2015 Husqvarna FC 450 Service Repair Manual

REPAIR MANUAL 2015
TABLE OF CONTENTS 2
1 MEANS OF REPRESENTATION......................................... 6 7.4 Checking the throttle cable routing.................... 37

1.1 Symbols used........................................................ 6 7.5 Checking the play in the throttle cable............... 37
1.2 Formats used.......................................................... 6 7.6 Adjusting the play in the throttle cable............... 38
2 SAFETY ADVICE................................................................ 7 8 FRAME.............................................................................. 39
2.1 Repair Manual........................................................ 7 8.1 Checking the frame.............................................. 39
2.2 Safety advice......................................................... 7 9 SHOCK ABSORBER, SWINGARM.................................. 40
2.3 Degrees of risk and symbols................................ 7 9.1 Adjusting the high-speed compression
2.4 Work rules.............................................................. 7 damping of the shock absorber.......................... 40
3 IMPORTANT NOTES.......................................................... 8 9.2 Adjusting the low-speed compression
damping of the shock absorber.......................... 40
3.1 Manufacturer and implied warranty...................... 8
9.3 Adjusting the rebound damping of the shock
3.2 Operating and auxiliary substances..................... 8
absorber............................................................... 41
3.3 Spare parts, accessories...................................... 8
9.4 Measuring rear wheel sag unloaded................... 41
3.4 Figures................................................................... 8
9.5 Checking the static sag of the shock
4 SERIAL NUMBERS............................................................. 9 absorber............................................................... 41
4.1 Chassis number..................................................... 9 9.6 Checking the riding sag of the shock
4.2 Type label............................................................... 9 absorber............................................................... 42
4.3 Engine number....................................................... 9 9.7 Adjusting the spring preload of the shock
4.4 Fork part number................................................... 9 absorber............................................................... 42
4.5 Shock absorber article number............................ 9 9.8 Adjusting the riding sag...................................... 43
5 MOTORCYCLE................................................................. 10 9.9 Removing the shock absorber............................ 43
5.1 Raising the motorcycle with a lift stand.............. 10 9.10 Installing the shock absorber.............................. 44
5.2 Removing the motorcycle from the lift stand..... 10 9.11 Checking the shock absorber linkage................ 45
5.3 Starting................................................................ 10 9.12 Servicing the shock absorber............................. 47
5.4 Starting the motorcycle for a check.................... 11 9.13 Removing the spring............................................ 48
6 FORK, TRIPLE CLAMP.................................................... 12 9.14 Disassembling the damper................................. 48
6.1 Adjusting the compression damping of the 9.15 Disassembling the piston rod............................. 49
fork........................................................................ 12 9.16 Disassembling the seal ring retainer................... 50
6.2 Adjusting the rebound damping of the fork....... 12 9.17 Changing the pilot bushing................................. 51
6.3 Bleeding the fork legs.......................................... 13 9.18 Checking the damper.......................................... 52
6.4 Cleaning the dust boots of the fork legs............ 13 9.19 Removing the heim joint..................................... 52
6.5 Removing the fork legs....................................... 13 9.20 Installing the heim joint........................................ 53
6.6 Installing the fork legs.......................................... 14 9.21 Assembling the seal ring retainer........................ 54
6.7 Removing the fork protector............................... 14 9.22 Assembling the piston rod.................................. 55
6.8 Installing the fork protector................................. 15 9.23 Assembling the damper...................................... 56
6.9 Performing a fork service.................................... 15 9.24 Bleeding and filling the damper.......................... 58
6.10 Disassembling the fork legs................................ 15 9.25 Filling the damper with nitrogen......................... 60
6.11 Removing the spring............................................ 17 9.26 Installing the spring.............................................. 61
6.12 Disassembling the cartridge............................... 18 9.27 Checking the swingarm...................................... 62
6.13 Disassembling the cartridge............................... 19 9.28 Removing the swingarm..................................... 62
6.14 Disassembling the piston rod............................. 20 9.29 Installing the swingarm........................................ 63
6.15 Disassembling the hydrostop unit...................... 21 9.30 Changing the swingarm bearing......................... 64
6.16 Disassembling the seal ring retainer................... 22 10 EXHAUST.......................................................................... 67
6.17 Checking the fork legs........................................ 22 10.1 Removing the manifold........................................ 67
6.18 Assembling the seal ring retainer........................ 23 10.2 Installing the manifold.......................................... 67
6.19 Assembling the hydrostop unit........................... 24 10.3 Removing the main silencer................................ 68
6.20 Assembling the piston rod.................................. 25 10.4 Installing the main silencer.................................. 68
6.21 Assembling the cartridge.................................... 26 10.5 Changing the glass fiber yarn filling of the
6.22 Assembling the fork legs.................................... 27 main silencer........................................................ 68
6.23 Greasing the steering head bearing.................... 31 11 AIR FILTER........................................................................ 70
6.24 Removing the lower triple clamp........................ 31 11.1 Removing the air filter box lid............................... 70
6.25 Installing the lower triple clamp.......................... 32 11.2 Installing the air filter box lid............................... 70
6.26 Checking the steering head bearing play.......... 33 11.3 Removing the air filter........................................... 70
6.27 Changing the steering head bearing................... 34 11.4 Installing the air filter............................................ 70
6.28 Adjusting the steering head bearing play.......... 35 11.5 Cleaning the air filter and air filter box................. 71
7 HANDLEBAR, CONTROLS............................................... 36 11.6 Sealing the air filter box....................................... 71
7.1 Handlebar position............................................... 36 12 FUEL TANK, SEAT, TRIM.................................................. 72
7.2 Adjusting the handlebar position........................ 36 12.1 Opening the filler cap........................................... 72
7.3 Adjusting the basic position of the clutch 12.2 Closing the filler cap............................................ 72
lever...................................................................... 36 12.3 Removing the right side cover............................ 72
TABLE OF CONTENTS 3
12.4 Installing the right side cover.............................. 73 16.9 Changing the rear brake linings........................ 109
12.5 Removing the seat............................................... 73 16.10 Checking the free travel of foot brake lever.... 111
12.6 Mounting the seat................................................ 73 16.11 Adjusting the basic position of the foot brake
12.7 Removing the fuel tank....................................... 73 lever................................................................... 111
12.8 Installing the fuel tank.......................................... 74 16.12 Checking the rear brake fluid level................... 112
12.9 Checking the fuel pressure................................. 75 16.13 Adding rear brake fluid..................................... 112
12.10 Changing the fuel pump..................................... 77 16.14 Changing the rear brake fluid........................... 113
12.11 Changing the fuel filter......................................... 78 17 ENGINE........................................................................... 116
12.12 Changing the fuel screen.................................... 81 17.1 Removing the engine......................................... 116
13 MASK, FENDER............................................................... 82 17.2 Installing the engine........................................... 120
13.1 Removing the front fender.................................. 82 17.3 Engine disassembly........................................... 125
13.2 Installing the front fender.................................... 82 17.3.1 Preparations.................................................. 125
13.3 Removing the start number plate....................... 82 17.3.2 Draining the engine oil.................................. 125
13.4 Installing the start number plate......................... 83 17.3.3 Removing the clutch push rod..................... 126
14 WHEELS............................................................................ 84 17.3.4 Removing the oil filter................................... 126
14.1 Checking the tire air pressure............................. 84 17.3.5 Removing the starter motor......................... 126
14.2 Checking the tire condition................................. 84 17.3.6 Removing the spark plug............................. 126
14.3 Checking the brake discs................................... 84 17.3.7 Removing the valve cover............................ 127
14.4 Checking spoke tension..................................... 85 17.3.8 Removing the alternator cover..................... 127
14.5 Front wheel.......................................................... 85 17.3.9 Positioning the engine at ignition top dead
center............................................................ 127
14.5.1 Removing the front wheel.............................. 85
17.3.10 Removing the timing chain tensioner............ 128
14.5.2 Installing the front wheel................................ 86
17.3.11 Removing the camshaft............................... 128
14.5.3 Removing the brake disc of the front
brake............................................................... 87 17.3.12 Removing the cylinder head......................... 129
14.5.4 Installing the brake disc of the frontbrake...... 87 17.3.13 Removing the piston.................................... 129
14.5.5 Changing the front wheel bearing.................. 87 17.3.14 Removing the rotor........................................ 130
14.6 Rear wheel............................................................ 88 17.3.15 Removing the timing chain........................... 130
14.6.1 Removing the rear wheel................................ 88 17.3.16 Removing the ignition pulse generator....... 131
14.6.2 Installing the rear wheel.................................. 89 17.3.17 Removing the suction pump........................ 131
14.6.3 Removing the brake disc of the rear brake.... 90 17.3.18 Removing the water pump cover.................. 131
14.6.4 Installing the brake disc of the rear brake...... 91 17.3.19 Removing the clutch cover............................ 132
14.6.5 Checking the chain tension............................ 91 17.3.20 Removing the clutch discs............................ 132
14.6.6 Adjusting the chain tension............................ 92 17.3.21 Removing the outer clutch hub.................... 133
14.6.7 Checking the chain, rear sprocket, engine 17.3.22 Removing the torque limiter......................... 134
sprocket, and chain guide.............................. 93 17.3.23 Removing the starter idler gear.................... 134
14.6.8 Checking for chain dirt accumulation........... 94 17.3.24 Removing the shift shaft................................ 134
14.6.9 Cleaning the chain........................................... 94 17.3.25 Removing the shift drum locating unit......... 134
14.6.10 Changing the drivetrain kit............................. 95 17.3.26 Removing the locking lever.......................... 135
14.6.11 Changing the rear wheel bearing................... 97 17.3.27 Removing the force pump............................ 135
15 WIRING HARNESS, BATTERY......................................... 99 17.3.28 Removing the primary gear.......................... 136
15.1 Changing the main fuse...................................... 99 17.3.29 Removing the freewheel gear....................... 136
15.2 Removing the battery........................................... 99 17.3.30 Removing the left engine case section....... 136
15.3 Installing the battery.......................................... 100 17.3.31 Removing the shift rails................................ 137
15.4 Recharging the battery..................................... 100 17.3.32 Removing the shift drum............................... 137
15.5 Checking the charging voltage......................... 101 17.3.33 Removing the shift forks............................... 137
15.6 Checking the open-circuit current.................... 102 17.3.34 Removing the transmission shafts................ 138
15.7 Checking the capacitor..................................... 102 17.3.35 Removing the crankshaft............................. 138
15.8 Checking the starter relay................................. 103 17.4 Working on individual parts.............................. 138
16 BRAKE SYSTEM............................................................ 104 17.4.1 Work on the right section of the engine
16.1 Checking the front brake linings........................ 104 case............................................................... 138
16.2 Changing the front brake linings....................... 104 17.4.2 Work on the left section of the engine
case............................................................... 140
16.3 Checking the free travel of the hand brake
lever................................................................... 105 17.4.3 Removing the oil pressure regulator
valve.............................................................. 141
16.4 Adjusting the basic position of the hand
brake lever......................................................... 106 17.4.4 Checking spring length of oil pressure
regulator valve............................................... 141
16.5 Checking the brake fluid level of the front
brake................................................................... 106 17.4.5 Installing the oil pressure regulator valve...... 142
16.6 Adding front brake fluid.................................... 107 17.4.6 Changing the crankshaft seal ring in the
clutch cover................................................... 142
16.7 Changing the front brake fluid........................... 108
17.4.7 Removing the water pump............................ 142
16.8 Checking the rear brake linings......................... 109
TABLE OF CONTENTS 4
17.4.8 Installing the water pump............................. 143 17.5.20 Installing the ignition pulse generator......... 173
17.4.9 Removing the timing chain sprocket........... 144 17.5.21 Installing the timing chain............................. 174
17.4.10 Installing the timing chain sprocket............. 144 17.5.22 Installing the rotor.......................................... 174
17.4.11 Changing the connecting rod, conrod 17.5.23 Installing the piston...................................... 174
bearing, and crank pin................................. 144 17.5.24 Installing the cylinder head........................... 176
17.4.12 Checking crankshaft run-out at bearing 17.5.25 Installing the camshaft.................................. 177
pin.................................................................. 146 17.5.26 Installing the timing chain tensioner............. 177
17.4.13 Cylinder - Nikasil® coating............................ 146 17.5.27 Checking the valve clearance...................... 178
17.4.14 Checking/measuring the cylinder................. 146 17.5.28 Adjusting the valve clearance....................... 178
17.4.15 Checking/measuring the piston................... 147 17.5.29 Installing the alternator cover........................ 179
17.4.16 Checking the piston ring end gap................ 147 17.5.30 Installing the valve cover.............................. 179
17.4.17 Measuring the piston/cylinder mounting 17.5.31 Installing the spark plug............................... 179
clearance....................................................... 148
17.5.32 Installing the starter motor........................... 180
17.4.18 Checking the oil pumps............................... 148
17.5.33 Installing the oil filter..................................... 180
17.4.19 Disassembling the autodecompressor......... 148
17.5.34 Installing the clutch push rod........................ 180
17.4.20 Assembling the autodecompressor............. 149
17.5.35 Installing the oil screens............................... 180
17.4.21 Checking camshaft...................................... 150
17.5.36 Removing the engine from the engine
17.4.22 Checking the timing assembly..................... 150 assembly stand............................................. 181
17.4.23 Removing the rocker arm............................. 151 18 CLUTCH.......................................................................... 182
17.4.24 Removing the valves.................................... 151 18.1 Checking/correcting the fluid level of the
17.4.25 Changing camshaft bearing......................... 152 hydraulic clutch.................................................. 182
17.4.26 Checking the valves..................................... 152 18.2 Changing the hydraulic clutchfluid................... 182
17.4.27 Checking valve springs................................ 153 19 WATER PUMP, COOLING SYSTEM.............................. 184
17.4.28 Checking valve spring seat.......................... 153 19.1 Cooling system.................................................. 184
17.4.29 Checking the cylinder head.......................... 153 19.2 Checking the antifreeze and coolant level....... 184
17.4.30 Checking the rocker arm shafts................... 154 19.3 Checking the coolant level................................ 185
17.4.31 Installing the valves...................................... 154 19.4 Draining the coolant........................................... 185
17.4.32 Installing the rocker arm............................... 155 19.5 Refilling coolant................................................. 186
17.4.33 Checking the clutch..................................... 156 20 LUBRICATION SYSTEM................................................ 187
17.4.34 Checking the shift mechanism..................... 157 20.1 Oil circuit............................................................ 187
17.4.35 Preassembling the shift shaft....................... 158 20.2 Checking the engine oil level............................ 187
17.4.36 Disassembling the main shaft....................... 159 20.3 Changing the engine oil and oil filter,
17.4.37 Disassembling the countershaft................... 159 cleaning the oil screens.................................... 188
17.4.38 Checking the transmission........................... 160 20.4 Adding engine oil............................................... 190
17.4.39 Assembling the main shaft........................... 161 20.5 Checking the engine oil pressure..................... 190
17.4.40 Assembling the countershaft........................ 162 21 IGNITION SYSTEM......................................................... 192
17.4.41 Checking the starter drive............................. 163 21.1 Ignition coil - checking the secondary
17.4.42 Checking the freewheel................................ 163 winding............................................................... 192
17.4.43 Removing the freewheel............................... 164 21.2 Checking the spark plug connector.................. 192
17.4.44 Installing the freewheel................................. 164 21.3 Alternator - checking stator winding................. 192
17.5 Engine assembly................................................ 165 21.4 Removing the stator........................................... 193
17.5.1 Installing the crankshaft............................... 165 21.5 Installing the stator............................................ 193
17.5.2 Installing the transmission shafts................. 165 22 ELECTRIC STARTER...................................................... 194
17.5.3 Installing the shift forks................................ 165 22.1 Checking the starter motor............................... 194
17.5.4 Installing the shift drum................................ 166 23 THROTTLE VALVE BODY.............................................. 195
17.5.5 Installing the shift rails.................................. 166 23.1 Adjusting the idle speed................................... 195
17.5.6 Installing the left engine case....................... 166 23.2 Executing the initialization run.......................... 195
17.5.7 Installing the freewheel gear......................... 167 24 TECHNICAL DATA......................................................... 197
17.5.8 Installing the primary gear............................ 167 24.1 Engine................................................................. 197
17.5.9 Installing the force pump.............................. 167 24.2 Tolerance, engine wear limits........................... 197
17.5.10 Installing the locking lever............................ 168 24.3 Engine tightening torques................................. 198
17.5.11 Installing the shift drum locating unit.......... 169 24.4 Capacities.......................................................... 199
17.5.12 Installing the shift shaft................................ 169 24.4.1 Engine oil....................................................... 199
17.5.13 Installing the starter idler gear...................... 169 24.4.2 Coolant.......................................................... 199
17.5.14 Installing the torque limiter............................ 169 24.4.3 Fuel................................................................. 199
17.5.15 Installing the outer clutch hub....................... 169 24.5 Chassis.............................................................. 199
17.5.16 Installing the clutch discs............................. 170 24.6 Electrical system................................................ 200
17.5.17 Installing the clutch cover............................. 172 24.7 Tires.................................................................... 200
17.5.18 Installing the water pump cover.................... 173 24.8 Fork..................................................................... 200
17.5.19 Installing the suction pump.......................... 173 24.9 Shock absorber................................................. 201
TABLE OF CONTENTS
24.10 Chassis tightening torques................................. 201
25 CLEANING/PROTECTIVE TREATMENT....................... 203
25.1 Cleaning the motorcycle................................... 203
26 STORAGE........................................................................ 204
26.1 Storage.............................................................. 204
26.2 Preparing for use after storage......................... 204
27 SERVICE SCHEDULE..................................................... 205
27.1 Service schedule................................................ 205
27.2 Service work (as additional order).................... 206
28 WIRING DIAGRAM......................................................... 208
28.1 Page 1 of 3 (FC EU)........................................... 208
28.2 Page 2 of 3 (FC EU)........................................... 210
28.3 Page 3 of 3 (FC EU)........................................... 212
28.4 Page 1 of 3 (FC US)........................................... 214
28.5 Page 2 of 3 (FC US)........................................... 216
28.6 Page 3 of 3 (FC US)........................................... 218
29 SUBSTANCES................................................................ 220
30 AUXILIARY SUBSTANCES............................................. 221
31 SPECIAL TOOLS............................................................ 223
32 STANDARDS.................................................................. 237
INDEX...................................................................................... 238
1 MEANS OF REPRESENTATION 6
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).
0‘ Indicates a page reference (more information is provided on the specified page)
Indicates information with more details or tips,
Indicates the result of a testing step

»
Denotes a voltage measurement,
Denotes a current measurement,
Denotes a resistance measurement.
1.2 Formats used

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
2.1 Repair Manual

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.
2.2 Safety advice

A number 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
I The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If
they are missing, you or others may not recognize dangers and may therefore be injured.
2.3 Degrees of risk and symbols

Danger
Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.
Warning
Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Indicates a danger that may lead to minor injuries if the appropriate measures are not taken.
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.
2.4 Work rules

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 (e.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. Loctite®) 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 8
3.1 Manufacturer and implied warranty

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; otherwise, all warranty
claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by
the warranty.
Additional information on the manufacturer or implied warranty and the procedures involved can be found in the Service & Warranty
Booklet.
3.2 Operating and auxiliary substances

Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
- Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Use the operating and auxiliary substances (such as fuel and lubricants) as specified in the manual.
3.3 Spare parts, accessories

Only use spare parts and accessories approved and/or recommended by Husqvarna. Husqvarna accepts no liability 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.
International Husqvarna Motorcycles website: www.husqvarna-motorcycles.com
3.4 Figures
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 9
4.1 Chassis number

The chassis number o is stamped on the right side of the steering head.
4.2 Type label

The type label o is fixed to the front of the steering head.
4.3 Engine number

The engine number o is stamped on the left side of the engine under the engine
sprocket.
4.4 Fork part number

The fork part number o is stamped on the inside of the axle clamp.
4.5 Shock absorber article number

The shock absorber article number O is stamped on the top of the shock absorber
above the adjusting ring towards the engine side.
5 MOTORCYCLE 10
5.1 Raising the motorcycle with a lift stand

Note
Danger of damage The parked vehicle can roll away or fall over.
- Park the vehicle on a firm and level surface.
- Raise the motorcycle at the frame underneath the engine.
Lift stand (81329955000) p p. 231)

S Neither wheel is in contact with the ground.
- Secure the motorcycle against falling over.
5.2 Removing the motorcycle from the lift stand

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 lift stand.

Remove the lift stand.
To park the motorcycle, insert plug-in stand O into the left side of the wheel
spindle.
• Info
I Remove the plug-in stand before riding.
5.3 Starting
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 revving 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 o

- Shift gear to neutral.
Condition
Ambient temperature: < 20 °C (< 68 °F)
- Pull the cold start button out all the way.
5 MOTORCYCLE 11
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.
5.4 Starting the motorcycle for a check

Danger
Info
Press the starter for a maximum of 5 seconds. Wait for at least 5 seconds before trying again.
Shift the transmission to idle.

Press the electric starter button ©.
• Info
I Do not open the throttle.
6 FORK, TRIPLE CLAMP 12
6.1 Adjusting the compression damping of the fork

• Info
I The hydraulic compression damping determines the fork suspension behavior.
Turn the white adjusting screw o all the way clockwise.
• Info
I Adjusting screw o is located at the upper end of the 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 leg REB
(red adjusting screw).
Turn back counterclockwise by the number of clicks corresponding to the fork

type.
Guideline
Compression damping
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
• Info
I Turn clockwise to increase damping; turn counterclockwise to reduce
damping.
6.2 Adjusting the rebound damping of the fork

• Info
I The hydraulic rebound damping determines the fork suspension behavior.
Turn the red adjusting screw o all the way clockwise.
• Info
I Adjusting screw o is located at the upper end of the right fork leg.
The rebound damping is located in the right fork leg REB (red adjusting
screw). The compression damping is located in the left fork leg COMP
(white adjusting screw).
Turn back counterclockwise by the number of clicks corresponding to the fork

type.
Guideline
Rebound damping
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
• Info
damping.
6.3 Bleeding the fork legs

Preparatory work
- Raise the motorcycle with a lift stand. ( p. 10)
Main work
- Release bleeder screws o
S Any excess pressure escapes from the interior of the fork.
- Tighten the bleeder screws.
Finishing work
- Remove the motorcycle from the lift stand. ( p. 10)
6.4 Cleaning the dust boots of the fork legs

Preparatory work
- Raise the motorcycle with a lift stand. (S3 p. 10)
- Remove the fork protector. ( p. 14)
Main work
- Push dust boots o of both fork legs downward.
• Info
I The dust boots remove dust and coarse dirt particles from the inside fork
tubes. Over time, dirt can accumulate behind the dust boots. If this dirt is
not removed, the oil seals behind can start to leak.
Warning
Danger of accidents Oil or grease on the brake discs reduces the brak-
ing effect.
- Always keep the brake discs free of oil and grease.
- Clean the brake discs with brake cleaner when necessary.
- Clean and oil the dust boots and inner fork tubes of both fork legs.
Universal oil spray (H p. 222)
- Press the dust boots back into their installation position.

- Remove excess oil.
Finishing work
- Install the fork protector. ( p. 15)
6.5 Removing the fork legs

Preparatory work
- Remove the front wheel. ( p. 85)
Main work
- Remove screws o and take off the clamp.
- Remove screws © and take off the brake caliper.
- Allow the brake caliper and brake line to hang tension-free to the side.
• Info
I Do not pull the hand brake lever if the front wheel has been removed.
Loosen screws © . Take out the left fork leg.

Unscrew screws Q. Take out the right fork leg.
6.6 Installing the fork legs

Main work
- Position the fork legs.
y Bleeder screws o face forward.
• Info
I The compression damping is located in the left fork leg COMP (white
adjusting screw). The rebound damping is located in the right fork leg REB
(red 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.
Tighten screws
Guideline
Screw, top triple clamp M8 17 Nm (12.5 Ibfft)
Tighten screws ©.
Guideline
Screw, bottom triple clamp M8 12 Nm (8.9 Ibfft)
- Position the brake caliper. Mount and tighten screws ©

Guideline
Screw, front brake caliper M8 25 Nm Loctite® 243™
(18.4 Ibf ft)
- Position the brake line and clamp. Mount and tighten screws Q.
Finishing work
- Install the front wheel. ( p. 86)
6.7 Removing the fork protector

Remove screws O on the left fork leg. Take off the clamp.
Remove screws 0 on the left fork leg. Take off the left fork protector.
Remove screws © on the right fork leg. Take off the right fork protector.
6.8 Installing the fork protector

- Position the fork protector on the left fork leg. Mount and tighten screws ©
Guideline
Remaining screws, chassis M6 10 Nm (7.4 Ibf ft)
- Position the brake line and clamp. Mount and tighten screws ©
- Position the fork protector on the right fork leg. Mount and tighten screws ©
Guideline
6.9 Performing a fork service

Condition
The fork legs have been removed.
- Disassemble the fork legs. (2J 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)
- Assemble the seal ring retainer. ( p. 23)
- Assemble the hydrostop unit. (IS p. 24)
- Assemble the piston rod. ( p. 25)
- Assemble the cartridge. ( p. 26)
- Assemble the fork legs. ( p. 27)
6.10 Disassembling the fork legs

• Info
i The steps are identical for both fork legs.
Condition
The fork legs are disassembled.
- Note down the current state of rebound damping o REB (red adjuster of right
fork leg).
- Note down the current state of compression damping © COMP (white adjuster
of left fork leg).
- Fully open the adjusters of the rebound and compression damping.
Clamp the fork leg in the area of the lower triple clamp.
Clamping stand (T1403S) ( p.234)
Remove the screw. Remove adjuster ©
Release screw cap ©.
Special socket (T14047) ( p. 235)
• Info
I The cartridge cannot be taken off yet.
Unclamp the fork leg.

Push the outer tube down. Drain the fork oil.
Clamp the fork leg with the axle clamp.

Release hydrostop unit © and remove it.
• Info
I Do not use an impact wrench.
Place a pan underneath since oil will run out.
Remove the cartridge from the fork leg.
Removing the O-ring seat from the cartridge usually requires the applica
tion of force.
Remove dust boot ©

Remove fork protection ring ©.
• Info
I The fork protection ring does not necessarily need to be removed for
repair work.
201705-10
Remove lock ring e
• Info
I The lock ring has a ground end against which a screwdriver can be posi
tioned.
Warm the outer tube in area © of the lower sliding bushing.

Guideline
50 °C (122 °F)
Pull the outer tube forcefully off of the inner tube.
• Info
I The lower sliding bushing © must be pulled out of its bearing seat.
Remove the upper sliding bushing ©
Info
Do not use a tool; pull the ends apart slightly by hand
Take off the lower sliding bushing ©

Take off support ring ©
Take off seal ring ©
Take off lock ring ©
Take off dust boot ©
Unclamp the fork leg.
6.11 Removing the spring

• Info
I The steps are identical for both fork legs.
Preparatory work
- Disassemble the fork legs. ( p. 15)
Main work
- Pull the spring down. Mount the open end wrench on the hexagonal part.
Clamp the open end wrench in the vise. Release screw cap o but do not
remove it yet.
Special socket (T14047) (SI p. 235)
Pull the spring down. Remove the open end wrench.

Remove the screw cap.
Remove the spring with the preload spacer(s).
6.12 Disassembling the cartridge

• Info
Preparatory work
Main work
- Degrease piston rod o and clamp it in the vise.
- Remove adjusting tube © . Unscrew spring guide ©
Remove spring seat ©

Pull the piston rod out of the cartridge.
201726-12
Clamp the tube of the cartridge into a vise.
Release seal ring retainer 0 and remove with the washer.

- Remove lock ring ©

- Pull reservoir © off of the tube.
- Pull sleeve © out of the reservoir.

- Remove spring ©
- Remove seal rings © and O-ring ©

- Remove pilot bushings ©
6.13 Disassembling the cartridge

• Info
i The steps are identical for both fork legs.
Preparatory work
Main work
- Degrease piston rod o and clamp it in the vise.

- Remove adjusting tube © . Unscrew spring guide ©
- Remove spring seat ©

- Pull the piston rod out of the cartridge.
- Clamp the tube of the cartridge into a vise.

- Release seal ring retainer © and remove with the washer.
Remove lock ring ©

Pull reservoir O off of the tube.
Pull sleeve © out of the reservoir.
© © Remove spring ©
201795-10
Remove seal rings © and O-ring ©

Remove pilot bushings ©
6.14 Disassembling the piston rod

• Info
I The steps are identical for both fork legs, except for the hydrostop needle and valve.
Preparatory work
- Disassemble the cartridge. (BS p. 19)
Main work
O - Degrease the piston rod.
- Clamp the piston rod with the special tool as far up as possible.
Clamping stand (T14049S) (®S p. 235)
- Release hydrostop needle o and remove it from the piston rod.

S The valve © usually remains in the hydrostop needle.
0]
flJI Info
201728-10
© - silver hydrostop needle on compression damping side.
© - red hydrostop needle on rebound damping side.
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.
201789-10
6.15 Disassembling the hydrostop unit

• Info
Preparatory work
Main work
- Mount the hydrostop unit on a fitting hexagon socket and clamp into a vice.
- Remove sleeve o
- Remove shim stack ©
Remove adapter ©
Remove hub Q with washers ©
• Info
I It is possible that only one washer or no washer is present.
Remove the O-ring from the hub.
Remove shim stack ©

Remove washer o
Remove O-ring ©
6.16 Disassembling the seal ring retainer

Info
The steps are identical for both fork legs.
Preparatory work
- Disassemble the cartridge. ( . p. 19)
Main work
- Remove pilot bushing support ©
- Remove O-ring © and seal ring ©.
6.17 Checking the fork legs

Condition
The fork legs have been disassembled.
- Check the inner tube and axle clamp for damage.
» If there is damage:
- Change the inner tube.
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)
» If the measured value is smaller than the specified value:

Measure the run-out of the inner tube.

Inner tube run-out < 0.20 mm (< 0.0079 in)
» If the measured value is larger than the specified value:

Measure the inside diameter at multiple locations of the outer tube.

Inside diameter of outer tube <49.20 mm (< 1.937 in)

- Change the outer tube.
Check the outer tube for damage.
» If there is damage:
- Change the outer tube.
Check the surface of the sliding bushings.

» If the bronze-colored layer under sliding layer 0 is visible or the surface
is rough:
- Change the sliding bushings.
Check the spring length.

Guideline
Spring length with preload spacer(s) 480 mm (18.9 in)

- Reduce the thickness of the preload spacers.
» If the measured value is smaller than the specified value:
- Increase the thickness of the preload spacers.
200666-10
6.18 Assembling the seal ring retainer

Info
Mount and grease seal ring ©.
Lubricant (T158) ( p. 221)
Mount and grease O-ring ©.
Position pilot bushing support ©.
6.19 Assembling the hydrostop unit

Info
Mount and grease O-ring ©-
Lubricant (T158) {& p. 221)
Mount washer ©
Mount shim stack © with the smaller washers facing downward.
Mount the new O-ring on hub ©.

Mount the hub with washers ©
• Info
I It is possible that only one or no washer is present.
Mount and tighten adapter 0

Guideline
Hydrostop unit adapter M6x0.5 7 Nm (5.2 Ibf ft)
Mount shim stack © with the smaller washers facing downward.

Mount and tighten sleeve ©
Guideline
Hydrostop unit sleeve M6x0.5 7 Nm (5.2 Ibf ft)
Check distance Q and total length 0 of the hydrostop.

Guideline
Hydrostop distance >1.5 mm (> 0.059 in)
Hydrostop length 108.5... 109.5 mm (4.272... 4.311 in)
» If the dimensions are out of tolerance:
- Add or remove washers ©.
201975-10
6.20 Assembling the piston rod

• 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.
Lubricate the O-ring. Mount valve needle O 'n the piston rod.
Mount spring ©
Mount and tighten adapter © with spring © and washer.
Guideline
J Adapter of piston rod M6x0.5 12 Nm (8.9 1 bf ft)
201791-10
Position the spring.

Mount the compression shim stack © with the smaller washers facing down
ward.
Grind the piston on both sides on a surfacing plate using 1200 grit sandpaper.
Clean the piston.
Lubricate the piston ring.
Mount the piston with chamfer © facing down.
Mount the rebound shim stack © with the smaller washers facing upward.
Press the piston downward against the spring.

y The piston should not squeeze the shims.
Position valve e in the hydrostop needle ©. Mount and tighten the hydrostop
needle.
Guideline
Hydrostop needle on piston rod M6x0.5 7 Nm (5.2 Ibf ft)
• Info
i © - silver hydrostop needle on compression damping side.
© - red hydrostop needle on rebound damping side.
- Unclamp the piston rod.
6.21 Assembling the cartridge

• Info
Preparatory work
Main work
- Mount and grease seal rings O ar|d O-ring
Lubricant (T158) (IS p. 221)
- Mount and lubricate pilot bushings ©
- Check the length of the reservoir spring.

Guideline
Reservoir spring length with preload 46 mm (1.81 in)
spacer
» If the length is out of tolerance:

- Correct the preload spacers.
- Position the spring with the preload spacers in the reservoir.
- Position sleeve Q in the reservoir.
- Clamp the tube of the cartridge into a vise.
- Slide reservoir © onto the tube.
• Info
I Hold the sleeve in the reservoir to prevent it from sliding out.
- Mount lock ring ©
- Mount seal ring retainer © with the washer and tighten.

Guideline
Seal ring retainer M23.5x0.75 46 Nm Loctite® 2701 ™
(33.9 Ibf ft)
- Unclamp the cartridge.

Slide piston rod © into the cartridge.
• Info
I Ensure that the piston ring is seated correctly.
Mount spring seat ©
201797-10
Degrease piston rod © and clamp in the vise.
Screw spring guide © all the way on.
• Info
I 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 spacer(s).
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.
Preparatory work
- Assemble the hydrostop unit. ( p. 24)
Main work
- Clamp the inner tube with the axle clamp.
Guideline
Use soft jaws.
- Mount special tool.

Protecting sleeve (T1401) ( p.234)
- Lubricate and mount dust boot o
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) (SB p. 221)
• Info
I Mount with the sealing lip facing down and the open side facing up.
- Slide on support ring ©

- Remove the special tool.
Grind the edges of the sliding bushings with sandpaper grit 600, clean the bush
ings and lubricate them.
Slide on the lower sliding bushing 0

Mount the upper sliding bushing ©
• Info
I Do not use a tool; pull the ends apart slightly by hand.
Warm the outer tube in area Q 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 of the special tool.
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.
Push the seal ring and support ring all the way into the outer tube.
Mount lock ring 0
Info
The lock ring must engage audibly.
Mount dust boot o

Mount fork protection ring ©.
201705-11
Lubricate the O-ring. Slide the cartridge all the way into the fork leg.
Turn the fork. Have the entire filling quantity of fork oil available.
Oil capacity per 665 ml Fork oil (SAE 4) (48601166S1)
fork leg (22.48 fl. oz.) (tt p. 220)
Add some of the fork oil while pulling out and pushing in the piston rod numerous
times.
Guideline
Fork oil quantity 510 ml (17.24 fl. oz.)
Mount and tighten hydrostop unit o

Guideline
Hydrostop unit M30x1 40 Nm (29.5 Ibf ft)
Clamp the fork vertically.

Add the remaining quantity of fork oil.
Pull out the piston rod and push it back in numerous times while pressing it to
one side slightly.
y Air bubbles emerge and the cartridge is bled.
Keep bleeding until no more air bubbles emerge.
y The piston rod moves out automatically to the middle of the total stroke
distance.
• Info
I When fully bled, the correct air chamber length is achieved automatically.
Position spring.
Pull the spring down. Mount screw cap (•).
• Info
I When assembling, ensure that the screw caps are correctly mounted
according to the hydrostop needles.
Rebound damping side - red hydrostop needle, screw cap with
mark REB.
Compression damping side - silver hydrostop needle, screw cap with
mark COMP.
- Pull the spring down. Mount the open end wrench on the hexagonal part.
- Hold the open end wrench. Tighten screw cap ©.
Guideline
Screw cap on piston rod M8x0.75 18 Nm (13.3 Ibfft)
- Push the outer tube up.

- Clamp the outer tube in the area of the lower triple clamp.
Clamping stand (T1403S) ( 1 p. 234)
Tighten screw cap ©.

Guideline
Cartridge on outer tube M51x1.5 40 Nm (29.5 Ibf ft)
Mount the adjuster. Mount and tighten screw ©.

Guideline
Screw, adjuster M4x0.5 2.5 Nm
(1.84 Ibf ft)
201700-11
Alternative 1
- Turn the adjuster of compression damping © (mark COMP) and the adjuster
of rebound damping (mark REB) all the way clockwise.
Guideline
Rebound damping
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Compression damping
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
- Turn counterclockwise by the number of clicks corresponding to the fork
type.
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.
Set the adjusters to the positions determined upon removal.

6.23 Greasing the steering head bearing

- Remove the lower triple clamp. ( p. 31)
- Install the lower triple clamp. ( p. 32)
• •••••• •
• m*
a 0
•
|
•
•
•
•
•
• %
%
• %
• _ %
« « * \
• 1 \ »
• | \ %
'* ** *
800010-10
6.24 Removing the lower triple clamp

Preparatory work
- Raise the motorcycle with a lift stand. (£! p. 10)
- Remove the front wheel. ( p. 85)
- Remove the fork legs. ( p. 13)
- Remove the handlebar cushion.
- Remove the start number plate. ( p. 82)
- Remove the front fender. (®J p. 82)
Main work
- Take off cable holder o in front of the left radiator.
- Remove screw ©.
- Remove screw ©.
- Take off the top triple clamp with the handlebar and set it aside.
• Info
I Protect the components against damage by covering them.
Do not bend the cables and lines.
- Remove O-ring ©. Remove protective ring

- Take out the lower triple clamp with the steering stem.
- Take out the upper steering head bearing.
6.25 Installing the lower triple clamp

Main work
- Clean the bearing and sealing elements, check for damage, and grease.
High viscosity grease (8i p. 221)
- Insert the lower triple clamp with the steering stem. Mount the upper steering
head bearing.
- Check whether upper steering head seal o is correctly positioned.
- Slide on protective ring and O-ring ©
- Position the upper triple clamp with the handlebar.

- Mount screw o but do not tighten yet.
- Position the fork legs.

^ Bleeder screws © are positioned toward the front.
• Info
I The rebound damping is located in right fork leg REB (red adjusting
screw). The compression damping is located in left fork leg COMP (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.
Tighten screws ©.
Guideline
Screw, bottom triple clamp M8 12 Nm (8.9 Ibfft)
- Tighten screw ©
Guideline
Screw, top steering head M20x1.5 12 Nm (8.9 Ibf ft)
- Mount and tighten screw o

Guideline
Screw, top steering stem M8 17 Nm Loctite® 243™
(12.5 Ibf ft)
Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses.
Tighten screws ©.
Guideline
Screw, top triple clamp M8 17 Nm (12.5 Ibf ft)
Secure the wiring harness with cable holder ®.
Position the brake caliper. Mount and tighten screws

Guideline
Screw, front brake caliper M8 25 Nm Loctite® 243™
(18.4 Ibf ft)
Position the brake line and clamp. Mount and tighten screws (ty.
Finishing work
- Install the front fender. ( p. 82)
- Install the start number plate. (S3 p. 83)
- Install the front wheel. (S3 p. 86)
- Check that the wiring harness, throttle cables, and brake and clutch lines can
move freely and are routed correctly.
- Check the steering head bearing play. ( p. 33)
- Mount the handlebar cushion.
6.26 Checking the steering head bearing play

Warning
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components.
- Correct incorrect steering head bearing play immediately.
• Info
I If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam
aged over time.
Preparatory work
Main work
- Move the handlebar to the straight-ahead position. Move the fork legs to and fro
in the direction of travel.
No play should be noticeable in the steering head bearing.
» If there is noticeable play present:

- Adjust the steering head bearing play. ( p. 35)
- 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. ( p. 35)
- Check the steering head bearing and change if necessary.
Finishing work
6.27 Changing the steering head bearing

Preparatory work
- Remove the front wheel. (13 p. 85)
- Remove the fork legs. ( p. 13)
- Remove the front fender. (CU p. 82)
- Remove the lower triple clamp. ( p. 31)
Main work
- Remove the lower bearing race o using a suitable tool.
- Press in the new bearing race all the way using a suitable tool.
- Remove the upper bearing race © using a suitable tool.
^G01806-10
- Press in the new bearing race all the way using a suitable tool.
- Pull off bearing ©

- Remove seal ring retainer.
- Remove O-ring.
- Grease the new O-ring and mount with seal ring retainer.
- Press on the new bearing with a suitable tube as far as it will go.
Finishing work
- Install the lower triple clamp. ( p. 32)
- Install the front fender. ( p. 82)
- Install the start number plate. ( p. 83)
- Install the front wheel. (M p. 86)
- Check that the wiring harness, throttle cables, and brake and clutch lines can
move freely and are routed correctly.
6.28 Adjusting the steering head bearing play

Preparatory work
Main work
- Loosen screws ©
- Remove screw ©
- Loosen and retighten screw ©
Guideline
Screw, top steering head M20x1.5 12 Nm (8.9 Ibf ft)
- Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses.
- Mount and tighten screw
Guideline
Screw, top steering stem M8 17 Nm Loctite® 243™
(12.5 Ibf ft)
Tighten screws O-
Guideline
Screw, top triple clamp M8 17 Nm (12.5 Ibf ft)

Finishing work
7 HANDLEBAR, CONTROLS 36
7.1 Handlebar position

On the upper triple clamp, there are two holes at a distance of Q to each other.
Hole distance A 15 mm (0.59 in)
The holes on the handlebar support are placed at a distance of © from the center.
Hole distance B 3.5 mm (0.138 in)

The handlebar can be mounted in four different positions. In this way, the handlebar
can be mounted in the most comfortable position for the rider.
7.2 Adjusting the handlebar position

Remove screws o . Take off the handlebar clamps. Take off the handlebar and
lay it to one side.
• Info
Do not bend the cables and lines.
Remove screws © Remove the handlebar supports.

Place the handlebar supports in the required position. Mount and tighten
screws ©
Guideline
Screw, handlebar support Ml 0 40 Nm Loctite® 243™
(29.5 Ibf ft)
• Info
I Position the left and right handlebar supports evenly.
- Position the handlebar.
• Info
1 Make sure the cables and wiring are positioned correctly.
Position the handlebar clamps. Mount and tighten screws O evenly.

Guideline
Screw, handlebar clamp M8 20 Nm (14.8 Ibf ft)
7.3 Adjusting the basic position of the clutch lever

the basic setting of the clutch lever to your hand size by turning adjusting
o
Info
Turn the adjusting screw counterclockwise to decrease the distance
between the clutch lever and the handlebar.
Turn the adjusting screw clockwise to increase the distance between the
clutch lever and the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!
7.4 Checking the throttle cable routing

Preparatory work
- Remove the seat. ( p. 73)
- Remove the fuel tank. ( p. 73)
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.
» If the throttle cable is not routed as specified:

- Correct the throttle cable routing.
Finishing work
- Install the fuel tank. ( p. 74)
- Mount the seat. ( p. 73)
7.5 Checking the play in the throttle cable

Check the throttle grip for smooth operation.
Move the handlebar to the straight-ahead position. Turn the throttle grip back and
forth slightly and determine the play in throttle cable ©
Play in throttle cable 3... 5 mm (0.12... 0.2 in)
» If the throttle cable play does not meet specifications:

- Adjust the play in the throttle cable. ( p. 38)
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may
result in unconsciousness and death.
- Always make sure there is sufficient ventilation when running the
engine.
- Use an effective exhaust extraction system when starting or running
the engine in an enclosed space.
- Start the engine and let it run idle. Move the handlebar to and fro over the entire
steering range.
The idle speed must not change.
» If the idle speed changes:

- Adjust the play in the throttle cable. ( p. 38)
7.6 Adjusting the play in the throttle cable

Preparatory work
- Remove the seat. (U p. 73)
- Check the throttle cable routing. ( p. 37)
Main work
- Move the handlebar to the straight-ahead position.
- Push back sleeves ©
- Loosen nut © . Turn adjusting screw in as far as possible.
- Loosen nut o . Turn adjusting screw © so that there is play in the throttle cable
at the throttle grip.
Guideline
Play in throttle cable 3... 5 mm (0.12... 0.2 in)
Tighten nut ©
- Press and hold the throttle grip in the closed setting. Turn adjusting screw © out
until there is no play in the throttle cable ©
- Tighten nut ©
- Push sleeves o on. Check the throttle grip for smooth operation.
Finishing work
- Check the play in the throttle cable. ( p. 37)
- Install the fuel tank. (SI p. 74)
- Mount the seat, (fil p. 73)
8 FRAME 39
8.1 Checking the frame

Check the frame for cracks and deformation.
» If the frame exhibits cracks or deformation due to a mechanical impact:
- Change the frame.
• Info
I Always replace a frame that has been damaged due to a mechan
ical impact. Repair of the frame is not authorized by Husqvarna
Motorcycles.
9 SHOCK ABSORBER, SWINGARM 40
9.1 Adjusting the high-speed compression damping of the shock absorber

Caution
A Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly.
The shock absorber is filled with highly compressed nitrogen.
- Please follow the description provided.
• Info
I The high-speed setting can be seen during the fast compression of the shock absorber.
Turn adjusting screw o all the way clockwise with a socket wrench.
• Info
I Do not loosen fitting ©.
Turn counterclockwise by the number of turns corresponding to the shock

absorber type.
Guideline
Compression damping, high-speed
Comfort 2.5 turns
Standard 2 turns
Sport 1.5 turns
• Info
damping.
9.2 Adjusting the low-speed compression damping of the shock absorber

Caution
Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly.
Info
The low-speed setting can be seen during the slow to normal compression of the shock absorber.
Turn adjusting screw o clockwise with a screwdriver up to the last perceptible

click.
• Info
I Do not loosen fitting 0
Turn counterclockwise by the number of clicks corresponding to the shock

absorber type.
Guideline
Compression damping, low-speed
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
• Info
damping.
9.3 Adjusting the rebound damping of the shock absorber

Caution
Turn adjusting screw o clockwise up to the last perceptible click.

Turn counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
Rebound damping
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
• Info
damping.
9.4 Measuring rear wheel sag unloaded

Preparatory work
Main work
- Measure the vertical distance between the rear axle and a fixed point such as a
marking on the side cover.
- Note down the value as dimension ©
Finishing work
9.5 Checking the static sag of the shock absorber

Measure distance Q of rear wheel unloaded. ( p. 41)
Hold the motorcycle upright with the aid of an assistant.
Measure the distance between the rear axle and the fixed point again.
Note down the value as dimension ©
• Info
1 The static sag is the difference between measurements © and ©.
Check the static sag.
Static sag 30 mm (1.18 in)
» If the static sag is less or more than the specified value:

- Adjust the spring preload of the shock absorber. ( p. 42)
9.6 Checking the riding sag of the shock absorber

Measure distance Q of rear wheel unloaded. (§1 p. 41)
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.
S The rear wheel suspension levels out.
Another person now measures the distance between the rear axle and a fixed
point.
Note down the value as dimension ©
• Info
I The riding sag is the difference between measurements Q and ©
Check the riding sag.
Riding sag 100 mm (3.94 in)
» If the riding sag differs from the specified measurement:

- Adjust the riding sag. ( p. 43)
9.7 Adjusting the spring preload of the shock absorber

Caution
• Info
I Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.
Preparatory work
- Remove the right side cover. ( p. 72)
- Remove the main silencer. ( p. 68)
- Remove the shock absorber. ( p. 43)
- After removing the shock absorber, clean it thoroughly.
Main work
Loosen screw o
Turn adjusting ring © until the spring is no longer under tension.
Hook wrench (T106S) (S3 p. 232)

- Measure the overall spring length while the spring is not under tension.
- Tighten the spring by turning adjusting ring 0 to measurement ©
Guideline
Spring preload 8 mm (0.31 in)
• Info
l Depending on the static sag and/or the riding sag, it may be necessary to
increase or decrease the spring preload.
Tighten screw O-
Guideline
Screw, shock absorber adjusting ring M5 5 Nm (3.7 Ibf ft)
Finishing work
- Install the shock absorber. ( p. 44)
- Install the main silencer. ( p. 68)
- Install the right side cover. ( p. 73)
9.8 Adjusting the riding sag

Preparatory work
- Raise the motorcycle with a lift stand. (' p. 10)
- Remove the right side cover. ( . p. 72)
- Remove the shock absorber. ( p. 43)
- After removing the shock absorber, clean it thoroughly.
Main work
- Choose and mount a suitable spring.
Guideline
Spring rate
Weight of rider: 65... 75 kg (143... 54 N/mm (308 Ib/in)
165 lb.)
187 lb.)
209 lb.)
• Info
I The spring rate is shown on the outside of the spring.
Finishing work
- Install the shock absorber. ( p. 44)
- Install the main silencer. ( . p. 68)
- Mount the seat. (S p. 73)
- Check the static sag of the shock absorber. ( p. 41)
- Check the riding sag of the shock absorber. ( p. 42)
- Adjust the rebound damping of the shock absorber. (O p. 41)
9.9 Removing the shock absorber

Preparatory work
Main work
- Remove screw O-
- Remove fitting ©
Press angle lever © toward the rear.

Press linkage lever o downward.
Detach springs ©
Remove screw © and take off the manifold.
Remove screws O on both sides.

Loosen screws © on both sides.
Remove screw ©
Raise the rear frame slightly and remove the shock absorber toward the top.
9.10 Installing the shock absorber

Main work
- Raise the rear frame slightly and insert the shock absorber from above.
- Position the shock absorber.
Guideline
Screw, top shock M10 60 Nm Loctite® 2701 ™
absorber (44.3 Ibf ft)
- Position the rear frame.

- Mount and tighten screws @ on both sides.
Guideline
Screw, subframe M8 30 Nm Loctite® 2701 ™
(22.1 Ibf ft)
Remove screws © on both sides.

Mount and tighten screws © on both sides.
Guideline
(22.1 Ibf ft)
- Position the manifold.

- Attach springs ©
Mount and tighten screw ©.

Guideline
Screw, manifold holder M8 15 Nm (11.1 Ibf ft)
- Position the angle lever and linkage lever.

- Mount and tighten fitting ©.
Guideline
Nut, linkage lever to angle lever M14x1.5 80 Nm (59 Ibf ft)
- Mount and tighten screw ©

Guideline
Screw, bottom shock M10 60 Nm Loctite® 2701 ™
Finishing work
- Install the main silencer. (Si p. 68)
- Mount the seat. (8J p. 73)
9.11 Checking the shock absorber linkage

Preparatory work
Main work
- Remove screw o
- Remove screw connection ©
• Info
I Raise the wheel slightly to make it easier to remove the screws.
Remove screw connection ©

Take off the angle lever.
- Check needle bearing Q and © for damage and wear.

» If there is damage or wear:
- Change the needle bearing.
- Check spacers © and O f°r damage and wear.
- Change the spacers.
- Check the shaft seal rings for damage and wear.
- Change the shaft seal rings.
Check dimension ©
54.91... 55.00 mm (2.1618... 2.1654 in)
» If dimension Q is less than the specified value:

- Add the corresponding spacing washers ©
Position the angle lever.

Mount screw connection © but do not tighten yet.
Guideline
Nut, linkage lever on swingarm M14x1.5 80 Nm (59 Ibf ft)
- Mount screw o but do not tighten yet.

Guideline
• Info
I Raise the wheel slightly to make it easier to mount the screw.
Position the linkage lever.

Mount and tighten fitting
Guideline
Nut, linkage lever to angle lever M14x1.5 80 Nm (59 Ibf ft)
• Info
I Raise the wheel slightly to make it easier to mount the screw.
- Tighten screws o
Guideline
- Tighten fitting
Guideline
Nut, linkage lever on swingarm M14x1.5 80 Nm (59 Ibf ft)
Finishing work
9.12 Servicing the shock absorber

Caution
Condition
The shock absorber has been removed.
- Disassemble the damper. ( p. 48)
- Disassemble the piston rod. (II p. 49)
- Disassemble the seal ring retainer. ( p. 50)
- Check the damper. ( p. 52)
- Remove the heim joint. ( p. 52)
- Install the heim joint. ( 3 p. 53)
- Assemble the damper. ( p. 56)
- Install the spring. ( p. 61)
201457-01
9.13 Removing the spring

Condition
- Clamp the shock absorber in the vise using soft jaws for protection.
- Measure and note spring length in its preloaded state.
- Loosen screw o
- Turn adjusting ring until the spring is no longer under tension.
Hook wrench (T106S) (Si p. 232)
- Remove ring ©
- Remove spring retainer © and intermediate washer ©
- Remove the spring.
9.14 Disassembling the damper

Preparatory work
- Remove the spring. ( 3 p. 48)
Main work
- Note down the current state of rebound damping © ar|d compression damp
ing ©.
- Completely open the adjusters of the rebound and compression damping.
- Remove rubber cap © of the reservoir.

- Open screw © slowly.
y The pressurized nitrogen escapes.
- Remove locking cap ©

Press in seal ring retainer © using the special tool.
Disassembly tool (T1216) (v p. 234)
Remove lock ring O-
Info
Do not scratch the inner surface,
Remove the piston rod.
Remove adjusting ring © with the intermediate washer.

Drain the oil.
Remove compression adjuster © . Remove the spring and piston.
9.15 Disassembling the piston rod

Preparatory work
Main work
- Clamp the piston rod with the fork in a vise.
Guideline
Use soft jaws.
- Remove nut o
- Remove washer ©
- Remove rebound shim stack ©
• Info
I Place the rebound shim stack onto a screwdriver and set it down as a unit.
- Remove piston ©
- Remove compression shim stack ©.
• Info
I Place the compression shim stack onto a screwdriver and set it down as a
unit.
- Remove rebound washer ©
- Remove seal ring retainer e

- Remove locking cap © and rubber buffer ©
9.16 Disassembling the seal ring retainer

Preparatory work
- Remove the spring. (US p. 48)
- Disassemble the piston rod. ( p. 49)
Main work
- Remove spring o
- Remove O-ring ©
- Remove rebound rubber ©
Remove centering disk ©

Remove seal ring ©.
201406-10
- Remove washer for seal ring ©

- Remove washer o
- Remove dust boot.
9.17 Changing the pilot bushing

Preparatory work
- Disassemble the piston rod. (S p. 49)
- Disassemble the seal ring retainer. ( p. 50)
Main work
- Press pilot bushing o out of seal ring retainer © with the special tool.
- Slide the new pilot bushing © onto the special tool.
Press drift (T1504) ( p. 235)

Position the pilot bushing in the seal ring retainer using the special tool.
Press drift (T1504) ( p. 235)
Support seal ring retainer © with sleeve © of the special tool. Press the pilot
bushing all the way in.
Assembly tool (T150S) ( p. 235)
Lubricate the special tool.
Shock absorber fluid (SAE 2.5) (50180751 SI) p p. 220)

Calibration pin (T1205) ( p. 233)
Support seal ring retainer © with sleeve © of the special tool.
Assembly tool (T150S) ( p. 235)
Press the special tool through the new pilot bushing.

Calibration pin (T1205) ( p. 233)
y The pilot bushing is calibrated.

Finishing work
9.18 Checking the damper

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 < 50.08 mm (< 1.9716 in)
» If the measured value is greater than the specified value:

- Change the damper cartridge.
Check the damper cartridge for damage and wear.
- Change the damper cartridge.
Check the heim joint for damage and wear.
- Change the heim joint.
Measure the diameter of the piston rod.
Piston rod
Diameter > 17.95 mm (> 0.7067 in)
» If the measured value is less than the specified value:

- Change the piston rod.
Measure the run-out of the piston rod.
Piston rod
Run-out < 0.02 mm (< 0.0008 in)

- Check the piston rod for damage and wear.
- Check the piston rings for damage and wear.
» If damage or a bronze-colored surface is visible:
- Change the piston.
9.19 Removing the heim joint

Condition
- Clamp the shock absorber in the vise using soft jaws for protection.
Remove the collar bushing of the heim joint.
- Turn the shock absorber and remove the second collar bushing of the heim joint.
Remove seal rings o on both sides.
Press the heim joint against a lock ring using the special tool.
Pressing tool (T1207S) (SJ p. 233)
Remove the second lock ring ©
Place special tool Q underneath and press out heim joint © with special
tool ©.
Pressing tool (T1207S) (83 p. 233)
Press the heim joint against the lock ring using the special tool.
Pressing tool (T1207S) (iS p. 233)
Mount the second lock ring ©.
Mount seal rings © on both sides.

Position both collar bushings o and press them in.
9.21 Assembling the seal ring retainer

Mount dust boot O using the special tool.
Mounting sleeve (T1204) (t p.233)
Lubricate the sealing lip of the dust boot.
Lubricant (T625) (S3 p. 221)
Mount washer ©
Position washer @ on seal ring ©.
Grease seal ring o and mount with the washer facing downward.
Lubricant (T511) (S3 p. 221)
Mount centering disk ©.
Mount rebound rubber ©

Lubricate the groove of the O-ring.
Lubricant (T158) p p. 221)
Mount O-ring 0
Mount spring ©
9.22 Assembling the piston rod

Preparatory work
Main work
- Clamp the piston rod with the fork in a vise.
Guideline
Use soft jaws.
- Mount rubber buffer o and locking cap ©

- Position special tool on the piston rod.
Mounting sleeve (T1215) (IS p. 233)
- Grease the dust boot and push seal ring retainer © onto the piston rod.
Lubricant (T625) (SS p. 221)

- Mount rebound washer o with the cut-out facing downward.
- Mount the compression shim stack © with the smaller shims facing downward.
- Sand both sides of piston © on a surface plate using 1200-grit sandpaper.

- Clean the piston.
- Assemble the piston.
Guideline
View Q Piston from above
View ({) Piston from below
- Mount the rebound shim stack o with the smaller shims facing upward.
Mount washer © with the collar facing downward.
Grease the thread of the piston rod.

Lubricant (T152) (m p. 221)
Mount and tighten nut ©

Guideline
Nut, piston rod Ml 6x1 45 Nm (33.2 Ibf ft)
9.23 Assembling the damper

Preparatory work
Main work
- Lubricate the O-rings of the compression adjuster.
Lubricant (T158) (S® p. 221)
- Lubricate the threads.

- Mount the piston with the spring.

- Mount and tighten the compression adjuster o
Guideline
Compression adjuster M31x1 45 Nm (33.2 Ibf ft)
- Clamp the damper in a bench vise.

Guideline
Use soft jaws.
- Mount adjusting ring © with the intermediate washer.
Info
The adjusting ring cannot be mounted after the piston rod is mounted.
201390-10
- Fill the damper cartridge about half full.
Shock absorber fluid (SAE 2.5) (50180751 SI) p p. 220)
- Lubricate O-ring © of the seal ring retainer.
Lubricant (T158) (SM p. 221)
- Mount the piston rod carefully.

- Install the seal ring bearer o and push it under the ring groove.
• Info
I 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 © of the damper cartridge.

- Bleed and fill the damper. ( p. 58)
- Fill the damper with nitrogen. ( p. 60)
- Mount rubber cap O °f the reservoir.
Alternative 1
- Turn adjusting screw © clockwise with a screwdriver up to the last percepti
ble click.
- Turn counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
- Turn adjusting screw © all the way clockwise with a socket wrench.
- Turn counterclockwise by the number of turns corresponding to the shock
absorber type.
Guideline
Comfort 2.5 turns
Standard 2 turns
Sport 1.5 turns
- Turn adjusting screw <E> clockwise up to the last perceptible click.

- Turn counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
Rebound damping
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Alternative 2
Warning
- 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 filling port.

Install adapter o on the damper.
• Info
I Tighten only hand-tight, without the use of tools.
Connect the adapter o to connector © of the vacuum pump.

Vacuum pump (T1240S) (SI p. 234)
Clamp the damper with soft jaws or hold it as shown in the figure.
• Info
I Clamp the damper only lightly.
The filling port must be at the highest point.
The piston rod slides in and out during filling - do not hold it tight with your
hand!
Clamp the control lever as shown in the figure.

y The External tank © control lever is on Closed, Damper © on Vacuum,
and Oil reservoir © on Vacuum.
Operate the On/Off switch ©.
y The vacuum pump process starts.
y Pressure gauge © drops to the specified value.
< 0 bar
y The vacuum gauge © falls to the specified value.

4 mbar
Measure distance © between the floating piston and reservoir hole with the spe
cial tool.
Depth micrometer (T107S) (H p. 232)
y The floating piston is positioned all the way at the bottom.

When the vacuum pressure gauge reaches the specified value, turn the Oil reser
voir control lever 0 to Equalize pressure.
Guideline
4 mbar
The pressure gauge increases to the specified value.

0 bar
200267-10
-Check all oil levels regularly!
'rl When the pressure gauge reaches the specified value, turn the Damper control
o
•
lever to Pressure.
Closed ressure Vacuum Guideline
0 bar
Open Vacuum Equalize y Oil is pumped into the damper.
pressure
y The pressure gauge increases to the specified value.

xternal Damper Oil
tank reservoir
3 bar
200268-10
-Chock all oil levels regularly! When the pressure gauge reaches the specified value, turn the Damper o con
trol lever to Vacuum.
Guideline
3 bar
Open Vacuum Equalize

The pressure gauge drops to the specified value.
pressure
0 bar
When the pressure gauge reaches the specified value, turn the Oil reservoir ©
control lever to Vacuum.
Guideline
0 bar
The vacuum gauge falls to the specified value.

8 mbar
When the vacuum pressure gauge reaches the specified value, turn the Oil reser
0
voir control lever to Equalize Pressure.
Guideline
8 mbar

0 bar
When the pressure gauge reaches the specified value, turn the Damper control
lever o to Pressure.
Guideline
0 bar
y Oil is pumped into the damper.

y The pressure gauge increases to the specified value.
3 bar
When the pressure gauge reaches the specified value, turn the Damper o con
trol lever to Vacuum.
Guideline
3 bar
0 bar
When the pressure gauge reaches the specified value, operate the On/Off switch.
Guideline
0 bar
S The vacuum pump is switched off.

Slide O-ring © to the end of the special tool by the specified value (distance ©
minus specified value).
Guideline
10 mm
Depth micrometer (T107S) (US p. 232)
Slide the floating piston into the reservoir to the shortened position using the spe
cial 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 o from connection © of the vacuum pump.
• Info
I Hold the damper so that the filling port is at the highest point.
Remove the adapter.

Guideline
Screw, filling port Ml 0x1 14 Nm (10.3 Ibf ft)
9.25 Filling the damper with nitrogen

Screw in screw o by approx. 2 rotations but do not tighten.
Info
The piston rod is fully extended.
Clamp the special tool in the vise.

Nitrogen filling tool (T170S1) (US p. 236)
Connect the special tool to the pressure regulator of the filling cylinder.
Filling gas - nitrogen
Adjust the pressure regulator.

Guideline
Gas pressure 10 bar (145 psi)
Position the damper in the special tool.

S The hexagonal part of the tap handle © engages in the hexagon socket of
the filling port screw.
- Open filler tap ©

- Fill the damper for at least 15 seconds.
Guideline
• Info
I Watch the pressure regulator dial.
Make sure that the damper is filled to the specified pressure.
- Close the filling port screw using tap handle ©

- Close spigot © and take the damper out of the special tool.
- Tighten the filling port screw.
Guideline
Screw, reservoir filling port M5 3 Nm (2.2 Ibf ft)
9.26 Installing the spring

Ensure that adjusting ring o is screwed on with the intermediate washer.
- Measure the overall spring length while the spring is not under tension.
- Position spring.
Guideline
Spring rate
165 lb.)
187 lb.)
209 lb.)
- Mount intermediate washer © and spring retainer ©

- Mount ring ©
Alternative 1
- Tension the spring to the prescribed amount by turning the adjusting ring.
Guideline
Hook wrench (T106S) ( p. 232)
Alternative 2
Warning
- Tension the spring to the amount measured during dismantling by turning the
adjusting ring.
Hook wrench (T106S) (8S p. 232)

Tighten screw ©
Guideline
Screw, shock absorber adjusting ring M5 5 Nm (3.7 Ibf ft)
9.27 Checking the swingarm

- Check the swingarm for damage, cracking, and deformation.
» If the swingarm shows signs of damage, cracking, or deformation:
- Change the swingarm.
• Info
1 Always change a damaged swingarm. Repair of the swingarm is
not authorized by Husqvarna Motorcycles.
401520-01
9.28 Removing the swingarm

Preparatory work
- Remove the rear wheel. (S3 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
I Cover the components to protect them against damage.
- Remove screws o and ©

- Remove the engine sprocket cover.
Remove connecting link © of the chain.
• Info
Take off the chain.
Remove fitting ©.
Lower the swingarm.
Remove nut ©
Remove the swingarm pivot.
Remove the swingarm.
9.29 Installing the swingarm

Main work
- Position the swingarm. Mount the swingarm pivot.
- Mount and tighten nut ©
Guideline
Nut, swingarm pivot Ml 6x1.5 100 Nm
(73.8 Ibf ft)
Lift the swingarm.

Mount and tighten fitting ©.
Guideline
Nut, linkage lever on swingarm Ml 4x1.5 80 Nm (59 Ibf ft)
- Mount the chain.

- Connect the chain with connecting link ©.
- Position the engine sprocket cover and mount in the holder.

- Mount and tighten screws Q and ©.
Guideline
Screw, clutch slave cylinder M6 10 Nm (7.4 Ibfft)
Remaining screws, chassis M8 25 Nm (18.4 Ibfft)
- Position the brake caliper and pull it back.
- Position the brake line in the guide.
Finishing work
- Install the rear wheel. ( p. 89)
9.30 Changing the swingarm bearing
• Info
I These operations are the same on both swingarm bearings.
Preparatory work
- Remove the rear wheel. (SJJ p. 88)
- Remove the swingarm. ( p. 62)
Main work
- Remove collar bushings o
- Remove bushing ©
- Remove shaft seal rings © using a suitable tool.
- Press out the bearing with a suitable tool.
- Press in the new bearing until it is flush using a suitable tool.

- Press in shaft seal rings
- Mount bushing ©
G01814-10
- Grease the shaft seal rings.
- Position collar bushings o with the shoulder facing inward.
Finishing work
- Install the swingarm. ( p. 63)
10 EXHAUST 67
10.1 Removing the manifold

Detach springs O-
Remove screw 0
Take off manifold.
10.2 Installing the manifold

Position the manifold.
Mount screw o but do not tighten yet.
Guideline
Screw, manifold holder M8 15 Nm (11.1 Ibfft)
Attach springs ©.
Tighten screw O-
Guideline
10 EXHAUST 68
10.3 Removing the main silencer
Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
- Allow the exhaust system to cool down before performing any work on the vehicle.
Preparatory work
Main work
- Disconnect spring O-
- Remove screws © and take off the main silencer.
10.4 Installing the main silencer

Main work
- Mount the main silencer. Mount screws o but do not tighten yet.
- Reconnect spring ©
- Tighten screws O-
Guideline
Finishing work
10.5 Changing the glass fiber yarn filling of the main silencer
Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
- Allow the exhaust system to cool down before performing any work on the vehicle.
• Info
I Over time, the fibers of the glass fiber yarn escape and the damper "burns" out.
Not only is the noise level higher, the performance characteristic changes.
Preparatory work
10 EXHAUST 69
Main work
- Remove all screws on the main silencer.
- Take off silencer cap o and O-ring ©
- Take off outer tube ® and O-ring ©
- Pull glass fiber yarn filling © off of inner tube ©
- Clean the parts that need to be reinstalled and check for damage.
- Mount new glass fiber yarn filling © on inner tube ©
- Slide O-ring © and outer tube © over the glass fiber yarn filling ©
- Insert O-ring © and silencer cap O into outer tube ©.
- Mount and tighten all of the screws.
Finishing work
11 AIR FILTER 70
11.1 Removing the air filter box lid

Release catch 0>pull off the air filter box lid sideways in areas e and ©, and
remove toward the rear.
11.2 Installing the air filter box lid

Position the air filter box lid and tab o Engage the air filter box lid in areas o
and
Engage tab o
11.3 Removing the air filter
Note
Engine damage Unfiltered intake air has a negative effect on the service life of the engine.
Dust and dirt will enter the engine without an air filter.
- Never start to use the vehicle without an air filter.
Warning
Environmental hazard Hazardous substances cause environmental damage.
- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable
regulations.
Preparatory work
- Remove the air filter box lid. ( p. 70)
Main work
- Push air filter holder o toward the air filter at position Q and detach it at
end © . Swing the air filter holder to one side and remove the air filter with the air
filter support.
- Remove the air filter from the air filter support.
11.4 Installing the air filter

Main work
- Mount the clean air filter on the air filter support.
- Grease the air filter in area ©■
11 AIR FILTER 71
- Insert both parts together, position them, and fasten them using air filter
holder o in area ©
S The arrow of marking UP faces upward.
• Info
I If the air filter is not correctly mounted, dust and dirt can enter the engine
and cause damage.
Finishing work
- Install the air filter box lid. (Sfi p. 70)
11.5 Cleaning the air filter and air filter box
Warning
regulations.
Info
Do not clean the air filter with fuel or petroleum since these substances attack the foam.
Preparatory work
- Remove the air filter. ( p. 70)
Main work
- Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.
Air filter cleaning agent (HI p. 221)
• Info
I Only press the air filter to dry it, never wring it out.
- Oil the dry air filter with a high quality filter oil.
Oil for foam air filter (®S p. 221)
- Clean the air filter box.

- Check the intake flange for damage and looseness.
Finishing work
- Install the air filter. ( p. 70)
- Install the air filter box lid. ( p. 70)
11.6 Sealing the air filter box

Preparatory work
- Remove the air filter box lid. (U p. 70)
Main work
- Seal the air filter box in marked area ©
Finishing work
12 FUEL TANK, SEAT, TRIM 72
Danger
A Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled
- Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
- Switch off the engine for refueling.
- Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
- If any fuel is spilled, wipe it off immediately.
- Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
- Avoid skin, eye and clothing contact with fuel.

- Immediately consult a doctor if you swallow fuel.
- Do not inhale fuel vapors.
- In case of skin contact, rinse the affected area with plenty of water.
- Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
- Change your clothing in case of fuel spills on them.
- Keep fuels correctly in a suitable canister, and out of the reach of children.
Warning
Turn filler cap O counterclockwise and lift it off.
12.2 Closing the filler cap

Mount filler cap o and turn it clockwise until the fuel tank is tightly closed.
Info
Run the fuel tank breather hose © without kinks.
12.3 Removing the right side cover

Remove screw o
Pull off the side cover in area © sideways and remove it toward the rear.
12.4 Installing the right side cover

Position the side cover and engage in area O-
Mount and tighten screw o
Guideline
12.5 Removing the seat

- Remove screws ©
- Lift up the seat at the rear, pull it back and then remove it from above.
12.6 Mounting 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.
Make sure that the seat is correctly locked in.
Mount and tighten the screws for securing the seat.
Guideline
12.7 Removing the fuel tank
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
Warning

Preparatory work
Main work
- Unplug connector o 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
I Under no circumstances should dirt enter into the fuel line. Dirt in the fuel
line clogs the injection valve.
- Disconnect the plug-in connection of the fuel line.

- Mount wash cap set ©
Wash cap set (81212016100)
- Remove screws © with the collar bushing.
- Remove screw © with the rubber bushing.
- Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank.
12.8 Installing the fuel tank
Danger
Warning

Main work
- Check the throttle cable routing. ( p. 37)
- Position the fuel tank and fit the two spoilers to the sides of the radiator bracket.
- Make sure that no cables are trapped or damaged.
- Mount the fuel tank breather.
- Mount and tighten screw o with the rubber bushing.
Guideline
- Mount and tighten screws © with the collar bushing.

Guideline
- Attach connector © of the fuel pump.

- Remove the wash cap set and thoroughly clean the plug-in connection of the fuel
line using compressed air.
• Info
line clogs the injection valve.
- Lubricate the O-ring and connect plug-in connection o of the fuel line.
• Info
I Route the cable and fuel line at a safe distance from the exhaust system.
Finishing work
12.9 Checking the fuel pressure
Danger
Warning

Condition
The fuel tank is completely full.
Ensure that the battery voltage does not drop below 12.5 V.
The diagnostic tool is disconnected.
- Press on the small metal plate and disconnect fuel hose connection ©
• Info
I Remaining fuel may flow out of the fuel hose.
- Mount special tool ©
Pressure tester (61029094000) (KB p. 227)
Mount special tool © with nozzle code 0,60.
Testing hose (61029093000) p p. 227)
Position the hose end in a fuel can.

Guideline
Minimum size, fuel can 10 1(2.6 US gal)
Connect the diagnostic tool and start it.

Select the "Function test of fuel pump control" actuator test.
Guideline
Maximum duration of the actuator test 3 min
Check the fuel pressure with the filler cap closed.
Fuel pressure
When the fuel pump is active 3.3... 3.7 bar (48... 54 psi)
» If the specification is not reached:

- Open the filler cap. ( p. 72)
- Check the tank air vent system.
- Check the fuel pressure with the filler cap open.
Fuel pressure
When the fuel pump is active 3.3... 3.7 bar (48... 54 psi)

- Check that the fuel line is clear.
- Change the fuel filter. ( . p. 78)
- Change the fuel pump. ( p. 77)
- Stop the "Function test of fuel pump control" actuator test by pressing the
"Quit" button.
- Remove the special tools.

- Join the fuel hose connection.
12.10 Changing the fuel pump
Danger
Warning

Warning
Preparatory work
- Drain the fuel from the fuel tank into a suitable container.
- Remove the seat. (US p. 73)
Main work
- Remove nut o with the gasket.
- Remove fuel connection © with the gasket.
- Remove screws ©
Pull out the fuel pump.
Position the fuel pump.

Mount fuel connection © with the gasket but do not tighten yet.
Mount and tighten nut o with the gasket.
Guideline
Nut, fuel pump fastener Ml 2x1.75 15 Nm (11.1 Ibf ft)
Tighten fuel connection

Guideline
Fuel connection on fuel tank M8x1.25 10 Nm (7.4 Ibf ft)
Mount and tighten screws ©.

Guideline
Screw, fuel pump EJOT 3 Nm (2.2 Ibf ft)
G01785-10
Finishing work
12.11 Changing the fuel filter
Danger
Warning

Warning
Preparatory work
- Drain the fuel from the fuel tank into a suitable container.
Main work
- Remove nut o with the gasket.
- Remove fuel connection © with the gasket.
- Remove screws ©.
- Pull out the fuel pump.

- Remove hose clamps ©
- Remove fuel filter ©.
- Press locking mechanism ©

- Pull back fuel pump housing ©
- Change fuel screen @

- Mount the fuel pump housing.
- Mount fuel filter ©

Arrow O points away from the fuel pump.
- Mount hose clamps ©
- Position the fuel pump.

- Mount fuel connection ® with the gasket but do not tighten yet.
- Mount and tighten nut o with the gasket.
Guideline
Nut, fuel pump fastener M12x1.75 15 Nm (11.1 Ibf ft)
Tighten fuel connection ©.

Guideline
Fuel connection on fuel tank M8x1.25 10 Nm (7.4 Ibf ft)

Guideline
Screw, fuel pump EJOT 3 Nm (2.2 Ibf ft)
G01785-10
Finishing work
- Mount the seat. (ES p. 73)
Danger
A Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled
Warning

Warning
Clean plug-in connection o of the fuel line thoroughly with compressed air.
• Info
line clogs the injection valve!
Disconnect the plug-in connection of the fuel line.
• Info
I Remaining fuel may flow out of the fuel hose.
Pull fuel screen © out of the connecting piece.

Insert the new fuel screen all the way into the connecting piece.
Lubricate the O-ring and connect plug-in connection of the fuel line.
Danger
engine.
Start the engine and check the response.

13 MASK, FENDER 82
13.1 Removing the front fender

Preparatory work
Main work
- Remove screws o and 0 . Remove the front fender.
13.2 Installing the front fender

Main work
- Position the front fender. Mount and tighten screws o and
Guideline
Finishing work
- Install the start number plate. ( p. 83)
13.3 Removing the start number plate

Take brake line o out of the brake line guide.
Remove screw Take off the start number plate.
13 MASK, FENDER 83
- Position the start number plate. Mount and tighten screw O-

Guideline
The holding lugs engage.

- Position brake line in the brake line guide.
14 WHEELS 84
Info
I Low tire air pressure leads to abnormal wear and overheating of the tire.
Correct tire air pressure ensures optimal riding comfort and maximum tire service life,
Remove the protection cap.

Check the tire air pressure when the tires are cold.
Tire air pressure off road

Front 1.0 bar (15 psi)
Rear 1.0 bar (15 psi)
» If the tire pressure does not meet specifications:

- Correct the tire pressure.
Mount the protection cap.
14.2 Checking the tire condition
• Info
I Only mount tires approved and/or recommended by Husqvarna Motorcycles.
Other tires could have a negative effect on handling characteristics.
The type, condition, and air pressure of the tires all have a major impact on the handling of the motorcycle.
The tires mounted on the front and rear wheels must have a similar profile.
Worn tires have a negative effect on handling characteristics, especially on wet surfaces.
Check the front and rear tires for cuts, run-in objects, and other damage.
» If the tires have cuts, run-in objects, or other damage:
- Change the tires.
Check the tread depth.
• Info
I Adhere to the legally required minimum tread depth.
Minimum tread depth > 2 mm (> 0.08 in)
» If the tread depth is less than the minimum tread depth:

- Change the tires.
Check the tire age.
• Info
I The tire date of manufacture is usually contained in the tire label and is
indicated by the last four digits of the DOT number. The first two digits
indicate the week of manufacture and the last two digits the year of manu
facture.
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.
14.3 Checking the brake discs
Warning
Danger of accidents Worn-out brake discs reduce the braking effect.
- Make sure that worn-out brake discs are replaced immediately.

14 WHEELS 85
Check the thickness of the front and rear brake discs at multiple points on each
brake disc to ensure it is at least thickness ©
• Info
I Wear reduces the thickness of the brake disc around the area used by the
brake linings.
Brake discs - wear limit

Front 2.5 mm (0.098 in)
Rear 3.5 mm (0.138 in)
» If the brake disc thickness is less than the specified value:

- Change the front brake disc.
- Change the rear brake disc.
Check the front and rear brake discs for damage, cracking, and deformation.
» If the brake disc exhibits damage, cracking, or deformation:
- Change the front brake disc.
- Change the rear brake disc.
14.4 Checking spoke tension
Warning
Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary damage.
The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes is too low, then lat
eral and radial run-out will form in the wheel. Other spokes will become looser as a result.
- Check spoke tension regularly, and in particular on a new vehicle.
Strike each spoke briefly using a screwdriver blade.
• Info
I The frequency of the sound depends on the spoke length and spoke
diameter.
If you hear different tone frequencies from different spokes of equal length
and diameter, this is an indication of different spoke tensions.
You should hear a high note.
» If the spoke tension differs:

- Correct the spoke tension.
Check the spoke torque.
Guideline
Spoke nipple, front wheel M4.5 6 Nm (4.4 Ibf ft)
Spoke nipple, rear wheel M4.5 6 Nm (4.4 Ibf ft)
Torque wrench with various accessories in set (58429094000) ( p. 226)
Preparatory work
Main work
- Press the brake caliper onto the brake disc by hand in order to push back the
brake pistons.
• Info
I Make sure that you do not press the brake caliper against the spokes
when pushing back the brake pistons.
14 WHEELS 86
Loosen screw o by several rotations.

Loosen screws ©.
Press on screw o to push the wheel spindle out of the axle clamp.
Remove screw o
Warning
Danger of accidents Damaged brake discs reduce the braking effect.
- Always lay the wheel down in such a way that the brake disc is not
damaged.
Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.
Info
Do not pull the hand brake lever when the front wheel is removed.
Remove spacers ©
14.5.2 Installing the front wheel
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.

Check the wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn:
- Change the front wheel bearing. ( p. 87)
Clean and grease the shaft seal rings o and mating surfaces © of the spacers.
Long-life grease (IS p. 221)
Insert the spacers.

Position the front wheel and insert the wheel spindle.
S The brake linings are correctly positioned.
Guideline
Screw, front wheel spindle M20x1.5 35 Nm (25.8 Ibf ft)
Operate the hand brake lever several times until the brake linings are seated cor
rectly against the brake disc.
Remove the motorcycle from the lift stand. ( p. 10)
Operate the front brake and compress the fork a few times firmly.
y The fork legs straighten.
Tighten screws ©
Guideline
Screw, fork stub M8 15 Nm (11.1 Ibf ft)
14 WHEELS 87
14.5.3 Removing the brake disc of the front brake

Preparatory work
- Remove the front wheel. ( ; p. 85)
Main work
- Remove screws O- Take off the brake disc.
G01387-10
14.5.4 Installing the brake disc of the front brake

Main work
- Clean the contact surface of the brake disc.
- Position the brake disc with the label facing outward. Mount and tighten
screws ©
Guideline
Screw, front brake disc M6 14 Nm Loctite® 243™
(10.3 Ibf ft)
Finishing work
14.5.5 Changing the front wheel bearing

Preparatory work
- Remove the front wheel. (iS p. 85)
Main work
- Remove shaft seal rings O and ©
- Press out bearing © using a suitable tool.
• Info
I Spacing tube © can be pushed aside.
- Remove the spacing tube.

14 WHEELS 88
- Press out bearing © using a suitable tool.

- Press in the new bearing © all the way using a suitable tool.
• Info
I Only press the bearing in via the outer ring otherwise the bearing will be
damaged when it is pressed in.
- Position spacing tube ©.

- Press in the new bearing 0 all the way using a suitable tool.
• Info
- Grease new shaft seal rings 0 and o and press in until they are flush.
Finishing work
Preparatory work
Main work
(FC EU)
brake piston.
• Info
I Make sure when pushing back the brake piston that you do not press
the brake caliper against the spokes.
- Remove nut o
- Remove chain adjuster 0
. Withdraw wheel spindle 0 only enough to allow
the rear wheel to be pushed forward.
14 WHEELS 89
(FC US)
brake piston.
• Info
I Make sure when pushing back the brake piston that you do not press
the brake caliper against the spokes.
- Remove nut O-
- Remove chain adjuster © . Withdraw wheel spindle © only enough to allow
the rear wheel to be pushed forward.
- Push the rear wheel forward as far as possible. Remove the chain from the rear
sprocket.
• Info
- Holding the rear wheel, withdraw the wheel spindle. Take the rear wheel out of
the swing arm.
• Info
I Do not operate the foot brake when the rear wheel is removed.
Always lay the wheel down in such a way that the brake disc is not dam
aged.
- Remove spacers ©.
14.6.2 Installing the rear wheel
Warning

Main work
- Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
- Change the rear wheel bearing. (63 p. 97)
- Clean and grease the shaft seal rings O ar|d contact surface © of the spacers.
Long-life grease ( p. 221)
- Insert the spacers.
(FC EU)
- Position the rear wheel and insert wheel spindle ©
- Mount the chain.
14 WHEELS 90
- Position chain adjuster © Mount nut © but do not tighten it yet.

- Make sure that chain adjusters © are fitted correctly on adjusting
screws ©.
- Check the chain tension. ( p. 91)
- Tighten nut ©
Guideline
The wide adjustment range of the chain adjusters (32 mm (1.26 in))
enables different secondary ratios with the same chain length.
Chain adjusters © can be turned by 180°.
(FC US)
- Position the rear wheel and insert wheel spindle ©
- Mount the chain.
- Position chain adjuster © . Mount nut © , but do not tighten it yet.

screws ©.
- Check the chain tension. ( p. 91)
- Tighten nut ©
Guideline
Nut, rear wheel spindle M25x1.5 80 Nm (59 Ibfft)
• Info
I The wide adjustment range of the chain adjusters (32 mm (1.26 in))
- Operate the foot brake lever repeatedly until the brake linings are in contact with
the brake disc and there is a pressure point.
Finishing work
14.6.3 Removing the brake disc of the rear brake

Preparatory work
- Remove the rear wheel. ( p. 88)
14 WHEELS 91
Main work
- Remove screws o . Take off the brake disc.
14.6.4 Installing the brake disc of the rear brake

Main work
- Clean the contact surface of the brake disc.
- Position the brake disc with the label facing outward. Mount and tighten
screws O-
Guideline
Screw, rear brake disc M6 14 Nm Loctite® 243™
(10.3 Ibfft)
Finishing work
14.6.5 Checking the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear
more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the rear wheel locks or
the engine will be damaged.
- Check the chain tension regularly.

- Set the chain tension in accordance with the specification.
Preparatory work
Main work
- Pull the chain at the end of the chain sliding component upwards to measure
chain tension ©
• Info
1 The lower chain section Q must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
Chain tension 55... 58 mm (2.17... 2.28 in)
» If the chain tension does not meet specifications:

- Adjust the chain tension. ( p. 92)
Finishing work
14 WHEELS 92
14.6.6 Adjusting the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear
more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the rear wheel locks or
the engine will be damaged.
- Check the chain tension regularly.

- Set the chain tension in accordance with the specification.
Preparatory work
- Check the chain tension. ( . p. 91)
Main work
(FC EU)
- Loosen nut o
- Loosen nuts ©
- Adjust the chain tension by turning adjusting screws © left and right.
Guideline
Chain tension 55 • ■ • 58 mm (2.17... 2.28 in)
Turn adjusting screws © on the left and right so that the markings on the
left and right chain adjusters are in the same position relative to reference
marks © . The rear wheel is now correctly aligned.
- Tighten nuts ©
screws ©.
- Tighten nut o
Guideline
Nut, rear wheel spindle M20x1.5 80 Nm (59 Ibf ft)
• Info
I The wide adjustment range of the chain adjusters (32 mm (1.26 in))
(FC US)
- Loosen nut o
- Loosen nuts ©.
- Adjust the chain tension by turning adjusting screws © left and right.
Guideline
Chain tension 55... 58 mm (2.17... 2.28 in)
Turn adjusting screws © on the left and right so that the markings on the
left and right chain adjusters are in the same position relative to reference
marks © . The rear wheel is now correctly aligned.
- Tighten nuts ©.
screws ©
- Tighten nut ©
Guideline
Nut, rear wheel spindle M25x1.5 80 Nm (59 Ibf ft)
Info
The wide adjustment range of the chain adjusters (32 mm (1.26 in))
14 WHEELS 93
Finishing work
14.6.7 Checking the chain, rear sprocket, engine sprocket, and chain guide
Preparatory work
- Raise the motorcycle with a lift stand. (U p. 10)
Main work
- Shift the transmission to idle.
- Check the rear sprocket and engine sprocket for wear.
» If the rear sprocket or engine sprocket is worn:
- Change the drivetrain kit. ( p. 95)
• Info
I The engine sprocket, rear sprocket, and chain should always be
replaced together.
- Pull at the top part of the chain with the specified weight ©
Guideline
Weight, chain wear measurement 10... 15 kg (22... 33 lb.)
Measure distance © of 18 chain rollers in the lower chain section.
• Info
1 Chain wear is not always even, so you should repeat this measurement at
different chain positions.
Maximum distance © at the longest 272 mm (10.71 in)

chain section
» If the distance Q is greater than the specified measurement:

- Change the drivetrain kit. ( p. 95)
• Info
I When the chain is replaced, the rear sprocket and engine sprocket
should also be changed.
12 3 16 17 18 New chains wear out faster on an old, worn rear sprocket or engine
400987-10 sprocket.
Check the chain sliding guard for wear.

» If the lower edge of the chain pins is in line with or below the chain sliding
guard:
- Change the chain sliding guard.
Check that the chain sliding guard is firmly seated.
» If the chain sliding guard is loose:
- Tighten the screws on the chain sliding guard.
Guideline
Screw, chain sliding M6 6 Nm Loctite® 243™
guard (4.4 Ibf ft)
14 WHEELS 94
- Check the chain sliding piece for wear.

» If the lower edge of the chain pins is in line with or below the chain sliding
piece:
- Change the chain sliding piece.
- Check that the chain sliding piece is firmly seated.
» If the chain sliding piece is loose:
- Tighten the screw on the chain sliding piece.
Guideline
Screw, chain sliding piece M8 15 Nm
(11.1 Ibfft)
- Check the chain guide for wear.
• Info
I Wear can be seen on the front of the chain guide.
» If the light part of the chain guide is worn:

- Change the chain guide.
- Check that the chain guide is firmly seated.

» If the chain guide is loose:
- Tighten the screws on the chain guide.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 Ibfft)
Finishing work
14.6.8 Checking for chain dirt accumulation

Check the chain for coarse dirt accumulation.
» If the chain is very dirty:
- Clean the chain. ( p. 94)
14.6.9 Cleaning the chain
Warning
Danger of accidents Oil or grease on the tires reduces the road grip.
Remove the lubricant from the tires using a suitable cleaning agent.
14 WHEELS 95
Warning

Warning
regulations.
• Info
I The service life of the chain depends largely on its maintenance.
Preparatory work
Main work
- Clean the chain regularly and then treat with chain spray.
Offroad chain spray (H p. 221)
Finishing work
14.6.10 Changing the drivetrain kit

Preparatory work
Main work
- Remove screws o and ©
- Remove the engine sprocket cover.
- Have an assistant operate the rear brake.

- Remove screw with washer.
- Remove connecting link o of the chain.
• Info
- Take off the chain.

14 WHEELS 96
- Remove engine sprocket ©
- Remove fittings © . Take off the rear sprocket.

- Position the new rear sprocket. Mount and tighten the fittings.
Guideline
Nut, rear sprocket screw M8 35 Nm Loctite® 2701 ™
(25.8 Ibf ft)
- Slide new engine sprocket © onto the countershaft.
- Mount the new chain.

- Connect the chain with connecting link ©.
Guideline
The closed side of the chain joint lock must face in the direction of travel.
- Install the rear wheel. (U p. 89)
- Have an assistant operate the rear brake.

- Mount and tighten screw © with the washer.
Guideline
Screw, engine sprocket M10 60 Nm Loctite® 2701 ™
(44.3 Ibf ft)
- Position the engine sprocket cover.

Guideline
Screw, clutch slave cylinder M6 10 Nm (7.4 Ibf ft)

Guideline
Finishing work
14 WHEELS 97
14.6.11 Changing the rear wheel bearing

Preparatory work
Main work
- Remove shaft seal ring o
- Remove shaft seal ring ©
- 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.
- Check spacer washer o for damage and wear.
» If the spacer washer is damaged or worn:
- Replace the spacer washer.
- Position spacer washer ©.

- Press new bearing © all the way in from the outside to the inside.
• Info
14 WHEELS 98
- Clean, grease, and mount spacing tube
- Press new bearing o all the way in from the outside to the inside.
• Info
- Grease new shaft seal ring © and press it in until it is flush.

y The lock ring engages audibly.
- Grease new shaft seal ring O ar|d press it in until it is flush.
Finishing work
15 WIRING HARNESS, BATTERY 99
15.1 Changing the main fuse
Warning
A Fire hazard Incorrect fuses overload the electrical system.
- Only use fuses with the required ampere value.

- Do not bypass or repair fuses.
Info
The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the air filter box lid.
Preparatory work
- Switch off all power consumers and switch off the engine.
Main work
- Take off protection caps o
- Remove the faulty main fuse ©
• Info
1 A defective fuse can be identified by the burned-out fuse wire O-
A spare fuse © is located in the starter relay.
Install a new main fuse.
Fuse (58011109110) p p. 200)
Check that the electrical equipment is functioning properly.
• Tip
l Insert the spare fuse so that it is available if needed.
- Mount the protection caps.
Finishing work
15.2 Removing the battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
- Keep batteries out of the reach of children.

- Wear suitable protective clothing and goggles.
- Avoid contact with battery acid and battery gases.
- Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms.
- In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at
least 15 minutes and contact a physician.
Preparatory work
- Remove the seat. (SE p. 73)
Main work
- Pull back the negative terminal cover o and disconnect the negative cable from
the battery.
- Pull back the positive terminal cover © and disconnect the positive cable from
the battery.
- Detach rubber band © at the bottom.
- Lift out the battery.
15.3 Installing the battery

Main work
- Position the battery in the battery compartment with the terminals facing forward.
Battery (YTX5L-BS) (SS p. 200)

Reconnect rubber band O-
• Info
1 Contact disks © must be mounted under screws © and cable sock-
ets © with the claws toward the battery terminal.
Position the positive cable and mount and tighten the screw.
Guideline
Screw, battery terminal M5 2.5 Nm
(1.84 Ibf ft)
Slide positive terminal cover © over the positive terminal.

Position the negative cable and mount and tighten the screw.
Guideline
Screw, battery terminal M5 2.5 Nm
(1.84 Ibf ft)
- Slide negative terminal cover © over the negative terminal.

Finishing work
15.4 Recharging the battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
- Keep batteries out of the reach of children.

- Wear suitable protective clothing and goggles.
- Avoid contact with battery acid and battery gases.
- Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms.
- In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at
least 15 minutes and contact a physician.
Warning
Environmental hazard Batteries contain environmentally-hazardous materials.
- Do not dispose of batteries as household waste.

- Return batteries to your authorized Husqvarna Motorcycles dealer or dispose of them at a collection point for used bat
teries.
Warning
regulations.
• Info
I Even when there is no load on the battery, it discharges steadily.
The charging level and the method of charging are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the service life of the battery.
If the charging current, charging voltage, and charging time are exceeded, the battery will be destroyed.
If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfated, destroying the
battery.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
Preparatory work
- Remove the seat. (KS p. 73)
Main work
- Connect the battery charger to the battery. Set the battery charger.
Alternative 1
Battery charger XCharge-professional EU (00029095050) ( p. 223)
Alternative 2
Battery charger XCharge-professional US (00029095051) ( p. 223)
Alternative 3
311910-10 Battery charger XCharge-professional GB (00029095052) (11 p. 224)
Alternative 4
Battery charger XCharge-professional CH (00029095053) (El p. 224)
• Info
I Follow the instructions of the charger and the manual.
- Disconnect the battery charger after charging the battery.

Guideline
The charging current, charging voltage, and charging time must not be
exceeded.
Charge the battery regularly when the 3 months
motorcycle is not in use
Finishing work
— Mount the seat. ( p. 73)
15.5 Checking the charging voltage

Condition
The battery must be fully functional and completely charged.
Preparatory work
- Remove the seat. ( . p. 73)
Main work
- Pull back the positive terminal cover.
- Start the motorcycle for a check. ( p. 11)
Measure the voltage between the specified points.
Measuring point Plus (+) - Measuring point Ground (-)
Charging voltage
5,000 rpm 13.5... 15.0 V
» If the displayed value is less than the specified value:

- Check the plug-in connections from the alternator to the voltage regulator.
- Check the plug-in connections from the voltage regulator to the wiring
harness.
- Check the stator winding of the alternator. ( p. 192)
» If the displayed value is greater than the specified value:
- Change the voltage regulator.
Finishing work
- Mount the seat. (EJ p. 73)
15.6 Checking the open-circuit current

Preparatory work
- Remove the seat. (® p. 73)
Main work
- Disconnect the negative cable of the battery.
- Measure the current between battery ground (-) and the negative cable.
• Info
I The value of the quiescent current applies only to vehicles in the original
state, i.e. without additional power consumers.
Maximum open-circuit current <1.0 mA

- Disconnect the voltage regulator from the wiring harness and perform the
measurement again.
- Check the capacitor. ( p. 102)
Finishing work
- Connect the negative cable of the battery.
15.7 Checking the capacitor

Condition
The battery is disconnected.
- Remove the capacitor.
- Discharge the capacitor by bridging the two contacts.
- Connect the capacitor with a 12 V test lamp on one connector and connect it to
the battery as shown in the figure.
• Info
I As the charge of the capacitor increases, the test lamp becomes dimmer.
» The lamp lights up for: 0.5... 2.0 s

The capacitor is functional.
» The lamp lights up for: < 0.5 s
Change the capacitor.
» The lamp lights up for: > 2.0 s
- Discharge the capacitor with a 12 V test lamp as shown in the figure.
• Info
I As the charge of the capacitor decreases, the test lamp becomes dimmer.
» The lamp lights up for: 0.5... 2.0 s

The capacitor is functional.
» The lamp lights up for: < 0.5 s
601204-11 » The lamp lights up for: > 2.0 s
- Install the capacitor.
15.8 Checking the starter relay

Preparatory work
- Remove the seat. (®8 p. 73)
Main work
- Disconnect the negative cable of the battery.
- Pull off connector o
- Pull back the cover.
- Detach cable © from the starter relay.
- Pull the starter relay off of the holder.
- Connect the starter relay to a 12 V power supply as shown.

- Measure the resistance between the specified points.
Resistance of open circuit on
» If the value displayed does not meet specifications:

- Change the starter relay.
601201-10
- Mount the starter relay onto the holder and lay the cable.
- Clamp cable © on the starter relay.
- Position the cover.
- Plug in connector o
- Clamp on the negative cable of the battery.
Finishing work
16 BRAKE SYSTEM 104
16.1 Checking the front brake linings
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
- Ensure that worn-out brake linings are replaced immediately.
Check the brake linings for minimum thickness ©
Minimum thickness Q > 1 mm (> 0.04 in)
» If the minimum thickness is less than specified:

- Change the front brake linings. ( p. 104)
Check the brake linings for damage and cracking.
» If damage or cracking is visible:
- Change the front brake linings. ( p. 104)
16.2 Changing the front brake linings
Warning
Danger of accidents Incorrect maintenance will cause the brake system to fail.
- Ensure that service work and repairs are performed professionally.
Warning
Skin irritation Brake fluid causes skin irritation.
- Keep brake fluid out of the reach of children.

- Wear suitable protective clothing and safety glasses.
- Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
- Consult a doctor immediately if brake fluid has been swallowed.
- Rinse the affected area with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes.
- If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
Warning
regulations.
• Info
I Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5
brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Remove screws ©
Remove cover © with membrane ©
16 BRAKE SYSTEM 105
Manually press the brake caliper toward the brake disc to push back the brake
pistons. Ensure that brake fluid does not flow out of the brake fluid reservoir, if
necessary extract excess.
• Info
I Make sure that you do not press the brake caliper against the spokes
when pushing back the brake pistons.
Remove cotter pins o , pull out pin © , and remove the brake linings.
Clean the brake caliper and brake caliper support.
Check that leaf spring © in the brake caliper and sliding plate © in the brake
caliper support are seated correctly.
Insert the new brake linings, insert pin © , and mount cotter pins ©
• Info
I Always change the brake linings in pairs.
Operate the hand brake lever repeatedly until the brake linings are in contact with
Add brake fluid up to level ©.

Guideline
Level © (brake fluid level below 5 mm (0.2 in)
reservoir rim)
Brake fluid DOT 4 p p. 220)
Position cover © with membrane ©.

Mount and tighten screws ©•
• Info
1 Clean up overflowed or spilled brake fluid immediately with water.
16.3 Checking the free travel of the hand brake lever
Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit.
- Set the free travel on the hand brake lever in accordance with the specification.
16 BRAKE SYSTEM 106
Push the hand brake lever forward and check free travel
Free travel of hand brake lever > 3 mm (> 0.12 in)
» If the free travel does not meet specifications:

- Adjust the basic position of the hand brake lever. ( p. 106)
16.4 Adjusting the basic position of the hand brake lever

Preparatory work
- Check the free travel of the hand brake lever. ( p. 105)
Main work
- Adjust the basic position of the hand brake lever to your hand size by turning
adjusting screw ©
• Info
I Turn the adjusting screw clockwise to increase the distance between the
hand brake lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance
between the hand brake lever and the handlebar.
The range of adjustment is limited.
Only turn the adjusting screw by hand, and do not use force.
Do not make any adjustments while riding.
16.5 Checking the brake fluid level of the front brake
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake
linings are worn down.
- Check the brake system and do not continue riding until the problem is eliminated.
Warning
Preparatory work
- Check the front brake linings. (13 p. 104)
Main work
- Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
- Check the brake fluid level in level viewer ©
» If the brake fluid level has dropped below marking ©
- Add front brake fluid, (d p. 107)
16 BRAKE SYSTEM 107
16.6 Adding front brake fluid
Warning
Warning
A Skin irritation Brake fluid causes skin irritation.

Warning
Warning
regulations.
• Info
brake fluid.
Preparatory work
- Check the front brake linings. ( p. 104)
Main work
- Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
- Remove screws ©
- Remove cover © with membrane ©
- Add brake fluid to level ©.
Guideline
Level Q (brake fluid level below 5 mm (0.2 in)
reservoir rim)
Brake fluid DOT 4 (U p. 220)
Position the cover with the membrane. Mount and tighten the screws.
• Info
16 BRAKE SYSTEM 108
16.7 Changing the front brake fluid
Warning

Warning
regulations.
• Info
I Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Cover the painted parts.
Remove screws o
Remove cover © with the membrane.
Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill
with fresh brake fluid.
Bleed syringe (50329050000) ( p. 225)

Brake fluid DOT 4 (S® p. 220)
Mount bleeder cover ©.
Bleeder cover (00029013005) ( S p. 223)
Connect the bleeding device.
Bleeding device (00029013100) p p. 223)
Open shut-off valve ©
# Info
1 Follow the operating instructions of the bleeding device.
Ensure that the filling pressure is set on pressure gauge ©. Adjust the filling
pressure on pressure regulator © if necessary.
Guideline
Filling pressure 2... 2.5 bar (29... 36 psi)
16 BRAKE SYSTEM 109
Pull off protection cap © of the brake caliper bleeder screw. Connect the hose
of the bleeder bottle.
Open bleeder screw © by approx, one-half turn.
• Info
I Drain until the fresh brake fluid emerges from the hose of the bleeder bot
tle without bubbles.
Tighten the bleeder screw.

Close shut-off valve ©
Open the bleeder screw again until brake fluid stops emerging.
• Info
I 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 ©.
Guideline
Level © (brake fluid level below con 5 mm (0.2 in)
tainer rim)
309386-10
• Info
1 Clean up overflowed or spilt brake fluid immediately with water.
Check the hand brake lever for a firm pressure point.
16.8 Checking the rear brake linings
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
- Ensure that worn-out brake linings are replaced immediately.
Check the brake linings for minimum thickness ©.
Minimum thickness Q > 1 mm (> 0.04 in)
» If the minimum thickness is less than specified:

- Change the rear brake linings. ( p. 109)
Check the brake linings for damage and cracking.
» If damage or cracking is visible:
- Change the rear brake linings. ( p. 109)
16.9 Changing the rear brake linings
Warning
Danger of accidents Incorrect maintenance will cause the brake system to fail.
- Ensure that service work and repairs are performed professionally.

16 BRAKE SYSTEM 110
Warning

Warning
Warning
regulations.
• Info
brake fluid.
Stand the vehicle upright.

Remove screw cap o with membrane © and the O-ring.
Manually press the brake caliper to the brake disc to push back the brake piston.
Ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it
by suction if it does.
• Info
I Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.
Remove cotter pins © , pull out pin © , and remove the brake linings.
Clean the brake caliper and brake caliper support.
Check that leaf spring © in the brake caliper and sliding plate © in the brake
caliper support are seated correctly.
• Info
I The arrow on the leaf spring points in the rotation direction of the brake
disc.
16 BRAKE SYSTEM 111
Insert the new brake linings, insert pin o , and mount cotter pins e
• Info
I Always change the brake linings in pairs.
Make sure that decoupling plate o is mounted on the piston side brake
lining.
Operate the foot brake lever repeatedly until the brake linings are in contact with
Add brake fluid to level ©.
Mount and tighten screw cap o with membrane © and the O-ring.
• Info
I Clean up overflowed or spilled brake fluid immediately with water.
16.10 Checking the free travel of foot brake lever
Warning
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
- Set the free travel on the foot brake lever in accordance with the specification.
Disconnect spring Q.
Move the foot brake lever back and forth between the end stop and the contact
to the foot brake cylinder piston and check free travel ©.
Guideline
Free travel at foot brake lever 3... 5 mm (0.12... 0.2 in)
» If the free travel does not meet specifications:

- Adjust the basic position of the foot brake lever. ( p. Ill)
Reconnect spring o
16.11 Adjusting the basic position of the foot brake lever
Warning
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
- Set the free travel on the foot brake lever in accordance with the specification.
16 BRAKE SYSTEM 112
Detach spring ©
Loosen nut o and, with push rod © , turn it back until you have maximum free
travel.
To adjust the basic position of the foot brake lever to individual requirements,
loosen nut © and turn screw © accordingly.
• Info
I The range of adjustment is limited.
Turn push rod © accordingly until you have free travel © . If necessary, adjust
the basic position of the foot brake lever.
Guideline
Free travel at foot brake lever 3... 5 mm (0.12... 0.2 in)
Hold screw © and tighten nut ©

Guideline
Nut, foot brake lever stop M8 20 Nm (14.8 Ibf ft)
Hold push rod © and tighten nut ©

Guideline
Remaining nuts, chassis M6 10 Nm (7.4 Ibf ft)
Attach spring o
16.12 Checking the rear brake fluid level
Warning
Warning
Preparatory work
- Check the rear brake linings. (Si p. 109)
Main work
- Stand the vehicle upright.
- Check the brake fluid level in the viewer o
» If the brake fluid level drops below marking
- Add rear brake fluid. ( p. 112)
16.13 Adding rear brake fluid
Warning
Check the brake system and do not continue riding until the problem is eliminated.
16 BRAKE SYSTEM 113
Warning

Warning
Warning
regulations.
• Info
brake fluid.
Preparatory work
- Check the rear brake linings. ( p. 109)
Main work
- Stand the vehicle upright.
- Remove screw cap o with membrane 0 and the O-ring.
- Add brake fluid to level ©.
- Mount and tighten the screw cap with the membrane and O-ring.
• Info
16.14 Changing the rear brake fluid
Warning

Warning
regulations.
16 BRAKE SYSTEM 114
• Info
I Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.
Cover the painted parts.

Remove screw cap o with membrane and the O-ring.
Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill
with fresh brake fluid.
Bleed syringe (50329050000) (8S p. 225)

Brake fluid DOT 4 (8JI p. 220)
Mount bleeder cover
Bleeder cover (00029013006) |S8 p. 223)
Connect the bleeding device.
Open shut-off valve ©
• Info
I Follow the operating instructions of the bleeding device.
Ensure that the filling pressure is set on pressure gauge © Adjust the filling
pressure on pressure regulator © if necessary.
Guideline
Filling pressure 2... 2.5 bar (29... 36 psi)
Pull off protection cap Q of the bleeder screw. Connect the hose of the bleeder
bottle.
Bleeding device (00029013100) ( p. 223)
Open bleeder screw © by approx, one-half turn.
• Info
I Drain until the fresh brake fluid emerges from the hose of the bleeder bot
tle without bubbles.
Tighten the bleeder screw.

Close shut-off valve ©
Open the bleeder screw again until brake fluid stops emerging.
• Info
I 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.
16 BRAKE SYSTEM 115
Stand the vehicle upright.

Correct the brake fluid up to marking 0
Brake fluid DOT 4 (Si p. 220)
Mount and tighten the screw cap with the membrane and O-ring.
• Info
I Clean up overflowed or spilt brake fluid immediately with water.
Check the foot brake lever for a firm pressure point.

17 ENGINE 116
17.1 Removing the engine

Preparatory work
- Drain the coolant. ( p. 185)
- Remove the seat. (?C p. 73)
- Remove the right side cover. (H p. 72)
Main work
- Disconnect negative cable Q of the battery.
- Remove cable tie(s) ©

- Pull EFI control unit ® from the holder and hang it to one side.
- Disconnect plug-in connectors ©

- Remove cable tie(s) ©.
- Disconnect plug-in connector ©
- Loosen hose clip o
- Pull back the protection cap.

- Unplug connector ©.
- Remove screws ©
- Remove the intake air temperature sensor.
17 ENGINE 117
Remove screw ©
Loosen screws
Repeat these steps on the opposite side.
Lift the subframe.
Push back hose clamp ©

Pull off the bleeder hose.
Pivot up the subframe and secure it.
Remove screw ©
Pivot the shock absorber toward the rear and twist it slightly.
Remove springs ©
Remove screw ©
Take off the manifold.
Loosen hose clips ©

Pull off the radiator hoses.
17 ENGINE 118
Loosen hose clips ©

Remove the radiator hose.
Pull back the protection cap.

Remove nut ©
Remove screw ©
Remove screw
Take off the engine sprocket cover.
Remove screws ©
Remove the cable tie(s).
Remove cable holder ©.
Take off the slave cylinder of the clutch and hang it to one side.
• Info
I Do not kink the clutch line.
Do not activate the clutch lever while the slave cylinder of the clutch is
removed.
Remove the connecting link of the chain.

Take off the chain.
17 ENGINE 119
Remove screw
Take off the shift lever.
Pull back the protection cap.

Unplug connector
Disconnect spark plug connector ©.
Loosen hose clip

Pull the throttle valve body out of the intake flange toward the rear and hang it to
one side.
Remove fittings ©
Take off the engine braces.
Remove the vent hose.
Remove spring
Remove nut
Remove the swingarm pivot.
Pull the swingarm slightly toward the rear.
17 ENGINE 120
Remove screws ^).
Lift out the engine sideways.
• Info
I The help of an assistant is useful in this step.
Make sure that the engine is sufficiently secured against falling over.
Protect the frame and attachments against damage.
17.2 Installing the engine

Main work
- Position the engine in the frame.
• Info
I The help of an assistant is useful in this step.
Make sure that the engine is sufficiently secured against falling over.
Protect the frame and attachments against damage.
- Mount screws o but do not tighten yet.

Guideline
Engine carrying screw M10 60 Nm (44.3 Ibf ft)
- Position the swingarm.

- Insert the swingarm pivot.
- Mount and tighten nut ©
Guideline
Nut, swingarm pivot Ml 6x1.5 100 Nm
(73.8 Ibf ft)
Tighten screws Q.
Guideline
Engine carrying screw M10 60 Nm (44.3 Ibf ft)
- Mount spring ©
17 ENGINE 121
Position the engine braces.

Mount and tighten fittings o
Guideline
Screw, engine brace M8 33 Nm (24.3 Ibfft)
Mount the vent hose.
Position the throttle valve body.

Tighten hose clip ©
Plug in connector ©
Position the protection cap.
Plug in spark plug connector ©
Position the shift lever.

Mount and tighten screw © with the washers.
Guideline
Screw, shift lever M6 14 Nm Loctite® 243™
(10.3 Ibfft)
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.
Position the clutch slave cylinder with the gasket.

Mount and tighten screws ©
Guideline
Screw, clutch slave cylinder M6 10 Nm (7.4 Ibfft)
Position the wiring harness. Mount cable binder © and cable holder ©
17 ENGINE 122
Position the engine sprocket cover.

Mount and tighten screw ©
Guideline
Screw, clutch slave cylinder M6 10 Nm (7.4 1 bf ft)
Mount and tighten screw

Guideline
Position the positive cable on the starter motor.

Mount and tighten nut
Guideline
Remaining nuts, chassis M6 10 Nm (7.4 Ibfft)
Mount the radiator hose.

Position and tighten hose clips
Mount the radiator hoses.

Position and tighten hose clips (^.
202900-11
Feed in the manifold.

Mount screw but do not tighten yet.
Guideline
17 ENGINE 123
Mount springs ©
Tighten screw ©
Guideline
Screw, manifold holder M8 15 Nm (11.1 Ibf ft)
Position the shock absorber.

Mount and tighten screw
Guideline
Screw, top shock M10 60 Nm Loctite® 2701 ™
Remove the fixation and lower the subframe.

Mount the vent hose and hose clamp ©
Position the subframe.
• Info
1 Watch out for the intake flange.
Mount and tighten screws

Guideline
(22.1 Ibf ft)
Remove screw
Mount and tighten screw ■
Guideline
(22.1 Ibf ft)
Repeat these steps on the opposite side.

Position the intake air temperature sensor.
Mount and tighten screws
Guideline
Screw, intake air temperature sensor M5 2 Nm (1.5 Ibf ft)
Plug in connector ©.
17 ENGINE 124
- Position and tighten hose clip
- Connect plug-in connectors

- Connect plug-in connector
- Route the wiring harness without tension and secure it with cable tie
- Mount EFI control unit

- Mount cable tie(s) ©
- Connect negative cable @ of the battery.
- Remove filler plug © and add engine oil.
Engine oil 1.50 I (1.59 qt.) Engine oil (SAE 10W/50) ( p. 220)
- Mount and tighten filler plug ^).
Finishing work
- Install the right side cover. (U p. 73)
- Install the fuel tank. ( . p. 74)
- Refill the coolant. (ffl p. 186)
- Execute the initialization run. ( p. 195)
- Go for a short test ride.
- Read out the fault memory using the Husqvarna Motorcycles diagnostics tool.
17 ENGINE 125
- Check the engine for leak tightness.

- Check the engine oil level. ( p. 187)
- Check the coolant level. (U p. 185)
17.3.1 Preparations
Mount the special tool on the engine assembly stand.
Engine fixing arm (78029002000) p p. 230)

Engine assembly stand (61229001000) (11 p. 228)
Mount the engine on the special tool.
• Info
I Have an assistant help you or use a motorized hoist.
17.3.2 Draining the engine oil

Remove oil drain plug o with the magnet and seal ring.
Remove screw plug ©

Completely drain the engine oil.
Remove the long oil screen ©
Remove screw plug © with the short oil screen.

17 ENGINE 126
17.3.3 Removing the clutch push rod

Remove clutch push rod o
17.3.4 Removing the oil filter

Remove screws o
Remove the oil filter cover 0 with the O-ring.
Pull oil filter © out of the oil filter housing.
Circlip pliers reverse (51012011000) ( p. 225)
17.3.5 Removing the starter motor

Remove screws Q ar|d take off the starter motor.
17.3.6 Removing the spark plug

17 ENGINE 127
17.3.7 Removing the valve cover

Remove screws O-
Take off the valve cover with the valve cover seal.
17.3.8 Removing the alternator cover

Remove screws o
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

Turn the crankshaft counterclockwise until the markings © are flush with the
marking © on the cylinder head.
Remove screw o
17 ENGINE 128
Screw in special tool ©
Locking screw (113080802) ( p. 224)
17.3.10 Removing the timing chain tensioner

Remove screw O with the washer and spring.
Remove screws ©
Take off the chain adjuster with the gasket.
17.3.11 Removing the camshaft

Remove screw o Remove the camshaft support plate ©
Pull the camshaft out of the bearing seats. Take the timing chain off the camshaft
gear. Remove the camshaft.
17 ENGINE 129
17.3.12 Removing the cylinder head

Remove screw o
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
I Only push the cylinder as far up as necessary to take the piston pin out.
Remove the piston pin retainer ©

Remove the piston pin.
Take off the cylinder and piston.
Push the piston upward out of the cylinder.
• Info
I If no further work is to be performed on the cylinder and piston, the piston
can remain in the cylinder.
Take off dowels © and cylinder base gasket ©.

17 ENGINE 130
17.3.14 Removing the rotor

Remove nut o with the spring washer.
Mount special tool © on the rotor.
Extractor (58012009000) p p. 226)
Hold it tight using the special tool and pull off the rotor by turning the screw in.
Remove the woodruff key.
17.3.15 Removing the timing chain

Remove screw o
Take off timing chain guide rail toward the top.
Remove screw ©
Remove timing chain tensioning rail Q toward the top.
Remove screws ©.
Remove the timing chain securing guide.
Take off the timing chain.
• Info
I If the timing chain is going to be used again, mark the direction of travel.
17 ENGINE 131
17.3.16 Removing the ignition pulse generator

- Remove screws O-
- Pull the cable sleeve out of the engine case.
- Take off the crankshaft position sensor.
17.3.17 Removing the suction pump

Remove screws o
Take off oil pump cover © of the suction pump.
Remove external rotor © and internal rotor ©.
Take off pin 0

Remove pin © upward.
Remove O-ring 0
17.3.18 Removing the water pump cover

Remove screws O- Take off the water pump cover.
Take off the water pump cover seal.
17 ENGINE 132
17.3.19 Removing the clutch cover

Remove screws O-
Take off the clutch cover.
• Info
I 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 ©
17.3.20 Removing the clutch discs

Remove screws O-
Take off spring retainer ©
Take off spring washer
- Take off pretension ring ©

©
17 ENGINE 133
Take off pressure cap ©.
Completely remove clutch disc pack ©

Remove clutch pressure piece Q.
Remove special tool ©
Locking screw (113080802) p p. 224)
17.3.21 Removing the outer clutch hub

Lock the outer clutch hub and primary gear using special tool ©
Gear segment (80029004000) (SS p. 231)
Remove nut ©
• Info
I Left-handed thread.
Bend up the lock washer.

Hold the inner clutch hub with the special tool.
Clutch holder (51129003000) p p. 225)
Remove nut © with the lock washer.
Take off inner clutch hub © and washer ©
• Info
I The washer usually sticks to the inner clutch hub.
Take off ©.
17 ENGINE 134
Take off both needle bearings o and collar bushing ©
17.3.22 Removing the torque limiter

Remove screw O 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

Push sliding plate o away from the shift drum locating unit.
Remove shift shaft © with the washer.
17.3.25 Removing the shift drum locating unit

Remove screw O-
Push away locking lever © from shift drum locating unit © and remove the shift
drum locating unit.
Relieve tension from the locking lever.
17 ENGINE 135
17.3.26 Removing the locking lever

Unscrew o and remove together with locking lever © , washer, sleeve and
spring.
17.3.27 Removing the force pump

Remove lock ring o
Take off washer
Remove oil pump idler gear
Remove lock washer ©

Take off washer 0
Take off oil pump gear wheel
Remove pin ©
Remove screws
Take off oil pump cover
17 ENGINE 136
Remove internal rotor <E> 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 o in the crankshaft.
Protection cap (75029090000) (15 p. 229)
- Install special tool ©
Extractor (75029021000) (£S p. 228)
- Hold it using the special tool and pull off the primary gear by turning the screw in.
17.3.29 Removing the freewheel gear

Remove woodruff key o
Take off freewheel gear ©
17.3.30 Removing the left engine case section

Remove screws ©
Mount special tool © with suitable screws.
Use the drill hole with marking 781.
Tilt the left section of the engine case upward and remove the fitting of the engine
fixing arm.
Pull off the section of the engine case.
Info
Do not tension the section of the engine case.

17 ENGINE 137
Take off the left section of the engine case.

Remove spacer ©.
Remove dowels O-
17.3.31 Removing the shift rails

- Remove shift rails o together with upper springs © and lower springs.
17.3.32 Removing the shift drum

Swing shift forks o to one side.
• Info
I Do not misplace the shift rollers.
Remove shift drum ©
17.3.33 Removing the shift forks

Take shift forks o out of the shift grooves.
Info
Do not misplace shift rollers ©
17 ENGINE 138
17.3.34 Removing the transmission shafts

Remove O-ring o
Position the engine upright.

Remove lock ring ©
Pull both transmission shafts out of the bearing seats together.
• Info
I Make sure not to misplace the washers.
17.3.35 Removing the crankshaft

- Attach the special tool to the crankshaft.
Protection cap (75029090000) (®S p. 229)
- Mount special tool o onto the engine case with suitable screws.
Removal tool (78029049100) (KS p. 230)
- Press the crankshaft out of the bearing seat.

- Take out crankshaft.
- Take off the right section of the engine case.
17.4 Working on individual parts
17.4.1 Work on the right section of the engine case

Preparatory work
- Remove the oil pressure regulator valve. ( p. 141)
17 ENGINE 139
Main work
- Remove all remaining dowels.
- Remove oil nozzles o and ©
- Remove the bearing retainer of main shaft bearing , of countershaft bear
ing Q 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
150 °C (302 °F)
- Knock the engine case section against a level wooden plate. This will cause the
bearings to drop out of the bearing seats.
• Info
I Any bearings that remain in the engine case section must be removed
using a suitable tool.
- Press out shaft seal ring ® of the crankshaft from the inside to the outside.
• Info
I Do not press the shaft seal ring from the outside toward the inside, as
there is a small collar on the inside.
- Warm the engine case section again.

Guideline
150 °C (302 °F)
- Insert the new cold bearings into the bearing seats of the hot engine case section
and, if necessary, use a suitable press drift to push the bearing from the inside to
the outside, all the way to the stop or so it is flush.
• Info
I When pressing the bearing in, ensure that the engine case section is level
to prevent damage.
Only press the bearings in via the outer bearing race; otherwise, the bear
ings will be damaged when they are pressed in.
- After the engine case section has cooled, check that the bearings are firmly
seated.
• Info
I If the bearings are not firmly seated after cooling, it is likely that they will
rotate in the engine case when warm. In this case, the engine case must
be renewed.
- Press in the shaft seal ring from the outside toward the inside, with the open side
facing outward.
- Position all bearing locks. Mount and tighten the screws.
Guideline
Screw, bearing retainer M5 6 Nm Loctite® 2701 ™
(4.4 Ibf ft)
Mount and tighten oil nozzle O-

Guideline
Oil nozzle, piston cooling M5 2 Nm Loctite® 243™
(1.5 Ibf ft)
- Mount and tighten oil nozzle 0

Guideline
Oil nozzle for conrod bearing lubrica- M6x0.75 4 Nm (3 Ibf ft)
tion
17 ENGINE 140
- Blow compressed air through all oil channels and check that they are clear.
401797-01
Finishing work
- Install the oil pressure regulator valve. ( p. 142)
17.4.2 Work on the left section of the engine case

Remove all remaining dowels.
Remove screw o
Remove oil spray tube ©
Remove screws ©
Remove membrane support plate o and the membrane.
Remove shaft seal ring © of the countershaft and shaft seal ring © of the shift
shaft.
• Info
I Shaft seal ring © of the crankshaft can only be removed after the
crankshaft bearing is removed because of a smaller collar on the outside.
Remove screws (•).

Remove membrane support plate © and the membrane.
Remove any sealing mass remnants and clean the engine case section
thoroughly.
Warm the engine case section in an oven.
Guideline
150 °C (302 °F)
Knock the engine case section against a level wooden plate. This will cause the
bearings to drop out of the bearing seats.
• Info
I Any bearings that remain in the engine case section must be removed
using a suitable tool.
- Press shaft seal ring © of the crankshaft from the inside to the outside.
- Warm the engine case section again.
Guideline
150 °C (302 °F)
- Insert the new cold bearings into the bearing seats of the hot engine case section
and, if necessary, use a suitable press drift to push the bearing all the way to the
stop or so that it is flush.
• Info
I When pressing the bearing in, ensure that the engine case section is level
to prevent damage.
Only press the bearings in via the outer bearing race; otherwise, the bear
ings will be damaged when they are pressed in.
- After the engine case section has cooled, check that the bearings are firmly
seated.
• Info
I If the bearings are not firmly seated after cooling, it is likely that they will
rotate in the engine case when warm. In this case, the engine case must
be renewed.
17 ENGINE 141
Press the shaft seal ring o 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.
Position membrane support plate © together with the membrane.
Guideline
Screw, membrane M3 1.5 Nm Loctite® 243™
(1.11 Ibfft)
Position membrane support plate Q together with the membrane.

Guideline
Screw, membrane M3 1.5 Nm Loctite® 243™
(1.11 Ibfft)
Position oil spray tube ©.

Mount and tighten screw O-
Guideline
Screw, oil spray tube M4 5 Nm Loctite® 243™
(3.7 Ibf ft)
Mount the dowels.

Blow compressed air through all oil channels and check that they are clear.
17.4.3 Removing the oil pressure regulator valve

” ir«j a.*u _ Remove screw plug o with sealing washer ©
- Remove pressure spring ® and ball ©
304671-10
17.4.4 Checking spring length of oil pressure regulator valve

Preparatory work
- Remove the oil pressure regulator valve. P-141)
17 ENGINE 142
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.
Finishing work
- Install the oil pressure regulator valve. ( p. 142)
17.4.5 Installing the oil pressure regulator valve

Install ball o and pressure spring ©
Mount and tighten plug © with sealing washer ©
Guideline
Plug, oil pressure regulator valve M12x1.5 20 Nm (14.8 Ibfft)
17.4.6 Changing the crankshaft seal ring in the clutch cover

Remove crankshaft seal ring o
Press the new crankshaft seal ring into the clutch cover with the open side facing
inward until it is flush.
Grease the sealing lip.
17.4.7 Removing the water pump

Remove nut ©
Remove water pump impeller ©
• Info
I If the water pump impeller cannot be detached, then the water pump shaft
can be pressed out toward the inside.
Remove balancer shaft ©

17 ENGINE 143
Remove shaft seal ring ©
Press out water pump bearing © toward the inside with an appropriate tool.
• Info
I Provide suitable support for the clutch cover while pressing out.
17.4.8 Installing the water pump

Press water pump shaft bearing o in until it is flush using the appropriate tool.
Info
Support the clutch cover sufficiently when pressing in.
Press shaft seal ring © all the way in.
309435-11
Mount special tool © on the water pump shaft.
Mount balancer shaft ©
• Info
I Be careful not to damage the shaft seal rings.

17 ENGINE 144
Mount water pump impeller ©

Mount and tighten nut 0
Guideline
Nut, water-pump wheel M6 8 Nm Loctite® 243™
(5.9 Ibf ft)
17.4.9 Removing the timing chain sprocket

- Warm up the timing chain sprocket o with a blow-dryer.
- Pull off the timing chain sprocket with the special tool.
Puller, 2-arm (60029033000) p p. 227)
• Info
I The timing chain sprocket is usually damaged by the disassembly and
must be replaced.
17.4.10 Installing the timing chain sprocket
• Info
I Never clamp the crankshaft with a crankshaft journal in the bench vise and try to hammer on the timing chain sprocket.
In such a case, the crank webs will be distorted rendering the crankshaft unserviceable.
Warm up the new timing chain sprocket and immediately push it onto the
crankshaft.
Guideline
180 °C (356 °F)
17.4.11 Changing the connecting rod, conrod bearing, and crank pin
Main work
- Position the crankshaft with special tool o in the press.
Separator plate (78929009000) (ffl p. 231)
- Press the crank pin out of the upper crank web with special tool 0
Pressing tool for crankshaft, complete (75029047000) ( p. 228)
• Info
I Hold the lower crank web.
Take off the connecting rod and bearing.

Press crank pin © out of the lower crank web.
17 ENGINE 145
- Place the crank web onto special tool ©
Insert for crankshaft pressing tool (78929008000) ( p. 231)
• Info
I The special tool must be positioned with the flat surface facing downward.
- Press the new crank pin © all the way in.

S Oil channel Ois aligned with oil channel ©
X If the oil channels are not correctly aligned, the conrod bearing will not be
supplied with oil.
- Blow compressed air through the oil channels to check that they are clear.
- Mount the new connecting rod ©
Info
Lubricate the bearing thoroughly.
- Position special tools O ancl © on the press.
Pressing tool for crankshaft, complete (75029047000) (U p. 228)

- Place the crank web in with the connecting rod and the bearing. Position the sec
ond crank web.
- Position special tool © with the heel at the bottom.
- Press the upper crank web in as far as possible.
• Info
I The press mandrel must be applied above the crank pin.
- Take the crankshaft out of the special tool, and check the connecting rod for free
dom of movement.
- Measure axial play © between the connecting rod and the crank webs using the
special tool.
Feeler gauge (59029041100) ( p. 226)
Connecting rod - end play of lower 0.20... 0.45 mm (0.0079... 0.0177 in)
conrod bearing
» If the measured value is less than the specification:

- Correct until it complies with the specified value.
306596-10
Finishing work
- Check the crankshaft run-out at bearing pin. ( p. 146)
17 ENGINE 146
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 < 0.04 mm (< 0.0016 in)
» If the crankshaft run-out at the bearing pin is larger than the specification:
- Align the crankshaft.
17.4.13 Cylinder - Nikasil® coating

Nikasil® is a surface protection layer for a coating procedure developed by Mahle.
The name is derived from the two materials used in this procedure - a layer of nickel
into which is embedded the particularly hard silicone carbide.
The most important advantages of the Nikasil® coating are very good heat conduc
tivity, resulting in much improved performance, low wear, and a lightweight cylinder.
17.4.14 Checking/measuring the cylinder

Check the cylinder bearing surface for damage.
» If the cylinder bearing surface is damaged:
- Change the cylinder and piston.
Measure the cylinder diameter at several locations on the Q - and o -axes using
a micrometer to identify oval wear.
Guideline
Cylinder - drill hole diameter
Size 1 95.000... 95.012 mm (3.74015...
3.74062 in)
Size II 95.013... 95.025 mm (3.74066...
3.74113 in)
The cylinder size Ois labeled on the side of the cylinder.
306590-10
Using a straightedge and the special tool, check the sealing area of the cylinder
head for distortion.
Feeler gauge (59029041100) ( p. 226)
Cylinder/cylinder head - sealing area < 0.10 mm (< 0.0039 in)

distortion

- Change the cylinder.
17 ENGINE 147
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.
Tip
306591-10 An old piston ring can be used to clean the piston ring groove.
- Check the piston rings for damage.

» If the piston ring is damaged:
- Replace the piston ring.
• Info
I Mount the piston ring with the marking facing upward.
Check the piston pins for discoloration or signs of wear.

» If the piston pin shows severe discoloration/signs of wear:
- Replace the piston pin.
Place the piston pin in the connecting rod and check the seating for play.
» If the piston pin seating has excessive play:
- Replace the connecting rod and piston pin.
Measure the piston at the piston skirt, parallel to the gudgeon pin,at a distance
] of ©.
Guideline
Distance © 7 mm (0.28 in)
Piston - diameter
Size 1 94.93... 94.96 mm (3.7374...
3.7386 in)
Size II 94.94... 94.97 mm (3.7378... 3.739 in)
• Info
I Piston dimensions o are marked on the piston head.
17.4.16 Checking the piston ring end gap
- Remove the piston ring from the piston.
- Place the piston ring in the cylinder and align with the piston.
Guideline
Below the upper edge of the cylinder 10 mm (0.39 in)
Using special tool O’ measure the end gap.

Guideline
Piston ring end gap
Compression ring < 1.00 mm (< 0.0394 in)
Oil scraper ring <1.20 mm (< 0.0472 in)
Feeler gauge (59029041100) ( p. 226)
» If the end gap is greater than the specified value:

- Check/measure the cylinder. ( . p. 146)
» If cylinder wear lies within the specified tolerance:
- Change the piston ring.
- Mount the piston ring with the marking facing upward.
17 ENGINE 148
17.4.17 Measuring the piston/cylinder mounting clearance

Check/measure the cylinder. ( p. 146)
Check/measure the piston. ( p. 147)
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.
Guideline
Piston/cylinder - mounting clearance
Size 1 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)
17.4.18 Checking the oil pumps
• Info
I The following steps apply to both oil pumps.
Use special tool o to measure the play between the external rotor and the
engine case.
Feeler gauge (59029041100) (H9 p. 226)
Oil pump
External rotor/engine case clear < 0.20 mm (< 0.0079 in)
ance

- Change the oil pump and, if necessary, the engine case.
Use special tool o to measure the play between the external rotor and the inter
nal rotor.
Feeler gauge (59029041100) ( p. 226)
Oil pump
External rotor/internal rotor clear < 0.20 mm (< 0.0079 in)
ance

- Replace the oil pump.
17.4.19 Disassembling the autodecompressor

- Take lock ring O from the autodecompression shaft and dispose of it,
17 ENGINE 149
- Pull autodecompression shaft © out of the camshaft.
304674-10
- Release and remove autodecompression spring ©.
• Info
I Autodecompression weight o cannot be taken off.
17.4.20 Assembling the autodecompressor

Insert long flange o
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.
304674-11
Mount new lock ring ©.

Perform a function check.
» The autodecompression spring does not turn the autodecompression shaft
back to the stop:
- Pre-tension the autodecompression spring more or replace it.
17 ENGINE 150
17.4.21 Checking camshaft

Check the camshaft for damage and 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... 33.30 mm (1.3031... 1.311 in)
Intake 33.90... 34.10 mm (1.3346...
1.3425 in)

- Change the camshaft.
17.4.22 Checking the timing assembly
- Clean all parts well.

- Check the timing chain gear/timing chain sprocket o for damage and wear.
- Change the camshaft/timing chain sprocket.
- Check the timing chain tensioning rail © for damage and wear.
- Replace the timing chain tensioning rail.
- Check the timing chain guide rail © for damage and wear.
- Replace the timing chain guide rail.
- Check the timing chain securing guide Q for damage and wear.
- Replace the timing chain securing guide.
- Check timing chain © for damage and wear.
- Replace the timing chain.
- Check the timing chain links for smooth operation. Let the timing chain hang down freely.
» The chain links no longer align in a straight line:
17 ENGINE 151
- Replace the timing chain.
17.4.23 Removing the rocker arm

- Remove screws o and of the rocker arm shafts.
- Remove plugs 0 with the O-rings.
- Screw appropriate screw o into the rocker arm shafts. Pull out rocker arm
shafts ©.
- Take off rocker arm 0
17.4.24 Removing the valves

Take the shims out of the valve spring retainers and lay them to one side accord
ing to their normal built-in position.
Pretension the valve springs using the special tool.
Valve spring mounter (59029019000) ( ® p. 226)

Insert for valve spring lever (77029041200) ( P- 229)
Remove valve keys o and relax the valve springs.
Remove valve spring retainer 0 and the valve spring.

Pull the valve out of the valve guide from below and remove valve stem seal ©
and valve spring seat ©
304686-10
Mark the valves corresponding to their installation position.
£V$ EM'fy • Info

I Place the valves in a box corresponding to their installation position and
label them.
17 ENGINE 152
17.4.25 Changing camshaft bearing

Mount the cylinder head.
Clamping plate (75029050000) ( 1 p. 229)
Remove the large camshaft bearing using the special tool.
Push-out drift (75029051000) (Si p. 229)
Remove the small camshaft bearing o using the special tool.
Bearing puller (15112017000) (W p. 224)

Internal bearing puller (15112018100) ( p. 224)
- Press the small camshaft bearing in until flush using the special tool
Push-in drift (75029044020) ( p. 228)
- Press the large camshaft bearing in until flush using special tool ©
200201-10
17.4.26 Checking the valves
• Info
I The valve shaft is hard-chrome plated; wear generally appears at the valve guide.
Check the run-out at the valve plate.
Valve
Run-out at valve plate < 0.05 mm (< 0.002 in)

- Change the valve.
17 ENGINE 153
Check sealing seat Q 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.
17.4.27 Checking valve springs

Check the valve springs for breakage and wear (visual check).
» If the valve spring is broken or worn:
- Change the valve spring.
Measure the length of the valve springs.
Valve spring
Intake minimum length (without 40.7 mm (1.602 in)
valve spring seat)
Valve spring
Exhaust minimum length (without 40.7 mm (1.602 in)
valve spring seat)

- Change the valve spring.
17.4.28 Checking valve spring seat

Check the valve spring seat for breakage and wear (visual check).
» If the valve spring seat is broken or worn:
- Change the valve spring seat.
Measure the thickness of the valve spring seat.
Valve spring
Valve spring seat 1.8 mm (0.071 in)

- Change the valve spring seat.
17.4.29 Checking the cylinder head

Check exhaust valve guides O using the special tool.
Limit plug gauge (59029026006) (S3 p. 226)
» If the special tool is easy to insert in the valve guide:

- Change the valve guide and valve.
Check intake valve guides © using the special tool.
Limit plug gauge (59029026006) (13 p. 226)
» If the special tool is easy to insert in the valve guide:

- Change the valve guide and valve.
Check the sealing area of the spark plug thread and the valve seats from damage
and cracking.
» If there is damage or cracking:
- Change the cylinder head.
17 ENGINE 154
Using a straightedge and the special tool, check the sealing area of the cylinder
for distortion.
Feeler gauge (59029041100) ( p. 226)
Cylinder/cylinder head - sealing area < 0.10 mm (< 0.0039 in)

distortion

- Change the cylinder head.
Check sealing seat Q of the valves.
Valve
Intake sealing seat width 2.00 mm (0.0787 in)
Valve
Exhaust sealing seat width 2.00 mm (0.0787 in)

- Rework the valve seat.
Blow compressed air through all oil channels and check that they are clear.
17.4.30 Checking the rocker arm shafts

Check the rocker arm shafts for damage and wear.
- Change the rocker arm shafts.
306609-10
17.4.31 Installing the valves

Position valve spring seats o . Mount the new valve stem seals ©
Mount the valves according to their normal built-in position.
Mount the springs and spring retainers ©.
Pretension the valve springs using the special tool.
Valve spring mounter (59029019000) ( p. 226)

Insert for valve spring lever (77029041200) ( p. 229)
17 ENGINE 155
Mount the valve keys.
• Info
I 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 O and mount rocker arm shaft ©.
S The rocker arm shaft with marking © is installed on the intake side.
y Markings O face upward.
• Info
I Make sure that the tapped hole of the rocker arm shaft is facing outward.
Align drill holes © of the rocker arm shafts with drill holes © of the cylin
der head.
Use special tool © to set the distance of the intake rocker arm.
Guideline
Rocker arm - axial play 0.10 mm (0.0039 in)
Feeler gauge (59029041100) ( p. 226)
Press the rocker arm shaft of the intake side all the way into the cylinder head.
Guideline
Screw, rocker arm bearing M7 15 Nm (11.1 Ibfft)
- Remove special tool ©
Feeler gauge (59029041100) ( p. 226)
Repeat these operations on the rocker arm of the exhaust side.

Mount and tighten screws G
Guideline
Screw, rocker arm bearing M7 15 Nm (11.1 Ibfft)
Mount and tighten screw plugs © with the O-ring.

Guideline
Screw plug, rocker arm Ml 8x1.5 30 Nm (22.1 Ibfft)
17 ENGINE 156
17.4.33 Checking the clutch
- Check pressure piece o for damage and 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.
- Change the spring retainer.
- Check pretension ring o for damage and wear.
- Change the pretension ring.
- Check spring washer 0 for damage and wear.
- Change the spring washer.
- Check the thrust face of pressure cap 0 for damage and wear.
- Change the pressure cap.
- Check clutch center 0 for damage and wear.
- Change the clutch center.
- Check damping rubber © for damage and wear.
- Change the damping rubbers.
- Check the inner clutch hub 0 for damage and wear.
- Change the inner clutch hub.
- Check the contact surfaces of the clutch facing disks in outer clutch hub © for damage and wear.
- Change the clutch facing discs and the clutch basket.
- Check needle bearings 0 and collar bushing 0 for damage and wear.
17 ENGINE 157
- 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.
- Check the thickness of clutch facing discs ©.
Clutch facing disc - thickness > 1.9 mm (> 0.075 in)
» If the clutch facing disc does not meet specifications:

- Change all clutch facing discs.
17.4.34 Checking the shift mechanism
Shift fork
Thickness at leaf 4.85... 4.95 mm (0.1909... 0.1949 in)

- Change the shift fork.
- Check shift grooves © of shift drum © for wear.
» If the shift groove is worn:
- Change the shift drum.
- Check the seat of the shift drum in bearing ©
» If the shift drum is not correctly seated:
- Change the shift drum and/or bearing.
- Check bearing © for stiffness and wear.
» If the bearing does not move easily or is worn:
- Change the bearing.
- Check shift rollers © for surface damage and cracking.
» If the shift roller exhibits surface damage or cracking:
- Change the shift drum.
- Check springs © of the shift rails for damage and wear.
» If the spring is damaged or worn:
- Change the spring of the shift rail.
17 ENGINE 158
- 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.
- Check sliding plate o for wear on contact areas ©
» If the sliding plate is worn:
- Change the sliding plate.
- Check return surface © on the sliding plate for wear.
» If there is severe grooving:
- Check guide bolts © for firm seating and wear.
» If the guide bolts are loose or worn:
- Preassemble the shift shaft. ( p. 158)
Check clearance © between the sliding plate and the shift quadrant.
Shift shaft - play in sliding plate/shift 0.40... 0.80 mm (0.0157... 0.0315 in)
quadrant

17.4.35 Preassembling the shift shaft

Secure the short end of the shift shaft in the bench vise.
Guideline
Use soft jaws.
Mount sliding plate o with the guide pin facing downward and put the guide pin
on the shift quadrant.
Mount pressure spring ©.
Slide on spring guide © , push return spring © , with the offset end facing
upward, over the spring guide and lift the offset end over abutment bolt ©
Mount stop disk ©
17 ENGINE 159
17.4.36 Disassembling the main shaft
Guideline
Use soft jaws.
- Remove stop disk O and 2nd-gear fixed gear ©.

- Remove needle bearing Q and distance sleeve ©.
- Remove 3rd/4th-gear sliding gear ©
- Remove lock ring o and stop disk ©
- Remove 5th-gear idler gear ©.
- Remove needle bearing ©
17.4.37 Disassembling the countershaft
- Fix the countershaft in the vice with the toothed end facing downward.
Guideline
Use soft jaws
17 ENGINE 160
- Remove stop disk o and Ist-gear idler gear ©

- Remove needle bearing © and stop disk ©
- Remove 5th-gear sliding gear © and lock ring ©
- Remove stop disk e and 3rd-gear idler gear ©
- Remove needle bearing © and 4th-gear idler gear ©.
- Remove needle bearing © and stop disk ©
- Remove lock ring © and 2nd/4th gear shift collar ©
- Remove lock ring © and stop disk ©
- Remove 2nd-gear idler gear © and needle bearing ©
17.4.38 Checking the transmission

Condition
The transmission has been disassembled.
o/ p®
° ^
. @
uott
#
O /°© ©
•/J9®
0
/
306614-10
- Check needle bearings o for damage and wear.

- Change the needle bearings.
- Check the pivot points of main shaft © and countershaft © for damage and wear.
- Change the main shaft and/or countershaft.
- Check the tooth profiles of main shaft 0 and countershaft © for damage and wear.
- Change the main shaft and/or countershaft.
- Check the pivot points of idler gears © for damage and wear.
- Change the gear wheel pair.
- Check the shift dogs of idler gears © and sliding gears © for damage and wear.
- Check the tooth faces of idler gears ©, sliding gears ©, and fixed gear © for damage and wear.
- Check the tooth profiles of sliding gears © for damage and wear.
17 ENGINE 161

- 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.
- Change the shift collar.
- Check sliding gear 0 and shift collar 0 for smooth operation in the profile of countershaft 0
» If the sliding gear or shift collar is stiff:
- Change the sliding gear, shift collar, or countershaft.
- Check stop disks 0 for damage and wear.
- Change the stop disks.
- Use new lock rings with every repair.
- Check distance sleeves 0 for damage and wear.
- Change the distance sleeves.
17.4.39 Assembling the main shaft
• Info
I Use new lock rings with every repair.
Preparatory work
- Carefully grease all parts before assembling.
- Check the transmission. ( p. 160)
Main work
- Secure the main shaft with the toothed end facing downward in the vise.
Guideline
Use soft jaws
- Mount needle bearing o , attach 5th-gear idler gear 0 with the shift dogs facing upward.
- Mount stop disk © and lock ring ©
- Mount 3rd/4th-gear sliding gear 0 with the small gear wheel facing downward.
- Mount distance sleeve © and needle bearing 0
17 ENGINE 162

- 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
I Use new lock rings with every repair.
Preparatory work
- Carefully grease all parts before assembling.
- Check the transmission, (ES p. 160)
Main work
- Fix the countershaft in the vice with the toothed end facing downward.
Guideline
Use soft jaws
- Mount needle bearing o and 2nd-gear idler gear © onto the countershaft with the protruding collar facing downward.
- Mount 2nd/4th gear shift collar © with the shift groove facing up.
- Mount lock ring © and stop disk ©
- Mount needle bearing © and the 4th-gear idler gear © with the collar facing up.
- Mount needle bearing © and the 3rd-gear idler gear © with the collar facing down.
- Mount the 5th-gear sliding gear © with the shift groove facing down and stop disk ©
- Mount needle bearing ©, Ist-gear idler gear © with the recess facing down and stop disk ©
- Finally, check all gear wheels for smooth operation.
17 ENGINE 163
17.4.41 Checking the starter drive
_______________________________________________________________________________________________ 304688-10
- Check the gear mesh and bearing of starter idler gear o for damage and wear.
- Change the starter idler gear.
- Check the gear mesh and bearing of torque limiter © for damage and wear.
- Change the torque limiter.
- Check the gear mesh and bearing of freewheel gear for damage and wear.
- Change the freewheel gear or bearing.
- Check freewheel 0 for damage and wear when it is disassembled.
- Change the freewheel.
- Check the gear mesh of starter motor © for damage and wear.
- Change the starter motor.
- Change the O-ring © of the starter motor.
- Connect the negative cable of a 12 volt power supply to the housing of the starter motor. Connect the positive cable of the
power supply briefly with connector of the starter motor.
» If the starter motor does not turn when the circuit is closed:
17.4.42 Checking the freewheel

- Insert freewheel gear o into primary gear turning the primary gear clock
wise; do not wedge!
- Check the locking action of freewheel gear O-
» If the primary gear does not turn clockwise or if it does not lock counterclock
wise:
- Remove the freewheel. ( p. 164)
- Turn the freewheel 180°.
- Install the freewheel. ( p. 164)
17 ENGINE 164
17.4.43 Removing the freewheel
Thoroughly oil all parts.

Push the freewheel © into the primary gear.
• Info
I Note the direction of rotation.
Mount spreader ring ©
Ensure that all lugs of the spreader ring pass through slots © of the freewheel
and engage in groove © of the primary gear.
17 ENGINE 165
17.5 Engine assembly
17.5.1 Installing the crankshaft

- Tighten the right section of the engine case in the engine assembly stand.
- Heat the crankshaft bearing.
Guideline
80 °C (176 °F)
Info
Do not damage the seal ring.
- Mount the special tool on the clutch end of the crankshaft.
Mounting sleeve (78029005100) (U p. 230)
- Push the crankshaft all the way into the bearing seat of the right section of the
engine case.
17.5.2 Installing the transmission shafts

Lubricate all bearings.
Slide both transmission shafts into the bearing seats.
• Info
I Make sure not to misplace the washers.
Mount lock ring o
17.5.3 Installing the shift forks

Lubricate all parts thoroughly.
Mount shift fork O 'n the upper shift groove of the main shaft.
Mount shift fork 0 in the lower shift groove of the countershaft.
Mount shift fork © in the upper shift groove of the countershaft.
Mount shift rollers ©.
• Info
I Fix the shift rollers in the shift forks with grease.
17 ENGINE 166
17.5.4 Installing the shift drum

- Push shift drum o into the bearing seat.
- Put shift forks © in the shift drum.
• Info
I Do not misplace the shift rollers.
17.5.5 Installing the shift rails

Install shift rails o together with upper springs © and lower springs.
• Info
I Fix the springs in the shift rails with grease.
17.5.6 Installing the left engine case

Mount dowels o onto the left section of the engine case.
Grease the sealing surfaces. Apply the sealing compound to the left section of the
engine case.
Loctite® 5910
• Info
I To prevent sealing compound from entering into the oil channels, dow
els o must be mounted first.
Mount the left engine casing. If necessary, strike it lightly with a rubber mallet.
• Info
1 Do not use the screws to pull the two sections of the engine case
together.
Mount screws @ but do not tighten them yet.

Guideline
Screw, engine case M6x40 10 Nm (7.4 Ibfft)
Mount screws © but do not tighten them yet.

Guideline
Screw, engine case M6x60 10 Nm (7.4 Ibfft)
Mount screws o but do not tighten them yet.

17 ENGINE 167
Guideline
Screw, engine case M6x75 10 Nm (7.4 Ibf ft)
Mount screw © but do not tighten yet.

Guideline
Mount screw © and tighten all screws in a crisscross pattern.

Guideline
Mount the O-ring on the countershaft.

Lightly grease and mount spacer ©.
17.5.7 Installing the freewheel gear

Mount freewheel gear o
17.5.8 Installing the primary gear

Mount woodruff key o
Degrease the cone and thinly apply thread locker to it.
Loctite® 648™
Mount primary gear ©.
• Info
I Turn the freewheel gear to ease engagement.
17.5.9 Installing the force pump

Oil the oil pump shaft, internal rotor and external rotor before assembly.
Mount oil pump shaft ©
Mount pin ©
Mount the internal rotor with the recess facing inward.
Mount external rotor © with the bevel facing inward.
17 ENGINE 168
Position oil pump cover ©.

S The Top marking © faces up.
Guideline
Screw, pressure pump M6 10 Nm Loctite® 243™
cover (7.4 Ibf ft)
Insert pin ©
Position oil pump gear wheel Q.

Position washers ©
Mount lock washer 0
Mount oil pump idler gear (E).

Mount washer © and lock ring ©
Crank the oil pump gear wheels and ensure that they can move easily.
17.5.10 Installing the locking lever

Mount locking lever o with the washer, sleeve and spring.
Guideline
Screw, locking lever M5 6 Nm Loctite® 243™
(4.4 Ibf ft)
17 ENGINE 169
17.5.11 Installing the shift drum locating unit

Push away locking lever o from the shift drum locating unit and position the
shift drum locating unit ©
• Info
1 The flat areas of the shift drum locating unit are not symmetric.
Relieve tension from the locking lever.

Guideline
Screw, shift drum locating M6 10 Nm Loctite® 243™
(7.4 Ibf ft)
17.5.12 Installing the shift shaft

Slide shift shaft Q with the washer into the bearing seat.
Push sliding plate 0 away from the shift drum locating unit and insert the shift
shaft all the way.
Let the sliding plate engage in the shift drum locating unit ©
Shift through the transmission.
17.5.13 Installing the starter idler gear

Slide on starter idler gear o with the collar facing the engine case.
Position the washer and mount the lock ring.
17.5.14 Installing the torque limiter

Position the washer.
Mount the torque limiter.
Mount and tighten screw O with the washer.
Guideline
Screw, bearing bolt, M6 10 Nm Loctite® 243™
torque limiter (7.4 Ibf ft)
17.5.15 Installing the outer clutch hub

Mount collar bushing O and both needle bearings ©.
17 ENGINE 170
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 ©
Position the new lock washer and mount nut © . Tighten the nut, holding the
inner clutch hub with a special tool.
Guideline
Nut, inner clutch hub M18x1.5 80 Nm (59 Ibf ft)
Clutch holder (51129003000) ( p. 225)
Secure the nut with the lock washer.
Lock the outer clutch hub and primary gear using special tool ©.
Gear segment (80029004000) ( p. 231)
Mount and tighten nut ©.

Guideline
Nut, primary gear M20LHx1.5 100 Nm Loctite® 648™
(73.8 Ibf ft)
Set the crankshaft to top dead center and lock it with special tool ©.
Locking screw (113080802) (fiS p. 224)
17.5.16 Installing the clutch discs

Thoroughly oil the clutch facing discs.
Beginning with an intermediate clutch disc, alternately insert all other clutch fac
ing discs and intermediate clutch discs into the outer clutch hub.
Mount pressure piece O-
17 ENGINE 171
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 M5 6 Nm (4.4 Ibf ft)
17 ENGINE 172
Using a straightedge and the special tool, check the spring washer for distortion
Spring washer distortion 0... 0.10 mm (0... 0.0039 in)
» If the specified value is not reached:

- Remove screws © and mount spring retainer with marking II.

- Remove screws © and mount spring retainer with marking III.

- Change the clutch facing discs.
17.5.17 Installing the clutch cover

Position the balancer shaft with special tool o
S Marking © and the special tool are aligned.
Mount dowels © and position the clutch cover gasket ©
Mount the clutch cover.

Mount screws © but do not tighten them yet.
Guideline
Screw, clutch cover M6x25 10 Nm (7.4 Ibfft)

Guideline

Guideline
Fixing drift (78129032000) (3P p. 231)

17 ENGINE 173
17.5.18 Installing the water pump cover

- Put the water pump cover seal in place.
- Mount the water pump cover.
- Mount screw o with the sealing washer but to not tighten yet.
Guideline
Screw, water pump cover M6x25 10 Nm (7.4 Ibf ft)

Guideline

Guideline
17.5.19 Installing the suction pump

Oil the internal rotor and external rotor before mounting.
Insert O-ring o
Position pin ® into the oil pump shaft from above.
Position pin ©
Mount internal rotor o and external rotor ©

S' The rounded sides of the external rotor face the engine case.
Position oil pump cover © Mount and tighten screws Q

Guideline
Screw, suction pump M5 6 Nm Loctite® 243™
cover (4.4 Ibf ft)
17.5.20 Installing the ignition pulse generator

Position the ignition pulse generator.
• Info
I Use the middle drill hole pair.
Mount and tighten screws o

Guideline
Screw, crankshaft posi- M5 6 Nm Loctite® 243™
tion sensor (4.4 Ibf ft)
Position the cable and insert the cable sleeve into the engine case.
17 ENGINE 174
17.5.21 Installing the timing chain

Thread in the timing chain and place it over the timing chain sprocket.
• Info
I If the timing chain was used before, ensure it is running in the correct
direction.
Position the timing chain securing guide.

Guideline
Screw, timing chain M6 10 Nm Loctite® 243™
securing guide (7.4 Ibf ft)
Thread in the timing chain tensioning rail © from above.

Guideline
Screw, timing chain ten- M6 10 Nm Loctite® 243™
sioning rail (7.4 Ibf ft)
Slip in the timing chain guide rail © from above.

Guideline
Screw, timing chain guide M6 10 Nm Loctite® 243™
rail (7.4 Ibf ft)
17.5.22 Installing the rotor

Mount the woodruff key.
Mount the rotor.
Mount and tighten nut o with the spring washer.
Guideline
Nut, rotor M12x1 60 Nm Thread, oiled with
(44.3 Ibf ft) engine oil/cone
degreased
17.5.23 Installing the piston

Move the joints of the compression ring and oil scraper ring so they are offset by
180°.
Place the oiled piston on the cylinder.
Compress the piston rings using the special tool.
Piston ring mounting tool (60029015000) (IS p. 227)

17 ENGINE 175
Tap lightly on the piston ring mounting tool from above with a plastic hammer so
that it lies flush with the cylinder.
y 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.
y The piston rings should not catch or they will be damaged.
Mount dowels o and put cylinder base gasket 0 in place.
Ensure that piston mark © faces toward the exhaust side.
304606-10
Cover the engine housing opening with a cloth.

Feed the timing chain through the timing chain shaft and mount the piston pin.
• Info
I In order to present them more clearly, the following steps are shown with a
removed piston.
17 ENGINE 176
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) (U p. 230)
Ensure that the piston pin retainer is seated properly on both sides.
Remove the cloth. Keep the timing chain taut.

Carefully push the cylinder downward, letting the dowels engage.
17.5.24 Installing the cylinder head

Mount dowels o and put cylinder base gasket 0 in place.
17 ENGINE 177
Put the cylinder head in place.

Mount screws © with the washers and tighten them in a crisscross pattern.
Guideline
Screw, cylinder head Ml 0x1.25 Step 1 Lubricated with
10 Nm engine oil
(7.4 Ibf ft)
Step 2
30 Nm
(22.1 Ibf ft)
Step 3
50 Nm
(36.9 Ibf ft)

Guideline
Screw, cylinder head M6 10 Nm (7.4 Ibf ft)
17.5.25 Installing the camshaft

Place the timing chain over the camshaft gear.
Push the camshaft into the bearing seats.
S The camshaft © and cylinder head © markings are lined up with each
other.
• Info
I Ensure that the crankshaft is at top dead center (TDC).
Position the camshaft support plate.

Guideline
Screw, camshaft support M6 10 Nm Loctite® 243™
plate (7.4 Ibf ft)
17.5.26 Installing the timing chain tensioner

Activate release Q and push the timing chain tensioner all the way back.
17 ENGINE 178
Position the timing chain tensioner with the gasket.

Mount and tighten screws O-
Guideline
Screw, timing chain tensioner M6 10 Nm (7.4 Ibf ft)
Mount and tighten screw plug © with washer © and spring ©

Guideline
Plug, timing chain tensioner M8 8 Nm (5.9 Ibf ft)
17.5.27 Checking the valve clearance

Remove special tool o
Locking screw (113080802) (SS p. 224)
Crank over the engine repeatedly.

Position the engine at ignition top dead center. ( p. 127)
Check the valve clearance at all valves between the valve and rocker arm.
Guideline
Valve clearance
Intake at: 20 °C (68 °F) 0.10... 0.15 mm (0.0039... 0.0059 in)
Exhaust at: 20 °C (68 °F) 0.12... 0.17 mm (0.0047... 0.0067 in)
Feeler gauge (59029041100) ( p. 226)
» If the valve clearance does not meet specifications:

- Adjust the valve clearance. ( p. 178)
Locking screw (113080802) ( p. 224)

Guideline
Screw plug, crankshaft location M8 10 Nm (7.4 Ibf ft)
17.5.28 Adjusting the valve clearance

Remove the timing chain tensioner. ( p. 128)
Remove the camshaft. ( p. 128)
17 ENGINE 179
Raise rocker arm o 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 suitable shims.
Install the camshaft. ( p. 177)
Install the timing chain tensioner. ( p. 177)
Check the valve clearance. ( 1 p. 178)
17.5.29 Installing the alternator cover

Mount locating pins O-
Position alternator cover gasket ©
Position the alternator cover.

Mount screw © with washer but do not tighten it yet.
Guideline
Screw, alternator cover M6x25 10 Nm (7.4 Ibf ft)
Mount screws Q and tighten all screws in a crisscross pattern.

Guideline
Screw, alternator cover M6x25 10 Nm (7.4 Ibf ft)
17.5.30 Installing the valve cover

Position the valve cover seal.
Position the valve cover.
Guideline
Screw, valve cover M6 10 Nm (7.4 Ibf ft)
309418-10
17.5.31 Installing the spark plug

Mount and tighten the spark plug using the special tool.
Guideline
Spark plug M12x1.25 15... 20 Nm
(11.1... 14.8 Ibf ft)
17 ENGINE 180
17.5.32 Installing the starter motor

Grease the O-ring.
Mount the starter motor.
Guideline
Screw, starter motor M6 10 Nm (7.4 Ibf 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.
Insert oil filter o into the oil filter housing.
Oil the O-ring of the oil filter cover.

Mount oil filter cover
Guideline
Screw, oil filter cover M5 6 Nm (4.4 Ibf ft)
17.5.34 Installing the clutch push rod

Mount clutch push rod o
17.5.35 Installing the oil screens

Mount and tighten screw plug o with the short oil screen and the O-ring.
Guideline
Screw plug, oil screen M20x1.5 15 Nm (11.1 Ibf ft)
17 ENGINE 181
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.

Guideline
Screw plug, oil screen M20x1.5 15 Nm (11.1 Ibfft)
Mount and tighten the oil drain plug © with the magnet and the new seal ring.
Guideline
Oil drain plug with magnet M12x1.5 20 Nm (14.8 Ibfft)
17.5.36 Removing the engine from the engine assembly stand

Remove the screw connection from the special tool.
Remove the engine from the engine assembly stand.
• Info
I Have an assistant help you or use a motorized hoist.
18 CLUTCH 182
18.1 Checking/correcting the fluid level of the hydraulic clutch
Warning

• Info
I The fluid level rises with increasing wear of the clutch facing discs.
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not designed for DOT 5
brake fluid.
Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
Remove screws ©
Remove cover @ with membrane ©
Check the fluid level.
Fluid level below container rim 4 mm (0.16 in)
» If the fluid level does not meet specifications:

- Correct the fluid level of the hydraulic clutch.
• Info
18.2 Changing the hydraulic clutch fluid
Warning

Warning
regulations.
• Info
I Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not designed for DOT 5
brake fluid.
18 CLUTCH 183
Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
Remove screws O-
Remove cover © with membrane ©
Fill bleeding syringe © with the appropriate hydraulic fluid.
Bleed syringe (50329050000) p p. 225)

Mount bleeding syringe Q on bleeder screw © using a fitting section of hose.

Only loosen bleeder screw © on the clutch slave cylinder to the point where fill
ing is possible.
Now inject the fluid into the system until it emerges from drill hole © of the mas
ter cylinder without bubbles.
Now and then, extract fluid from the master cylinder reservoir to prevent overflow.
Tighten the bleeder screw and remove the bleeding syringe with the hose.
Correct the fluid level of the hydraulic clutch.
Guideline
Fluid level below container rim 4 mm (0.16 in)
• Info
19 WATER PUMP, COOLING SYSTEM 184
19.1 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.
120 °C (248 °F)
Cooling is effected by the air stream.

The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the
cooling effect.
19.2 Checking the antifreeze and coolant level
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
- Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are
at operating temperature.
- Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other compo
nents of the cooling system.
- In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is toxic and a health hazard.
- Keep coolant out of the reach of children.

- Do not allow coolant to come into contact with the skin, the eyes and clothing.
- Consult a doctor immediately if coolant is swallowed.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
- Change clothing if coolant spills onto your clothing.
Condition
The engine is cold.
- Stand the motorcycle upright on a horizontal surface.
- Remove the radiator cap.
- Check the antifreeze in the coolant.
-25... -45 °C (-13... -49 °F)
» If the antifreeze in the coolant does not match the specified value:
- Correct the antifreeze in the coolant.
- Check the coolant level in the radiator.
Coolant level © above the radiator 10 mm (0.39 in)

fins
» If the coolant level does not match the specified value:

- Correct the coolant level.
Coolant p. 220)
19 WATER PUMP, COOLING SYSTEM 185
- Mount the radiator cap.
19.3 Checking the coolant level
Warning
Warning

Condition
The engine is cold.
- Remove the radiator cap.
- Check the coolant level in the radiator.
Coolant level Q above the radiator 10 mm (0.39 in)

fins
» If the coolant level does not match the specified value:

- Correct the coolant level.
Coolant ( p. 220)
- Mount the radiator cap.
19.4 Draining the coolant
Warning
Warning

Condition
The engine is cold.
19 WATER PUMP, COOLING SYSTEM
Position the motorcycle upright.
Place a suitable container under the water pump cover.
Remove screw O- Take off radiator cap ©.
Completely drain the coolant.
Mount and tighten screw o with a new seal ring.
Guideline
Screw, water pump cover M6 10 Nm (7.4 Ibfft)
19.5 Refilling coolant
Warning

Make sure that screw o is tightened.

Position the motorcycle upright.
Pour coolant in up to measurement Q above the radiator fins.
Guideline
Dimension © over the radiator fins 10 mm (0.39 in)
Coolant 1.20 1 (1.27 qt.) Coolant (U p. 220)
Mount the radiator cap.

Take a short test ride.
Check the coolant level. ( p. 185)
20 LUBRICATION SYSTEM 187
20.1 Oil circuit
401628-60
1 Oil screen
2 Force pump
3 Oil pressure regulator valve
4 Oil filter
5 Oil nozzle for conrod bearing lubrication
6 Oil nozzle, piston cooling
7 Oil nozzle for cam follower lubrication
8 Suction pump
9 Oil channel, transmission lubrication
20.2 Checking the engine oil level

Condition
The engine is at operating temperature.
Preparatory work
Main work
- Check the engine oil level.
• Info
I After switching off the engine, wait one minute before checking the level.
The engine oil level is between Q and ©.
» If the engine oil level is below marking ©

- Add engine oil. p. 190)
» If the engine oil level is at marking © or above:
- Correct the engine oil level.
20.3 Changing the engine oil and oil filter, cleaning the oil screens
Warning
Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden.
- Wear suitable protective clothing and safety gloves.

Warning
regulations.
Info
Drain the engine oil only when the engine is warm.
Preparatory work
- Park the motorcycle on a level surface.
Main work
- Place a suitable container under the engine.
- Remove oil drain plug o with the magnet and seal ring.
- Remove screw plug @ with the short oil screen and the O-rings.
Info
Do not remove screw O-
- Remove screw plug © with the long oil screen o and the O-rings.
- Completely drain the engine oil.
- Thoroughly clean the parts and sealing surfaces.
- Mount and tighten screw plug © with the short oil screen and the O-rings.
Guideline
Place the long oil screen o 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.

Guideline
Mount and tighten the oil drain plug O with the magnet and a new seal ring.
Guideline
Oil drain plug with magnet M12x1.5 20 Nm (14.8 Ibf ft)
Remove screws © Remove the oil filter cover with the O-ring.
Pull oil filter © out of the oil filter housing.
Circlip pliers reverse (51012011000) (U p. 225)
Completely drain the engine oil.

Thoroughly clean the parts and sealing surface.
Lay the motorcycle on its side and fill the oil filter housing to about Vz full with
engine oil.
Insert the oil filter into the oil filter housing.
Lubricate the O-ring of the oil filter cover and mount it with the oil filter cover ©
Mount and tighten the screws.
Guideline
Stand the motorcycle upright.
Remove the oil filler plug © with the O-ring from the clutch cover and fill up with
engine oil.
Engine oil 1.50 I (1.59 qt.) Engine oil (SAE 10W/50) ( p. 220)
• Info
I Too little engine oil or poor-quality engine oil results in premature wear to
the engine.
Install and tighten the oil filler plug with O-ring.

Danger
engine.
- Start the engine and check that it is oil-tight.

Finishing work
20.4 Adding engine oil
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
Remove the oil filler plug O with the O-ring from the clutch cover.
Add the same engine oil that was used when the motor was changed.
For optimal performance of the engine oil, do not mix different types of
engine oil.
If appropriate, change the engine oil.
Install and tighten the oil filler plug with O-ring.
Danger
engine.
- Start the engine and check that it is oil-tight.
20.5 Checking the engine oil pressure

Main work
- Place a suitable container under the engine.
- Remove screws o Remove the oil filter cover with the O-ring.
- Remove the oil filter.
Circlip pliers reverse (51012011000) ( p. 225)
- Position special tool © with the O-ring. Mount and tighten the screws.
Guideline
Oil pressure adapter (75029094000) ( p. 229)
Connect the pressure tester without the t-plate to the special tool.
Pressure tester (61029094000) (\ p. 227)
Check the engine oil level. ( p. 187)

Danger
engine.
- Start the engine and let it warm up.

- Check the engine oil pressure.
Engine oil pressure

Engine oil temperature: 80 °C 0.9 bar (13 psi)
(176 °F)
Engine speed: 1,600 rpm
Engine oil temperature: 80 °C 2.5 bar (36 psi)
(176 °F)
Engine speed: 6,000 rpm
» If the measured value is less than the specification:

- Check the oil pump for wear. Check all oil channels for free flow.
- Switch off the engine.
Warning
Danger of burns Some vehicle components get very hot when the
machine is driven.
- Wear appropriate protective clothing and safety gloves. In case of
burns, rinse immediately with lukewarm water.

- Grease the O-ring of the oil filter cover. Mount the oil filter cover.
- Mount and tighten the screws.
Guideline
Finishing work
21 IGNITION SYSTEM 192
21.1 Ignition coil - checking the secondary 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: 11.075... 15.525 kQ
20 °C (68 °F)
» If the displayed value does not correspond to specifications:

- Change the ignition coil.
21.2 Checking the spark plug connector

Condition
Spark plug connector cylinder 1 has been removed.
Measuring point 1 - Measuring point 2
Spark plug connector

Resistance at: 20 °C (68 °F) 3.75... 6.25 kQ

- Change the spark plug connector.
21.3 Alternator - checking stator winding

Condition
The alternator is disconnected.
Stator winding - checking the resistance
Alternator, connector CR pin 1 - Alternator, connector CR pin 1
Alternator
Resistance of stator winding at: 1.19... 1.61 Q
20 °C (68 °F)
» If the displayed value does meet specifications:

- Change the stator.
Stator winding - check the short circuit to ground (terminal 31)

Alternator, connector CR pin 1 - Measuring point Ground (-)
Resistance 00 Q
» If the displayed value does meet specifications:

- Change the stator.
21 IGNITION SYSTEM 193
Condition
The alternator cover has been removed.
- Remove screw O 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
Position the stator in the alternator cover.

Guideline
Screw, stator M4 4 Nm (3 Ibfft) Loctite® 648™
Position cable support sleeve © in the alternator case.

—
Position the cable holder. Mount and tighten screw ©.
Guideline
306639-11 Screw, cable holder in M4 4 Nm (3 Ibfft) Loctite® 243™
alternator cover
22 ELECTRIC STARTER 194
22.1 Checking 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 O
of the starter motor.
» If the starter motor does not turn when the circuit is closed:
23 THROTTLE VALVE BODY 195
23.1 Adjusting the idle speed
Danger
Warning
Danger of accidents The engine may go out spontaneously if the idle speed is set too low.
- Set the idle speed to the specified value.
Run the engine until warm.

Set the idle speed by turning idle speed adjusting screw ©
Guideline
Idle speed 2,250... 2,350 rpm
Tachometer (45129075000) ( p. 225)
• Info
I Turning counterclockwise lowers the idle speed.
Turning clockwise raises the idle speed.
23.2 Executing the initialization run

Condition
The diagnostic tool is connected and running.
- Execute "Engine electronics" > "Functions" > "Deleting adaptation values".
S The adaptation values are deleted.
- Select "Engine electronics" > "Measured values" > "Engine coolant tempera
ture sensor (TW1)".
S The coolant temperature is displayed during the initialization run.
Danger
engine.
- Start the engine without operating the throttle grip.

Guideline
Coolant temperature < 25 °C (< 77 °F)
Let the engine idle until it reaches the specified temperature.

Guideline
Coolant temperature 80... 90 °C (176... 194 °F)
• Info
I Do not operate the throttle grip during the initialization process.
23 THROTTLE VALVE BODY 196
- As soon as the specified temperature is reached, switch off the ignition.
• Info
I If the initialization is not completed or the initialization process is inter
rupted, the entire process must be restarted.
24 TECHNICAL DATA 197
24.1 Engine
Design 1-cylinder 4-stroke engine, water-cooled
Displacement 449.3 cm3 (27.418 cu in)
Stroke 63.4 mm (2.496 in)
Bore 95 mm (3.74 in)
Compression ratio 12.6:1
Idle speed 2,250... 2,350 rpm
Control OHC, 4 valves controlled via rocker arm
Valve diameter, intake 40 mm (1.57 in)
Valve diameter, exhaust 33 mm (1.3 in)
Valve clearance
Intake at: 20 °C (68 °F) 0.10... 0.15 mm (0.0039... 0.0059 in)
Exhaust at: 20 °C (68 °F) 0.12... 0.17 mm (0.0047... 0.0067 in)
Crankshaft bearing 2 grooved ball bearings
Conrod bearing Slide bearing
Piston pin bearing Not a bearing bush - DLC-plated piston pins
Pistons Forged light alloy
Piston rings 1 compression ring, 1 oil scraper ring
Engine lubrication Pressure circulation lubrication with two Eaton pumps
Primary transmission 32:76
Clutch Multidisc clutch in oil bath/hydraulically activated
Gearbox 5-gear, claw shifted
Transmission ratio
1 st gear 16:32
2nd gear 18:30
3rd gear 20:28
4th gear 22:26
5th gear 24:24
Alternator 12 V, 75 W
Ignition Contactless controlled fully electronic ignition with digital igni
tion adjustment
Spark plug NGK LKAR8AI-9
Spark plug electrode gap 0.9 mm (0.035 in)
Cooling Water cooling, permanent circulation of coolant by water pump
Starting aid Electric starter
24.2 Tolerance, engine wear limits

Camshaft - cam height
Exhaust 33.10... 33.30 mm (1.3031... 1.311 in)
Intake 33.90... 34.10 mm (1.3346... 1.3425 in)
Valve spring
Intake minimum length (without valve spring seat) 40.7 mm (1.602 in)
Exhaust minimum length (without valve spring seat) 40.7 mm (1.602 in)
Valve spring seat 1.8 mm (0.071 in)
Cylinder/cylinder head - sealing area distortion < 0.10 mm (< 0.0039 in)
Piston - diameter
Size 1 94.93... 94.96 mm (3.7374... 3.7386 in)
Size II 94.94... 94.97 mm (3.7378... 3.739 in)
Cylinder - drill hole diameter
Size 1 95.000... 95.012 mm (3.74015... 3.74062 in)
Size II 95.013... 95.025 mm (3.74066... 3.74113 in)
Piston/cylinder - mounting clearance

Size 1 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 < 1.00 mm (< 0.0394 in)
Oil scraper ring < 1.20 mm (< 0.0472 in)
Connecting rod - end play of lower conrod bearing 0.20... 0.45 mm (0.0079... 0.0177 in)
Crankshaft - run-out on bearing pin < 0.04 mm (< 0.0016 in)
Clutch facing disc - thickness > 1.9 mm (> 0.075 in)
Thrust surface, clutch facing discs in outer clutch hub < 0.5 mm (< 0.02 in)
Minimum length of preload spring 24.5 mm (0.965 in)
Shift shaft - play in sliding plate/shift quadrant 0.40... 0.80 mm (0.0157... 0.0315 in)
24.3 Engine tightening torques

Screw, membrane M3 1.5 Nm (1.11 Ibfft) Loctite® 243™
Screw, cable holder in alternator M4 4 Nm (3 Ibfft) Loctite® 243™
cover
Screw, oil jet for piston cooling M4 2 Nm (1.5 Ibf ft) Loctite® 243™
Screw, stator M4 4 Nm (3 Ibfft) Loctite® 648™
Oil nozzle, piston cooling M5 2 Nm (1.5 Ibf ft) Loctite® 243™
Oil nozzle, rocker arm lubrication M5 2 Nm (1.5 Ibf ft) Loctite® 243™
Screw, bearing retainer M5 6 Nm (4.4 Ibf ft) Loctite® 2701 ™
Screw, clutch spring retainer M5 6 Nm (4.4 Ibf ft) —
Screw, crankshaft position sensor M5 6 Nm (4.4 Ibf ft) Loctite® 243™

Screw, locking lever M5 6 Nm (4.4 Ibf ft) Loctite® 243™
Screw, oil filter cover M5 6 Nm (4.4 Ibf ft) —
Screw, suction pump cover M5 6 Nm (4.4 Ibf ft) Loctite® 243™

Nut, water-pump wheel M6 8 Nm (5.9 Ibf ft) Loctite® 243™
Plug, vacuum connection M6 2.5 Nm (1.84 Ibfft) Loctite® 243™
Screw, alternator cover M6 10 Nm (7.4 Ibfft) —
Screw, bearing bolt for starter idler M6 10 Nm (7.4 Ibfft) Loctite® 243™
gear
Screw, bearing bolt, torque limiter M6 10 Nm (7.4 Ibf ft) Loctite® 243™
Screw, camshaft support plate M6 10 Nm (7.4 Ibfft) Loctite® 243™
Screw, clutch cover M6 10 Nm (7.4 Ibf ft) —
Screw, cylinder head M6 10 Nm (7.4 Ibfft) —
Screw, engine case M6 10 Nm (7.4 Ibfft) —
Screw, EVAP M6 5 Nm (3.7 Ibf ft) Loctite® 243™

Screw, exhaust flange M6 10 Nm (7.4 Ibfft) Loctite® 243™
Screw, pressure pump cover M6 10 Nm (7.4 Ibfft) Loctite® 243™
Screw, shift drum locating M6 10 Nm (7.4 Ibf ft) Loctite® 243™
Screw, shift lever M6 14 Nm (10.3 Ibfft) Loctite® 243™
Screw, starter motor M6 10 Nm (7.4 Ibfft) —
Screw, timing chain guide rail M6 10 Nm (7.4 Ibfft) Loctite® 243™

Screw, timing chain securing guide M6 10 Nm (7.4 Ibf ft) Loctite® 243™
Screw, timing chain tensioner M6 10 Nm (7.4 Ibfft) —
Screw, timing chain tensioning rail M6 10 Nm (7.4 Ibf ft) Loctite® 243™
Screw, valve cover M6 10 Nm (7.4 Ibf ft) —
Screw, water pump cover M6 10 Nm (7.4 Ibfft) —

Oil nozzle for conrod bearing lubrica M6x0.75 4 Nm (3 1 bf ft) —
tion
Plug, oil channel M7 9 Nm (6.6 Ibf ft) Loctite® 243™
Screw, rocker arm bearing M7 15 Nm (11.1 Ibf ft) —
Plug, timing chain tensioner M8 8 Nm (5.9 Ibf ft) —
Screw plug, crankshaft location M8 10 Nm (7.4 Ibf ft) —
Plug, oil channel M10 15 Nm (11.1 Ibf ft) Loctite® 243™

Screw, engine sprocket M10 60 Nm (44.3 Ibf ft) Loctite® 2701 ™
Screw, cylinder head Ml 0x1.25 Step 1 Lubricated with engine oil
10 Nm (7.4 Ibf ft)
Step 2
30 Nm (22.1 Ibf ft)
Step 3
50 Nm (36.9 Ibf ft)
Nut, rotor M12x1 60 Nm (44.3 Ibf ft) Thread, oiled with engine
oil/cone degreased
Spark plug Ml 2x1.25 15... 20 Nm (11.1... —
14.8 Ibf ft)

Engine coolant temperature sensor M12x1.5 12 Nm (8.9 Ibf ft) —
Oil drain plug with magnet M12x1.5 20 Nm (14.8 Ibf ft) —
Plug, oil pressure regulator valve Ml 2x1.5 20 Nm (14.8 Ibf ft) —
Plug, SLS M12x1.5 20 Nm (14.8 Ibf ft) —
Nut, inner clutch hub Ml 8x1.5 80 Nm (59 Ibf ft) —
Screw plug, rocker arm Ml 8x1.5 30 Nm (22.1 Ibf ft) —
Nut, primary gear M20LHx1.5 100 Nm (73.8 Ibf ft) Loctite® 648™
Screw plug, oil screen M20x1.5 15 Nm (11.1 Ibf ft) —
Total fuel tank capacity, 7.5 1 (1.98 US gal) Super unleaded (ROZ 95/RON 95/PON 91) (H p. 220)
approx.
24.5 Chassis
Frame Central tube frame made of chrome molybdenum steel tubing
Fork WP Suspension Up Side Down 4860 MXMA 4CS
Suspension travel
Front 300 mm (11.81 in)
Suspension travel
Rear 317 mm (12.48 in)
Fork offset 22 mm (0.87 in)
Shock absorber WP Suspension 5018 BAVP DCC
Brake system Disc brakes, brake calipers on floating bearings
Brake discs - diameter
Front 260 mm (10.24 in)
Rear 220 mm (8.66 in)
Brake discs - wear limit
Front 2.5 mm (0.098 in)

Rear 3.5 mm (0.138 in)
Tire air pressure off road
Front 1.0 bar (15 psi)
Rear 1.0 bar (15 psi)
Secondary ratio 13:50
Chain 5/8 x 1/4"
Rear sprockets available 48, 50, 52
Steering head angle 63.5°
Wheelbase 1,495±10 mm (58.86±0.39 in)
Ground clearance, unloaded 371 mm (14.61 in)
Seat height, unloaded 992 mm (39.06 in)
Weight without fuel, approx. 107.2 kg (236.3 lb.)
Maximum permissible front axle load 145 kg (320 lb.)
Maximum permissible rear axle load 190 kg (419 lb.)
Maximum permissible overall weight 335 kg (739 lb.)
24.6 Electrical system

Battery YTX5L-BS Battery voltage: 12 V
Nominal capacity: 4 Ah
Maintenance-free
Fuse 58011109110 10 A
FI warning lamp LED
24.7 Tires
Front tires Rear tires
80/100-21 M/C 51MTT 110/90- 19 62MTT
Dunlop GEOMAX MX 52 F Dunlop GEOMAX MX 52
The tires specified represent one of the possible series production tires. Additional information is available in the Service section
under:
www.husqvarna-motorcycles.com
24.8 Fork
Fork part number 24.18.70.57
Fork WP Suspension Up Side Down 4860 MXMA 4CS
Compression damping
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Rebound damping
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Spring length with preload spacer(s) 480 mm (18.9 in)
Spring rate
Weight of rider: 65... 75 kg (143... 165 lb.) 4.6 N/mm (26.3 Ib/in)
Fork length 940 mm (37.01 in)
Air chamber length 68 mm (2.68 in)
Oil capacity per fork leg 665 ml (22.48 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 220)
24.9 Shock absorber

Shock absorber article number 18.18.70.59
Shock absorber WP Suspension 5018 BAVP DCC
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Comfort 2.5 turns
Standard 2 turns
Sport 1.5 turns
Rebound damping
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Spring rate
Weight of rider: 65... 75 kg (143... 165 lb.) 54 N/mm (308 Ib/in)
Spring length 260 mm (10.24 in)
Static sag 30 mm (1.18 in)
Riding sag 100 mm (3.94 in)
Fitted length 490 mm (19.29 in)
Shock absorber oil Shock absorber fluid (SAE 2.5) (50180751 SI) ( p. 220)
24.10 Chassis tightening torques

Screw, pressure regulator EJOT PT® K60x25-Z 3 Nm (2.2 Ibf ft) —
Spoke nipple, front wheel M4.5 6 Nm (4.4 Ibf ft) —
Spoke nipple, rear wheel M4.5 6 Nm (4.4 Ibf ft) —
Remaining nuts, chassis M5 5 Nm (3.7 Ibf ft) —
Remaining screws, chassis M5 5 Nm (3.7 Ibf ft) —
Screw, battery terminal M5 2.5 Nm (1.84 Ibf ft) —
Screw, intake air temperature sensor M5 2 Nm (1.5 Ibf ft) —
Screw, shock absorber adjusting ring M5 5 Nm (3.7 Ibf ft) —
Screw, ball joint of push rod on foot M6 10 Nm (7.4 Ibf ft) Loctite® 243™
brake cylinder
Screw, chain sliding guard M6 6 Nm (4.4 Ibf ft) Loctite® 243™
Screw, electric starter cable connec M6 4 Nm (3 Ibf ft) —
tion
Screw, front brake disc M6 14 Nm (10.3 Ibf ft) Loctite® 243™
Screw, rear brake disc M6 14 Nm (10.3 Ibf ft) Loctite® 243™
Screw, throttle grip M6 5 Nm (3.7 Ibf ft) —
Fuel connection on fuel tank M8 10 Nm (7.4 Ibf ft) —
Nut, foot brake lever stop M8 20 Nm (14.8 Ibf ft) —
Nut, rear sprocket screw M8 35 Nm (25.8 Ibf ft) Loctite® 2701 ™

Nut, rim lock M8 12 Nm (8.9 Ibf ft) —

Remaining screws, chassis M8 25 Nm (18.4 Ibfft) —
Screw, bottom triple clamp M8 12 Nm (8.9 Ibf ft) —
Screw, chain sliding piece M8 15 Nm (11.1 Ibfft) —
Screw, engine brace M8 33 Nm (24.3 Ibf ft) —
Screw, fork stub M8 15 Nm (11.1 Ibfft) —
Screw, front brake caliper M8 25 Nm (18.4 Ibfft) Loctite® 243™

Screw, handlebar clamp M8 20 Nm (14.8 Ibfft) —
Screw, subframe M8 30 Nm (22.1 Ibfft) Loctite® 2701 ™

Screw, top steering stem M8 17 Nm (12.5 Ibfft) Loctite® 243™
Screw, top triple clamp M8 17 Nm (12.5 Ibfft) —
Engine carrying screw M10 60 Nm (44.3 Ibf ft) —
Screw, bottom shock absorber M10 60 Nm (44.3 Ibf ft) Loctite® 2701 ™
Screw, handlebar support M10 40 Nm (29.5 Ibf ft) Loctite® 243™
Screw, top shock absorber M10 60 Nm (44.3 Ibf ft) Loctite® 2701 ™
Nut, fuel pump M12 15 Nm (11.1 Ibfft) —
Nut, frame to linkage lever Ml 4x1.5 80 Nm (59 Ibf ft) —
Nut, linkage lever on swingarm Ml 4x1.5 80 Nm (59 Ibf ft) —
Nut, linkage lever to angle lever Ml 4x1.5 80 Nm (59 Ibf ft) —
Nut, swingarm pivot Ml 6x1.5 100 Nm (73.8 Ibfft) —
Nut, rear wheel spindle (FC EU) M20x1.5 80 Nm (59 Ibf ft) —
Screw, front wheel spindle M20x1.5 35 Nm (25.8 Ibf ft) —
Screw, top steering head M20x1.5 12 Nm (8.9 Ibf ft) —
Screw-in nozzles, cooling system M20x1.5 12 Nm (8.9 Ibfft) Loctite® 243™

Nut, rear wheel spindle (FC US) M25x1.5 80 Nm (59 Ibf ft) —
25 CLEANING/PROTECTIVE TREATMENT 203
25.1 Cleaning the motorcycle
Note
Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly.
The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc.
Pressure which is too high causes malfunctions and destroys components.
- Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.
- Maintain a minimum distance between the nozzle of the pressure cleaner and the component.
Minimum clearance 60 cm (23.6 in)
Warning
regulations.
• Info
I If you clean the motorcycle regularly, its value and appearance will be maintained over a long period.
Avoid direct sunshine on the motorcycle during cleaning.
Close off the exhaust system to prevent water from entering.

First remove coarse dirt particles with a gentle spray of water.
Spray very dirty areas with a normal motorcycle cleaner and then clean with a
paintbrush.
• Info
I Use warm water containing normal motorcycle cleaner and a soft sponge.
Never apply motorcycle cleaner to the dry vehicle; always rinse with water
first.
After rinsing the motorcycle with a gentle spray of water, allow it to dry
thoroughly.
Remove the plug from the exhaust system.
Warning
A Danger of accidents Moisture and dirt impair the brake system.
- Brake carefully several times to dry out and remove dirt from the brake
linings and the brake discs.
- After cleaning, ride a short distance until the engine reaches operating tempera
ture.
• Info
I The heat produced causes water at inaccessible locations in the engine
and the brake system to evaporate.
- After the motorcycle has cooled off, lubricate all moving parts and bearings.
- Clean the chain. ( p. 94)
- Treat bare metal parts (except for brake discs and the exhaust system) with a
corrosion inhibitor.
- Treat all plastic parts and powder-coated parts with a mild cleaning and care
agent.
Preserving materials for paints, metal and rubber ( p. 222)

26 STORAGE 204
26.1 Storage
Warning

• Info
I If you plan to garage the motorcycle for a longer period, perform the following steps or have them performed.
Before storing the motorcycle, check all parts for function and wear. If service, repairs, or replacements are necessary, you
should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at
the start of the new season.
When refueling for the last time before taking the motorcycle out of service, add
fuel additive.
Refuel.
Clean the motorcycle. ( p. 203)
Change the engine oil and oil filter and clean the oil screens. ( : p. 188)
Check the antifreeze and coolant level. ( p. 184)
Check the tire air pressure. ( p. 84)
Remove the battery. ( p. 99)
Charge the battery.
Guideline
Storage temperature of battery with- 0... 35 °C (32... 95 °F)
out direct sunshine
Store the vehicle in a dry location that is not subject to large fluctuations in tem
perature.
• Info
I Husqvarna Motorcycles recommends raising the motorcycle.
- Raise the motorcycle with a lift stand. (®S p. 10)

- Cover the vehicle with a tarp or similar cover that is permeable to air.
• Info
I Do not use non-porous materials since they prevent humidity from escap
ing, thus causing corrosion.
Avoid running the engine for a short time only. Since the engine cannot
warm up properly, the water vapor produced during combustion con
denses and causes valves and the exhaust system to rust.
26.2 Preparing for use after storage

Install the battery. ( p. 100)
Remove the motorcycle from the lift stand. ( p. 10)
Perform checks and maintenance measures when preparing for use.
Make a test ride.
27 SERVICE SCHEDULE
27.1 Service schedule

Every 30 operating hours - corresponds to about 210 liters of fuel (55.5 US gal)
Every 20 operating hours - corresponds to about 140 liters of fuel (37 US gal)
Every 10 operating hours - corresponds to about 70 liters of fuel (18.5 US gal) / after every race
Once after 1 operating hour - corresponds to about 7 liters of fuel (1.8 US gal)
Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. O • • •
Check and charge the battery. • • •
Check the front brake linings. (S3 p. 104) • • •
Check the rear brake linings. (S3 p. 109) • • •
Check the brake discs. (IS p. 84) • • •
Check the brake lines for damage and leakage. • • •
Check the rear brake fluid level. (S3 p. 112) • • •
Check the free travel of the foot brake lever. (El p. Ill) • • •
Check the frame and swingarm. • • •

Check the swingarm bearing. •
Check the heim joints at the top of the shock absorber. • • •
Check the shock absorber linkage. (S3 p. 45) • • •
Check the tire condition. (S3 p. 84) O • • •
Check the tire air pressure. (S3 p. 84) o • • •
Check the wheel bearing for play. # • •
Check the wheel hubs. • • •
Check the rim run-out. o • • •
Check the spoke tension. (S3 p. 85) o • • •
Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 93) • • •
Check the chain tension. (S3 p. 91) o • • •
Grease all moving parts (e.g., hand lever, chain,...) and check for smooth operation. • • •
Check/correct the fluid level of the hydraulic clutch. (S3 p. 182) • • •
Check the brake fluid level of the front brake. (S3 p. 106) • • •
Check the free travel of the hand brake lever. (U p. 105) • • •
Check the steering head bearing play. (S3 p. 33) o • • •
Check the valve clearance. o •
Check the clutch. •
Change the engine oil and oil filter and clean the oil screens. (S3 p. 188) o • • •
Check all hoses (e. g. fuel, cooling, bleeding, drainage) and sleeves for tearing, leaks and incorrect routing. o • • •
Check the antifreeze and coolant level. (S3 p. 184) o • • •
Check the cables for damage and routing without sharp bends. • • •
Check that the cables are undamaged, routed without sharp bends and set correctly. o • • •
Clean the air filter and air filter box. (S3 p. 71) • • •
Change the glass fiber yarn filling of the main silencer. (S3 p. 68) •
Check the screws and nuts for tightness. o • • •
Change the fuel screen. (S3 p. 81) o • • •
Check the fuel pressure. (S3 p. 75) • • •
Check idle. o • • •
Final check: Check the vehicle for safe operation and take a test ride. o • • •
Read out the fault memory after the test ride using the Husqvarna Motorcycles diagnostics tool. o • • •
Make the service entry in the Husqvarna Motorcycles Dealer.net and in the Service and Warranty Booklet. o • • •
o One-time interval
• Periodic interval
27 SERVICE SCHEDULE 206
27.2 Service work (as additional order)

Annually
Every 50 operating hours - corresponds to about 350 liters of fuel (92.5 US gal)
Once after 20 operating hours
Once after 10 operating hours
Change the front brake fluid. (U p. 108) •
Change the rear brake fluid. (IS p. 113) •
Change the hydraulic clutch fluid. (S3 p. 182) •
Grease the steering head bearing. (S® p. 31) •
Perform a fork service. (83 p. 15) O •
Service the shock absorber, (tl p. 47) O •
Change the spark plug and spark plug connector. •
Change the piston. • •
Check/measure the cylinder. • •
Check the cylinder head. • •
Change the valves, valve springs and valve spring seats. •
Check the camshaft and rocker arm. • •
Change the connecting rod, conrod bearing, and crank pin. •
Change the shaft seal rings of the water pump. • •
Check the transmission and shift mechanism. •
Check the oil pressure regulator valve. •
Change the suction pump. •
Check the pressure pump and lubrication system. •
Replace the timing chain. •
Check the timing assembly. • •
Change all engine bearings. •
O One-time interval
• Periodic interval
207
28 WIRING DIAGRAM 208
o o CD
ro i
wh-rd 14
ro ro
wh-bl 30
2H
o> c3
T| O)
0
01
o
m
CO
c co
ro
0
1
N)
0
01
cn cn
cr> cn
co co
cr co
ro ro
OJ
O o CO 202799-01
Components:
All EFI control unit
CIO Capacitor
G10 Battery
G20 Alternator
K10 Starter relay with main fuse
K30 Power relay
Ml 0 Starter motor
T20 Voltage regulator
S21 Electric starter button
X295 Diagnostics connector
28.2 Page 2 of 3 (FC EU)

Components:
M13 Fuel pump
M51 Injection valve (cylinder 1)
P25 FI warning lamp (MIL)
R30 CAN bus terminating resistor
S20 Kill switch
28.3 Page 3 of 3 (FC EU)

Components:
BIO Throttle position sensor circuit A
B12 Intake air temperature sensor
B21 Engine coolant temperature sensor (cylinder 1)
B26 Rollover sensor
B37 Crankshaft position sensor
B41 Manifold absolute pressure sensor (cylinder 1)
R51 Ignition coil (cylinder 1)
S51 Map-Select switch for ride mode (optional)
S55 Map-Select switch (optional)
Cable colors:
bl Black
br Brown
bu Blue
gn Green
gr Gray
Ibu Light blue
or Orange
pk Pink
pu Violet
rd Red
wh White
ye Yellow
o o CD
ro i
wh-rd 14
ro ro
wh-bl 30
2H
o> c3
T| O)
0
ui
o
CO
C co
0)
ro
0
1
l\)
0
01
cn cn
cr> cn
co co
cr co
ro ro
OJ
o o CO G00601-01
Components:
CIO Capacitor
G10 Battery
G20 Alternator
K10 Starter relay with main fuse
K30 Power relay
Ml 0 Starter motor
T20 Voltage regulator
S21 Electric starter button
28.5 Page 2 of 3 (FC US)

Components:
M13 Fuel pump
M51 Injection valve (cylinder 1)
P25 FI warning lamp (MIL)
R30 CAN bus terminating resistor
S20 Kill switch
28.6 Page 3 of 3 (FC US)

Components:
BIO Throttle position sensor circuit A
B12 Intake air temperature sensor
B21 Engine coolant temperature sensor (cylinder 1)
B26 Rollover sensor
B37 Crankshaft position sensor
B41 Manifold absolute pressure sensor (cylinder 1)
R51 Ignition coil (cylinder 1)
S51 Map-Select Switch for ride mode (optional)
S55 Map-Select switch (optional)
Cable colors:
bl Black
br Brown
bu Blue
gn Green
gr Gray
Ibu Light blue
or Orange
pk Pink
pu Violet
rd Red
wh White
ye Yellow
29 SUBSTANCES 220
Brake fluid DOT 4

Standard/classification
- DOT
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). Using
inferior antifreeze can result in corrosion and foaming.
Mixture ratio
Antifreeze protection: -25... -45 °C (-13... anti-corrosion/antifreeze
-49 °F) distilled water
Bel-Ray®
- Moto Chill Racing Coolant
Engine oil (SAE 10W/50)

- JASO T903 MA p p. 237)
- SAE p p. 237) (SAE 10W/50)
Guideline
- Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre
sponding properties.
Synthetic engine oil
Bel-Ray®
- Works Thumper Racing Synthetic Ester 4T
Fork oil (SAE 4) (48601166S1)

- SAE p p. 237) (SAE 4)
Guideline
- Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding
properties.
Shock absorber fluid (SAE 2.5) (50180751 SI)

- SAE ( p. 237) (SAE 2.5)
Guideline
- Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding
properties.
Super unleaded (ROZ 95/RON 95/PON 91)

- DIN EN 228 (ROZ 95/RON 95/PON 91)
Guideline
- Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.
- Fuel with an ethanol content of up to 10 % (El 0 fuel) is safe to use.
• Info
I Do not use fuel containing methanol (e. g. Ml 5, M85, Ml 00) or more than 10 % ethanol (e. g. El 5, E25, E85, El 00).
30 AUXILIARY SUBSTANCES 221
Air filter cleaning agent

Bel-Ray®
- Foam Filter Cleaner & Degreaser
High viscosity grease

SKF®
- LGHB 2
Long-life grease
Bel-Ray®
- Waterproof Grease
Lubricant (T158)
Lubcon®
- Turmogrease® PP 300
Lubricant (T511)
Lubcon®
- Turmsilon® GTI 300 P
Lubricant (T625)
Molykote®
- 33 Medium
Lubricant (T152)
Bel-Ray®
- Molylube® Anti-Seize
Lubricant (T159)
Bel-Ray®
- MC-11®
Offroad chain spray

Guideline
Bel-Ray®
- Blue Tac Chain Lube
Oil for foam air filter

Bel-Ray®
- Foam Filter Oil
30 AUXILIARY SUBSTANCES
Preserving materials for paints, metal and rubber

Bel-Ray®
- Silicone Detailer & Protectant Spray
Universal oil spray

Bel-Ray®
- 6 in 1
31 SPECIAL TOOLS 223
Bleeder cover
Art. no.: 00029013005
A
00029013005
H00504-01
Bleeder cover
Art. no.: 00029013006
Bleeding device
Art. no.: 00029013100
00029013100
H00518-01
Battery charger XCharge-professional EU

Art. no.: 00029095050
Battery charger XCharge-professional US

Art. no.: 00029095051
Battery charger XCharge-professional GB

Art. no.: 00029095052
Battery charger XCharge-professional CH

Art. no.: 00029095053
Locking screw
Art. no.: 113080802
Bearing puller
Art. no.: 15112017000
Internal bearing puller

Art. no.: 15112018100
Feature
18... 23 mm (0.71... 0.91 in)
15112018100
H00522-01
31 SPECIAL TOOLS
Tachometer
Art. no.: 45129075000
o<%
45129075000
H00525-01
Spring hook
Art. no.: 50305017000
50305017000
H00973-01
Bleed syringe
/2\ A\
Art. no.: 50329050000
50329050000
H00565-01
Circlip pliers reverse

Art. no.: 51012011000
51012011000
H00572-01
Clutch holder
Art. no.: 51129003000
A
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 plug gauge

Art. no.: 59029026006
/K
59029026006
H00612-01
Feeler gauge
Art. no.: 59029041100
59029041100
H00616-01
Piston ring mounting tool

Art. no.: 60029015000
60029015000
H00628-01
Puller, 2-arm
Art. no.: 60029033000
2x
60029033000
H00633-01
Hose clamp pliers

Art. no.: 60029057000
A
60029057000
H00650-01
Testing hose
Art. no.: 61029093000
61029093000
H00659-01
Pressure tester
Art. no.: 61029094000
4x /2\
61029094000
H00660-01
Engine assembly stand

Art. no.: 61229001000
Extractor
Art. no.: 75029021000
Push-in drift
Art. no.: 75029044010
75029044010
H00712-01
Push-in drift
Art. no.: 75029044020
75029044020
H00713-01
Pressing tool for crankshaft, complete

Art. no.: 75029047000
Clamping plate
Art. no.: 75029050000
75029050000
H00719-01
Push-out drift
Art. no.: 75029051000
A
(m
75029051000
H00721-01
Protection cap
Art. no.: 75029090000
A
75029090000
H00726-01
Oil pressure adapter

Art. no.: 75029094000
A
75029094000
H00728-01
Insert for valve spring lever

Art. no.: 77029041200
A
77029041200
H00746-01
Art. no.: 77229172000
Art. no.: 77329030100
Art. no.: 78029002000
&
Art. no.: 78029005100
78029005100
H00785-01
Art. no.: 78029049100

Art. no.: 78129032000
Art. no.: 78929008000
78929008000
HOI 016-01
Art. no.: 78929009000
Art. no.: 80029004000

A
80029004000
H00813-01
Art. no.: 81329955000

Mounting sleeve
Art. no.: 90129005000
90129005000
H00816-01
Case separating tool

Art. no.: 90129048100
2x /4\
90129048100
H00828-01
Hook wrench
Art. no.: T106S
A
T106S
H00841-01
Depth micrometer
Art. no.: T107S
T107S
H00842-01
Pin
Art. no.: T120
A
T120
H00844-01
Mounting sleeve
Art. no.: T1204
T1204
H00878-01
Calibration pin
Art. no.: T1205
A
T1205
H00879-01
Pressing tool
Art. no.: T1206
A
T1206
H00880-01
Pressing tool
Art. no.: T1207S
<^sP
T1207S
H00881-01
Mounting sleeve
Art. no.: T1215
A
T1215
H00886-01
Art. no.: T1216
Art. no.: T1240S
T1240S
H00890-01
Art. no.: T1401
Art. no.: T1403S
Art. no.: T14040S

Special socket
Art. no.: T14047
T14047
H00923-01
Clamping stand
Art. no.: T14049S
(if?
T14049S
H00924-01
Press-out tool
Art. no.: T14051
T14051
H00926-01
Press drift
Art. no.: T1504
T1504
H00899-01
Assembly tool
Art. no.: T150S
T150S
H00852-01
32 STANDARDS 237
JASO T903 MA
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. In most motorcycles, the gearbox and the clutch are lubricated with the same oil as the
engine. The JASO MA Standard meets these special requirements.
SAE
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their
viscosity. The viscosity describes only one property of oil and says nothing about quality.
INDEX 238
fork legs, disassembling ...............................................18-19

A
Chain
Accessories ................................................. ........................... 8 checking............................................................................... 93
Air filter cleaning ............................................................................... 94
cleaning .................................................... ......................... 71 Chain guide
installing.................................................... ......................... 70 checking............................................................................... 93
removing ................................................. ......................... 70
Chain tension
Air filter box adjusting............................................................................... 92
cleaning .................................................... ......................... 71 checking............................................................................... 91
sealing ...................................................... ......................... 71
Charging voltage
Air filter box lid checking............................................................................ 101
installing.................................................... ......................... 70
Chassis number .......................................................................... 9
removing ................................................. ......................... 70
Clutch
Alternator
fluid level, checking/correcting ..................................... 182
stator winding, checking......................... ...................... 192
fluid, changing................................................................... 182
Antifreeze
Clutch lever
checking.................................................... ...................... 184
basic position, adjusting .................................................... 36
Assembling the engine
Compression damping
crankshaft, installing................................ ...................... 165
fork, adjusting ..................................................................... 12
valve clearance, checking ...................... ...................... 178
Auxiliary substances ................................. ........................... 8
shock absorber, adjusting................................................. 40
B
Battery shock absorber, adjusting................................................. 40
installing.................................................... ...................... 100 Coolant
recharging ............................................... ...................... 100 antifreeze and coolant level, checking ......................... 184
removing ................................................. ......................... 99 checking the level ........................................................... 185
Brake disc draining ............................................................................ 185
front brake, installing .............................. ......................... 87 refilling ............................................................................... 186
front brake, removing .............................. ......................... 87 Cooling system..................................................................... 184
rear brake, installing................................ ......................... 91 Cylinder - Nikasil® coating................................................. 146
rear brake, removing .............................. ......................... 90
D
Brake discs
checking.................................................... ......................... 84 Drivetrain kit
changing ............................................................................ 95
Brake fluid
front brake, adding................................... ...................... 107 E
front brake, changing .............................. ...................... 108 Engine
rear brake, adding ................................... ...................... 112 installing.............................................................................. 120
rear brake, changing .............................. ...................... 113 removing .......................................................................... 116
Brake fluid level Engine - work on individual parts
front brake, checking .............................. ...................... 106 autodecompressor, assembling..................................... 149
rear brake, checking................................ ...................... 112 autodecompressor, disassembling.................................. 148
Brake linings camshaft bearing, changing ............................................ 152
front brake, checking .............................. ...................... 104 camshaft, checking ......................................................... 150
of front brake, changing ......................... ...................... 104 clutch, checking .............................................................. 156
of rear brake, changing........................... ...................... 109 connecting rod, conrod bearing, and crank pin, changing 144
rear brake, checking................................ ...................... 109 countershaft, assembling ................................................. 162
countershaft, disassembling ............................................ 159
C
crankshaft run-out at the bearing pin, checking.......... 146
Capacitor crankshaft seal ring in clutch cover, changing .............. 142
checking 102 cylinder - Nikasil® coating ............................................ 146
Capacity cylinder head, checking ................................................. 153
coolant . . . . 186, 199 cylinder, checking/measuring ......................................... 146
engine oil 124, 189, 199 freewheel, checking ......................................................... 163
fuel . . . ............ 199 freewheel, installing ......................................................... 164
Cartridge freewheel, removing......................................................... 164
fork legs, assembling 26 left engine case section ................................................. 140
INDEX 239
main shaft, assembling.................................................... 161 transmission shafts, installing ........................ 165

main shaft, disassembling............................................... 159 valve clearance, adjusting................................ 178
oil pressure regulator valve, installing ........................... 142 valve cover, installing ....................................... 179
oil pressure regulator valve, removing........................... 141 water pump cover, installing ........................... 173
oil pumps, checking......................................................... 148 Engine disassembly
piston, checking/measuring .......................................... 147 alternator cover, removing ............................. 127
piston/cylinder, determining the mounting clearance . 148 camshaft, removing .......................................... 128
right engine case section ............................................... 138 clutch cover, removing ..................................... 132
rocker arm shafts, checking .......................................... 154 clutch discs, removing ..................................... 132
rocker arm, removing ...................................................... 151 clutch push rod, removing................................ 126
shift mechanism, checking ............................................. 157 crankshaft, removing ....................................... 138
shift shaft, preassembling ............................................... 158 cylinder head, removing .................................. 129
spring length of oil pressure regulator valve, checking 141 engine oil, draining............................................ 125
starter drive, checking .................................................... 163 engine, positioning at ignition top dead center 127
timing assembly, checking ............................................. 150 force pump, removing ..................................... 135
timing chain sprocket, installing..................................... 144 freewheel gear, removing ................................ 136
timing chain sprocket, removing ................................... 144 ignition pulse generator, removing ................. 131
transmission, checking.................................................... 160 left engine case section, removing ................. 136
valve spring seat, checking............................................. 153 locking lever, removing..................................... 135
valve springs, checking ................................................. 153 oil filter, removing ............................................ 126
valves, checking .............................................................. 152 outer clutch hub, removing ............................. 133
water pump, installing .................................................... 143 piston, removing ............................................... 129
water pump, removing .................................................... 142 preparations ...................................................... 125
Engine - work on the individual parts primary gear, removing..................................... 136
piston ring end gap, checking ........................................ 147 rotor, removing ................................................. 130
rocker arm, installing ...................................................... 155 shift drum locating unit, removing ................. 134
valves, installing .............................................................. 154 shift drum, removing ....................................... 137
valves, removing .............................................................. 151 shift forks, removing.......................................... 137
Engine assembly shift rails, removing .......................................... 137
alternator cover, installing............................................... 179 shift shaft, removing.......................................... 134
camshaft, installing ......................................................... 177 spark plug, removing ....................................... 126
clutch cover, installing .................................................... 172 starter idler gear, removing ............................. 134
clutch discs, installing .................................................... 170 starter motor, removing .................................. 126
clutch push rod, installing ............................................... 180 suction pump, removing .................................. 131
cylinder head, installing ................................................. 176 timing chain tensioner, removing ................... 128
engine, removing from engine assembly stand .......... 181 timing chain, removing ..................................... 130
force pump, installing...................................................... 167 torque limiter, removing .................................. 134
freewheel gear, installing................................................. 167 transmission shafts, removing ........................ 138
ignition pulse generator, installing ................................ 173 valve cover, removing....................................... 127
left engine case, installing............................................... 166 water pump cover, removing........................... 131
locking lever, installing .................................................... 168 Engine number .................................................... . 9
oil filter, installing .............................................................. 180 Engine oil
oil screens, installing ...................................................... 180 adding ............................................................................... 190
outer clutch hub, installing ............................................ 169 changing .......................................................................... 188
piston, installing................................................................ 174
Engine oil level
primary gear, installing .................................................... 167
checking............................................................................ 187
rotor, installing................................................................... 174
shift drum locating unit, installing................................... 169 Engine oil pressure
checking............................................................................ 190
shift drum, installing......................................................... 166
shift forks, installing ......................................................... 165 Engine sprocket
shift rails, installing........................................................... 166 checking............................................................................... 93
shift shaft, installing ......................................................... 169 F
spark plug, installing ...................................................... 179
Figures........................................................................................ 8
starter idler gear, installing ............................................ 169
Filler cap
starter motor, installing.................................................... 180
closing ................................................................................. 72
suction pump, installing ................................................. 173
opening ............................................................................... 72
timing chain tensioner, installing ................................... 177
timing chain, installing .................................................... 174 Foot brake lever
torque limiter, installing.................................................... 169 basic position, adjusting ................................................. Ill
INDEX 240
free travel, checking................. Ill fork legs, disassembling .................................................... 21

Fork legs I
assembling ................................ , . 27
Idle speed
bleeding ..................................... . 13
adjusting............................................................................ 195
cartridge, assembling............... , . 26
cartridge, disassembling.......... 18-19 Ignition coil
secondary winding, checking ........................................ 192
checking..................................... , . 22
compression damping, adjusting . 12 Implied warranty....................................................................... 8
disassembling ........................... , . 15 Initialization run
dust boots, cleaning................. , . 13 executing .......................................................................... 195
fork service, performing .......... , . 15
L
hydrostop unit, assembling . . . , . 24
hydrostop unit, disassembling . , . 21 Lower triple clamp
installing..................................... , . 14 installing............................................................................... 32
piston rod, assembling ............ , . 25 removing ............................................................................ 31
piston rod, disassembling .... . 20 M
rebound damping, adjusting . . , . 12
Main fuse
removing ................................... , . 13
changing ............................................................................ 99
seal ring retainer, assembling . , . 23
Main silencer
seal ring retainer, disassembling . 22
glass fiber yarn filling, changing....................................... 68
spring, removing ...................... , . 17
installing............................................................................... 68
Fork part number ........................ , . . 9
removing ............................................................................ 68
Fork protector
Manifold
installing..................................... , . 15
installing............................................................................... 67
removing .................................. , . 14
removing ............................................................................ 67
Fork service, performing ............ . 15
Motorcycle
Frame cleaning ............................................................................ 203
checking..................................... . 39 lift stand, raising with ......................................................... 10
Front fender lift stand, removing from.................................................... 10
installing..................................... , . 82 O
removing .................................. . 82
Oil circuit ............................................................................... 187
Front wheel
Oil filter
installing..................................... , . 86
changing .......................................................................... 188
removing .................................. , . 85
Fuel filter
installing............................................................................ 142
changing .................................. , . 78
removing .......................................................................... 141
Fuel pressure spring length, checking.................................................... 141
checking..................................... , . 75
Oil screens
Fuel pump cleaning ............................................................................ 188
changing ............................................................................ 77
Open-circuit current
Fuel screen checking............................................................................ 102
changing ............................................................................ 81
Operating substances .............................................................. 8
Fuel tank
P
installing............................................................................... 74
removing ............................................................................. 73 Piston rod
fork legs, assembling ......................................................... 25
Fuse
fork legs, disassembling .................................................... 20
main fuse, changing........................................................... 99
Play in throttle cable
H
adjusting............................................................................... 38
Hand brake lever
Preparing for use
basic position, adjusting ................................................. 106
after storage ..................................................................... 204
free travel, checking......................................................... 105
R
Handlebar position................................................................ 36
adjusting............................................................................... 36 Rear sprocket
checking............................................................................... 93
Hydrostop unit
fork legs, assembling ......................................................... 24
INDEX 241
Rear wheel Start number plate

Installing............................................................................... 89 installing............................................................................... 83
removing ............................................................................. 88 removing ............................................................................ 82
Rebound damping Starter motor
fork, adjusting ..................................................................... 12 checking............................................................................ 194
shock absorber, adjusting................................................. 41 Starter relay
Riding sag checking............................................................................ 103
adjusting.................................................................................. 43 Starting...................................................................................... 10
Right side cover for checking ........................................................................ 11
installing............................................................................... 73 Stator
removing ............................................................................. 72 installing............................................................................ 193
S removing .......................................................................... 193
Seal ring retainer Steering head bearing

fork legs, assembling ................................ ... 23 changing ...................... 34
fork legs, disassembling ........................... ... 22 greasing ......................... 31
Seat Steering head bearing play

mounting .................................................... ... 73 adjusting......................... 35
removing .................................................... ... 73 checking......................... 33
Service schedule.......................................... 205-206 Storage............................... 204

Servicing the shock absorber ................... ... 47 Swingarm
Shock absorber checking............................................................................... 62
damper, assembling................................... ... 56 installing............................................................................... 63
damper, bleeding and filling .................... ... 58 removing ............................................................................ 62
damper, checking ..................................... ... 52 Swingarm bearing
damper, disassembling.............................. ... 48 changing ............................................................................ 64
damper, filling with nitrogen .................... ... 60 T
heim joint, installing ................................... ... 53
heim joint, removing................................... ... 52 Technical data
capacities...................................................... ................. 199
high speed compression damping, setting ... 40
chassis........................................................... ................. 199
installing...................................................... ... 44
chassis tightening torques ........................ ................. 201
low speed compression damping, setting ... 40
electrical system .......................................... ................. 200
pilot bushing, changing.............................. ... 51
engine ................. ......................................... ................. 197
piston rod, assembling .............................. ... 55
engine - tolerance, wear limits.................... ................. 197
piston rod, disassembling ......................... ... 49
engine tightening torques ........................... ................. 198
rebound damping, adjusting .................... ... 41
fork ................................................................ ................. 200
removing .................................................... ... 43
shock absorber ............................................ ................. 201
riding sag, checking................................... ... 42
tires ................................................................ ................. 200
seal ring retainer, assembling ................. ... 54
seal ring retainer, disassembling ............ ... 50 Throttle cable play
shock absorber, servicing ......................... ... 47 checking........................................................ .................... 37
spring preload, adjusting ......................... ... 42 Throttle cable routing
spring, installing.......................................... ... 61 checking........................................................ .................... 37
spring, removing ....................................... ... 48 Tire air pressure
static sag, checking ................................... ... 41 checking........................................................ .................... 84
Shock absorber article number ................. ____9 Tire condition
Shock absorber linkage checking........................................................ .................... 84
checking...................................................... ... 45 Type label........................................................... ...................... 9
Spare parts.................................................... ____8
W
Spark plug connector Warranty...................................................................................8
checking...................................................... . . 192
Wheel bearing
Spoke tension changing, rear..................................................................... 97
checking...................................................... ... 85 front, changing .................................................................. 87
Spring Wiring diagram.............................................................. 208-219
fork legs, removing ................................... ... 17 page 1 of 3 ................................................................ 208, 214
page 2 of 3 ................................................................ 210, 216
INDEX 242
page 3 of 3 ................................................................ 212, 218

Work rules ................................................................................. 7

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REPAIR MANUAL 2015

1 MEANS OF REPRESENTATION......................................... 6 7.4 Checking the throttle cable routing.................... 37

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).

0‘ Indicates a page reference (more information is provided on the specified page)

Indicates information with more details or tips,

Indicates the result of a testing step

Denotes a voltage measurement,

Denotes a current measurement,

Denotes a resistance measurement.

1.2 Formats used

Name® Identifies a protected name.

Brand™ Identifies a trademark.

2.1 Repair Manual

2.2 Safety advice

2.3 Degrees of risk and symbols

2.4 Work rules

3.1 Manufacturer and implied warranty

3.2 Operating and auxiliary substances

3.3 Spare parts, accessories

4.1 Chassis number

4.2 Type label

4.3 Engine number

4.4 Fork part number

4.5 Shock absorber article number

5.1 Raising the motorcycle with a lift stand

- Raise the motorcycle at the frame underneath the engine.

Lift stand (81329955000) p p. 231)

5.2 Removing the motorcycle from the lift stand

Remove the motorcycle from the lift stand.

- Remove plug-in stand o

Press the electric starter button ©.

5.4 Starting the motorcycle for a check

Shift the transmission to idle.

6.1 Adjusting the compression damping of the fork

Turn the white adjusting screw o all the way clockwise.

Turn back counterclockwise by the number of clicks corresponding to the fork

6.2 Adjusting the rebound damping of the fork

Turn the red adjusting screw o all the way clockwise.

Turn back counterclockwise by the number of clicks corresponding to the fork

6.3 Bleeding the fork legs

6.4 Cleaning the dust boots of the fork legs

Universal oil spray (H p. 222)

- Press the dust boots back into their installation position.

6.5 Removing the fork legs

Loosen screws © . Take out the left fork leg.

6.6 Installing the fork legs

- Position the brake caliper. Mount and tighten screws ©

6.7 Removing the fork protector

6.8 Installing the fork protector

6.9 Performing a fork service

6.10 Disassembling the fork legs

Remove the screw. Remove adjuster ©

Release screw cap ©.

Special socket (T14047) ( p. 235)

Unclamp the fork leg.

Clamp the fork leg with the axle clamp.

Remove the cartridge from the fork leg.

Remove dust boot ©

Remove lock ring e

Warm the outer tube in area © of the lower sliding bushing.

Remove the upper sliding bushing ©

Take off the lower sliding bushing ©