Husqvarna FC 450 2014 Repair Manual
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Husqvarna FC 450 2014 Repair Manual

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PIONEERING SINCE 1903
REPAIR MANUAL2014
FC 450 EU
®
Husqvarna
Art. no. 3403000en
MOTORCYCLES

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Summary of Contents for Husqvarna FC 450 2014

  • Page 1 PIONEERING SINCE 1903 REPAIR MANUAL2014 FC 450 EU ® Husqvarna Art. no. 3403000en 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 6.32 Changing the steering head bearing ....40 MEANS OF REPRESENTATION ........6 6.33 Adjusting the steering head bearing play ... 41 Symbols used ............6 HANDLEBAR, CONTROLS ..........42 1 .2 Formats used ............6 Handlebar position ..........
  • Page 5 TABLE OF CONTENTS 11.4 Installing the air filter ........... 76 16.4 Adjusting the basic position of the hand brake lever ............111 11.5 Cleaning the air filter and air filter box ....
  • Page 6 TABLE OF CONTENTS 17.4.3 Removing the oil pressure regulator 17.5.12 Installing the shift shaft ........ valve ............. 145 17.5.13 Installing the starter idler gear ...... 17.4.4 Checking spring length of oil pressure 17.5.14 Installing the torque limiter ......regulator valve ..........145 17.5.15 Installing the outer clutch hub ......
  • Page 7 TABLE OF CONTENTS 24.4 Capacities............202 24.4.1 Engine oil ............202 24.4.2 Coolant ............202 24.4.3 Fuel ............... 202 24.5 Chassis ............. 202 24.6 Electrical system ..........203 24. 7 Tires ..............203 24.8 Fork ..............203 24.9 Shock absorber ..........204 24.10 Chassis tightening torques .......

  • 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 right side of the steering head. 401945-10 The type label is fixed to the front of the steering head. 401946-10 The engine number is stamped on the left side of the engine under the engine sprocket.

  • Page 12: Motorcycle

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

  • Page 13: Starting The Motorcycle For A Check

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

  • Page 14: Fork, Triple Clamp

    FORK, TRIPLE CLAMP Ad"ustin in of the fork Info The hydraulic compression damping determines the fork suspension behavior. Turn adjusting screws clockwise all the way. • Info Adjusting screws are located at the top end of the fork legs. Make the same adjustment on both fork legs. Turn counterclockwise by the number of clicks corresponding to the fork type.

  • Page 15: Cleaning The Dust Boots Of The Fork Legs

    FORK, TRIPLE CLAMP Finishing work Remove the motorcycle from the lift stand. (..- p. 10) Cleaning the dust boots of the fork legs Preparatory work Raise the motorcycle with a lift stand. (..- p. 10) Loosen the fork protection. (..- p. 13) Main work Push dust boot downward of both fork legs.

  • Page 16: Removing The Fork Legs

    FORK, TRIPLE CLAMP 6. 7 Removin the fork le s Preparatory work Raise the motorcycle with a lift stand. (.- p. 10) Remove the front wheel. (.- p. 92) Main work Remove screws and take off the clamp. Remove screws and take off the brake caliper.

  • Page 17: Removing The Fork Protector

    FORK, TRIPLE CLAMP rotector Preparatory work Raise the motorcycle with a lift stand. (.,. p. 10) Remove the front wheel. (.,. p. 92) Remove the fork legs. (.,. p. 14) Main work Remove screws on the left fork leg. Lift off the fork protector . Remove the screws on the right fork leg.

  • Page 18: Conducting Minor Fork Service

    FORK, TRIPLE CLAMP Conductin minor fork service Info The steps are identical for both fork legs. Condition The fork legs are disassembled. Disassemble the fork legs. (,..p. 16) Check the fork legs - during a minor fork service. (,..p. 25) Assemble the fork legs.(,..
  • Page 19 FORK, TRIPLE CLAMP Remove the screw. Remove adjuster of the compression damping. 201363-10 Loosen cartridge Ring wrench (T14017) (.- p. 230) • Info The cartridge cannot be taken off yet. Unclamp the fork leg. Push the outer tube down. Drain the fork oil. 201361-10 Clamp the fork leg with the axle clamp.
  • Page 20 FORK, TRIPLE CLAMP Remove the preload spacers and spring. 201359-10 Remove dust boot Remove fork protection ring G). • Info The fork protection ring does not necessarily need to be removed for repair work. Remove lock ring • Info The lock ring has a ground end against which a screwdriver can be posi­ tioned.

  • Page 21: Disassembling The Cartridge

    FORK, TRIPLE CLAMP Disassemblin the cartridge Info The steps are identical for both fork legs. Preparatory work Disassemble the fork legs. (- p. 16) Main work Remove adjusting tube and nut 200835-10 Clamp the cartridge into a vise. • Info Use soft jaws.
  • Page 22 FORK, TRIPLE CLAMP Empty the cartridge. 200840-10 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 @.

  • Page 23: Disassembling The Piston Rod

    FORK, TRIPLE CLAMP Disassemblin iston rod Info The steps are identical for both fork legs. Preparatory work Disassemble the fork legs. (- p. 16) Disassemble the cartridge. (- p. 19) Main work Remove screw sleeve and washer from the piston rod. 200856-10 Degrease the piston rod.

  • Page 24: Disassembling The Screw Cap With The Membrane Holder

    FORK, TRIPLE CLAMP Remove tap rebound Remove spring with the sleeve. Remove the valve with the spring from tap rebound Remove the 0-rings. 200862-10 Disassemblin the screw ca with the membrane holder Info The steps are identical for both fork legs. Preparatory work Disassemble the fork legs.

  • Page 25: Disassembling The Screw Sleeve

    FORK, TRIPLE CLAMP Remove rebound washer Remove compression piston@. Remove 0-ring Remove compression shim stack@). Remove 0-ring G'i). Disassemblin the screw sleeve Info The steps are identical for both fork legs. Preparatory work Disassemble the fork legs. (,... p. 16) Disassemble the cartridge.

  • Page 26: Checking The Fork Legs

    FORK, TRIPLE CLAMP 6.18 Checkin the fork le s Condition The fork legs have been disassembled. Check the inner tube and axle clamp for damage. If there is damage: Change the inner tube. 200728-10 Measure the outside diameter of the inner tube at several locations. Outside diameter of the inner tube 47.975 ...

  • Page 27: Checking The Fork Legs - During A Minor Fork Service

    FORK, TRIPLE CLAMP Check the spring length. Guideline Spring length with preload spacer(s) 490 mm (19.29 in) If the measured value is greater than the specified value: Reduce the thickness of the preload spacers. If the measured value is less than the specified value: Increase the thickness of the preload spacers.

  • Page 28: Changing The Pilot Bushing

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

  • Page 29: Assembling The Screw Sleeve

    FORK, TRIPLE CLAMP Slide the new pilot bushing @ onto the special tool. Mounting tool (T14022) (- p. 231) Ensure that special tool is mounted and that there is an overhang to protect the thread. Guideline Overhang 11 mm (0.04 in) Threaded bushing (T14023) (- p.

  • Page 30: Assembling The Piston Rod

    FORK, TRIPLE CLAMP Grind compression piston on both sides on a surfacing plate using 1200 grit sandpaper. Clean the compression piston. Mount and grease O-ring Lubricant (T158) ( p. 217) Mount the compression piston. Guideline Compression piston from above ViewG 200874-10 Compression piston from below ViewC,...
  • Page 31 FORK, TRIPLE CLAMP Degrease the piston rod. Clamp the piston rod with the special tool. Clamping stand (T14016S) (- p. 230) Mount spring with the sleeve. Mount and tighten tap rebound Guideline Tap rebound M9x1 18 Nm Loctite 2701 ® (13.3 lbf ft) Mount spring Mount compression shim stack...

  • Page 32: Assembling The Cartridge

    FORK, TRIPLE CLAMP Assembling the cartridge Info The steps are identical for both fork legs. Preparatory work Check the fork legs. ( p. 24) ,... Assemble the screw cap with the membrane holder. ( ,... p. 27) Assemble the piston rod. ( p.

  • Page 33: Assembling The Fork Legs

    FORK, TRIPLE CLAMP Mount filling screw with the O-ring. 200845-11 Clamp the cartridge vertically and fill with fork oil to the lower edge of the upper part of the cartridge. Fork oil (SAE 4) (48601166S1) (.- p. 216) ✓ The piston rod is fully extended. Mount the screw cap with the membrane holder and tighten with the special tool.
  • Page 34 FORK, TRIPLE CLAMP Info Always change the dust boot, seal ring, lock ring and support ring. Mount the sealing lip with the spring expander facing downward. Slide on lock ring Lubricate and slide on seal ring Lubricant (T511) ( p. 217) ✓...
  • Page 35 FORK, TRIPLE CLAMP Install dust boot Mount fork protector ring G). Mount the preload spacers and spring. Guideline Spring rate Weight of rider: 65 ... 75 kg (143 ... 4.8 N/mm (27.4 lb/in) 165 lb.) Weight of rider: 75 ... 85 kg (165 ... 5.0 N/mm (28.6 lb/in) 187 lb.) Weight of rider: 85 ...

  • Page 36: Bleeding And Filling The Cartridge

    FORK, TRIPLE CLAMP Lubricate O-ring of the cartridge. Lubricant (T158) ( p. 217) Push the outer tube upward. Clamp the outer tube in the area of the lower triple clamp. Clamping stand (T1403S) ( p. 232) Tighten the cartridge. Guideline Cartridge on the outer tube M51x1.5 50 Nm (36.9 lbf ft)
  • Page 37 FORK, TRIPLE CLAMP Clamp the cartridge as shown in the figure. Guideline Use soft jaws. Info Clamp the cartridge only lightly. The filling port must be located at the highest point. During the filling procedure, the cartridge must be lower than the oil tank of the vacuum pump.

  • Page 38: Filling The Cartridge With Nitrogen

    FORK, TRIPLE CLAMP When the pressure gauge reaches the required value, turn control lever Damper to Vacuum. Guideline 3 bar ✓ The pressure gauge drops to the required value. 0 bar When the pressure gauge reaches the required value, activate the switch.

  • Page 39: Greasing The Steering Head Bearing

    FORK, TRIPLE CLAMP 6.28 Greasing the steering head bearing Remove the lower triple clamp. (- p. 37) � Install the lower triple clamp. (- p. 38) ! � > 800010-10 6.29 Removin the lower tri Preparatory work Raise the motorcycle with a lift stand. (- p. 10) Remove the front wheel.

  • Page 40: Installing The Lower Triple Clamp

    FORK, TRIPLE CLAMP 6.30 Installing the lower tri Main work Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease (,r p. 217) Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

  • Page 41: Checking The Steering Head Bearing Play

    FORK, TRIPLE CLAMP Mount and tighten screw@. Guideline Screw, top steering stem 17 Nm Loctite ® ™ (12.5 lbf ft) Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains. Tighten screws Guideline Screw, top triple clamp 17 Nm (12.5 lbf ft) Secure the wiring harness with cable holder@).

  • Page 42: Changing The Steering Head Bearing

    FORK, TRIPLE CLAMP 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. ('r p. 41) Check the steering head bearing and change if necessary.

  • Page 43: Adjusting The Steering Head Bearing Play

    FORK, TRIPLE CLAMP 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. G01808-10 Finishing work Install the lower triple clamp.

  • Page 44: Handlebar,Controls

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

  • Page 45: Checking The Throttle Cable Routing

    HANDLEBAR,CONTROLS Checkin the throttle cable routin Preparatory work Remove the seat. (.,. p. 79) Remove the fuel tank. (.,. p. 79) Main work 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 bracket.

  • Page 46: Checking The Play In The Throttle Cable

    HANDLEBAR,CONTROLS in the throttle cable Preparatory work Remove the seat. (.- p. 79) Remove the fuel tank. (.- p. 79) Check the throttle cable routing. (.- p. 43) Main work Move the handlebar to the straight-ahead position. Push back sleeves Loosen nut @.

  • Page 47: 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 48: Shock Absorber, Swingarm

    SHOCK ABSORBER, SWINGARM Ad"ustin Caution Danger of accidents Disassembly of pressurized parts can lead to injury. The shock absorber is filled with high density nitrogen. Adhere to the description provided. Info The high-speed setting can be seen during the fast compression of the shock absorber. Turn adjusting screw all the way clockwise with a socket wrench.

  • Page 49: Adjusting The Rebound Damping Of The Shock Absorber

    SHOCK ABSORBER, SWINGARM Ad"ustin the rebound dam in of the shock absorber Caution Disassembly of pressurized parts can lead to injury. Danger of accidents The shock absorber is filled with high density nitrogen. Adhere to the description provided. Turn adjusting screw clockwise up to the last perceptible click.

  • Page 50: Checking The Riding Sag Of The Shock Absorber

    SHOCK ABSORBER, SWINGARM sag of the shock absorber Measure distance of rear wheel unloaded.( p. 47) With another person holding the motorcycle, the rider, wearing full protective clothing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down a few times.

  • Page 51: Adjusting The Riding Sag

    SHOCK ABSORBER, SWINGARM Finishing work Install the shock absorber. (.- p. 50) Install the main silencer. (.- p. 7 4) Install the right side cover. (.- p. 79) Mount the seat. (.- p. 79) Remove the motorcycle from the lift stand. (.- p. 10) Adjusting the riding sag Preparatory work Raise the motorcycle with a lift stand.

  • Page 52: Installing The Shock Absorber

    SHOCK ABSORBER, SWINGARM Press angle lever toward the rear. Press linkage lever downward. Detach springs Spring hook (50305017000) (- p. 220) Remove screw and take off the manifold. Remove screws @ on both sides. Loosen screws on both sides. Remove screw Raise the rear frame slightly and remove the shock absorber toward the top.

  • Page 53: Checking The Shock Absorber Linkage

    SHOCK ABSORBER, SWINGARM Position the rear frame. Mount and tighten screws on both sides. Guideline Screw, subframe 30 Nm Loctite ® 2701 (22.1 lbf ft) Remove screws on both sides. Mount and tighten screws on both sides. Guideline Screw, subframe 30 Nm Loctite 2701...

  • Page 54: Clearance

    SHOCK ABSORBER, SWINGARM Remove screw connection Take off the angle lever. 303096-10 Check needle bearing for damage and wear. If there is damage or wear: Change the needle bearing. Check spacers and @ for damage and wear. If there is damage or wear: Change the spacers.

  • Page 55: 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 make it easier to mount the screw. Position the linkage lever. Mount and tighten fitting @.

  • Page 56: 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) (- p.

  • Page 57: Disassembling The Piston Rod

    SHOCK ABSORBER, SWINGARM Press in seal ring retainer (3 using the special tool. Disassembly tool (T1216) (- p. 229) 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 58: 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 59: 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. 54) Disassemble the damper. ( p. 54) Disassemble the piston rod.

  • Page 60: 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 61: 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) (- p. 229) Remove the second lock ring Place special tool underneath and press out heim joint with special tool@).

  • Page 62: 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. 228) Lubricate the sealing lip of the dust boot. Lubricant (T625) ( p. 217) ,..Mount washer@}.

  • Page 63: Assembling The Piston Rod

    SHOCK ABSORBER, SWINGARM 9.22 Assembling the iston rod Preparatory work Assemble the seal ring retainer. ( p. 60) 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 64: Assembling The Damper

    SHOCK ABSORBER, SWINGARM Mount washer with the collar facing downward. Grease the thread of the piston rod. Lubricant (T152) ( p. 217) 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.
  • Page 65 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 66: 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 67 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 68: 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 69: Installing The Spring

    SHOCK ABSORBER, SWINGARM Open filler tap G). Fill the damper for at least 15 seconds. Guideline Gas pressure 11 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 70: 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. ('r p. 10) Remove the rear wheel.

  • Page 71: 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 72: Changing The Swingarm Bearing

    SHOCK ABSORBER, SWINGARM Position the engine sprocket cover and mount in the holder. Mount and tighten screws Guideline Screw, clutch slave cylinder 10 Nm (7.4 lbf ft) Remaining screws, chassis 25 Nm (18.4 lbf ft) Position the brake caliper and pull it back. Position the brake line in the guide.
  • Page 73 SHOCK ABSORBER, SWINGARM Main work Remove the outer collar bushings G01813-10 Remove bushing G01814-10 Remove shaft seal rings using a suitable tool. Using a suitable tool, press the bearing out from the inside to the outside. Press in the new bearing until it is flush using a suitable tool.
  • Page 74 SHOCK ABSORBER, SWINGARM Press in shaft seal rings Mount bushing(!}. G01814-10 Grease the shaft seal rings. Long-life grease (- p. 217) •- Position collar bushings with the shoulder facing inward. G01819-10 Finishing work Install the swingarm. (- p. 69) Install the rear wheel. (- p. 95) Remove the motorcycle from the lift stand.

  • Page 75: Exhaust

    EXHAUST Detach springs Spring hook (50305017000) (- p. 220) Remove screw @ . Take off manifold. Position the manifold. Mount screw but do not tighten yet. Guideline Screw, manifold holder 1 15 Nm (11.1 lbf ft) Attach springs @ . Spring hook (50305017000) (- p.

  • Page 76: Removing The Main Silencer

    EXHAUST 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. Do not touch hot components. Preparatory work Remove the right side cover. (.- p. 78) Main work Disconnect spring Remove screws...
  • Page 77 EXHAUST Main work Remove all screws on the main silencer. and O-ring @ . Take off silencer cap Take off outer tube and O-ring off of inner tube (D . Pull glass fiber yarn filling Clean the parts that need to be reinstalled and check for damage. on inner tube (D .

  • Page 78: 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 lid and tab Engage the air filter box lid in areas f) and G). Engage tab 11.3 Removin the air filter...

  • Page 79: Cleaning The Air Filter And Air Filter Box

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

  • Page 80: Fuel Tank, Seat, Trim

    FUEL TANK, SEAT, TRIM 12.1 0 ening the filler ca Danger Fire hazard Fuel is highly flammable. Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. The fuel in the fuel tank expands when warm and may emerge if overfilled.

  • Page 81: 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) Remove screws Lift up the seat at the rear, pull it back and then remove it from above. Mountin the seat Hook in the front of the seat at the collar bushing of the fuel tank, lower it at the rear and simultaneously it push forward.

  • Page 82: Installing The Fuel Tank

    FUEL TANK, SEAT, TRIM Main work Unplug connector of the fuel pump. Remove the tube from the fuel tank breather. Thoroughly clean plug-in connection of the fuel line using compressed air. • Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve.

  • Page 83: Checking The Fuel Pressure

    FUEL TANK, SEAT, TRIM Warning Fuel is poisonous and a health hazard. Danger of poisoning Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water.

  • Page 84: Changing The Fuel Pump

    FUEL TANK, SEAT, TRIM Press on the small metal plate and disconnect fuel hose connection Info Remaining fuel may flow out of the fuel hose. Mount special tool @. Pressure tester (61029094000) (- p. 223) Mount special tool with nozzle label 0,60.
  • Page 85 FUEL TANK, SEAT, TRIM Warning Improper handling of fuel is a danger to the environment. Environmental hazard Do not allow fuel to get into the ground water, the ground, or the sewage system. Preparatory work Drain the fuel from the fuel tank into a suitable container. Remove the seat.

  • Page 86: Changing The Fuel Filter

    FUEL TANK, SEAT, TRIM Mount and tighten screws Guideline Screw, fuel pump EJOT I 3 Nm (2.2 lbf ft) Finishing work Install the fuel tank. (,... p. 80) Mount the seat. (,... p. 79) 12.11 Chan in the fuel filter Danger Fuel is highly flammable.
  • Page 87 FUEL TANK, SEAT, TRIM Pull out the fuel pump. Remove hose clamps Remove fuel filter Press locking mechanism (D. Pull back fuel pump housing 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) (,...

  • Page 88: Changing The Fuel Screen

    FUEL TANK, SEAT, TRIM Position the fuel pump. Mount fuel connection fj with the gasket but do not tighten yet. Mount and tighten nut with the gasket. Guideline Nut, fuel pump fastener M12x1.75 15 Nm (11.1 lbf ft) Tighten fuel connection fj. Guideline Fuel connection on fuel tank M8x1 .25...
  • Page 89 FUEL TANK, SEAT, TRIM Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. When running the engine, always make sure there is sufficient ventila­ tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 90: Mask, Fender

    MASK, FENDER 13.1 Removin the front fender Preparatory work Remove the start number plate. (.- p. 88) Main work Remove screws and @. Remove the front fender. Main work Position the front fender. Mount and tighten screws and @. Guideline Remaining screws, chassis 110Nm(7.41bf ft) Finishing work...

  • Page 91: Installing The Start Number Plate

    MASK, FENDER Installing the start number late 13.4 Position the start number plate. Mount and tighten screw Guideline Remaining screws, chassis 110 Nm (7.4 lbf ft) ✓ The holding lugs engage. Position brake line in the brake line guide.

  • Page 92: Wheels

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

  • Page 93: Checking The Spoke Tension

    WHEELS Check the thickness of the front and rear brake discs at multiple points on each brake disc to ensure it is at least thickness f). • Info Wear reduces the thickness of the brake disc around the area used by the brake linings.

  • Page 94: Front Wheel

    WHEELS 14.5 Front wheel Removing the front wheel 14.5.1 Preparatory work Raise the motorcycle with a lift stand. (- p. 10) Main work Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. •...

  • Page 95: Removing The Brake Disc Of The Front Brake

    WHEELS Check the wheel bearing for damage and wear. If the wheel bearing is damaged or worn: Change the front wheel bearing. (,r- p. 93) Clean and grease the shaft seal rings and contact surface of the spacers. Long-life grease (,r- p. 217) Insert the spacers.
  • Page 96 WHEELS Main work Remove shaft seal rings and @. Press out bearing (D using a suitable tool. • Info Spacing tube can be pushed aside. Remove the spacing tube. Press out bearing using a suitable tool. Press in the new bearing all the way using a suitable tool.

  • Page 97: Rear Wheel

    WHEELS 14.6 Rear wheel Removing the rear wheel 14.6.1 Preparatory work Raise the motorcycle with a lift stand. (- p. 10) Main work Press the brake caliper onto the brake disc by hand in order to push back the brake piston. •...

  • Page 98: Removing The Brake Disc Of The Rear Brake

    WHEELS Position the rear wheel and insert wheel spindle ✓ The brake linings are correctly positioned. Put the chain on. Position chain adjuster (D. Mount nut but do not tighten it yet. Make sure that chain adjusters (D are fitted correctly on adjusting screws Check the chain tension.

  • Page 99: Checking The Chain Tension

    WHEELS Checking the chain tension 14.6.5 Warning Danger caused by incorrect chain tension. Danger of accidents If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bearings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause the chain or the countershaft of the transmission to break in extreme cases.

  • Page 100: Adjusting The Chain Guide

    WHEELS Info The wide adjustment range of the chain adjusters (32 mm (1 .18 in)) enables different secondary ratios with the same chain length. Chain adjusters can be turned by 180 ° Finishing work Remove the motorcycle from the lift stand. (..- p. 10) 14.6.7 Adjusting the chain guide Loosen screw...
  • Page 101 WHEELS Pull at the top part of the chain with the specified weight 6). Guideline 110 ... 15 kg (22 ... 33 lb.) Weight, chain wear measurement Measure distance G) of 18 chain rollers on the lower chain section. Info •...

  • Page 102: Checking For Chain Dirt Accumulation

    WHEELS Check the chain guide for wear. • Info The wear can be found 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 103: Changing The Drivetrain Kit

    WHEELS Main work Clean the chain regularly and then treat with chain spray. Offroad chain spray( p. 217) ,..400725-01 Finishing work Remove the motorcycle from the lift stand. ( p. 10) ,..14.6.11 Changing the drivetrain kit Preparatory work Raise the motorcycle with a lift stand.

  • Page 104: Changing The Rear Wheel Bearing

    WHEELS Remove screw connections (D. Remove the rear sprocket. Position the new rear sprocket. Mount and tighten fittings. Guideline Nut, rear sprocket screw 35 Nm Loctite ® 2701 (25.8 lbf ft) Slide the new engine sprocket onto the countershaft. Mount the new chain. Connect the chain with connecting link Have an assistant operate the rear brake.
  • Page 105 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 the new bearing all the way in from the outside to the inside.

  • Page 106: Finishing Work - Install The Rear Wheel

    WHEELS Grease the new shaft seal ring and press it in until it is flush. Mount lock ring@. ✓ The lock ring engages audibly. Grease the new shaft seal ring and press it in until it is flush. Finishing work Install the rear wheel.

  • Page 107: Wiring Harness, Battery

    WIRING HARNESS, BATTERY Changing the main fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. Use only fuses with the prescribed amperage. Never 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 108: Installing The Battery

    WIRING HARNESS, BATTERY Main work Position the battery in the battery compartment with the terminals facing forward. Battery (YTX5L-BS) Reconnect rubber band • Info Contact disk must be mounted between screw and cable lug with the claws facing down. Position the positive cable and mount and tighten the screw. Guideline Screw, battery terminal 2.5 Nm...

  • Page 109: Checking The Capacitor

    WIRING HARNESS, BATTERY Main work Disconnect the negative cable from the battery. Measure the current between battery ground (-) and the negative cable. • Info The value of the quiescent current applies only to vehicles in the original state, i.e. without additional power consumers. Maximum quiescent current <...
  • Page 110 WIRING HARNESS, BATTERY Connect the starter relay to a 12 V power supply as shown. Measure the resistance between the specified points. Resistance of open circuit 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 on the starter relay.

  • Page 111: Brake System

    BRAKE SYSTEM Checkin the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. Change worn brake linings immediately. Check the brake linings for minimum thickness 6). <'= 1 mm (<'= 0.04 in) Minimum thickness 6) If the minimum thickness is less than specified: Change the front brake linings.

  • Page 112: Checking The Free Travel Of The Hand Brake Lever

    BRAKE SYSTEM Manually press the brake caliper to the brake disc to push back the brake pistons. Ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suction if it does. Info • Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes.

  • Page 113: Brake Lever

    BRAKE SYSTEM Push the hand brake lever forward and check free travel Free travel of hand brake lever 2:: 3 mm (2:: 0.12 in) If the free travel does not meet specifications: Adjust the basic position of the hand brake lever. (r p. 111) 16.4 Adjusting the basic �osition of the hand brake lever Preparatory work...

  • Page 114: Adding Front Brake Fluid

    BRAKE SYSTEM Adding front brake fluid Warning Danger of accidents Brake system failure. If the brake fluid level drops below the specified marking or the specified value, this is an indication that the brake sys­ tem is leaking or that the brake linings are completely worn down. Check the brake system and do not continue riding. Warning Skin irritation Brake fluid can cause skin irritation on contact.

  • Page 115: Changing The Front Brake Fluid

    BRAKE SYSTEM Changing the front brake fluid Warning Skin irritation Brake fluid can cause skin irritation on contact. Avoid contact with skin and eyes, and keep out of the reach of children. Wear suitable protective clothing and goggles. If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 116: Checking The Rear Brake Linings

    BRAKE SYSTEM Open the bleeder screw again until brake fluid stops emerging. • Info This prevents overfilling of the brake fluid reservoir. Tighten the bleeder screw. Remove the hose of the bleeder bottle. Mount the pro­ tection cap. Lock the bleeding device. Remove the bleeder cover. Add brake fluid to level (9.
  • Page 117 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 118: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM Checkin the free travel of foot brake lever Warning Danger of accidents Brake system failure. If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to overheating.

  • Page 119: Adding Rear Brake Fluid

    BRAKE SYSTEM Preparatory work Check the rear brake linings. (,..p. 114) Main work Stand the vehicle upright. Check the brake fluid level in the viewer lf the brake fluid level drops below marking f): Add rear brake fluid. (,..p. 117) Adding rear brake fluid Warning Brake system failure.

  • Page 120: Changing The Rear Brake Fluid

    BRAKE SYSTEM Changing the rear brake fluid Warning Skin irritation Brake fluid can cause skin irritation on contact. Avoid contact with skin and eyes, and keep out of the reach of children. Wear suitable protective clothing and goggles. If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 121 BRAKE SYSTEM Open the bleeder screw again until brake fluid stops emerging. • Info This prevents overfilling of the brake fluid reservoir. Tighten the bleeder screw. Remove the hose of the bleeder bottle. Mount the pro­ tection cap. Lock the bleeding device. Remove the bleeder cover. Stand the vehicle upright.

  • Page 122: Engine

    ENGINE 17.1 Removin the engine Preparatory work Raise the motorcycle with a lift stand. (.- p. 10) Drain the coolant. (.- p. 188) Remove the seat. (.- p. 79) Remove the fuel tank. (.- p. 79) Remove the right side cover. (.- p. 78) Remove the main silencer.(.- p.
  • Page 123 ENGINE C&. Remove screw Release screws Repeat the operation on the opposite side. Lift the subframe. Push back hose clamp Detach the vent hose. Swing up the subframe and secure it. Remove screw Swing back the shock absorber and twist it slightly. Remove springs Spring hook (50305017000) (or p.
  • Page 124 ENGINE Loosen hose clips Remove the radiator hose. Pull back the protection cap. Remove nut Qi). Remove screw Remove screw Ci). Take off the engine sprocket cover. Remove screws •. Remove the cable binders. Remove cable holder �. Take off the clutch slave cylinder and hang it to the side. •...
  • Page 125 ENGINE Remove screw �. Take off the shift lever. Pull back the protection cap. Unplug connector�- Pull off the spark plug connector@,. Loosen hose clip �- Pull the throttle valve body toward the rear out of the intake flange and hang it to one side.

  • Page 126: Installing The Engine

    ENGINE Remove screws �. Lift out the engine from the side. • Info You should have an assistant for this step. Make sure that the motorcycle is sufficiently secured against falling over. Protect the frame and attachments from damage. Main work Position the engine in the frame.
  • Page 127 ENGINE Position the engine braces. Mount and tighten screws Guideline 33 Nm (24.3 lbf ft) Screw, engine brace Mount vent hose. Position the throttle valve body. Tighten hose clip Plug in connector (3 . Position the protection cap. Mount the spark plug connector @ . Position the shift lever.
  • Page 128 ENGINE Position the engine sprocket cover. Mount and tighten screw 41). Guideline Screw, clutch slave cylinder 10 Nm (7.4 lbf ft) 4D . Mount and tighten screw Guideline Remaining screws, chassis 25 Nm (18.4 lbf ft) Position the positive cable on the starter motor. 48 .
  • Page 129 ENGINE Mount springs �. Spring hook (50305017000) (r p. 220) Tighten screw G). Guideline Screw, manifold holder 15 Nm (11.1 lbf ft) Position the shock absorber. Mount and tighten screw �- Guideline Screw, top shock 60 Nm Loctite 2701 ® (44.3 lbf ft) absorber Remove the fixation and lower the subframe.
  • Page 130 79) Remove the motorcycle from the lift stand. ( p. 10) Refill the coolant. ( p. 189) Execute the initialization run. ( p. 198) Take a short test ride. Read out the fault memory using the Husqvarna Motorcycles diagnostics tool.

  • Page 131: Engine Disassembly

    ENGINE Check the engine for leakage. Check the engine oil level. (or p. 190) Check the coolant level. (or p. 188) 17.3 En ine disassembly 17.3.1 Preparations Mount the special tool on the engine assembly stand. Engine fixing arm (78029002000) (or p. 225) Engine assembly stand (61229001000) (or p.

  • Page 132: Removing The Clutch Push Rod

    ENGINE Removing the clutch push rod 17.3.3 Remove clutch push rod 17.3.4 Removing the oil filter Remove screws Remove the oil filter cover with the O-ring. Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) (or p. 220) 17.3.5 Removing the starter motor Remove screws...

  • Page 133: Removing The Valve Cover

    ENGINE 17.3.7 Removing the valve cover Remove screws Take off the valve cover with the valve cover seal. 17.3.8 Removing the alternator cover Remove screws Take off the alternator cover. Remove locating pins Take off the alternator cover gasket 17.3.9 Positioning the engine at ignition top dead center Align camshaft marking with marking...

  • Page 134: Removing The Timing Chain Tensioner

    ENGINE Screw in special tool Locking screw (113080802) ('r p. 219) 17.3.10 Removing the timing chain tensioner Remove screw with the washer and spring. Remove screws Take off the chain adjuster with the gasket. 17.3.11 Removing the camshaft Remove screw Remove the camshaft support plate@.

  • Page 135: Removing The Cylinder Head

    ENGINE 17 .3.12 Removing the cylinder head Remove screw Unscrew screws in a crisscross pattern and remove. Remove the cylinder head. Take off dowels@). Remove cylinder head gasket 17 .3.13 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.

  • Page 136: Removing The Rotor

    ENGINE 17 .3.14 Removing the rotor Remove nut with the spring washer. Mount special tool @ on the rotor. Extractor (58012009000) (,... p. 221) Hold it tight using the special tool and pull off the rotor by turning the screw in. Remove the woodruff key.

  • Page 137: Removing The Ignition Pulse Generator

    ENGINE 17.3.16 Removing the ignition pulse generator Remove screws Pull the cable sleeve out of the engine case. Take off the crankshaft position sensor. 17.3.17 Removing the suction pump Remove screws Take off oil pump cover of the suction pump. Remove external rotor @ and internal rotor Take off pin Remove pin...

  • Page 138: Removing The Clutch Cover

    ENGINE 17 .3.19 Removing the clutch cover Remove screws Take off the clutch cover. • Info If work is to be performed on the water pump, unscrew the nut of the water pump impeller. Remove dowels @ . Take off clutch cover gasket (s) . 17 .3.20 Removing the clutch discs Remove screws...

  • Page 139: Removing The Outer Clutch Hub

    ENGINE Take off pressure cap Completely remove clutch disc pack (D. Remove clutch pressure piece@. Remove special tool (D. Locking screw (113080802) ( p. 219) ,..17 .3.21 Removing the outer clutch hub Lock the outer clutch hub and primary gear using special tool Gear segment (80029004000) ( ,..

  • Page 140: Removing The Torque Limiter

    ENGINE Take off both needle bearings @ and collar bushing 17.3.22 Removing the torque limiter Remove screw with the washer. Take off the torque limiter. 17 .3.23 Removing the starter idler gear Remove the lock ring and washer. Take off starter idler gear 17 .3.24 Removing the shift shaft �...

  • Page 141: Removing The Locking Lever

    ENGINE 17.3.26 Removing the locking lever Unscrew and remove together with locking lever washer, sleeve and spring. 17.3.27 Removing the force pump Remove lock ring Take off washer Remove oil pump idler gear (D. Remove lock washer Take off washer Take off oil pump gear wheel 0).

  • Page 142: Removing The Primary Gear

    ENGINE Remove internal rotor� and external rotor Remove the pin. Push oil pump shaft inward and take it out of the engine from the ignition side. 17 .3.28 Removing the primary gear Insert special tool in the crankshaft. Protection cap (75029090000) (.- p. 224) Install special tool @.

  • Page 143: Removing The Shift Rails

    ENGINE Take off the left section of the engine case. Remove spacer Remove dowels 17 .3.31 Removing the shift rails Remove shift rails together with upper springs and lower springs. 17 .3.32 Removing the shift drum Swing shift forks to one side. •...

  • Page 144: Removing The Transmission Shafts

    ENGINE 17.3.34 Removing the transmission shafts Remove O-ring Position the engine upright. Remove lock ring Pull both transmission shafts out of the bearing seats together. Info Make sure not to misplace the washers. 17.3.35 Removing the crankshaft Attach the special tool to the crankshaft. Protection cap (75029090000) ( p.
  • Page 145 ENGINE Main work Remove all remaining dowels. Remove oil nozzles Remove the bearing retainer of main shaft bearing (D, of countershaft bear­ and of shift drum bearing@». Remove any sealing mass remnants and clean the engine case section thoroughly. Warm the engine case section in an oven. Guideline (302 °F) Knock the engine case section against a level wooden plate.

  • Page 146: Work On The Left Section Of The Engine Case

    ENGINE Blow compressed air through all oil channels and check that they are clear. Finishing work Install the oil pressure regulator valve. (,... p. 146) 17.4.2 Work on the left section of the engine case Remove all remaining dowels. Remove screw Remove oil spray tube@.

  • Page 147: Removing The Oil Pressure Regulator Valve

    ENGINE Press the shaft seal ring @ of the crankshaft from the outside to the inside with the open side facing out. • Info The shaft seal ring must be flush on the outside. Press in the shaft seal ring of the countershaft and shaft seal ring of the shift shaft with the open side facing inward until it is flush.

  • Page 148: Installing The Oil Pressure Regulator Valve

    ENGINE Main work Measure the spring length of the oil pressure regulator valve. Oil pressure regulator valve Minimum length of preload spring 24.5 mm (0.965 in) If the measured value does not meet specifications: Change the spring. 306115-10 Finishing work Install the oil pressure regulator valve.

  • Page 149: Installing The Water Pump

    ENGINE Remove shaft seal ring Press out water pump bearing toward the inside with an appropriate tool. Info Provide suitable support for the clutch cover while pressing out. 17.4.8 Installing the water pump Press water pump shaft bearing in until it is flush using the appropriate tool. Info Support the clutch cover sufficiently when pressing in.

  • Page 150: Removing The Timing Chain Sprocket

    ENGINE Mount water pump impeller Mount and tighten nut (D. Guideline Nut, water-pump wheel Loctite ® ™ (5.9 lbf ft) 17.4.9 Removing the timing chain sprocket Warm up the timing chain sprocket with a blow-dryer. Pull off the timing chain sprocket with the special tool. Puller, 2-arm (60029033000) (- p.
  • Page 151 ENGINE Place the crank web onto special tool Insert for crankshaft pressing tool (78929008000) (r p. 226) Info The special tool must be positioned with the flat surface facing downward. Press the new crank pin all the way in. ✓ Oil channel is aligned with oil channel G).

  • Page 152: Checking Crankshaft Run-Out At Bearing Pin

    ENGINE 17.4.12 Checking crankshaft run-out at 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 on bearing pin :5 0.04 mm (:5 0.0016 in) If the crankshaft run-out at the bearing pin is larger than the specification: Align the crankshaft.

  • Page 153: Checking/Measuring The Piston

    ENGINE 17.4.15 Checking/measuring the piston Check the piston sliding surface for damage. If the piston sliding surface is damaged: Replace the piston and, if necessary, the cylinder. Check that the piston rings move easily in the piston ring grooves. If the piston ring is stiff: Clean the piston ring groove.

  • Page 154: Measuring The Piston/Cylinder Mounting

    ENGINE 17.4.17 Measuring the piston/cylinder mounting clearance Check/measure the cylinder. ( p. 150) Check/measure the piston. ( p. 151) The smallest piston/cylinder mounting clearance equals the smallest cylinder bore diameter minus the largest piston diameter. The largest piston/cylinder mount- ing clearance equals the largest cylinder bore diameter minus the smallest piston diameter.

  • Page 155: Assembling The Autodecompressor

    ENGINE Pull autodecompression shaft out of the camshaft. 304674-10 Release and remove autodecompression spring Info e� Autodecompression weight cannot be taken off. 304675-10 17.4.20 Assembling the autodecompressor Insert long flange of the autodecompression spring in the hole, push the autodecompression spring over bearing bolt @ and hook it into autodecompression weight Mount autodecompression shaft in the camshaft.

  • Page 156: Checking Camshaft

    ENGINE 17.4.21 Checking camshaft Check the camshaft for damage and wear. If there is damage or wear: Change the camshaft. If the camshaft surface is damaged, check the oil supply of the camshaft and the rocker arm. Measure the cams of the camshaft. Camshaft - cam height Exhaust 33.10 ...

  • Page 157: Removing The Rocker Arm

    ENGINE Replace the timing chain. 17 .4.23 Removing the rocker arm Remove screws of the rocker arm shafts. Remove plugs with the O-rings. 306606-10 Screw appropriate screw into the rocker arm shafts. Pull out rocker arm shafts Take off rocker arm (D. 306607-10 17 .4.24 Removing the valves...

  • Page 158: Changing Camshaft Bearing

    ENGINE 17.4.25 Changing camshaft bearing Mount the cylinder head. Clamping plate (75029050000) ( p. 224) Remove the large camshaft bearing using the special tool. Push-out drift (75029051000) ( p. 224) Remove the small camshaft bearing using the special tool. Bearing puller (15112017000) ( p.

  • Page 159: Checking Valve Springs

    ENGINE Check sealing seat on the valve. Valve Intake sealing seat width 2.00 mm (0.0787 in) Valve Exhaust sealing seat width 2.00 mm (0.0787 in) If the sealing area is not in the center of the valve seat or deviates from the specified value: Rework the valve seat.

  • Page 160: Checking The Rocker Arm Shafts

    ENGINE Using a straightedge and the special tool, check the sealing area of the cylinder for distortion. Feeler gauge (590290411 00) (or p. 222) Cylinder/cylinder head - sealing area :5 0.10 mm (:5 0.0039 in) distortion If the measured value does not meet specifications: Change the cylinder head.

  • Page 161: Installing The Rocker Arm

    ENGINE Mount the valve keys. • Info When mounting the valve keys, check that they are seated correctly; preferably, fix the valve keys to the valve with a little grease. Place shims into the valve spring retainers according to the installation position. 17.4.32 Installing the rocker arm Position rocker arm...

  • Page 162: Checking The Clutch

    ENGINE 17.4.33 Checking the clutch 304690-10 Check pressure piece for damage and wear. If there is damage or wear: Change the pressure piece. Place push rod on a level surface and check for run-out. If there is run-out: Change the push rod. Check spring retainer for damage and wear.

  • Page 163: Checking The Shift Mechanism

    ENGINE Change the needle bearings and collar bushing. Check the intermediate clutch discs for damage and wear. If the intermediate clutch discs are not level and have pittings: Change all intermediate clutch discs. Check clutch facing discs for discoloration and scoring. If there is discoloration or scoring: Change all clutch facing discs.

  • Page 164: Preassembling The Shift Shaft

    ENGINE Check shift rails on a flat surface for run-out. If there is run-out: Change the shift rail. Check the shift rails for scoring, seizure marks, and stiffness in the shift fork. If the shift rail has scoring, seizure marks, or does not move easily in the shift fork: Change the shift rail.

  • Page 165: Disassembling The Main Shaft

    ENGINE 17.4.36 Disassembling the main shaft 306610-10 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 lock ring Remove needle bearing and distance sleeve@). Remove 3rd/4th-gear sliding gear (D.

  • Page 166: Checking The Transmission

    ENGINE Remove stop disk and 1st-gear idler gear Remove needle bearing and stop disk Remove 5th-gear sliding gear and lock ring 0). Remove stop disk@ and 3rd-gear idler gear@. Remove needle bearing and 4th-gear idler gear Gi). Remove needle bearing and stop disk Remove lock ring�...

  • Page 167: Assembling The Main Shaft

    ENGINE Change the gear wheel pair. Check sliding gear for smooth operation in the profile of main shaft @}. If the sliding gear does not move freely: Change the sliding gear or the main shaft. Check shift collar for damage and wear. If there is damage or wear: Change the shift collar.

  • Page 168: Assembling The Countershaft

    ENGINE Mount lock ring Mount 2nd-gear fixed gear with the collar facing downward and stop disk �. Finally, check all gear wheels for smooth operation. 17.4.40 Assembling the countershaft • Info Use new lock rings with every repair. Preparatory work Carefully grease all parts before assembling.

  • Page 169: Checking The Starter Drive

    ENGINE 17.4.41 Checking the starter drive 304688-10 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 170: Removing The Freewheel

    ENGINE 17 .4.43 Removing the freewheel Press expansion ring together with suitable pliers and take off. 304703-10 Take the freewheel @ out of the primary gear. 304704-10 17.4.44 Installing the freewheel Thoroughly oil all parts. Push the freewheel into the primary gear. Info Note the direction of rotation.

  • Page 171: Engine Assembly

    ENGINE 17.5 Engine assembl 17.5.1 Installing the crankshaft Tighten the right section of the engine case in the engine assembly stand. Heat the crankshaft bearing. Guideline (176 °F) Info • Do not damage the seal ring. Mount the special tool on the clutch end of the crankshaft. Mounting sleeve (78029005100) (�...

  • Page 172: Installing The Shift Drum

    ENGINE 17.5.4 Installing the shift drum Push shift drum into the bearing seat. Put shift forks in the shift drum. Info Do not misplace the shift rollers. 17.5.5 Installing the shift rails Install shift rails together with upper springs and lower springs. Info Fix the springs in the shift rails with grease.

  • Page 173: Installing The Freewheel Gear

    ENGINE Guideline Screw, engine case M6x75 1 10 Nm (7.4 lbf ft) Mount screw but do not tighten yet. Guideline Screw, engine case M6x80 1 10 Nm (7.4 lbf ft) Mount screw and tighten all screws in a crisscross pattern. Guideline Screw, engine case M6x85...

  • Page 174: Installing The Locking Lever

    ENGINE Position oil pump cover ✓ The marking faces up. Mount and tighten screws Guideline Screw, pressure pump 10 Nm Loctite ® ™ cover (7.4 lbf ft) Insert pin (D. Position oil pump gear wheel@. fD . Position washers Mount lock washer@). Mount oil pump idler gear Gi).

  • Page 175: Installing The Shift Drum Locating Unit

    ENGINE 17.5.11 Installing the shift drum locating unit Push away locking lever from the shift drum locating unit and position the shift drum locating unit • Info The flat areas of the shift drum locating unit are not symmetric. Relieve tension from the locking lever. Mount and tighten screw Guideline Screw, shift drum locating...

  • Page 176: Installing The Clutch Discs

    ENGINE Slide the outer clutch hub onto the gearbox main shaft. Turn oil pump gear wheel until the gear teeth of the clutch basket engage. Slide on washer and inner clutch hub (D. Position the new lock washer and mount nut @. Tighten the nut, holding the inner clutch hub with a special tool.
  • Page 177 ENGINE Position pressure cap Mount pretension ring with the Top marking facing up. Position spring washer Position spring retainer with the I marking. Install the screws and tighten them diagonally. Guideline Screw, clutch spring retainer I 6 Nm (4.4 lbf ft)

  • Page 178: Installing The Clutch Cover

    ENGINE Using a straightedge and the special tool, check the spring washer for distortion. Feeler gauge (590290411 00) (- p. 222) Spring washer distortion 0 ... 0.10 mm (0 ... 0.0039 in) If the specified value is not reached: Remove screws (3 and mount spring retainer with marking II. Using a straightedge and the special tool, check the spring washer for distortion.

  • Page 179: Installing The Water Pump Cover

    ENGINE 17.5.18 Installing the water pump cover Put the water pump cover seal in place. Mount the water pump cover. Mount screw with the sealing washer but to not tighten yet. Guideline Screw, water pump cover M6x25 10 Nm (7.4 lbf ft) Mount screw but do not tighten yet.

  • Page 180: Installing The Timing Chain

    ENGINE 17.5.21 Installing the timing chain Thread in the timing chain and place it over the timing chain sprocket. • Info If the timing chain was used before, ensure it is running in the correct direction. Position the timing chain securing guide. Mount and tighten screws Guideline Loctite...
  • Page 181 ENGINE Tap lightly on the piston ring mounting tool from above with a plastic hammer so that it lies flush with the cylinder. ✓ The special tool must press the piston rings together properly and lie flush with the cylinder. Carefully tap the piston into the cylinder using the handle of the hammer.

  • Page 182: Installing The Cylinder Head

    ENGINE Position the piston pin retainer. Insert the special tool and press it forcefully to the piston. Turn the special tool counterclockwise, thereby pushing the piston pin retainer into the groove. Insertion tool for piston ring lock (77329030100) (or p. 225) Ensure that the piston pin retainer is seated properly on both sides.

  • Page 183: Installing The Camshaft

    ENGINE Put the cylinder head in place. Mount screws with the washers and tighten them in a crisscross pattern. Guideline Screw, cylinder head M10x1 .25 Step 1 Lubricated with engine oil 10 Nm (7.4 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 50 Nm...

  • Page 184: Checking The Valve Clearance

    ENGINE Position the timing chain tensioner with the gasket. Mount and tighten screws Guideline Screw, timing chain tensioner 10 Nm (7.4 lbf ft) Mount and tighten screw plug with washer and spring Guideline Plug, timing chain tensioner I 8 Nm (5.9 lbf ft) 17.5.27 Checking the valve clearance Remove special tool...

  • Page 185: Installing The Alternator Cover

    ENGINE Raise rocker arm on the outside. Remove shims and set down in the position in which they were installed. Correct the shims according to the findings from checking the valve clearance. Insert suitab le shims. Install the camsha ft.( p.

  • Page 186: Installing The Starter Motor

    ENGINE Installing the starter motor 17.5.32 Grease the O-ring. Mount the starter motor. Mount and tighten screws Guideline Screw, starter motor 1 10 Nm (7.4 lbf ft) 17.5.33 Installing the oil filter Tilt the motorcycle to one side and fill the oil filter housing to about 1 /3 full with engine oil.

  • Page 187: Removing The Engine From The Engine

    ENGINE Place the long oil screen with the 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 188: Clutch

    CLUTCH Checkin /correctin the fluid level of the h draulic clutch Info The fluid level rises with increasing wear of the clutch facing discs. Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. Remove screws Remove cover with membrane Check the fluid level.

  • Page 189: Water Pump, Cooling System

    WATER PUMP, COOLING SYSTEM Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 190: Checking The Coolant Level

    WATER PUMP, COOLING SYSTEM Checkin the coolant level Warning During motorcycle operation, the coolant gets very hot and is under pressure. Danger of scalding Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 191: Refilling Coolant

    WATER PUMP, COOLING SYSTEM Refilling coolant Warning Coolant is poisonous and a health hazard. Danger of poisoning Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swallowed, contact a physician immediately.

  • Page 192: Lubrication System

    LUBRICATION SYSTEM 20.1 Oil circuit 401628-60 Oil screen Force pump Oil pressure regulator valve Oil filter Oil nozzle for conrod bearing lubrication Oil nozzle, piston cooling Oil nozzle for cam follower lubrication Suction pump Oil channel, transmission lubrication 20.2 ine oil level Condition The engine is at operating temperature.

  • Page 193: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens

    LUBRICATION SYSTEM Changing the engine oil and oil filter, cleaning the oil screens Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 194 LUBRICATION SYSTEM Place the long oil screen with the O-rings onto a pin wrench. Insert the pin wrench through the drill hole of the screw plug and into the engine case on the opposite side. Push the oil screen all the way into the engine case. Mount and tighten screw plug with the O-ring.

  • Page 195: Adding Engine Oil

    LUBRICATION SYSTEM Danger Exhaust gases are toxic and inhaling them may Danger of poisoning result in unconsciousness and/or death. When running the engine, always make sure there is sufficient ventila­ tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.
  • Page 196 LUBRICATION SYSTEM Danger Exhaust gases are toxic and inhaling them may Danger of poisoning result in unconsciousness and/or death. When running the engine, always make sure there is sufficient ventila­ tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 197: Ignition System

    IGNITION SYSTEM 21.1 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 198: Removing The Stator

    IGNITION SYSTEM 21.4 Removin the stator Condition The alternator cover has been removed. Remove screw and take off the cable holder. Remove cable support sleeve from the alternator case. Remove screws Take the stator out of the alternator cover. 306639-10 21.5 Installing the stator Position the stator in the alternator cover.

  • Page 199: Electric Starter

    ELECTRIC ST ARTER 22.1 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 with connector of the starter motor.

  • Page 200: Throttle Valve Body

    THROTTLE VALVE BODY 23.1 Ad"ustin the idle s eed Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.
  • Page 201 THROTTLE VALVE BODY As soon as the specified temperature is reached, switch off the ignition. • Info If the initialization is not completed or the initialization process is inter­ rupted, the entire process must be restarted.

  • Page 202: Technical Data

    TECHNICAL DATA 24.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 449.3 cm (27.418 cu in) Stroke 63.4 mm (2.496 in) Bore 95 mm (3.74 in) Compression ratio 12.6:1 2,250 ... 2,350 rpm Idle speed Control OHC, 4 valves controlled via rocker arm Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust...

  • Page 203: Engine Tightening Torques

    TECHNICAL DATA Piston/cylinder - mounting clearance Size I 0.040 ... 0.082 mm (0.00157 ... 0.00323 in) Size II 0.043 ... 0.085 mm (0.00169 ... 0.00335 in) Wear limit 0.120 mm (0.00472 in) Piston ring end gap Compression ring s; 1.00 mm (s; 0.0394 in) Oil scraper ring s;...

  • Page 204: Capacities

    TECHNICAL DATA Plug, oil channel 9 Nm (6.6 lbf ft) ® Loctite ™ Screw, rocker arm bearing 15 Nm (11.1 lbf ft) Plug, timing chain tensioner 8 Nm (5.9 lbf ft) Screw plug, crankshaft location 10 Nm (7.4 lbf ft) Plug, oil channel 15 Nm (11.1 lbf ft) ®...

  • Page 205: Electrical System

    Rear tires 80/100 - 21 M/C 51M TT 110/90 - 19 62M TT Dunlop GEOMAX MX 51 FA Dunlop GEOMAX MX 51 Additional information is available in the Service section under: www.husqvarna-motorcycles.com 24.8 Fork Fork part number 14.18. 7N.59 Fork...

  • Page 206: Shock Absorber

    TECHNICAL DATA 24.9 Shock absorber Shock absorber part number 18.15.7N.57 Shock absorber 5018 BAVP DCC WP Suspension Compression damping, low-speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping, high-speed Comfort 2.5 turns Standard 2 turns Sport 1.5 turns Rebound damping Comfort 17 clicks...
  • Page 207 TECHNICAL DATA 15 Nm (11.1 lbf ft) Screw, chain sliding piece Screw, engine brace 33 Nm (24.3 lbf ft) Screw, fork stub 15 Nm (11.1 lbf ft) ® Screw, front brake caliper 25 Nm (18.4 lbf ft) Loctite ™ Screw, handlebar clamp 20 Nm (14.8 lbf ft) Screw, subframe 30 Nm (22.1 lbf ft)

  • Page 208: Cleaning/Protective Treatment

    CLEANING/PROTECTIVE TREATMENT 25.1 Cleanin the motorc cle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts.

  • Page 209: Storage

    Store the vehicle in a dry location that is not subject to large fluctuations in tem­ perature. • Info Husqvarna Motorcycles recommends raising the motorcycle. Raise the motorcycle with a lift stand. (..- p. 10) Cover the vehicle with a tarp or similar cover that is permeable to air. Info •...

  • Page 210: Service Schedule

    Final check: Check the vehicle for safe operation 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 211: Service Work (As Additional Order)

    SERVICE SCHEDULE • Periodic interval 27.2 Service work {as additional order) Annually Every 100 operating hours - corresponds to about 700 liters of fuel (185 US gal) Every 50 operating hours - corresponds to about 350 liters of fuel (92.5 US gal) Every 40 operating hours - corresponds to about 280 liters of fuel (74 US gal) Once after 20 operating hours •...
  • Page 212 � " "" -© l� -X16 ,� 1 { " � � • X7 l . x 19 ls� FC/2 'i BR/4 EB/4 � S /2 - C 10 -S21 -M10 � s, -TI0nt1@·� • ·<WB L:n-J·G10� �1 - 1 �1AP/6 -X295 E - 1 , ,!:!,...

  • Page 213: Wiring Diagram

    WIRING DIAGRAM Components: A 11 EFI control unit Capacitor Battery Alternator Starter relay with main fuse Power relay Starter motor Voltage regulator Electric starter button X295 Diagnostics connector...
  • Page 214 . . . , I ('II � � ('II "" � -© w, , � / 3 .A1 � "' loma � "' -X16 -X16 -X16 -X16 -X16 -X16 � � i � � � � l � � 11 .. j-xs .,, ru �"...
  • Page 215 WIRING DIAGRAM Components: A 11 EFI control unit Fuel pump Injection valve (cylinder 1) warning lamp (MIL) CAN bus terminating resistor Kill switch X295 Diagnostics connector...
  • Page 216 . . . , "" •1DTI� iDTI� �• -© ' " ' '� '� l� -X16 -X16 -X16 -X16 -X16 -X16 -X16 -X16 -X16 -X16 ---l . , ,,, � iome ° ° ° ,,or ,� � � " � % { 1 ·...
  • Page 217 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 (optional) Cable colors:...

  • Page 218: 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 quality coolant with corrosion inhibitor for aluminum motors (even in countries with high temperatures).

  • Page 219: 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 220 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 221: 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 Locking screw Art. no.: 113080802 113080802 H00944-01 Bearing �uller Art. no.: 15112017000 15112017000 H00520-01...
  • Page 222 SPECIAL TOOLS Internal bearing uller Art. no.: 15112018100 Feature 1 18 ... 23 mm (0.71 ... 0.91 in) 15112018100 H00522-01 Tachometer Art. no.: 45129075000 45129075000 H00525-01 Sprin hook Art. no.: 50305017000 50305017000 H00973-01 Bleed syringe Art. no.: 50329050000 50329050000 H00565-01 Circli�...
  • Page 223 SPECIAL TOOLS Clutch holder Art. no.: 51129003000 51129003000 H00575-01 Extractor Art. no.: 58012009000 58012009000 H00592-01 Torque wrench with various accessories in set Art. no.: 58429094000 58429094000 H00606-01 Valve spring mounter Art. no.: 59029019000 59029019000 H00610-01 Limit �lug gauge Art. no.: 59029026006 59029026006 H00612-01...
  • Page 224 SPECIAL TOOLS Feeler gauge Art. no.: 59029041100 59029041100 H00616-01 tool Art. no.: 60029015000 60029015000 H00628-01 Puller, 2-arm Art. no.: 60029033000 2x.£. 60029033000 H00633-01 Hose clamp pliers Art. no.: 60029057000 60029057000 H00650-01 Testing hose Art. no.: 61029093000 61029093000 H00659-01...
  • Page 225 SPECIAL TOOLS Pressure tester Art. no.: 61029094000 4x £ 61029094000 H00660-01 En ine assembl stand Art. no.: 61229001000 61229001000 H00662-01 Extractor Art. no.: 75029021000 75029021000 H00707-01 Push-in drift Art. no.: 75029044010 75029044010 H00712-01 Push-in drift Art. no.: 75029044020 75029044020 H00713-01...
  • Page 226 SPECIAL TOOLS Pressin tool for crankshaft, com lete Art. no.: 75029047000 75029047000 H00714-01 Clam late Art. no.: 75029050000 75029050000 H00719-01 Push-out drift Art. no.: 75029051000 �<ij 75029051000 H00721-01 Protection cap Art. no.: 75029090000 75029090000 H00726-01 Oil �ressure ada�ter Art. no.: 75029094000 �...
  • Page 227 SPECIAL TOOLS Insert for valve s lever Art. no.: 77029041 000 77029041000 H00744-01 Art. no.: 77229172000 77229172000 H00761-01 Insertion tool for piston rin lock Art. no.: 77329030100 77329030100 H00768-01 Engine fixing arm Art. no.: 78029002000 78029002000 H00783-01 Mounting sleeve Art. no.: 78029005100 78029005100 H00785-01...
  • Page 228 SPECIAL TOOLS Removal tool Art. no.: 78029049100 2x.£. 78029049100 H00794-01 Fixin drift Art. no.: 78129032000 78129032000 H00796-01 Insert for crankshaft pressin tool Art. no.: 78929008000 78929008000 H01016-01 Separator plate Art. no.: 78929009000 78929009000 H00799-01 Gear segment Art. no.: 80029004000 80029004000 H00813-01...
  • Page 229 SPECIAL TOOLS Lift stand Art. no.: 81329955000 81329955000 H01015-01 Mountin sleeve Art. no.: 90129005000 90129005000 H00816-01 Case separatin tool Art. no.: 90129048000 90129048000 H00827-01 Pin wrench Art. no.: T103 T103 H00838-01 Hook wrench Art. no.: T106S T106S H00841-01...
  • Page 230 SPECIAL TOOLS De th micrometer Art. no.: T107S T107S H00842-01 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...
  • Page 231 SPECIAL TOOLS Pressin tool Art. no.: T1207S T1207S H00881-01 Mountin sleeve Art. no.: T1215 T1215 H00886-01 Disassembly tool Art. no.: T1216 T1216 H00887-01 Vacuum pump Art. no.: T1240S T1240S H00890-01 Protecting sleeve Art. no.: T1401 cs)) T1401 H00894-01...
  • Page 232 SPECIAL TOOLS Clam ing stand Art. no.: T14016S T14016S H01036-01 Rin wrench Art. no.: T14017 T14017 H00904-01 tool Art. no.: T14019 T14019 H00906-01 Support tool Art. no.: T14020 T14020 H00907-01 Calibrating unit Art. no.: T14021 T14021 H00908-01...
  • Page 233 SPECIAL TOOLS Mounting tool Art. no.: T14022 T14022 H00909-01 Threaded bushin Art. no.: T14023 T14023 H00911-01 Mountin sleeve Art. no.: T14029 T14029 H00917-01 Filling adapter Art. no.: T14030 T14030 H00918-01 Tweezers Art. no.: T14033 T14033 H00921-01...
  • Page 234 SPECIAL TOOLS Clam ing stand Art. no.: T1403S ❖ 2x£. T1403S H00896-01 Mountin tool Art. no.: T14040S � T14040S H00922-01 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 235: Standards

    STANDARDS JASOT903MA Different technical development directions required a new specification for 4-stroke motorcycles - the JASO T903 MA Standard. 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, high performance at high engine speeds are in the foreground for motorcycle engines.

  • Page 236: Index

    INDEX cleaning Chain guide 'Accessories ....... . . 8 adjusting ....... . . 98 'Air filter checking .
  • Page 237 INDEX main shaft, assembling ..... . 165 transmission shafts, installing ....169 main shaft, disassembling .
  • Page 238 INDEX free travel, checking free travel, checking ......110 Fork legs Handlebar position ......assembling .
  • Page 239 INDEX ........8 Spare parts Spark plug connector Rear sprocket checking ....... . 195 checking .
  • Page 240 INDEX Wiring diagram ......210-215 p a g e 1 of 3 ......210 p a g e 2 of 3 .
  • Page 241 I 1 1 11 1 11 1 1 1 1 11 1 1 1 111 1 11 1 1 1 1 111 1 1 111 1 1 111 1 1 1 1 1 1 1 1 1 II I I II 3403000en 08/2015 ® Husqvarna Husqvarna Motorcycles GmbH StallhofnerstraBe 3 5230 Mattighofen Austria Photo: Mitterbauer, www.husqvarna-motorcycles.com MOTORCYCLES...

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