levers. Guideline Valve clearance Intake at: 20 °c (68 °F)

  • Page 195: Installing The Torque Limiter

    ENGINE Installing the torque limiter 18.5.28 Position torque limiter 18.5.29 Installing the alternator cover Position alternator cover gasket Position the alternator cover. Mount screws and tighten once all of the alter­ nator cover screws have been mounted. Guideline Screw, alternator cover M6x30 I 6 Nm (4.4 lbf ft) Mount screws...

  • Page 196: Installing The Spark Plug

    ENGINE Position the valve cover with the gasket. Mount and tighten screws Guideline Screw, valve cover I 8 Nm (5.9 lbf ft) 18.5.31 Installing the spark plug Mount and tighten the spark plug with special tool Guideline Spark plug M10x1 10 ...

  • Page 197: Installing The Spacer

    ENGINE Push the oil screen with O-rings onto a pin wrench. Push the pin wrench through the opening into the drill hole of the opposite engine case wall and push the oil screen as far as possible into the engine case. Mount and tighten screw plug with the O-ring.

  • Page 198: Clutch

    CLUTCH Checkin /correctin the fluid level of the h draulic clutch Warning Brake fluid causes skin irritation. Skin irritation Keep brake fluid out of the reach of children. Wear suitable protective clothing and safety glasses. Do not allow brake fluid to come into contact with the skin, the eyes or clothing. Consult a doctor immediately if brake fluid has been swallowed.

  • Page 199: Changing The Hydraulic Clutch Fluid

    CLUTCH Changing the h draulic clutch 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 contact with the skin, the eyes or clothing. Consult a doctor immediately if brake fluid has been swallowed.
  • Page 200 CLUTCH (FE 350S US) Inject the liquid into the system until it escapes from openings (3 of the mas­ ter cylinder without bubbles. Now and then, extract fluid from the master cylinder reservoir to prevent over­ flow. Remove the bleeding syringe. Mount and tighten screws bleeder screw. Correct the fluid level of the hydraulic clutch.

  • Page 201: Water Pump, Cooling System

    WATER PUMP, COOLING SYSTEM Water pump in the engine circulates the coolant. The water flow through the radiator is controlled as a function of the coolant temper­ ature. The cooling system is divided into two circuits. In the warming-up phase of the engine, the coolant flows through the small cooling circuit.

  • Page 202: Checking The Coolant Level

    WATER PUMP, COOLING SYSTEM Mount the radiator cap. Checking the coolant level Warning During motorcycle operation, the coolant gets very hot and is under pressure. Danger of scalding Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

  • Page 203: Refilling Coolant

    WATER PUMP, COOLING SYSTEM (FE EU/ AU/US) Position the motorcycle upright. Place a suitable container under the water pump cover. Remove screw Take off radiator cap Completely drain the coolant. Mount and tighten screw with a new seal ring. Guideline 110 Nm (7.4 lbf ft) Screw, water pump cover (FE 350S US)

  • Page 204: Lubrication System

    LUBRICATION SYSTEM 21.1 Oil circuit 401362-60 Oil screen Force pump Oil pressure regulator valve Oil filter Oil nozzle, conrod lubrication Oil nozzle for cam follower lubrication Oil nozzle, piston cooling Oil nozzle for alternator cooling Oil nozzle for clutch lubrication Suction pump Oil channel, transmission lubrication Timing chain tensioner...

  • Page 205: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen

    LUBRICATION SYSTEM Changing the engine oil and oil filter, cleaning the oil screen Warning Engine and gear oil get very hot when the motorcycle is ridden. Danger of scalding Wear suitable protective clothing and safety gloves. In the event of scalding, rinse the area affected immediately with lukewarm water. Warning Hazardous substances cause environmental damage.
  • Page 206 LUBRICATION SYSTEM Remove screws Remove the oil filter cover with the 0-ring. Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) (l!!l p. 289) 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 ½...

  • Page 207: Adding Engine Oil

    LUBRICATION SYSTEM Adding engine oil Info Too little engine oil or poor-quality engine oil results in premature wear of the engine. Main work Remove oil filler plug with the O-ring from the clutch cover. Fill engine oil to the middle of the level viewer.
  • Page 208 LUBRICATION SYSTEM If the measured value is less than the specification: Check the oil pumps for wear. Check all oil holes for free flow. Switch off the engine. Warning Danger of burns Some vehicle components get very hot when the machine is driven.

  • Page 209: Ignition System

    IGNITION SYSTEM 22.1 Ignition coil - checking the seconds winding Condition Ignition coil cylinder 1 is disconnected. Spark plug connector cylinder 1 has been removed. Ignition coil cylinder 1 check the secondary winding resistance Measure the resistance between the specified points. Ignition coil cylinder 1 pin 2 (-) - Ignition coil cylinder 1 pin 3 Ignition coil Secondary winding resistance at:...

  • Page 210: Removing The Stator And Ignition Pulse Generator

    IGNITION SYSTEM 601211-10 Stator winding - check for a short circuit to ground (terminal 31) Measure the resistance between the specified points. - Measuring point Stator, connector Ground Resistance If the value displayed does not meet specifications: Change the stator. Removin the stator and i nition pulse enerator 22.4 Condition...

  • Page 211: Installing The Stator And Ignition Pulse Generator

    IGNITION SYSTEM 22.5 Installing the stator and ignition enerator Blow out oil nozzle with compressed air and check that it is clear. Guideline Oil nozzle for alternator Loctite ® ™ cooling (1.5 lbf ft) 305322-10 Position the stator in the alternator cover. Mount and tighten screws Guideline Screw, stator...

  • Page 212: Electric Starter

    ELECTRIC ST ARTER 23.1 Checkin the starter motor Condition The starter motor has been removed. Connect the negative cable of a 12 volt power supply to the housing of the starter motor. Connect the positive cable of the power supply briefly to connector the starter motor.

  • Page 213: Throttle Valve Body

    THROTTLE VALVE BODY Ad"ustin the idle s eed Warning Danger of accidents The engine may go out spontaneously if the idle speed is set too low. Set the idle speed to the specified value. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.

  • Page 214: Technical Data

    TECHNICAL DATA 25.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 349. 7 cm (21.34 cu in) Stroke 57.5 mm (2.264 in) Bore 88 mm (3.46 in) Compression ratio 12.3:1 2,050 ... 2,150 rpm Idle speed Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 36.3 mm (1.429 in)

  • Page 215: Engine Tightening Torques

    TECHNICAL DATA 87.965 ... 87.975 mm (3.46318 ... 3.46358 in) Size I Size II 87.976 ... 87.985 mm (3.46362 ... 3.46397 in) Cylinder - drill hole diameter Size I 88.000 ... 88.012 mm (3.46456 ... 3.46503 in) Size II 88.012 ... 88.025 mm (3.46503 ... 3.46554 in) Piston/cylinder - mounting clearance Size I 0.025 ...

  • Page 216: Capacities

    TECHNICAL DATA Screw, timing chain guide rail 10 Nm (7.4 lbf ft) ® Loctite ™ Screw, timing chain securing guide 10 Nm (7.4 lbf ft) ® Loctite ™ Screw, valve cover 8 Nm (5.9 lbf ft) Screw, water pump cover 10 Nm (7.4 lbfft) 10 Nm (7.4 lbfft) Stud, cylinder head...

  • Page 217: Chassis

    TECHNICAL DATA 25.5 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork WP Suspension Up Side Down 4860 4CS Suspension travel Front 300 mm (11.81 in) Suspension travel Rear 330 mm (12.99 in) Fork offset 20 mm (0. 79 in) Shock absorber WP Suspension 5018 BAVP DCC...

  • Page 218: Tires

    110/100 - 18 64M TT Dunlop GEOMAX AT81 F Dunlop GEOMAX AT81 The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: www.husqvarna-motorcycles.com Fork 25.8 Fork part number 24.18. 7N.67...

  • Page 219: Chassis Tightening Torques

    TECHNICAL DATA Weight of rider: 75 ... 85 kg (165 ... 187 lb.) 54 N/mm (308 lb/in) Weight of rider: 85 ... 95 kg (187 ... 209 lb.) 57 N/mm (325 lb/in) 260 mm (10.24 in) Spring length Gas pressure 10 bar (145 psi) Static sag 30 mm(1.18 in)
  • Page 220 TECHNICAL DATA Nut, angle lever on swingarm M14x1.5 80 Nm (59 lbf ft) Nut, frame on linkage lever M14x1.5 80 Nm (59 lbf ft) Nut, linkage lever on angle lever M14x1.5 80 Nm (59 lbf ft) Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) Nut, rear wheel spindle M20x1.5...

  • Page 221: Cleaning, Care

    CLEANING, CARE 26.1 Cleanin the motorc cle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.

  • Page 222: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE Checks and maintenance ste s for winter o eration Info If you use the vehicle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive road salt. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt.

  • Page 223: Storage

    • Info Husqvarna Motorcycles recommends raising the motorcycle. Raise the motorcycle with a lift stand.(� p. 11) Preferably cover the vehicle with a tarp or similar cover that is permeable to air. Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.

  • Page 224: Service Schedule

    • Final check: Check the vehicle for roadworthiness and take a test ride. • • Read out the fault memory after the test ride using the Husqvarna Motorcycles diagnostics tool. • • Make the service entry in the Husqvarna Motorcycles Dealer.net...

  • Page 225: Service Work As Additional Order

    SERVICE SCHEDULE One-time interval • Periodic interval 28.2 Service work as additional order Annually Every 135 operating hours Every 70 operating hours when used for motorsports Every 45 operating hours Once after 15 operating hours • Change the front brake fluid. p.

  • Page 227: Wiring Diagram

    WIRING DIAGRAM Components: Battery Starter relay with main fuse Starter motor Electric starter button...

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  • Page 229 WIRING DIAGRAM Components: A 11 EFI control unit Radiator fan temperature switch Fuse Fuse Fuse Alternator Light relay Power relay Radiator fan Voltage regulator X295 Diagnostics connector...

  • Page 230: Fe Eu)

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  • Page 231 WIRING DIAGRAM Components: A 11 EFI control unit Low beam, high beam Speedometer Horn Parking light Light switch, horn button, kill switch...

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  • Page 233 WIRING DIAGRAM Components: Brake light switch, front Brake light switch, rear License plate lamp Brake/tail light...

  • Page 234: Fe Eu)

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  • Page 235 WIRING DIAGRAM Components: Turn signal relay Turn signal indicator light Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right Turn signal switch...

  • Page 236: Fe Eu)

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  • Page 237 WIRING DIAGRAM Components: A 11 EFI control unit Fuel level indicator Lambda sensor (cylinder 1) Fuse Speedometer...

  • Page 238: Fe Eu)

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  • Page 239 WIRING DIAGRAM Components: A 11 EFI control unit Wheel speed sensor, front Fuel pump Injector (cylinder 1) CAN-bus terminating resistor 1 Speedometer X295 Diagnostics connector...

  • Page 240: Fe Eu)

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  • Page 241 WIRING DIAGRAM Components: A 11 EFI control unit Throttle position sensor circuit A Intake air temperature sensor Engine coolant temperature sensor (cylinder 1) Rollover sensor Ignition pulse generator Manifold absolute pressure sensor (cylinder 1) Ignition coil (cylinder 1) Map-Select switch for riding mode (optional) Map-Select switch for basic setting (optional) Cable colors:...
  • Page 243 WIRING DIAGRAM Components: Battery Starter relay with main fuse Starter motor Emergency OFF switch, electric starter button...

  • Page 244: Fe Au)

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  • Page 245 WIRING DIAGRAM Components: A 11 EFI control unit Radiator fan temperature switch Fuse Fuse Fuse Alternator Light relay Power relay Radiator fan Voltage regulator X295 Diagnostics connector...

  • Page 246: Fe Au)

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  • Page 247 WIRING DIAGRAM Components: A 11 EFI control unit Low beam, high beam Speedometer Horn Parking light Light switch, horn button, kill switch Emergency OFF switch, electric starter button...

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  • Page 249 WIRING DIAGRAM Components: Brake light switch, front Brake light switch, rear License plate lamp Brake/tail light...

  • Page 250: Fe Au)

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  • Page 251 WIRING DIAGRAM Components: Turn signal relay Turn signal indicator light Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right Turn signal switch...

  • Page 252: Fe Au)

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  • Page 253 WIRING DIAGRAM Components: A 11 EFI control unit Fuel level indicator Fuse Speedometer...

  • Page 254: Fe Au)

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  • Page 255 WIRING DIAGRAM Components: A 11 EFI control unit Wheel speed sensor, front Fuel pump Injector (cylinder 1) CAN-bus terminating resistor 1 Speedometer X295 Diagnostics connector...

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  • Page 257 WIRING DIAGRAM Components: A 11 EFI control unit Throttle position sensor circuit A Intake air temperature sensor Engine coolant temperature sensor (cylinder 1) Rollover sensor Ignition pulse generator Manifold absolute pressure sensor (cylinder 1) Ignition coil (cylinder 1) Map-Select switch for riding mode (optional) Map-Select switch for basic setting (optional) Cable colors:...
  • Page 259 WIRING DIAGRAM Components: Battery Starter relay with main fuse Starter motor Electric starter button...

  • Page 260: Fe 350 Us)

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  • Page 261 WIRING DIAGRAM Components: A 11 EFI control unit Radiator fan temperature switch (optional) Fuse Fuse Fuse Alternator Light relay Power relay Radiator fan (optional) Voltage regulator X295 Diagnostics connector...

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  • Page 263 WIRING DIAGRAM Components: A 11 EFI control unit Low beam Parking light Tail light Kill switch Light switch...

  • Page 264: Fe 350 Us)

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  • Page 265 WIRING DIAGRAM Components: A 11 EFI control unit Fuel tank sensor Fuse Speedometer...

  • Page 266: Fe 350 Us)

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  • Page 267 WIRING DIAGRAM Components: A 11 EFI control unit Front wheel speed sensor Fuel pump Injector (cylinder 1) Speedometer CAN-bus terminating resistor 1 X295 Diagnostics connector...

  • Page 268: Fe 350 Us)

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  • Page 269 WIRING DIAGRAM Components: A 11 EFI control unit Throttle position sensor circuit A Intake air temperature sensor Engine coolant temperature sensor (cylinder 1) Rollover sensor Crankshaft position sensor Manifold absolute pressure sensor (cylinder 1) Ignition coil (cylinder 1) Map-Select switch for ride mode (optional) Map-Select switch for basic position (optional) Cable colors:...

  • Page 270: Fe 350S Us)

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  • Page 271 WIRING DIAGRAM Components: Fuse Battery Starter relay with main fuse Starter motor Ignition lock S2 3 Emergency OFF switch, electric starter button...

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  • Page 273 WIRING DIAGRAM Components: A 11 EFI control unit Radiator fan temperature switch Fuse Fuse Alternator Light relay Power relay Radiator fan Voltage regulator X295 Diagnostics connector...

  • Page 274: Fe 350S Us)

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  • Page 275 WIRING DIAGRAM Components: A 11 EFI control unit Low beam, high beam Horn High beam indicator lamp Parking light Light switch, horn button, turn signal switch...
  • Page 276 � • �m "' " � ' _ /3.B8 g C>-- wh ·� "" "' f x1s � BY/4 -AH/2 -AH/2 ��" -D1/2 -X11 -AK/2 -B77 - ,... -AK/2 � -CV/4 -B76 - -P36 -X17 � CV/4 �00 BY/4 � ::: t �...
  • Page 277 WIRING DIAGRAM Components: Front brake light switch Rear brake light switch License plate lamp Brake/tail light...

  • Page 278: Fe 350S Us)

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  • Page 279 WIRING DIAGRAM Components: Turn signal relay Turn signal switch Front left turn signal Front right turn signal Rear left turn signal Rear right turn signal Light switch, horn button, turn signal switch...

  • Page 280: Fe 350S Us)

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  • Page 281 WIRING DIAGRAM Components: A 11 EFI control unit Fuel level sensor Fuse Fl warning lamp and low fuel warning lamp...

  • Page 282: Fe 350S

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  • Page 283 WIRING DIAGRAM Components: A 11 EFI control unit Front wheel speed sensor Fuel pump Fuel evaporation valve Injector cylinder 1 Speedometer Tripmaster switch CAN-bus terminating resistor 1 X295 Diagnostics connector...

  • Page 284: Fe 350S Us)

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  • Page 285 WIRING DIAGRAM Components: A 11 EFI control unit Throttle position sensor circuit A Intake air temperature sensor Engine coolant temperature sensor (cylinder 1) Rollover sensor Crankshaft position sensor Manifold absolute pressure sensor (cylinder 1) Ignition coil (cylinder 1) Map-Select switch for ride mode (optional) Map-Select switch for basic position (optional) Cable colors:...

  • Page 286: Substances

    SUBSTANCES Brake fluid DOT 4 Standard/classification Guideline Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the cor- responding properties. Recommended supplier ® Bel-Ray Super DOT 4 Brake Fluid Coolant Guideline Only use high-grade, silicate-free coolant with corrosion inhibitor additive for aluminum motors.
  • Page 287 SUBSTANCES Su er unleaded ROZ 95/RON 95/PON 91 Standard/classification DIN EN 228 (ROZ 95/RON 95/PON 91) Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade. Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use. Info use fuel containing methanol (e.

  • Page 288: Auxiliary Substances

    AUXILIARY SUBSTANCES Air filter cleaning agent Recommended supplier ® Bel-Ray Foam Filter Cleaner & Degreaser Hi h viscosity rease Recommended supplier ® LGHB2 rease Recommended supplier ® Bel-Ray Waterproof Grease Lubricant (T158) Recommended supplier ® Lubcon ® Turmogrease PP 300 Lubricant (T511) Recommended supplier ®...
  • Page 289 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...

  • Page 290: Special Tools

    SPECIAL TOOLS Bleeder cover Art. no.: 00029013005 00029013005 H00504-01 Bleeder cover Art. no.: 00029013006 00029013006 H00505-01 Bleedin device Art. no.: 00029013100 00029013100 H00518-01 Battery charger XCharge-professional EU Art. no.: 00029095050 H01065-01 Batte� charger XCharge-�rofessional US Art. no.: 00029095051 H01065-01...
  • Page 291 SPECIAL TOOLS Art. no.: 00029095052 H01065-01 Batte rofessional CH Art. no.: 00029095053 H01065-01 Sprin hook Art. no.: 50305017000 50305017000 H00973-01 Bleed syringe Art. no.: 50329050000 50329050000 H00565-01 Circli� �liers reverse Art. no.: 51012011000 51012011000 H00572-01...
  • Page 292 SPECIAL TOOLS Clutch holder Art. no.: 51129003000 51129003000 H00575-01 Extractor Art. no.: 58012009000 58012009000 H00592-01 Tool for inner bearin race Art. no.: 58429037037 58429037037 H00596-01 Torque wrench with various accessories in set Art. no.: 58429094000 58429094000 H00606-01 Valve s�ring mounter Art.
  • Page 293 SPECIAL TOOLS Feeler gauge Art. no.: 59029041100 59029041100 H00616-01 Plasti e clearance Art. no.: 60029012000 60029012000 H00627-01 tool Art. no.: 60029015000 60029015000 H00628-01 Hose clamp pliers Art. no.: 60029057000 60029057000 H00650-01 Testing hose Art. no.: 61029093000 61029093000 H00659-01...
  • Page 294 SPECIAL TOOLS Pressure tester Art. no.: 61029094000 4x £ 61029094000 H00660-01 En ine assembl stand Art. no.: 61229001000 61229001000 H00662-01 Release device for timin chain tensioner Art. no.: 61229021000 61229021000 H00675-01 Pressing tool for crankshaft, complete Art. no.: 75029047000 75029047000 H00714-01 Protection ca Art.
  • Page 295 SPECIAL TOOLS Extractor, camshaft gear Art. no.: 77229001044 � 77229001044 H00747-01 Art. no.: 77229002000 2x.&. 77229002000 H00748-01 Insert for crankshaft pressin tool Art. no.: 77229008000 ®B 77229008000 H00750-01 Extrude plate, base Art. no.: 77229009000 & 77229009000 H00751-01 Pliers for valve stem seals Art.
  • Page 296 SPECIAL TOOLS Limit auge Art. no.: 77229026000 77229026000 H00753-01 Insertion for lock Art. no.: 77229030000 77229030000 H00754-01 Protection cap Art. no.: 77229031000 77229031000 H00755-01 Separator plate Art. no.: 77229032000 77229032000 H00756-01 Insert, timing chain tensioner Art. no.: 77229035000 77229035000 H00757-01...
  • Page 297 SPECIAL TOOLS Puller Art. no.: 77229048000 2x.£. 77229048000 H00758-01 Ad"ustment bush brid e Art. no.: 77229050044 2x&.£ 77229050044 H00759-01 Insert for valve sprin lever Art. no.: 77229060000 77229060000 H00760-01 Spark plug wrench Art. no.: 77229172000 77229172000 H00761-01 Oil �ressure ada�ter Art.
  • Page 298 SPECIAL TOOLS Lift stand Art. no.: 81329955000 81329955000 H01015-01 Hook wrench Art. no.: T106S T106S H00841-01 Depth micrometer Art. no.: T107S T107S H00842-01 Art. no.: T120 T120 H00844-01 Mounting sleeve Art. no.: T1204 T1204 H00878-01...
  • Page 299 SPECIAL TOOLS Calibration in Art. no.: T1205 T1205 H00879-01 Pressin tool Art. no.: T1206 & � T1206 H00880-01 Pressin tool Art. no.: T1207S &.& <:))� T1207S H00881-01 Mounting sleeve Art. no.: T1215 T1215 H00886-01 Disassembly tool Art. no.: T1216 T1216 H00887-01...
  • Page 300 SPECIAL TOOLS Vacuum Art. no.: T1240S � T1240S H00890-01 Protectin sleeve Art. no.: T1401 cs)) T1401 H00894-01 Clampin stand Art. no.: T1403S ❖ 2x£ T1403S H00896-01 Mounting tool Art. no.: T14040S � T14040S H00922-01 S�ecial socket Art. no.: T14047 � T14047 H00923-01...
  • Page 301 SPECIAL TOOLS Clam ing stand Art. no.: T14049S 2x£ T14049S H00924-01 Press-out tool Art. no.: T14051 T14051 H00926-01 Press drift Art. no.: T1504 T1504 H00899-01 Assembly tool Art. no.: T150S .&& T150S H00852-01 Nitrogen filling tool Art. no.: T170S1 �! 2x.£3x£...

  • Page 302: Standards

    STANDARDS JASOT903MA Different technical development directions required a separate specification for 4-stroke motorcycles - the JASO T903 MA stan­ dard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 303: Index

    INDEX Chain checking ....... . . 99 'Accessories ....... . . 8 cleaning 'Activated charcoal filter Chain guide...
  • Page 304 INDEX electric starter drive, checking ....168 transmission shafts, installing ....177 freewheel, checking .
  • Page 305 INDEX Foot brake lever Headlight basic position, adjusting light range, adjusting free travel, checking Headlight adjustment checking ....... . 127 Fork legs assembling .
  • Page 306 INDEX Play in throttle cable Speedometer checking - - - - - - ......39 clock, setting kilometers or miles, setting ....Preparing for use service display, setting ..... . after storage ......221 setting ........
  • Page 307 INDEX Winter operation checks and maintenance steps ....220 Wiring diagram ......224-283 page 1 of 6 .
  • Page 308 I 1 1 11 1 11 1 1 1 1 11 1 1 1 111 1 11 1 1 1 1 111 1 11 1 1 11 1 1 1 1 1 1 1 1 1 1 1 1111 1 11 3403018en 07/2016 ® Husqvarna llmi Husqvarna Motorcycles GmbH StallhofnerstraBe 3 5230 Mattighofen Austria fiiiHiAv � LZZa" ·...

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