a PIONEERING SINCE 1903 REPAIR MANUAL 2015 FC 350 EU by At. no. 8408015en Husqvarna’ MOTORCYCLESINTRODUCTION 1 ead this repair manual carefully and thoroughly before beginning work, The vehicle will only be able to meet the demands placed on itf the specified service work is performed regularly and property This repair manual was written to correspond to the latest state of this model series. We reserve the right to make changes in the interest of technical advancement without updating this repair manual at the same time, We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here. Its assumed that the repair work will be performed by a fully trained mechanic. All specifications are non-binding. Husqvama Motorcycles GmbH specifically reserves the right to modify or delete technical speci- fications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to ‘adapt these to local conditions, as well as to stop production of a particular model without prior notice. Husqvarna accepts no ia- 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 (©2016 Husqvama Motorcycles GmbH, Mattighofen Austria Allrights reserved Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright osn1:2 000 TOV defined in the ISO 9001 international quality management standard, Issued by: TUV Management Service 3403015en 042018,TABLE OF CONTENTS 1 MEANS OF REPRESENTATION.. 6 1.1 Symbols used 6 1.2 — Formats used. 6 2 SAFETY ADVICE. 7 2.1 Repair Manual 7 22 Safety advice... 7 23 Degrees of risk and symbols... 7 2.4 Work rule... 7 3 IMPORTANT NOTES. 8 3.1 Manufacturer and implied warranty. 8 32 Operating and auxiliary substances 8 3.3 Spare parts, accessories. 8 34 Figures... 8 4 SERIAL NUMBERS... 9 4.1 Chassis number. 9 42 Typelabel.... 9 43° Engine number... 9 4.4 Fork part number 9 45 Shock absorber part number... 5 MOTORCYCLE.... 5.1. Raising the motorcycle with te it stand. 5.2 Removing the motorcycle from the lft stand. 53 Starting... o 5.4 Starting the motoreycle fora check. 6 FORK, TRIPLE CLAMP 6.1 Adjusting the compression damping of the fork 12 62 Adjusting the rebound damping of the fork win 12 63 Bleeding the fork legs. 12 6.4 Cleaning the dust boots of the fork leg neuen 13 65 Removing the fork legs, a3 66 Installing the fork lags.. snonnnonvne V4 6.7 Removing the fork protector. 4 6.8 Installing the fork protector. 69 Performing a fork service. 6.10 Disassembling the fork legs. 6.11 Removing the spring 6.12 Disassembling the cartridge. 6.13 Disassembling the cartridge. 6.14 Disassembling the piston rod... 6.15 Disassembling the hydrostop unit, 6.16 Disassembling the seal ring retainer. 22 6.17 Checking the fork 1698 nen 6.18 Assembling the seal ring retainer. 6.19 Assembling the hydrostop unit. 6.20 Assembling the piston rod. 621 Assembling the cartridge. 6.22 Assembling the fork legs 6.23 Greasing the steering head bearing, 31 6.24 Removing the lower triple clamp, 6.25 Installing the lower triple clamp 6.26 Checking the steering head bearing play. 6.27 Changing the steering head bearing 6.28 Adjusting the steering head bearing play... 7 HANDLEBAR, CONTROLS. 7.1 Handlebar position... 7.2 Adjusting the handlebar position 7.3 Adjusting the basic postion of the clutch lever 36 10 " 2 7.4 Checking the throttle cable routing 7.5 Checking the play inthe throtle cable 7.6 Adjusting the play in the throttle cable FRAME 8.1 Checking the fram a ‘SHOCK ABSORBER, SWINGARM, 40 9.1 Adjusting the high-speed compression damping of the shock absorber. 40 9.2 Adjusting the low-speed compression damping of the shock absorber. 40 88 Adjusting ne rebound damping ofthe sock ADSOFDET nen 9.4 Measuring rear whee! sag unloaded... 85 Checking the static sag of the shock absorber. a 9.6 Checking the riding sag ofthe shock 0507 nnn 9.7 Adjusting the spring preload ofthe shock 0S0FDE ns . 9.8 Adjusting the riding sag 43 9.9 Removing the shock absorber. 43 9.10. Instling the shock absorberanuncenennnne 4 8.11 Checking the shock absorber inkage unin 45 9.12 Servicing the shock abs01b0F nnn ar 9.43 Removing the 8prng...rnsnssnnnnns 4B 9.14 Disassembling the damper eon 48 8.18 Disassembling the piston rod 49 9.16 Disassembling the seal rng retainer om 50 9.17 Changing the pilot bushing 3 9.18 Checking the damper 52 9.49 Removing the heim joint 52 9.20 Installing the heim jot .nnnnsnnnnnanans 5B 9.21 Assembling the seal ring retainer. 54 9.22 Assembling the piston rod 55 9.23 Assembling the damper.. sn 58 9.24 Bleeding and filing the damper 58 9.25 Filing the damper with nitrogen ummm 60 9.26 Installing the sori 9.27 Checking the swingarm. 9.28 Removing the swingarm 9.29 _Instaling the swingarm. : 9.30 Changing the swingarm bearing 6a EXHAUST er 10.1 Removing the manifold sontnan OT 10.2 _ Instaling the manifold er 10.3 Removing the main sence. nnn 68 10.4 Installing the main silent. = 68 10.5 Changing the glass fiber yar filing ofthe main SENET en Eeecieneueetne 6) AIR FILTER.. eer 0) 11.4 Removing the ater box i 70 11.2 _Instaling the ai filter box id 11.3 Removing the air fier. 11.4 Installing the air fier. 11.5 Cleaning the air fiter and ar fter box. m 11.6 _ Sealing the air fter box... FUEL TANK, SEAT, TRIM. 12.1. Opening the filer cap. 12.2. Closing the filler cap. os 12.3 Removing the right side coverTABLE OF CONTENTS 12.4 _ Installing the right side cover 12.5 Removing the seat.. 12.6 Mounting the seat 12.7 Removing the fuel tank 12.8 Installing the fuel tank. 12.9 Checking the fuel pressure. 12.10 Changing the fuel pump... 42.14 Changing the fue filter. 12.12 Changing the fuel screen. 13. MASK, FENDER 18.1. Removing the front fender. 13.2 _ Installing the front fender. 18.3 Removing the start number plate. 18.4 _ Installing the start number plate. 14 WHEELS, o 14.1. Checking the tire air pressure. 14.2 Checking the tire condition. 143. Checking the brake discs. 14.4 Checking spoke tension 145 Front wheel... 14.5.1 Removing the front whee! 14.5.2 Installing the front wheel 14.5.3 Removing the brake disc of the front brake 14.5.4 Installing the brake disc of the front brake. 14.5.5 Changing the front whee! bearing. 146 Rear wheel 14.6.1 Removing the rear wheel... 146.2 Installing the rear wheel... 14.6.3 Removing the brake disc of the rear brake. 14.6.4 _Instaling the brake disc of the rear brake.. 14.6.5 Checking the chain tension.. 14.6.6 Adjusting the chain tension... 14.8.7 Checking the chain, rear sprocket, engine sprocket, and chain guide, 14.6.8 Checking for chain dirt accumulation. 146.9 Cleaning the chain. 146.10 Changing the erivetrain kit. 146.11 Changing the rear wheel bearing 15 WIRING HARNESS, BATTERY.. 15.1. Changing the main fuse... 16.2 Removing the battery. 15.3 _ Installing the battery 15.4 Recharging the battery. 15.5 Checking the charging voltage. 16. Checking the open-circuit current 15.7 Checking the capacitor. 15.8 Checking the starter relay. 16 BRAKE SYSTEM 16.1 Checking the front brake linings. 16.2 Changing the front brake linings, 16.3 Checking the free travel of the hand brake lever 16.4 Adjusting the basic position of the hand brake lever 16.5 Checking the brake fluid level of the front brake, 16.6 Adding front brake tluid 16.7 Changing the front brake fu. 16.8 Checking the rear brake linings. 82 87 87 90 100 101 101 102 . 103 . 103 103 104 105 105 106 107 108 7 3 16.9 Changing the rear brake linings. 108 16.10 Checking th free travel of foot brake lever... 110, 16.11 Adjusting the basic position of the foot brake lever sens 110 16.12 Checking the rear brake id lve. Th 16.13. Adding rear brake fluid 11 16.14 Changing the rear brake fd. 12 ENGINE 115 17.1. Removing the engine. 115 17.2 _ Installing the engine.. 120 17.3 Engine disassembly. 125 17.3.1 Preparations. 125 17.3.2 Removing the clutch push rod. 126 17.3.3. Removing the spacer 126 17.3.4 Draining the engine oll... 126 17.35 Removing the oil itr... 127 17.8.6 Removing the spark plug 127 17.3.7 Removing the valve cover 127 17.3.8 Removing the starter motor 128 17.3.3 Positioning the engine at ignition top dead center: snes 128 17.8.10 Removing the timing chain tensioner 129 17.3.1 Removing the camshaft 129 17.312 Removing the cylinder head. 130 17.38.13 Removing the piston . 130 17.3.14 Removing the rotor... 131 17.315 Removing the starter dtive... sonnes 134 17.3.16 Removing the suction PUMP srs 131 17.3.17 Removing the water pump wheel 192 17.318 Removing the clutch cover... 193 17.38.19 Removing the clutch discs. 133, 17.3.20 Removing the outer clutch hub. 133 17.3.21 Removing the shift shat..eurn 134 173.22 Removing the shitt drum locating unit... 134 17.38.23 Removing the lacking lever 134 17.3.24 Removing the force pump, 134 17.3.25 Removing the primary gear 138 17.3.28 Removing the timing chain. 135 17.3.27 Removing the spacer 196 173.28 Removing the let section ofthe engine case. snes 186 17.329 Removing the shit rls. . 187 17.3.30 Removing the shift drum. 137 17.3.31 Removing the shift forks sonnes 197 17.3.32 Removing the transmission shafts wecanue 137 17.3.33 Removing the crankshaft 138 17.4 Working on individual parts 138 17.4.1 Work on the right section of the engine case. 198 17.42 Work onthe left section ofthe engine case. snes 189 17.43 Work on the clutch cover 140 17.44 Checking the ol pressure regulator valve... 141 17.4.5 Checking the lubrication system... 142 17.4.6 Removing the crankshaft bearing inner race 17.7 Changing the connecting 103, conros bearing, and crank pin 143, 17.48 Checking the crankshaft run-out atthe bearing pin 144TABLE OF CONTENTS 17.49 17.4.10 17.441 17.412 17.413 17.414 174.15 17.4.16 174.17 17.4.18 17.4.19 17.4.20 17.4.21 17.422 17.4.23 17.4.24 17.4.25 17.4.26 17.427 17.4.28 17.4.29 17.4.0 17.431 17.4.2 17.433 17.434 17.4.35 17.4.36 17.437 17.4.38 17.4.39 17.440 17.481 175 1754 17.52 1753 175.4 1755 17.58 17.5.7 17.5.8 17.59 175.10 175.11 175.12 175.13 175.14 175.15 175.16 175.17 175.18 175.19 Instaling the crankshaft bearing inner race... . Measuring the crankshaft end play. Removing the drive wheel of the balancer shaft. Instaling the dive winee of the balancer shat o Cylinder - Nikasi coating CChecking/measuring the cylinder. CChecking/measuring the piston Measuring the piston/cylinder mounting clearance... Checking the piston ring end aap. Changing the camshaft bearing... Checking the camshafts, Checking the pivot points of the camshafts. ' Removing the valves. Checking the valves Checking the valve springs. Checking the valve spring seat. Checking the cam levers. Checking the oylinder head. Instaling the valves: Checking the freewheel Removing the freewheel. Instaling the freewheel Checking the electric starter drive (Checking the timing assembly Preparing the timing chain tensioner for instalation Checking the clutch .. (Checking the shift mechanism. Preassembling the shift shaft Disassembling the main shaft Disassembling the countershatt. Checking the transmission... Assembling the main shatt.. ‘Assembling the countershatt.. Engine assembly Instaling the crankshatt.. Instaling the transmission shafts Instaling the shift forks Instaling the shift drum: Instaling the shift rails. Instaling the let engine case..... Instaling the spacer ones Instaling the timing chain... Instaling the primary gear. Installing the force pump. Instaling the suction pump Instaling the locking lever. Instaling the shift drum locating unit Instaling the shift shaft Instaling the outer clutch hub. Installing the clutch dises. Instaling the clutch cover Instaling the water pump cover Instaling the starter drive. - 182 182 - 164 . 164 167 144 145 145 146 146 146 147 147 148 148 149 149 150 151 . 181 181 152 153 . 154 154 185 - 186 . 187 187 159 160 . 160 161 161 162 163 165 165 165 166 168 167 167 168 168 169 169 170 170 171 171 172 172 18 19 a 22 23 17-520 _Intlng the rtor an igniton pulse generator... : 17.5.21 Installing the piston. 175.22 Installing the cyinder head. 175.23 _Instaling the camshafts. 175.24 Checking the valve timing... 17.5.25 Adjusting the valve timing 17.5.26 Installing the timing chain tensioner. 17.5.27 Checking the valve clearance... 17.5.28 Adjusting the valve clearance. 17.5.29 Installing the starter motor 175.30 _ Installing the valve cover 17.5.31 Installing the spark plug. 17.5.2 _Instaling the ol fiter. 175.33 Installing the oll screen... 17.5.34 Installing the spacer. 175.35 Installing the clutch push rod. 17598 Removing to engine rom te engine assembly SAN ern ‘CLUTCH 18.1 Checking/correcting the fluid level of the hydraulic clutch 18.2 Changing the hydraulic clutch fluid WATER PUMP, COOLING SYSTEM 19.1. Cooling system.. 18.2 Checking the antiteeze and coolant level 19.3 Checking the coolant level. 19.4 Draining the coolant. 19.5 Refiling coolant. LUBRICATION SYSTEM. 20.1 Oil circuit 20.2 Checking the engine oil level 20.3 Changing the engine oil and oi fiter, ‘leaning the oil screen 20.4 Adding engine oil 20.5 Checking the engine oil pressure. IGNITION SYSTEM, 21.1 Ignition col- checking the secondary winding, — 21.2. Checking the spark plug connector... 21.3 Alterator - checking stator winding, 21.4 Removing the stator and ignition pulse ‘generator. 21.5 Installing the stator and ignition pulse GENEBLOT enn = ‘THROTTLE VALVE BODY... 22.1 Adjusting the idle speed... 22.2 Executing the initialization run.. TECHNICAL DATA 23.1 Engine... 23.2 Engine tolerance, wear ims. 23.3 Engine tightening torques 23.4 Capacities. 23.4.1 Engine oil 23.4.2 Coolant. 2343 Fuel. 23.5 Chassis 23.6 Electrical system. 23.7 Tires. 238 Fork. 173 175 173 176 176 176 178 178 179 179 180 181 181 182 182 183 183 184 184 . 184 186 186 186 187 187 188 189 189 . 189 120 192 192 194 194 104 194 195 195 196 196 - 196 197 197 197 198 199 199 199 199 200 200 200 201TABLE OF CONTENTS 23.9. Shock absorber - 201 28.10 Chassis tightening torques... 202 24 CLEANING. 203 24.1 Cleaning the motorcycle 203, 25. STORAGE. . ns se 208 25.1 Storage 204 25.2 Preparing for use after storage. sens 204 26 SERVICE SCHEDULE. 205 261 Service SCHEdUIE nnn none 205 26.2 Service work (as additional order) 208 27 WIRING DIAGRAM o . . 208 27.1 Page 1 of. 208 272 Page 2of5. 210 273 Page 3 of 3. 212 28 SUBSTANCES. rcsnnnonn 214 29 AUXILIARY SUBSTANCES.. moe 215 30 SPECIAL TOOLS. 217 31 STANDARDS... . 230 INDEX 2311 MEANS OF REPRESENTATION 6 Aa Symbols 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 tip. » Indicates the result ofa testing step. wi Denotes a voltage measurement. ry Denotes a current measurement. o Denotes a resistance measurement. ‘The typographical formats used in this document are explained below. Proprietary name Identifies a proprietary name. Name® Identifies a protected name. Brand™ Identifies a trademark, Underlined terms Refer to technical details of the vehicle or indicate technical terms, which are explained in the glossary.2 SAFETY ADVICE 7 2A RepairManual 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. ‘Anumber of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety instructions are highlighted in the text and are referred to at the relevant passages. Info The vehicle has various information and warning labels at prominent locations. Do not remove information/warring labels. I they are missing, you or others may not recognize dangers and may therefore be injured. Danger Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken, Warning Indicates a danger that is likely to lead to fatal or Serious injury f the appropriate measures are not taken. Caution Indicates a danger that may lead to minor injuries if the appropriate measures are not taken, Note Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken. Warning Indicates a danger that will lead to environmental damage if the appropriate measures are not taken. ‘Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in parentheses. E.g.: bearing puller (15112017000) During assembly, non-reusable parts (@.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced by new parts. In some instances, a thread locker (e.g. Lectite®) is required. The manufacturer instructions for use must be followed. After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts. ‘After you complete the repair or service work, check the operating safety of the vehicle.3 IMPORTANT NOTES ° The work prescribed in the service schedule must be cartied 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; otherwise, all warranty claims will be void. No warranty claims can be considered for damage or secondary damage resulting from modifications and/or alterations to the vehicle. ‘Additional information on the manufacturer or implied warranty and the procedures involved can be found in the service & warranty booklet. Warning Environmental hazard Improper handling of fuel is a danger to the environment. = Donnot allow fuel to enter the groundwater, the soll, or the sewage system, Use the operating and auxiliary substances (such as fuel and lubricants) as specified in the manual Only use spare parts and accessories approved and/or recommended by Husqvama, Husqvarna accepts no labiliy for other prod- ucts and any resulting damage or loss. ‘The current Husky Power parts for your vehicle can be found on the Husqvarna website. Intemational Husqvarna Motorcycles website: wwrw.husqvatna-motorcycles.com “The figures contained in the manual may depict special equipment. In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to disassemble the component to perform the activity in question, Please follow the instructions in the text.4 SERIAL NUMBERS ° ‘The chassis number @ Is stamped onthe right sie ofthe steering head. ‘The type label @ is fixed to the front of the steering head. ‘The engine number @ is stamped on the left side of the engine under the engine sprocket. “The fork part cumber @ is stamped onthe inside of the axle clam, ‘The shock absorber part number @ is stamped on the top of the shock absorber ‘above the adjusting ring on the engine side,5 MOTORCYCLE 10 54 Raising the motorcycle with the liftstand 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. ‘7 Neither wheel is in contact with the ground, = Secure the motorcycle against falling over. Lift stand (64829055000) (= p. 219) 401082-01 Note Danger of damage The parked vehicle can roll away or fall over. = Park the vehicle on a firm and level surface. = Remove the motorcycle from the lft stand, = Remove the lit stand, in stand @ into the left side of the wheel - ria ¢ Info D) mov te pin stand to ing ZX ad 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. Note Engine damage High rewing speed with a cold engine negatively impacts the lifespan of the engine. = Always run the engine warm at a low speed. = Remove plug-in stand @ = Shit gear to neutral Condition “Ambient temperature: < 20°C (< 68 °F) = Pullthe cold start button out al he way.5 MOTORCYCLE " Press the electric starter button Info I Press the electric starter button for at most 5 seconds. Wait for a least 5 seconds before trying again. FI warning lamp lights up briefly as a functional control when starting. 4o07a0-01 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 gine in an enclosed space. © Info I Press tne starter for a maximum of 5 seconds. Wait for atleast 5 seconds before trying again. = Shift the trangmission to idle. Press the electric starter button ©. Info T vo not open the throttle, 4o07a0-016 FORK, TRIPLE CLAMP 2 Info The hycrautic compression damping determines the fork suspension behavior. — Tum the white adjusting screw @ all the way clockwise. Info T Adjusting screw @ is located atthe upper end ofthe left fork leg. ‘The compression damping is located in the left fork leg COMP (white adjusting screw). The rebound damping is located in the right fork eg REB. (ted adjusting screw) = Turn counterclockwise by the number of clicks corresponding to the fork type. Guideline ‘Compression damping ‘Comfort 17 clicks ‘Standard 15 clicks ‘Sport 15 clicks Info T_Tum clockwise to increase damping; tum counterclockwise to reduce damping. Info The hydraulic rebound damping determines the fork suspension behavior. = Turn the red adjusting screw @ all the way clockwise. Info TAcdjusting screw @ is located at the upper end ofthe right fork leg, ‘The rebound damping is located in the right fork leg REB (red adjusting screw). The compression damping is located in the left fork leg COMP (white adjusting screw). = Turn counterclockwise by the number of clicks corresponding to the fork type. Guideline Rebound damping ‘Comfort 17 clicks Standard 15 clicks ‘Sport 49 clicks Info I Turn clockwise to increase damping: turn counterclockwise to reduce damping. Preparatory work = Raise the motorcycte with the lift stand. (“* p. 10)6 FORK, TRIPLE CLAMP 13 Main work = Release bleeder screws @. 7 Any excess pressure escapes from the interior of he fork. = Tighten th bleeder screws. 19 work = Remove the motorcycle from the lft stand. (™ p. 10) Preparatory work = Raise the motoroycle with the lift stand. (= p. 10) = Remove the fork protector. (= p. 14) Main work = Push dust boot @ dovinward on both fork legs. Info T The dust boots remove dust and coarse ditt particles from the inside fork tubes. Overtime, dirt can penetrate behind the dust boots If this dit is not removed, the oil seals behind can stat to leak. ‘Warning a Noce4e-10 Danger of accidents Oil or grease on the brake discs reduces the brak- ing effect. = Always keep the brake disos free of oll and grease. — Clean the brake discs with brake cleaner when necessary. Clean and oll the dust boots and inner fork tube of both fork legs. Universal oll spray (= p. 216) Press the dust boots back into their normal position. = Remove excess oil. Finishing work = Install the fork protector. (= p. 18) = Remove the motorcycle from the lft stand. (= p. 10) Preparatory work = Raise the motorcycle with the lift stand. (—* p. 10) = Remove the front wheel. (° p. 85) Main work ~ Remove screws @ and take off the clamp. 7 ~ Remove screws @ and take off the brake caliper. = Allow the brake caliper and brake line to hang tension-free to the side, Info y i) To not pul the hand brake lever ifthe front wheel has been removed. on24@-106 FORK, TRIPLE CLAMP 4 oo2s-18 ~ Loosen serens @. Takeout the et ork eg = Unsorew screws @. Take out the ight fork leg. Main work = Position the fork leg Bleeder screws @ face forward. © Info ‘The rebound damping is located in the right fork leg (red adjusting screw). ‘The compression damping is located in the left fork leg (white adjusting screw). Grooves are milled into the side of the upper end of the fork legs. The sec- ‘ond milled groove (from the top) must be flush with the top edge of the upper triple clamp. = Tighton scrows @. Guidatine Screw, top triple clamp MB 17 Nm (12.5 Ibf ft) = Tighten screws @. Guideine ‘Screw, bottom triple clamp MB 12 Nm (8.9 If ft) = Position the brake caliper. Mount and tighten screws @. Guideline Monese-13 Screw, front brake caliper [Ma 25Nm Loctite® 243 (18.4 tot) ~ Position the brake tine and clamp. Mount and tighten serews @. Finishing work = Install the front wheel. (© p. 86) = Remove serews @) on te let fork log and take ofthe clamp. ~ Remove screws @) onthe let fork leg anc takeoff the et fork protector. ~ Remove screws @ on te right fork leg and take ofthe ight ork protector.6 FORK, TRIPLE CLAMP 18 = Position the eft fork protector. Mount and tighten screws Guideline Remaining screws, chassis Me 10 Nm (7.4 IoF ft) ~ Position the brake line and clamp. Mount and tighten screws @) ~ Position the right fork protector. Mount and tighten screws @ Guideline Remaining screws, chassis M6 10.Nm (7.4 Ibf ft) Condition ‘The fork legs have been removed. = Disassemble the fork legs. (= p. 15) = Remove the spring, (= p. 17) = Disassemble the cartridge. (-* p. 18) Disassemble the piston rod, (°* p. 20) = Disassemble the hydrostop unit. (-* p. 21) = Disassemble the seal ring retainer. (-* p. 22) = Check the fork legs. (© p. 22) : S| — Assemble the seal rng retainer. (2 p. 23) : eS | ssomoe neyaetpunt (2 p28) i 28 ' S| = ASsoniine tna." ».25 : S| Assemble the cartridge. (0p. 26) a | = Assemble the fork legs. ("" p. 27) 2 oe ee ¢ Info ‘The steps are identical for both fork legs. 201690-10 Condition The fork legs are disassembled. = Note down the curtent state of rebound damping @) REB (ed adjuster of ight fork leg). ~ Note down the cutent stat of compression damping @) COMP (white adjuster of left fork leg). — Fully open the adjusters of the rebound and compression damping.6 FORK, TRIPLE CLAMP 16 201700-10 ft ff :201705-10 = Clamp the fork leg in the area of the lower triple clamp. Clamping stand (174035) ("= p. 227) = Remove the screw. Remove aduster @. = Release screw cap @ ‘Special socket (114047) (1) p. 228) Info “The cartridge cannot be taken off yet = Unclamp the fork leg. = Push the outer tube down. Drain the fork cil = Clamp the fork leg with the axle clamp. = Release hydrostop unit @ and remove it. Info Do not use an impact wrench. lace a pan undemeath since oil wll run out. = Remove the cartridge from the fork leg. Press-out tool (174051) (= p. 228) Info TRemoving the O-ring seat from the cartridge usually requires the applica tion of force. = Remove dust boot @. = Remove fork protection ring @. ¢ Info ‘The fork protection ring does not necessarly need to be removed for repair work6 FORK, TRIPLE CLAMP 7 201706-10 e © 2017010 26 = Remove lock ring @. Info I the lock ring has @ ground end against which a screwdriver can be post tioned. = Warm the outer tube in area @ ofthe lower siding bushing. Guideline 50 °C (122 °F) = Pull the outer tube forceful off of the inner tube, Info T the tower stsing bushing @ must be pulled out of its bearing seat. = Remove the upper sliding bushing @. Info: To not use a too: pull the ends apart slightly by hand. = Take off the lower sliding bushing @. ~ Take off support ring @. ~ Take off seal ring @. = Take off oct ring @. - Take off dust boot @. = _Unclamp the fork leg w 20v700-0 Info Tho stops are identical for both fork logs. Preparatory work = Disassemble the fork legs. (© p. 15) Main work \ 2ov720-14 = Pull the spring down. Mount the open end wrench on the hexagonal part.6 FORK, TRIPLE CLAMP 18 yt 201720-10 = Clamp the open end wrench in the vise, Release screw cap @ but do not remove it yet. ‘Special socket (114047) ( p. 228) = Pull the spring down. Remove the open end wrench. = Remove the screw cap. = Remove the spring with the preload spacers). Info TThe steps are identical for both fork legs. = 2080-10 Preparatory work = Disassemble the fork legs. (© p. 15) = Remove the spring. (© p. 17) Main work — Degrease piston rod @ and clamp it in the vise. Clamping stand (1140498) (= p. 228) ~ Remove acusting tube @. Unscrew spring guide = Remove spring seat @. = Pull the piston rod out of the cartridge. Clamp the tube ofthe cartridge into a vise. ‘Clamping stand (1140495) (™ p. 228) = Release seal rng retainer @ andl remove with the washer.6 FORK, TRIPLE CLAMP 19 = Remove lock ing @. 5 = Pullreservir @ of ofthe tube. 201704-10 = Pull sleeve @ out ofthe reservotr = Remove seal rings @ and O-ring @. — Remove pilot bushings @. 201790-11 ‘The steps are identical for both fork legs. Preparatory work = Disassemble the fork legs. (= p. 15) = Remove the spring. (=* p. 17) Main work ~~ Degrease piston rod @ and clamp it in the vise. ‘Clamping stand (1140488) (17 p. 228) = Remove adjusting tube @. Unscrew spring guide @. = Remove spring seat @. = Pulthe piston rod out othe cartridge,6 FORK, TRIPLE CLAMP 20 Clamp the tube ofthe cartridge into a vse. Clamping stand (T14049S) (-* p. 228) ~ Release sealing retainer @ and remove wit the washer, = Remove lock ing @. - ~ Pulreseroir @ of of te tube = Pull sleeve @ out of the reservoir. - Remove spring @. 201795-10 = Remove seal rings @ and O-ring @. = Remove pilot bushings ®. 201706-11 © Info T_Tho stops are identical for both fork logs, except forthe hydrostop needle and valve. Preparatory work = Disassemble the fork legs. (© p. 15) Remove the spring. (:= p. 17) Disassemble the cartridge. (~ p. 19) in work. = Degrease the piston rod. = Clamp the piston rod with the special tool as far up as possible. ‘Clamping stand (1140495) ("= p. 228) 201 Release hydrostop needle @ and remove it rom the piston rod. 7 Tho valve @ usually remains inthe hydrostop needle Info: - siver hycrostop needle on compression damping side. @ - red hydrostop needle on rebound damping side. 1728-106 FORK, TRIPLE CLAMP a '201720-10 ® 2179-10 20176010 ~ Remove the rebound shim stack @ = Remove piston @. ~ Remove the compression shim stack @) = Remove spring = Remove adapter @ with spring @ and washer. = Remove spring @. = Remove valve needle @ from the piston rod, © Info ‘The adjusting tube can be used for this. © Info H Tho steps are identical for both fork logs. E94 et | ee ree] Preparatory work = Disassemble the fork legs. (© p. 15) Main work = Mount the hydrostop unit on a fiting hexagon socket and clamp into a vice. = Remove sleeve @. = Remove shim stack @.6 FORK, TRIPLE CLAMP 2 201781-10 ~ Remove adapter @. ~ Remove hub @ with washers @. Info. T itis possible that only one washer or no washer is present. = Remove the O-ring from the hub. = Remove shim stack @. = Remove washer @. ~ Remove O-ing @. © Info ‘The steps are identical for both fork legs. e -—o ’ 200726-10 Preparatory work = Disassemble the fork logs. (©! p. 15) = Remove the spring. (© p. 17) = Disassemble the cartridge. (" p. 19) Main work = Remove pilot bushing support @. = Remove O-ring @ and seal ring @. Condition ‘The fork legs have been disassembled. = Check the inner tube and axle clamp for damage. » If there is damage: = Change the inner tube.6 FORK, TRIPLE CLAMP 2008-10 Measure the outside diameter at multiple locations of the inner tube. ‘Outside diameter of inner tube 47.975... 48.005 mm (1.88878. 1.88996 in) » Ifthe measured value is smaller than the specified value: = Change the inner tube, Measure the run-out of the inner tube. Tnner tube run-out '$0.20 mm (5 0.0079 in) » If the measured value is larger than the specified value: = Change the inner tube. Measure the inside diameter at multiple locations of the outer tube. Inside diameter of outer tube += 49.20 mm (= 1.987 in) » Ifthe measured value is larger than the specified value: = Change the outer tubs. ‘Check the outer tube for damage. » If there is damage: = Change the outer tube. ‘Check the surface of the sliding bushings. » Ifthe bronze-colored layer @ under sliding layer @ is visible or the surface is rough: = Change the sliding bushings. ‘Check the spring length. Guideline Spring length with preload spaceris) 480 mm (18.9 in) » If the measured value is larger than the specified value: = Reduce the thickness of the preload spacers. » Ifthe measured value is smaller than the specified value: = Increase the thickness of the preload spacers. Info ‘The steps are identical for both fork legs.6 FORK, TRIPLE CLAMP 24 Mount and grease seal ring @. e fe Lubricant (T158) ("" p. 215) @| ~ Norteraarese one @ Lubricant (T158) (-* p. 215) «| ~ Postion plot bushing support © 0100-0 a Into TThe steps are identical fr both fork legs. = Mount and grease O-ring @. Lubricant (T158) ("* p. 215) = Mount washer @ — Mount shim stack @ with the smaller washers facing downward. = Mount the new O-ring on hub © = Mount he hub wth washers ©. Info tis possible that only one or no washer is present. = Mount and tighten adapter Guideline Hydrostop unit adapter M605 7m 62 FF) = Mount shim stack @ withthe smaller washers facing downward, = Mount and tighten sleeve @. Guideline Hydrostop unit sleeve M6x0.5 7.Nm (6.2 bf ft) 201785-10 = Check distance @ and total length @ of the hydrostop. Guideline Hydrostop distance 21.5 mm (@ 0.059 in) Hydrostop length 108.8... 109.5 mm (4.272... 4.311 in) Ifthe dimensions are out of tolerance: = Add or remove washers @. 20107s-106 FORK, TRIPLE CLAMP 25 Info I The steps are identical for both fork legs, except for the hydrostop needle and valve. = Degrease the piston rod. = Clamp the piston rod with the special tool. ‘Clamping stand (T140498) (_" p. 228) ~ Lubricate the O-ring. Mount valve needle @ in the piston rod. Lubricant (T158) (= p. 218) a Hees 201790-1 ~ Mount spring @ ~ Mount and tighten adapter @ with spring @ and washer. Guideline ‘Adapter of piston rod M605 72Nm(@91bIA) = Position the spring. ~ Mount the compression shim stack @) wth the smal washers facing down- ward, zovra010 = Grind te piston on both sides ona surfacing plate using 1200 grt sandpaper. = Clean the piston. = Lubvcat the piston ing, Fork oil (SAE 4) (4860116681) ("* p. 214) = Mount the piston with chamter @) facing down, 2017800 — Mount the rebound shim stack @ with the smaller washers facing upward,6 FORK, TRIPLE CLAMP 26 o, | | o_ L oe £et fe 201700-10 Press the piston downward against the spring. ‘ The piston should not squeeze the shims. Position valve @ in the hydrostop needle @. Mount and tighten the hydrostop needle Guideline Hydrostop needle on piston rod M605 7Nm (62 fA) Info: TD @ -siver hycrostop needle on compression damping side. - re hydrostop needle on rebound damping sie. = Unclamp the piston rod, Info T The steps are identical for both fork legs. 201796-10| 201796-14 201796-10 Preparatory work = Assemble the seal rng retainer. ~ Assemble the piston rod. (-" p. 25) Main work = Mount and grease seal rings @ and O-ring @ Lubricant (1158) (= p. 218) — Mount and lubricate pilot bushings @. Fork oil (SAE 4) (4860116851) (= p. 214) p.23) = Check the length of the reservoir spring, Guideline Reservoir spring length with preload spacer Ifthe length is out of tolerance: = Correct the preload spacers. = Position the spring with the preload spacers in the reservoir. = Position sleeve @ in the reservoir. 46 mm (1.81 in) ~ Clamp the tube of the cartridge into a vise. ‘Clamping stand (T14049S) (-= p. 228) ~ Slide reservoir @ onto the tube. Info I Hod the sleeve in the reservoir to prevent it from siiding out. = Mount tock ring @ ~ Mount seal ring retainer @ with the washer and tighten. 2oadat-1t Guideline Seal rng retainer M23.5x0.75 | 46Nm Loctite® 2701™ e (33.9 lot) = Unclamp the cartridge.6 FORK, TRIPLE CLAMP a Slide piston rod @ into the cartridge. Info I Ensure that the piston ring is seated correctly. ~ Mount spring seat ©. = Degrease piston rod @ and clamp in the vise. Glarping sand (740495) (™ p26) ~ Serew spring guide @ all the way on. Info ‘The nut must be firmly tightened against the stop by hand. Do not use a tool Mount adjusting tube @. ~Unclamp the piston rod. Mount the preload spacers). Info When assembling, ensure that the right cartridge is mounted in the corresponding inner tube and the right adjuster is ‘mounted on the corresponding screw cap. ‘Compression damping side - screw cap with mark COMP, brake caliper holder, white adjuster. Rebound damping side ~ screw cap with mark REB, no brake caliper holder, red adjuster. bo Preparatory work = Assemble the hydrostop unit. ("2 p. 24) Main work = Clamp the inner tube with the axle clamp. Guideline Use soft jaws. = Mount special tool Protecting sleeve (T1401) (= p. 227) 201714-10 = Lubricate and mount ust boot @ Lubricant (TST) =p. 215) ¢ Info ‘Always change the dust boot, seal ing, lack ring and support rng ‘Mount the sealing lip wth the spring expander facing downward ~ Side on tok ring @. = Lubsicate and side on seal ring @. Lubricant (7511) (= p. 215) Info ‘Mount with the sealing lip facing down and the open side facing up, = Side on suppor cng @. = Remove the special tol6 FORK, TRIPLE CLAMP 28 D A: ei i ] 201717-10 A 2017-10 201705-15 = Grind the edges of the sliding bushings with sandpaper grit 600, clean the bush- ings and lubricate them. Fork oll (SAE 4) (4860116651) (= p. 214) ~ Side on the ower sing bushing @ = Mount the upper slicing bushing @ 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 50°C (122 °F) = Slide the outer tube onto the inner tube. = Hold the lower sliding bushing with the longer section ofthe special tool. Mounting tool (T140408) ( p. 228) Push the sliding bushing all the way into the outer tube. = Position the support ring = Hold the seal ring with the shorter section of the special tool. Mounting tool (7140408) ("= p. 228) = Push the seal ring and suppor ring all the way into the outer tube. = Mountlock ring @. © Info [The lock ring must engage audibly. = Mount dust boot @. = Mount fork protection ring @.6 FORK, TRIPLE CLAMP 2020ee-10 tfthere is damage or wear: = Change the needle bearing = check spacers @ and @ for damage and wear. = ttther is damage or wear: = Change the spacers = Check the shat seal rings for damage and wear. » tfthere is damage or wear: = Change the shaft sea rings. = Check dimension @. ma /— G81, 5.00 mm OTB. B1CEAT) * Hfdimension @ is ess than the specified value ~ Ada the corresponding spacing washers @. 0007-10 = Position the angle lever. = Mount screw connection @ but do not tighten yet. Guideline Nut, linkage lever on swingarm Max 5 80 Nm (69 FA) eore7e-t19 SHOCK ABSORBER, SWINGARM ar = Mount screw @ but do not tighten yet. Guideline Sorew, bottom shock | M10 GON Loctite® 2701™ absorber (44.3 lot) Info T Raise the whee! sightly to make it easier to mount the screw. o pam = Poston the linkage lever. = Mount and tighten fting @. Guidaine Nut inkage overt angle over [Tae Bonin GOBTT Info Raise the wheel slightly to make it easier to mount the screw. = Tighten screws @. uidetine ‘Screw, boliom shock | WO GONm | Loetite® a701 abcorbor (44.3 4 1) = Tigiten tens ©. Guideine Nut inkage lever on swingarm Mas 20 Nin (69 bt Ay Finishing work = Remove the motorcycle from the lft stand. ("* p. 10) a cu Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly. ‘The shock absorber is filed with highly compressed nitrogen. = Please follow the description provided, Condition ‘The shock absorber has been removed. = Remove the spring. (=* p. 48) Disassemble the damper. (© p. 48) = Disassemble the piston rod. ("* p. 49) = Disassemble the seal ring retainer. (" p. 50) = Check the damper. (© p. 52) = Remove the heim joint. ("9 p. 52) = Install the heim joint. (© p. $3) = Assemble the seal ring retainer. (© p. 54) = Assemble the piston rod. (*" p. 85) = Assemble the damper. (* p. 56) = Install the spring. (© p. 61) « ac) as EO Q Wwe 9 (200@Ga @ I¢— 2 @00 209 SHOCK ABSORBER, SWINGARM 48 \ o* e ° ose2-0 / I 798 A. Condition ‘The shock absorber has been removed. = Clamp the shock absorber inthe vse using sot jaws for protction. ~ Measure and note spring length i its preloaded state, = Loosen screw @. = Tamm acjusting ring until the spring is no longer under tension Hook wrench (T1065) (~ p. 225) 201570-10 = Remove ring @. ~ Remove spring retainer @ and intermediate washer @. = Remove the spring 201071-10 Preparatory work = Remove the spring. (© p. 48) Main work = Note down the current state of rebound damping @ and compression damp- ing @. = Completely open the adjusters of the rebound and compression damping. ~ Remove rubber cap @ ofthe reser. = open screw @ slowly ~The pressurized nitrogen escapes. = Remove locking cap @.9 SHOCK ABSORBER, SWINGARM 4 =) i = oraee-10 = Press in seal ring retainer @ using the special tool Disassembly tool (T1216) ("" p. 227) = Remove lock ring @. Into T Donot scratch the inner surface. = Remove the piston rod. = Remove adjusting ting @ with the intermediate washer. = Drain the ol, ~ Remove compression adjuster @ Remove the spring and piston, Preparatory work = Remove the spring. (= p. 48) = Disassemble the damper. (© p. 48)9 SHOCK ABSORBER, SWINGARM 50 e é eo = \ A. £ BBS cowis0 Main work = Clamp the piston rod with the fork in a vise, Guideline = Remove nut @. eer = Remove rebound shim stack @. Into I Place the rebound shim stack onto a screwdriver and set it down as a urit. = Remove piston @. ~ Remove compression shim stack @ Info Place the compression shim stack onto a sorewaiver and set it down as a unit = Remove rebound washer @. = Remove seal ring retainer @. = Remove locking cap @ and rubber butter @. 201405-10 Preparatory work - Remove the spring. (°* p. 48) — Disassemble the damper. (° p. 48) = Disassemble te piston rod. (2p. 49) Main work = Remove spring @. ~ Remove O-ring @. = Remove rebound rubber ©.9 SHOCK ABSORBER, SWINGARM st = Remove centering disk @. = Remove seal ring 201406-10 = Remove washer @ for searing ©. = Remove washer @. @| = renee © os S Preparatory work = Remove the spring. (= p. 48) = Disassemble the damper. (© p. 48) = Disassemble the piston rod. (=* p. 49) = Disassemble the seal ring retainer. (°° p. 50) Main work = Press pilot bushing @ out of seal ring retainer @ with the special tool. ress drift (T1504) (™ p. 228) ~ Sle the new pilot bushing @ ont the special ool Press drift (T1504) (-* p. 228) — Position the pilot bushing in the seal ring retainer using the special tool, Press drift (T1504) (== p. 228) ~ Support seal ring retainer @ with sleeve @) ofthe special tool. Press the pilot bushing al the way in. ‘Assembly tool (T1508) (= p. 228) = Lubricate the special tool. Shock absorber fluid (SAE 2.5) (6018075181) ( p. 214) Calibration pin (T1205) (** p. 226) ~ Support seal ring retainer @ with sleeve @ ofthe special tool. Assembly tool (T150S) ('" p. 229) = Press the special tool trough the new pilot bushing. Calibration pin (T1205) (~~ p. 226) 7 The pilot bushing is calibrated. Finishing work = Assemble the seal ring retainer. (= p. 54)9 SHOCK ABSORBER, SWINGARM 52 201402-10 201409-10 201408-10 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 '= 60.08 mm (= 1.9716 in) » Ifthe measured value is greater than the specified value: = Change the damper cartridge. = Check the damper cartridge for damage and wear. » I there is damage or wear = Change the damper cartridge. = Check the heim joint for damage and wear. » If there is damage or wear: = Change the heim joint. = Measure the diameter of the piston rod. Piston rod Diameter © 17.95 mm (@ 0.7087 in) » Ifthe measured value is less than the specified value: = Change the piston rod. — Measure the run-out ofthe piston rod, Piston rod Run-out '§ 0.02 mm (5 0.0008 in) » If the measured value is greater than the specified value: = Change the piston rod. = Check the piston rod for damage and wear. » If there is damage or wear: = Change the piston rod. = Check the piston rings for damage and wear. » If damage o a bronze-colored surface is visible: = Change the piston. Condition ‘The shock absorber has been removed. = Clamp the shock absorber in the vise using soft jaws for protection. = Remove the collar bushing of the heim joint. Pin (1120) (= p. 226) = Turn the shack absorber and remove the second collar bushing of the heim joint.9 SHOCK ABSORBER, SWINGARM Remove seal rings @ on both sides. = Press the heim joint against a lock ring using the special tool Pressing tool (712075) (~ p. 226) = Remove the second lock ring @. = Place special too! @ underneath and press out heim joint @ with special tool @. Pressing tool (112078) ("= p. 226) ~ Postion he new heim joint @ andthe special tol nto vise as shown, Guideline Use soft jaws. Pressing tool (11206) ("= p. 226) = Press the heim joint all the way in. = _Prass the heim joint against the lock ring using the special tool. Pressing tool (T1207S) (~* p. 226) = Mount the second lock ring @. ~ Mount seal rings @ on both sides.9 SHOCK ABSORBER, SWINGARM 54 = Position both collar bushings @ and press them in, aie = aS » & 201411-10 = Mount dust boot @ using the special tool, Mounting sleeve (11204) (= p. 226) Lubricate the seating lip of the dust boot. Lubricant (7625) ("= p. 215) = Mount washer @. ~ Position washer @ on sea ring @ = Grease searing @ and mount withthe washer facing downward Lubricant TST Dp. 215) = Mount centering disk @. = Mount rebound rubber @. Lubricate the groove of the O-ring, Lubricant (T158) ("= p. 215) ~ Mount O-ring @. = Mount sping @.9 SHOCK ABSORBER, SWINGARM 55 | 2o1416-10 e ; on 2 201418-10 ® 201410-10 “e 201420-10 Preparatory work = Assemble the seal ring retainer. (© p. 54) Main work = Clamp the piston rod with the fork in a vise. Guidetine Use soft jaws. ~ Mount rubber butfer @ and locking cap @. = Position special too! on the piston rod. Mounting sleeve (11045) ( p. 227) ~ Grease the dust boot and push sealing retainer @ onto the piston rod Lubricant (T625) (= p. 215) = Remove the special tool ~ Mount rebound washer @ with the cut-out facing downward. ~ Mount the compression shim stack @ wth the smal shims facing downward = Sand both sides of piston @ on a surface plate using 1200-grit sandpaper. = Clean the piston = Assemble the piston. Guideine View @ Piston from above view @ Piston from below — Mount the rebound shim stack @ with the smaller shims facing upward.9 SHOCK ABSORBER, SWINGARM 56 2 = Mount washer @ with the collar facing downward. 2142-10 = Grease the thread of the piston rod. = Mount and tighten nut ©. Nut, piston rod Mi16x1 45 Nm (33.2 Ibf ft) Paaeoe ea = Assemble the seal ring retainer. (°° p. 54) Assemble the piston rod. (= p. 58) Main work = Lubricate the O-rings of the compression adjuster. Lubricant (1758) (© p. 215) = Lubricate the threads. Lubricant (T7159) p. 215) Mount the piston with the spring. = Mount and tighten the compression adjuster @. Guideline ‘Compression adjuster Maixt 45 Nm (83.2 FA) = Clamp the damper in a bench vise. Guideline Use soft jaws. ~ Mount agusting ring @ with the intermediate washer Info. I The adjusting ring cannot be mounted after the piston rod is mounted. aorH0-10 = Fillthe damper cartridge about hat ul ‘Shock absorber fluid (SAE 2.5) (5018075181) {-* p. 214) ~ Lubscate O-ing @ of the sea rng retainer. Lubcant (7758) (0 p21) = Mount he piston rod earful.9 SHOCK ABSORBER, SWINGARM 201994-10 37 Install the seal ring bearer @ and push it under the ring groove. = Mountlock ring ©. ® Info TDonnot scratch the inner surface. = Pull out the piston rad so that the seal ring retainer rests against the lack ring. = Mount locking cap @ of the damper cartridge = Bleed and fil the damper. (" p. 58) = Fillthe damper with nitrogen. (° p. 60) = Mount rubber cap @ of the reservoir. Alternative 4 za Tum adjusting screw @ clockwise with a screwdriver up to the last percepti- @ CS ©: bble click. D - Turn counterclockwise by the number of clicks corresponding to the shock toot’ pe 8 eu Compression damping, low-speed Comer ates ee Sindard tBeels Spor ‘Beles = Turn adjusting screw @ all the way clockwise with a socket wrench. Turn counterclockwise by the number of tums corresponding to the shock absorber type. Guideline ‘Compression damping, high-speed Comfort 25 tums ‘Standard 2tums Sport iB tums = Tum adjusting screw € clockwise up Turn counterclockwise by the number of clicks corresponding to the shock 10 the last perceptible click absorber type. Guidetine Rebound damping Comfort 17 clicks Standard 16 clicks Sport 18 clicks9 SHOCK ABSORBER, SWINGARM 58 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 slowiy to start with after making adjustments to get the feel of the new handling characteristic. ~ Turn adjusting screws @, © and @ to the position determined during dis- assembly. Info : Before working with the vacuum pump, be sure to read the operating instructions carefully ‘Completely open the adjusters of the rebound and compression damping. Remove the screw of the filing port Install adapter @ on the damper. om / 20130010 © Info Tighten only hand-tight, without the use of tools. Connect the adapter @ to connector @ ofthe vacuum pump. ‘Vacuum pump (T12408) (~ p. 227) ‘Clamp the damper with soft jaws or hold it as shown in the figure. Info Clamp the damper only lightly. The filing port must be at the highest point. ‘The piston rod slides in and out during filing - do not hold it tight with your hand! ‘Clamp the control lever as shown in the figure, 7 The External tank @ control lever is on Closed, Damper @ on Vacuum, and Oil reservoir @ on Vacuum, Operate the On/OFt switch @. 7 The vacuum pump process stats. ~ Pressure gauge @ drops to the specified value. =O bar 7 The vacuum gauge @ falls to the specified value. ‘mbar Measure distance @ between the floating piston and reservoir hole with the spe- ial tool. Depth micrometer (T1075) (= p. 225) The floating piston is positioned all the way at the bottom,9 SHOCK ABSORBER, SWINGARM 50 ~ When the vacuum pressure gauge reaches the specified value, tur the Oil reser- voir control lever @ to Equalize pressure. Guideline ‘4mbar 7 The pressure gauge increases to the specified value. Obar = When the pressure gauge reaches the specified value, tum the Damper contol lover @ to Pressure. uideine ‘Obar ~ Oilis pumped into the damper. The pressure gauge increases tothe specitid valve, Sar - When the pressure gauge reaches the specified value, turn the Damper @ con- trol lever to Vacuum, Guideline ‘Sbar The pressure gauge drops to the specified value. Obar — When the pressure gauge reaches the specified value, turn the Oil reservoir @ control lever to Vacuum. Guideline ‘Obar 7 The vacuum gauge falls to the specified value. @ mbar = When the vacuum pressure gauge reaches the specified value, tum the Oil reser- voir control lever @ to Equalize Pressure. Guideine ‘mbar The pressure gauge drops to the specified value, ‘Obar = When the pressure gauge reaches the specified value, turn the Damper contol lover @ to Pressure. Guideline Obar ‘% Oilis pumped into the damper. 7 The pressure gauge increases to the specified value. 3 bar9 SHOCK ABSORBER, SWINGARM 60 f201400-10 20109610 When the pressure gauge reaches the specified value, turn the Damper @ con- trol lever to Vacuum, Guideline ‘Sbar ‘7 The pressure gauge drops to the specified value. Obar = When the pressure gauge reaches the specified value, operate the On/Off switch. Guideline ‘Obar 7 The vacuum pump is switched off = Slide O-ring @ to the end of the special tool by the specified value (distance @) minus specified value). Guidetine 10 mm Depth micrometer (1107S) (© p. 225) = Slide the floating piston into the reservoir to the shortened position using the spe~ cal tool. Info I The floating piston must be positioned at exactly this point when the rod is fully extended; otherwise, damage will occur during compression of the shock absorber. = Remove the special tool — Remove adapter @ from connection @ of the vacuum pump. Info Told the damper so thatthe filing port is at the highest point. = Remove the adapter. = Mount and tighten sorew @. Guideine Serew, fing pon tox TaN AOT A = Screw in screw @ by approx. 2 rotations but do not tighten. © Info ‘The piston rod is fully extended. = Clamp the special too! in the vise, Nitrogen filing tool (117084) (= p. 228) = Connect the special tool to the pressure regulator ofthe fing cylinder. Filling gas - nitrogen = Adjust the pressure regulator. Guideline Gas pressure 10 bar (145 psi) = Position the damper in the special tool 7 The hexagonal part of the tap handle @ engages in the hexagon socket of the filing port screw.9 SHOCK ABSORBER, SWINGARM 6 = Open file tap ®. ~ Fillthe damper fr atleast 15 seconds. Guideline [[Gas pressure TO bar (145 pad Info I Watch the pressure regulator ial Make sure that the damper is filed to the specified pressure, ~ Close the fling port screw using tap handle @). ~ Close spigot @ and take the damper out ofthe special ool. = Tighton the filing port screw. Guidoine ‘Screw, reservoir filling port ‘M5 3.Nm (2.2 Ibf ft) = Ensure that adjusting ring @ is screwed on with the intermediate washer. 20107210 = Measure the overall spring length while the spring is not under tension, = Position spring, Guideline Spring rate Weight of rider 65... 75kg (143... | 54 Nimm (808 Ib/in) 165 Ib.) Weight of rider: 75... 85 kg (165... | 57 N/mm (325 Ib/in) 1871b) [2017-10 Weight of rider 85... 95 kg (187... | 60 N/mm (843 bin) 2091.) — Mount intermediate washer @ and spring retainer @. = Mount ring @. Alternative 1 = Tension the spring to the prescribed amount by tuming the adjusting ring, Guideline ‘Spring preload 8mm (0.31 in) Hook wrench (T1065) (~ p. 225) 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 anc 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. = Tension the spring to the amount measured during dismantling by turning the agjusting ring Hook wrench (T1065) ("1 p. 225)9 SHOCK ABSORBER, SWINGARM e = Tighten screw @. Guideline Sorew, shock absorber adjusting ring | MS 51Nm (3.7 tof) 2o.a7o-1+ = Check the swingarm for damage, cracking, and deformation, » Ifthe swingarm shows signs of damage, cracking, or deformation: = Change the swingarm. Info 4 I Aiways change a damaged swingarm. Repair of the swingarm is not authorized by Husqvama Motorcycles. 500286.01 Preparatory work = Raise the motorcycle with the lift stand. (~ p. 10) = Remove the rear wheel. (© p. 88) Main work = Take the brake line out of the guide. Push the brake caliper forward, remove it, and hang it to the side, * Info Cover the components to protect them against damage. ~ Remove screws @ and @. Remove the engine sprocket cover9 SHOCK ABSORBER, SWINGARM 63 .601626-10 Remove connecting link @ of the chain. Info Cover the components to protect them against damage, ‘Take off the chain. Remove tttng @. Lower the swingarm, Romove nut @. Remove the swingarm pivot. Remove the swingarm, 601826-11 Main work Postion the swingarm. Mount the swingarm pivot Mount and tighten nut @. Guidoine ‘Nut, swingarm pivot MiextS 700Nm (73.8 Ib) Lit the swingarm, Mount and tighten iting @. Guideine Nut, linkage lever on swingarm M14x1.5 80 Nm (59 Ibf ft) Mount the chain, ‘Connect the chain with connecting link @. Guideline “The closed side of the chain joint lock must face in the direction of travel9 SHOCK ABSORBER, SWINGARM 64 = Position the engine sprocket cover and mount it in the holder. = Mount and tighten screws @ and @ Guideline Screw, clutch slave cylinder Me 10.Nm (7.4 Ibf ft) Remaining screws, chassis Ma 25 Nm (18.4 iF) = Position the brake caliper and pull it back. > coca = Position the brake line in the guide. Finishing work = Install the rear wheel. (© p. 89) = Remove the motorcycle from the lft stand. (=p. 10) Info I These operations are the same on both swingarm bearings. Preparatory work = Raise the motoroycle with the lift stand. (-* p. 10) = Remove the rear wheel. (= p. 88) = Remove the swingarm. (~ p. 62)9 SHOCK ABSORBER, SWINGARM Main work =" remove outer colar bushings @. see [o01819-10 = Remove bushing @. oo1916-10 — Remove shaft seal rings @ using a suitable tool. (00181610 = Using a suitable tool, press the bearing out from the outside to the inside. = Press in the new bearing until itis flush using a suitable tool \501818-109 SHOCK ABSORBER, SWINGARM Press in shaft seal rings @. Mount bushing @. 0181410 = Grease the shaft seal rings. Longrlfe grease ("> p. 215) Position collar bushings @ with the shoulder facing inward. EE ons Finishing work = Install the swingarm. (= p. 63) Install the rear wheel. (© p. 89) — Remove the motorcycle from the lift stand. (= p. 10)10 EXHAUST Detach springs Spring hook (50305017000) ( = Remove screw @. = Take of the manila = Position the manifold. Guideline = Mount screw @ but do not tighten yet. Sorew, manifold MB 15Nm (11.4 oF = attach springs @ Spring hook (50305017000) ( p28) = Tighten screw @. Guideline Sorew, manifold Ma 15. Nm (14.4 bf)10 EXHAUST 6 103 Removingthemain silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. — Allow the exhaust system to cool down before performing any work on the vehicle, Preparatory work = Remove the right side cover. (°° p. 72) Main work = "Disconnect spring @. ‘Spring hook (60305017000) (-* p. 218) ~ Remove screws @ and take off the main silencer. Main work = Mount the main silencer. Mount screws @ but donot tighten yet. Guideine Remaining screws, chassis M6 10. Nm (7.4 Ibf ft) ~ Reconnect spring @. = Tighten screws @. Guideline Remaining screws, chassis M6 10 Nm (7.4 Ibf ft) 1g work = Install the right side cover. (© p. 73) Warning Danger of burns The exhaust system gets very hot when the vehicle is driven, = Allow the exhaust system to cool down before performing any work on the vehicle. Info Hover time, the fibers ofthe glass fiber yarn escape and the damper ‘burns" out Not only is the noise level higher, the performance characteristic changes. Preparatory work = Remove the right side cover. (© p. 72) = Remove the main silencer. (" p. 68)10 EXHAUST Main work = Remove all screws on the main silencer. Take off silencer cap @ and O-ring @. ~ Take off outer tube @ and O-ring @. = Pullglass fiber yarn filing @ off of inner tube @. = Clean the pars that are to be reinstalled — Mount the new glass fiber yam filing @ on the inner tube ~ Side O-ring @ and outer tube @ over the lass fber yar filing ~ Insert O-ring @ and silencer cap @ into the outer tube. = Mount and tighten all srews. Finishing work = Install the main silencer. (~* p. 68) = Install the right side cover. (© p. 73)11. AIR FILTER 3 - Release catch @, pull off the air fiter box lid sideways in areas @ and @ and remove toward the rear. one6-10 = Position the air filter box lid and tab @. Engage the air filter box lid in areas @ and @. = Engage tab @. Note Engine damage _Untitered intake air has a negative effect on the service life of the engine. Dust and dirt will enter the engine without an air iter. — Never start to use the vehicle without an a iter. Warning Environmental hazard Hazardous substances cause environmental damage. = Dispose of olls, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Preparatory work - Remove the air filter box lid. (-* p. 70) Main work = Push airfiter holder @) toward the ar fite at postion @) and detach it at ‘end @. Swing the air fitr holder to one side and remove the air iter wth the air filer suppor. = Remove the ai fier from the airfiter support. Main work = Mount the clean air fiter on the ar fiter support. - Grease the air fiter in area @. Longrlfe grease (" p. 215) 101951-1011. AIR FILTER n” = Insert both parts together, position them, and fasten them using air fiter holder @ in area @. ‘The arrow of marking UP faces up. Info Tithe air iter is not correctly mounted, dust and dirt can enter the engine and cause damage. Finishing work = Install the ar fter box lid. (© p. 70) Warning Environmental hazard Hazardous substances cause environmental damage. = Dispose of oils, grease, fiters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Into To not clean the air fiter with fuel or petroleum since these substances attack the foam Preparatory work = Remove the ar fiter box lid. ( p. 70) = Remove the air iter. (© p. 70) Main work = Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter clearing agent (~ p. 218) Info. T onty press the air fitr to dry it, never wring tout. = Oilthe dry air iter with a high quality fiter oi .oo190-10| Ol for foam airfiter(™ p. 216) = Glean the air fiter box. Clean the intake flange and check it for damage and tightness. Finishing work Install the air fiter. ( p. 70) Install the ar fiter box lid. (= p. 70) Preparatory work = Remove the air filter box lid. (" p. 70) Main work = Seal the air filter box in the marked area @. 401559-01 Finishing work Install the ar flter box lid. (= p. 70)12 FUEL TANK, SEAT, TRIM n Danger Fire hazard Fuels highly flammable. ‘The fuel in the fuel tank expands when warm and can escape if overilled. = Donot refuel the vehicle in the vicinity of open flames or lit cigarettes. = Switch off the engine for refueling. = Make sure that no fuel s spilled; particularly not on hot parts of the vehicle, — Ifany fuels spilled, wipe it off immediately. = Observe the specifications for refueling. Warning Danger of poisoning Fuel is poisonous and a health hazard. = Avoid skin, eye and clothing contact with fue = Immediately consult a doctor if you swallow fuel = Donot inhale fuel vapors, = Incase of skin contact, rinse the affected area with plenty of water. = Rinse the eyes thoroughly with water, and consult @ doctor in case of fuel contact with the eyes. = Change your clothing in case of fuel spills on them. = Keep fuels correctly in a suitable canister, and out of the reach of children. Warning Environmental hazard Improper handling of fuel is a danger to the environment. = Donot allow fue! to enter the groundwater, the soll, or the sewage system. = Tumtitercap @ counterclockwise and itt of 0024-10 — Mount file cap @ and turn clockwise uti te fuel ‘anki tight closed. Info Fun the fuel tank breather hose @ without kinks - Remove screw @. ~ Pull off the side cover in area @ sideways and remove it toward the rear.