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Husqvarna FC 250 2015 Repair Manual
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Husqvarna FC 250 2015 Repair Manual

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PIONEERING SINCE 1903
REPAIR MANUAL2015
FC250
®
Husqvarna
Art. no. 3403012en
MOTORCYCLES

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Summary of Contents for Husqvarna FC 250 2015

  • Page 1 PIONEERING SINCE 1903 REPAIR MANUAL2015 FC250 ® Husqvarna Art. no. 3403012en MOTORCYCLES...
  • Page 3 Husqvarna accepts no lia­ bility for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Adjusting the basic position of the clutch MEANS OF REPRESENTATION ........6 lever ..............36 Symbols used ............6 Checking the throttle cable routing ....37 1 .2 Formats used ............6 Checking the play in the throttle cable ....
  • Page 5 TABLE OF CONTENTS 12.2 Closing the filler cap ........... 72 16.8 Checking the rear brake linings ......109 12.3 Removing the right side cover ......72 16.9 Changing the rear brake linings ......109 12.4 Installing the right side cover ......73 16.10 Checking the free travel of foot brake lever.

  • Page 6: Installing The Rotor And Ignition Pulse Generator

    TABLE OF CONTENTS 17.4.8 Changing the connecting rod, conrod 17.5.20 Installing the rotor and ignition pulse bearing, and crank pin ......... 145 generator ............1 7 4 17.4.9 Checking the crankshaft run-out at the 17.5.21 Installing the piston ........17 4 bearing pin ...........
  • Page 7 TABLE OF CONTENTS 24.9 Shock absorber ..........202 24.10 Chassis tightening torques ....... 203 CLEANING/PROTECTIVE TREATMENT ....... 204 25.1 Cleaning the motorcycle ........204 STORAGE ..............205 26.1 Storage ............. 205 26.2 Putting into operation after storage ....

  • Page 8: Means Of Representation

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

  • Page 9: Safety Advice

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

  • Page 10: Important Notes

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

  • Page 11: Serial Numbers

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

  • Page 12: Motorcycle

    MOTORCYCLE Raising the motorc cle with a lift stand Note Danger of damage The parked vehicle 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 (81329955100) (�...

  • Page 13: Starting The Motorcycle To Make Checks

    MOTORCYCLE Startin the motorc cle to make checks 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. Info Press the starter for a maximum of 5 seconds.

  • Page 14: Fork, Triple Clamp

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

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

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

  • Page 16: Installing The Fork Legs

    FORK, TRIPLE CLAMP Loosen screws Take out the left fork leg. Unscrew screws Take out the right fork leg. Installing the fork legs Main work Position the fork legs. ✓ Bleeder screws face forward. • Info The rebound damping is located in the right fork leg (red adjusting screw). The compression damping is located in the left fork leg (white adjusting screw).

  • Page 17: Installing The Fork Protector

    FORK, TRIPLE CLAMP Position the fork protector on the left fork leg. Mount and tighten screws Guideline Remaining screws, chassis 110 Nm (7.4 lbf ft) Position the brake line and clamp. Mount and tighten screws Position the fork protector on the right fork leg. Mount and tighten screws fi). Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft)
  • Page 18 FORK, TRIPLE CLAMP Clamp the fork leg in the area of the lower triple clamp. Clamping stand (T1403S) (lit!I p. 233) Remove the screw. Remove adjuster@). 201700-10 Release screw cap Special socket (T14047) (!ill p. 233) • Info The cartridge cannot be taken off yet. 201701-10 Unclamp the fork leg.

  • Page 19: Removing The Spring

    FORK, TRIPLE CLAMP Remove lock ring • Info The lock ring has a ground end against which a screwdriver can be posi­ tioned. Warm the outer tube in area G) of the lower sliding bushing. Guideline (122 °F) Pull the outer tube forcefully off of the inner tube. •...
  • Page 20 FORK, TRIPLE CLAMP Clamp the open end wrench in the vise. Release screw cap but do not remove it yet. Special socket (T14047) (!ill p. 233) Pull the spring down. Remove the open end wrench. Remove the screw cap. Remove the spring with the preload spacer(s). 201724-11 Disassemblin the cartrid e...

  • Page 21: Disassembling The Cartridge

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

  • Page 22: Disassembling The Piston Rod

    FORK, TRIPLE CLAMP Clamp the tube of the cartridge into a vise. Clamping stand (T14049S) p. 234) Release seal ring retainer and remove with the washer. Remove lock ring Pull reservoir @ off of the tube. Pull sleeve out of the reservoir. Remove spring 201795-10 Remove seal rings �...

  • Page 23: Disassembling The Hydrostop Unit

    FORK, TRIPLE CLAMP fD . Remove the rebound shim stack Remove piston Remove the compression shim stack@). Remove spring. • Remove adapter (3 with spring @ and washer. Remove spring 201788-10 Remove valve needle from the piston rod. Info The adjusting tube can be used for this. 201789-10 Disassembling the h�drostoR unit Info...

  • Page 24: Disassembling The Seal Ring Retainer

    FORK, TRIPLE CLAMP Remove adapter Remove hub with washers@). • Info It is possible that only one washer or no washer is present. Remove the O-ring from the hub. Remove shim stack Remove washer @. Remove O-ring Disassemblin the seal rin retainer Info The steps are identical for both fork legs.

  • Page 25: Assembling The Seal Ring Retainer

    FORK, TRIPLE CLAMP 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: Change the inner tube. Measure the run-out of the inner tube.

  • Page 26: Assembling The Hydrostop Unit

    FORK, TRIPLE CLAMP Mount and grease seal ring Lubricant (T158) (l!J:!1 p. 221) Mount and grease O-ring Lubricant (T158) (l!J:!1 p. 221) Position pilot bushing support (s). Assembling the h¥drosto� unit Info The steps are identical for both fork legs. Mount and grease O-ring Lubricant (T158) (l!J:!1...

  • Page 27: Assembling The Piston Rod

    FORK, TRIPLE CLAMP Assembling the iston rod Info The steps are identical for both fork legs, except for the hydrostop needle and valve. Degrease the piston rod. Clamp the piston rod with the special tool. Clamping stand (T14049S) (� p. 234) Lubricate the O-ring.

  • Page 28: Assembling The Cartridge

    FORK, TRIPLE CLAMP Press the piston downward against the spring. ✓ The piston should not squeeze the shims. Position valve@ in the hydrostop needle Mount and tighten the hydrostop needle. Guideline Hydrostop needle on piston rod M6x0.5 I 7 Nm (5.2 lbf ft) •...

  • Page 29: Assembling The Fork Legs

    FORK, TRIPLE CLAMP Slide piston rod into the cartridge. • Info Ensure that the piston ring is seated correctly. Mount spring seat Degrease piston rod and clamp in the vise. Clamping stand (T14049S) (l!\l p. 234) Screw spring guide Ci) all the way on. •...
  • Page 30 FORK, TRIPLE CLAMP Grind the edges of the sliding bushings with sandpaper grit 600, clean the bush­ ings and lubricate them. Fork oil (SAE 4) (48601166S1) (� p. 220) 201715-10 Slide on the lower sliding bushing Mount the upper sliding bushing (D. Info Do not use a tool;...
  • Page 31 FORK, TRIPLE CLAMP Lubricate the O-ring. Slide the cartridge all the way into the fork leg. Fork oil (SAE 4) (48601166S1) (� p. 220) 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.
  • Page 32 FORK, TRIPLE CLAMP 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 lbf ft) Special socket (T14047) (�...

  • Page 33: Greasing The Steering Head Bearing

    FORK, TRIPLE CLAMP 6.23 Greasing the steering head bearing Remove the lower triple clamp. (ll!:,!I p. 31) � Install the lower triple clamp. (ll!:,!I p. 32) ! � > 800010-10 6.24 Removin the lower tri Preparatory work Raise the motorcycle with a lift stand. (�...

  • Page 34: Installing The Lower Triple Clamp

    FORK, TRIPLE CLAMP 6.25 Installing the lower tri Main work Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease (il!.!J p. 221) Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

  • Page 35: Checking The Steering Head Bearing Play

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

  • Page 36: Changing The Steering Head Bearing

    FORK, TRIPLE CLAMP 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 play of the steering head bearing.

  • Page 37: Adjusting The Play Of The Steering Head Bearing

    FORK, TRIPLE CLAMP Press in the new bearing race all the way using a suitable tool. Pull off bearing (s). Remove seal ring retainer. Remove O-ring. Grease the new O-ring and mount with seal ring retainer. Press on the new bearing with a suitable tube as far as it will go. G01808-10 Finishing work Install the lower triple clamp.

  • Page 38: Handlebar,Controls

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

  • Page 39: Checking The Throttle Cable Routing

    HANDLEBAR,CONTROLS Checkin the throttle cable routin Preparatory work Remove the seat. (!ill p. 73) Remove the fuel tank. (!ill 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 bearing.

  • Page 40: Checking The Play In The Throttle Cable

    HANDLEBAR,CONTROLS in the throttle cable Preparatory work Remove the seat. (� p. 73) Remove the fuel tank. (� p. 73) Check the throttle cable routing. (� p. 37) Main work Move the handlebar to the straight-ahead position. Push back sleeves Loosen nut @.

  • Page 41: Frame

    FRAME Check the frame for cracking and deformation. If the frame exhibits cracking or deformation due to a mechanical impact: Change the frame. • Info A frame that has been damaged due to a mechanical impact must always be changed. Repair of the frame is not authorized by Husq­ varna.

  • Page 42: Shock Absorber, Swingarm

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

  • Page 43: Adjusting The Rebound Damping Of The Shock Absorber

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

  • Page 44: Checking The Riding Sag Of The Shock Absorber

    SHOCK ABSORBER, SWINGARM sag of the shock absorber Measure distance of rear wheel unloaded. 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.

  • Page 45: Adjusting The Riding Sag

    SHOCK ABSORBER, SWINGARM Finishing work Install the shock absorber. (l!!:!I p. 44) Install the main silencer. (l!!:!I p. 68) Install the right side cover. (l!!:!I p. 73) Mount the seat. p. 73) Remove the motorcycle from the lift stand. p. 10) Adjusting the riding sag Preparatory work Raise the motorcycle with a lift stand.

  • Page 46: Installing The Shock Absorber

    SHOCK ABSORBER, SWINGARM Press angle lever toward the rear. Press linkage lever downward. Detach springs Spring hook (50305017000) (� p. 224) Remove screw and take off the manifold. Remove screws @ on both sides. Loosen screws on both sides. Remove screw Raise the rear frame slightly and remove the shock absorber toward the top.

  • Page 47: Checking The Shock Absorber Linkage

    SHOCK ABSORBER, SWINGARM Position the rear frame. Mount and tighten screws on both sides. Guideline Screw, subframe 30 Nm Loctite ® 2701 (22.1 lbf ft) Remove screws on both sides. Mount and tighten screws on both sides. Guideline Screw, subframe 30 Nm Loctite 2701...
  • Page 48 SHOCK ABSORBER, SWINGARM Remove screw connection Take off the angle lever. 303096-10 Check needle bearing for damage and wear. If there is damage or wear: Change the needle bearing. Check spacers and @ for damage and wear. If there is damage or wear: Change the spacers.

  • Page 49: Servicing The Shock Absorber

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

  • Page 50: Removing The Spring

    SHOCK ABSORBER, SWINGARM 9.13 ring Condition The shock absorber has been removed. Clamp the shock absorber in the vise using soft jaws for protection. Measure and note spring length in its preloaded state. Loosen screw Turn adjusting ring until the spring is no longer under tension. Hook wrench (T106S) (�...

  • Page 51: Disassembling The Piston Rod

    SHOCK ABSORBER, SWINGARM Press in seal ring retainer (3 using the special tool. Disassembly tool (T1216) p. 232) Remove lock ring @. Info Do not scratch the inner surface. Remove the piston rod. Remove adjusting ring (;) with the intermediate washer. Drain the oil.

  • Page 52: Disassembling The Seal Ring Retainer

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

  • Page 53: Changing The Pilot Bushing

    SHOCK ABSORBER, SWINGARM Remove centering disk Remove seal ring 201406-10 Remove washer for seal ring Remove washer @. Remove dust boot. 201407-10 9.17 Chan ilot bushin Preparatory work Remove the spring. p. 48) Disassemble the damper. p. 48) Disassemble the piston rod. p.

  • Page 54: Checking The Damper

    SHOCK ABSORBER, SWINGARM 9.18 Condition The damper has been disassembled. Measure the inside diameter on both ends and in the middle of the damper car­ tridge. Damper cartridge Diameter s 50.08 mm (S 1.9716 in) If the measured value is greater than the specified value: Change the damper cartridge.

  • Page 55: Installing The Heim Joint

    SHOCK ABSORBER, SWINGARM Remove seal rings on both sides. Press the heim joint against a lock ring using the special tool. Pressing tool (T1207S) (il!l p. 232) Remove the second lock ring Place special tool underneath and press out heim joint with special tool@).

  • Page 56: Assembling The Seal Ring Retainer

    SHOCK ABSORBER, SWINGARM Position both collar bushings and press them in. 9.21 Mount dust boot using the special tool. Mounting sleeve (T1204) p. 231) Lubricate the sealing lip of the dust boot. Lubricant (T625) (l!ll p. 221) Mount washer@}. Position washer (Don seal ring 201409-10 Grease seal ring and mount with the washer facing downward.

  • Page 57: Assembling The Piston Rod

    SHOCK ABSORBER, SWINGARM 9.22 Assembling the iston rod Preparatory work Assemble the seal ring retainer. (ll!;!l p. 54) Main work Clamp the piston rod with the fork in a vise. Guideline Use soft jaws. Mount rubber buffer and locking cap Position special tool on the piston rod.

  • Page 58: Assembling The Damper

    SHOCK ABSORBER, SWINGARM Mount washer with the collar facing downward. Grease the thread of the piston rod. Lubricant (T152) p. 221) Mount and tighten nut Guideline Nut, piston rod M16x1 45 Nm (33.2 lbf ft) 9.23 Assemblin Preparatory work Assemble the seal ring retainer. p.
  • Page 59 SHOCK ABSORBER, SWINGARM Install the seal ring bearer and push it under the ring groove. Mount lock ring • Info Do not scratch the inner surface. Pull out the piston rod so that the seal ring retainer rests against the lock ring. Mount locking cap (3 of the damper cartridge.

  • Page 60: Bleeding And Filling The Damper

    SHOCK ABSORBER, SWINGARM Alternative 2 Warning Danger of accident Modifications to the suspension setting may seriously alter the handling characteristic. Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components. Only make adjustments within the recommended range. Ride slowly to start with after making adjustments to get the feel of the new handling characteristic.
  • Page 61 SHOCK ABSORBER, SWINGARM When the vacuum pressure gauge reaches the specified value, turn the Oil reser­ voir control lever to Equalize pressure. Guideline 4 mbar ✓ The pressure gauge increases to the specified value. 0 bar When the pressure gauge reaches the specified value, turn the Damper control lever...

  • Page 62: Filling The Damper With Nitrogen

    SHOCK ABSORBER, SWINGARM When the pressure gauge reaches the specified value, turn the con­ Damper trol lever to Vacuum. Guideline 3 bar ✓ The pressure gauge drops to the specified value. 0 bar When the pressure gauge reaches the specified value, operate the switch.

  • Page 63: Installing The Spring

    SHOCK ABSORBER, SWINGARM Open filler tap G). Fill the damper for at least 15 seconds. Guideline Gas pressure 11 0 bar (145 psi) • Info Watch the pressure regulator dial. Make sure that the damper is filled to the specified pressure. Close the filling port screw using tap handle f).

  • Page 64: Checking The Swingarm

    If the swingarm shows signs of damage, cracking, or deformation: Change the swingarm. • Info Always change a damaged swingarm. Repair of the swingarm is not authorized by Husqvarna M otorcycles. 500285-01 9.28 Removing the swingarm Preparatory work Raise the motorcycle with a lift stand.

  • Page 65: Installing The Swingarm

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

  • Page 66: Changing The Swingarm Bearing

    SHOCK ABSORBER, SWINGARM Position the engine sprocket cover and mount it in the holder. Mount and tighten screws Guideline Screw, clutch slave cylinder 10 Nm (7.4 lbf ft) Remaining screws, chassis 25 Nm (18.4 lbf ft) Position the brake caliper and pull it back. Position the brake line in the guide.
  • Page 67 SHOCK ABSORBER, SWINGARM Main work Remove collar bushings G01813-10 Remove bushing G01814-10 Remove shaft seal rings using a suitable tool. Press out the bearing with a suitable tool. Press in the new bearing until it is flush using a suitable tool.
  • Page 68 SHOCK ABSORBER, SWINGARM Press in shaft seal rings Mount bushing(!}. G01814-10 Grease the shaft seal rings. Long-life grease p. 221) •- Position collar bushings with the shoulder facing inward. G01819-10 Finishing work Install the swingarm. (l!l,,!l p. 63) Install the rear wheel. (l!l,,!l p.

  • Page 69: Exhaust

    EXHAUST Detach springs Spring hook (50305017000) (� p. 224) Remove screw @ . Take off the manifold. Position the manifold. Mount screw but do not tighten yet. Guideline Screw, manifold 1 15 Nm (11.1 lbf ft) Attach springs @ . Spring hook (50305017000) (�...

  • Page 70: Removing The Main Silencer

    EXHAUST Removin the main silencer Warning The exhaust system gets very hot when the vehicle is driven. Danger of burns Allow the exhaust system to cool down before performing any work on the vehicle. Preparatory work Remove the right side cover. (I!!.:! p.
  • Page 71 EXHAUST Main work Remove all screws from the main silencer. Take silencer cap and O-ring @. Take outer tube and O-ring Pull the glass fiber yarn filling from inner tube (D. Clean the parts that are to be reinstalled. Mount the new glass fiber yarn filling on the inner tube.

  • Page 72: Air Filter

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

  • Page 73: Cleaning The Air Filter And Air Filter Box

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

  • Page 74: Fuel Tank, Seat, Trim

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

  • Page 75: Installing The Right Side Cover

    FUEL TANK, SEAT, TRIM Installing the right side cover Position the side cover and engage in area f). Mount and tighten screw Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 12.5 Removin the seat Remove screws in the recessed grips on the left and right. Raise the rear of the seat, push the seat back, and lift it off.

  • Page 76: Installing The Fuel Tank

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

  • Page 77: Checking The Fuel Pressure

    FUEL TANK, SEAT, TRIM Warning Fuel is poisonous and a health hazard. Danger of poisoning Avoid skin, eye and clothing contact with fuel. Immediately consult a doctor if you swallow fuel. Do not inhale fuel vapors. In case of skin contact, rinse the affected area with plenty of water. Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
  • Page 78 FUEL TANK, SEAT, TRIM Warning Fuel is poisonous and a health hazard. Danger of poisoning Avoid skin, eye and clothing contact with fuel. Immediately consult a doctor if you swallow fuel. Do not inhale fuel vapors. In case of skin contact, rinse the affected area with plenty of water. Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.

  • Page 79: Changing The Fuel Pump

    FUEL TANK, SEAT, TRIM Remove the special tools. Join the fuel hose connection. 12.10 Changing the fuel Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. Switch off the engine for refueling.

  • Page 80: Changing The Fuel Filter

    FUEL TANK, SEAT, TRIM Pull out the fuel pump. G01786-10 Position the fuel pump. Mount fuel connection fj with the gasket but do not tighten yet. Mount and tighten nut with the gasket. Guideline Nut, fuel pump fastener M12x1.75 15 Nm (11.1 lbf ft) Tighten fuel connection fj.
  • Page 81 FUEL TANK, SEAT, TRIM Warning Fuel is poisonous and a health hazard. Danger of poisoning Avoid skin, eye and clothing contact with fuel. Immediately consult a doctor if you swallow fuel. Do not inhale fuel vapors. In case of skin contact, rinse the affected area with plenty of water. Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
  • Page 82 FUEL TANK, SEAT, TRIM Press lock (D. Pull back fuel pump housing Change fuel screen Mount the fuel pump housing. Mount fuel filter ✓ Arrow points away from the fuel pump. Mount hose clamps Hose clamp pliers (60029057000) p. 227) Position the fuel pump.

  • Page 83: Changing The Fuel Screen

    FUEL TANK, SEAT, TRIM Mount the seat. (� p. 73) 12.12 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. Switch off the engine for refueling.

  • Page 84: Mask, Fender

    MASK, FENDER 13.1 Removin the front fender Preparatory work Remove the start number plate. (!,Jl p. 82) Main work Remove screws and @. Remove the front fender. Main work Position the front fender. Mount and tighten screws and @. Guideline Remaining screws, chassis 110Nm(7.41bf ft) Finishing work...

  • Page 85: Installing The Start Number Plate

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

  • Page 86: Wheels

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

  • Page 87: Checking The Spoke Tension

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

  • Page 88: Front Wheel

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

  • Page 89: Removing The Brake Disc Of The Front Brake

    WHEELS Check the wheel bearing for damage and wear. If the wheel bearing is damaged or worn: Change the front wheel bearing. (ili) p. 87) Clean and grease the shaft seal rings and contact surface of the spacers. Long-life grease (ili) p.
  • Page 90 WHEELS Main work Remove shaft seal rings and @. Press out bearing (D using a suitable tool. • Info Spacing tube can be pushed aside. Remove the spacing tube. Press out bearing using a suitable tool. Press in the new bearing all the way using a suitable tool.

  • Page 91: Rear Wheel

    WHEELS 14.6 Rear wheel 14.6.1 Removing the rear wheel Preparatory work Raise the motorcycle with a lift stand. (ll!l p. 10) Main work (FC 250 EU) Press the brake caliper onto the brake disc by hand in order to push back the brake piston.

  • Page 92: Installing The Rear Wheel

    WHEELS 14.6.2 Installing the rear wheel Warning Oil or grease on the brake discs reduces the braking effect. Danger of accidents Always keep the brake discs free of oil and grease. Clean the brake discs with brake cleaner when necessary. Main work Check the wheel bearing for damage and wear.

  • Page 93: Removing The Brake Disc Of The Rear Brake

    WHEELS Position chain adjuster (D. Mount nut but do not tighten it yet. Make sure that chain adjusters (D are fitted correctly on adjusting screws@). Check the chain tension. (I!,) p. 91) Tighten nut Guideline Nut, rear wheel spindle M25x1.5 I 80 Nm (59 lbf ft) •...

  • Page 94: Adjusting The Chain Tension

    WHEELS Preparatory work Raise the motorcycle with a lift stand. (� p. 10) Main work Pull the chain at the end of the chain sliding component upwards to measure chain tension f). • Info The lower chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions.

  • Page 95: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    WHEELS (FC 250 US) Loosen nut 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 6).
  • Page 96 WHEELS 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 chain sliding guard.

  • Page 97: Checking For Chain Dirt Accumulation

    WHEELS 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. 95) 400678-01 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.
  • Page 98 WHEELS Have an assistant operate the rear brake. Remove screw with washer. Remove the rear wheel. (I!!) p. 89) Remove connecting link of the chain. • Info Cover the components to protect them against damage. Take off the chain. Remove engine sprocket@). Remove fittings Q).

  • Page 99: Changing The Rear Wheel Bearing

    WHEELS Have an assistant operate the rear brake. Mount and tighten screw with washer. Guideline 60 Nm Screw, engine sprocket Loctite ® 2701 (44.3 lbf ft) Position the engine sprocket cover. Mount and tighten screw Guideline Screw, clutch slave cylinder 10 Nm (7.4 lbf ft) Mount and tighten screw Guideline...
  • Page 100 WHEELS Using a suitable tool, press bearing out from the inside to the outside. Press new bearing all the way in from the outside to the inside. • Info Only press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in.

  • Page 101: Wiring Harness, Battery

    WIRING HARNESS, BATTERY Changing the main fuse Warning Fire hazard Incorrect fuses overload the electrical system. Only use fuses with the required ampere value. Do not bypass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the air filter box lid. Preparatory work Switch off all power consumers and switch off the engine.

  • Page 102: Installing The Battery

    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 Environmental hazard Hazardous substances cause environmental damage.

  • Page 103: Checking The Charging Voltage

    WIRING HARNESS, BATTERY Info 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.

  • Page 104: Checking The Open-Circuit Current

    WIRING HARNESS, BATTERY 15.6 en-circuit current Preparatory work Switch off all power consumers and switch off the engine. Remove the seat. (il!l p. 73) Main work Disconnect the negative cable of the battery. Measure the current between battery ground (-) and the negative cable. •...
  • Page 105 WIRING HARNESS, BATTERY Main work Disconnect the negative (minus) cable of the battery. Pull off connector 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 in the figure. Measure the resistance between the specified points.

  • Page 106: Brake System

    BRAKE SYSTEM Checkin 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 6) . Minimum thickness 6) <'= 1 mm (<'= 0.04 in) If the minimum thickness is less than specified: Change the front brake linings.

  • Page 107: Checking The Free Travel Of The Hand Brake Lever

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

  • Page 108: Checking The Front Brake Fluid Level

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

  • Page 109: Adding Front Brake Fluid

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

  • Page 110: Changing The Front Brake Fluid

    BRAKE SYSTEM Changing the front brake fluid Warning Skin irritation Brake fluid causes skin irritation. Keep brake fluid out of the reach of children. Wear suitable protective clothing and safety glasses. Do not allow brake fluid to come into contact with the skin, the eyes or clothing. Consult a doctor immediately if brake fluid has been swallowed.

  • Page 111: Checking The Rear Brake Linings

    BRAKE SYSTEM Pull off protection cap of the brake caliper bleeder screw. Connect the hose of the bleeder bottle. Bleeding device (00029013100) (il<ll p. 223) Open bleeder screw (3 by approx. one half turn. • Info Bleed until fresh brake fluid emerges from the bleeder bottle hose without bubbles.
  • Page 112 BRAKE SYSTEM Warning Brake fluid causes skin irritation. Skin irritation Keep brake fluid out of the reach of children. Wear suitable protective clothing and safety glasses. Do not allow brake fluid to come into contact with the skin, the eyes or clothing. Consult a doctor immediately if brake fluid has been swallowed.

  • Page 113: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM Insert the new brake linings, insert pin and mount cotter pins Info • Always change the brake linings in pairs. Make sure that decoupling plate @ is mounted on the piston side brake lining. Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.

  • Page 114: Checking The Rear Brake Fluid Level

    BRAKE SYSTEM Detach spring Loosen nut and, with push rod Ci), 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 The range of adjustment is limited.

  • Page 115: Changing The Rear Brake Fluid

    BRAKE SYSTEM Warning Brake fluid causes skin irritation. Skin irritation Keep brake fluid out of the reach of children. Wear suitable protective clothing and safety glasses. Do not allow brake fluid to come into contact with the skin, the eyes or clothing. Consult a doctor immediately if brake fluid has been swallowed.
  • Page 116 BRAKE SYSTEM Info 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 with the membrane and O-ring. Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid.
  • Page 117 BRAKE SYSTEM Stand the vehicle upright. Correct the brake fluid up to marking (9. Brake fluid DOT 4 p. 220) Mount and tighten the screw cap with the membrane and 0-ring. Info • Clean up overflowed or spilt brake fluid immediately with water. Check the foot brake lever for a firm pressure point.

  • Page 118: Engine

    ENGINE 17.1 Removin the engine Preparatory work Raise the motorcycle with a lift stand. (!:JI p. 10) Drain the coolant. (!:JI p. 186) Remove the seat. (!:JI p. 73) Remove the fuel tank. (il!JJ p. 73) Remove the right side cover. (il!ll p.
  • Page 119 ENGINE Unplug connector Remove the cable clamps and expose the cable. Remove screw (D. Loosen screw @. Repeat these steps on the opposite side. Pivot up the subframe and secure it. Remove screw @. Pivot the shock absorber toward the rear and twist it slightly. Remove springs@).
  • Page 120 ENGINE C&. Remove screw Take off the manifold. Loosen hose clip Pull off the radiator hose. Loosen hose clip �. Pull off the radiator hose. Push back protection cap G). Unplug connector Disconnect spark plug connector Remove screw...
  • Page 121 ENGINE Remove screw 41). Take off the engine sprocket cover. Remove screws Qi). Remove the cable tie(s). Take off the slave cylinder of the clutch and hang it to one side. • Info Do not kink the clutch line. Do not activate the clutch lever while the slave cylinder of the clutch is removed.
  • Page 122 ENGINE Loosen hose clip Pull the throttle valve body off of the cylinder head toward the rear and hang it to one side. Push back hose clamp � and remove the vent hose. Push back protection cap and remove the nut. Remove fittings �.

  • Page 123: Installing The Engine

    ENGINE Lift out the engine sideways. • Info 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. Main work Position the engine in the frame. •...
  • Page 124 ENGINE Position the positive cable on the starter motor. Mount and tighten the nut. Guideline Remaining nuts, chassis 10 Nm (7.4 lbf ft) Position protection cap Position the vent hose and mount hose clamp (D. Position the throttle valve body. Tighten hose clip@.
  • Page 125 ENGINE Position the clutch slave cylinder with the gasket. Mount and tighten screws Guideline 10 Nm (7.4 lbf ft) Screw, clutch slave cylinder Mount the cable tie(s). Position the engine sprocket cover. Mount and tighten screw Guideline Screw, clutch slave cylinder 10 Nm (7.4 lbf ft) Mount and tighten screw Guideline...
  • Page 126 ENGINE Mount the radiator hose. Position and tighten hose clip Feed in the manifold. Mount screw Qi) but do not tighten yet. Guideline Screw, manifold 15 Nm (11.1 lbf ft) Mount springs 41). Spring hook (50305017000) (!!l p. 224) Tighten screw Qi). Guideline Screw, manifold 15 Nm (11.1 lbf ft)
  • Page 127 ENGINE Route the cable without tension and secure with cable clamps. Plug in connector @) . Position and tighten hose clip � - Connect plug-in connector � of the crankshaft position sensor. Connect plug-in connectors � of the alternator. Route the cable without tension and secure with cable tie ( s ) . Mount EFI control unit �.

  • Page 128: Engine Disassembly

    187) Execute the initialization run. p. 196) Go for a short test ride. Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. Check the engine for leak tightness. Check the engine oil level. p. 188) Check the coolant level.

  • Page 129: Removing The Clutch Push Rod

    ENGINE 17.3.2 Removing the clutch push rod Remove clutch push rod 17.3.3 Removing the spacer Remove spacer of the countershaft. Remove O-ring. 17.3.4 Draining the engine oil Remove plug with oil screen and the O-rings. Remove the oil drain plug @ with the magnet and seal ring. Remove oil drain plug with the O-ring.

  • Page 130: Removing The Oil Filter

    ENGINE 17.3.5 Removing the oil filter Remove screws Remove the oil filter cover@ with the O-ring. Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) (� p. 225) 17.3.6 Removing the spark plug Remove the spark plug using special tool Spark plug wrench (77229172000) (�...

  • Page 131: Removing The Starter Motor

    ENGINE Remove spark plug shaft insert 17.3.8 Removing the starter motor Remove screws and take off cover Take off the gasket. Remove torque limiter Remove screws Remove the alternator cover. Remove screws and take off the starter motor.

  • Page 132: Positioning The Engine At Ignition Top Dead Center

    ENGINE 17.3.9 Positioning the engine at ignition top dead center Turn the crankshaft counterclockwise until marking is flush with the edge of the cylinder head. Remove screw Info • Check through the hole whether the position notch of the crankshaft is visible.

  • Page 133: Removing The Cylinder Head

    ENGINE Take the timing chain off the camshaft gear. Remove the camshafts. 17 .3.12 Removing the cylinder head Remove nut with the washer. Loosen nuts in a crisscross pattern and remove them with the washers. Remove the cylinder head. Remove cylinder head gasket (D. 17 .3.13 Removing the piston Push the cylinder upward.

  • Page 134: Removing The Rotor

    ENGINE Take off cylinder base gasket @. 17 .3.14 Removing the rotor Remove screw Insert special tool @ into the crankshaft. Protection cap (75029090000) (� p. 228) Attach special tool (D to the rotor. Hold it tight using the special tool and pull off the rotor by turning the screw in.

  • Page 135: Removing The Suction Pump

    ENGINE 17.3.16 Removing the suction pump Remove screws Take oil pump cover Remove O-ring Take suction pump Remove needle roller@). 17 .3.17 Removing the water pump wheel Remove screws Take the water pump cover.

  • Page 136: Removing The Clutch Cover

    ENGINE Remove nut Take off the two-part water pump impeller@. 17 .3.18 Removing the clutch cover Remove screws Take off the clutch cover. Remove the clutch cover seal. 17 .3.19 Removing the clutch discs Loosen screws and remove together with the washers and springs. Take off the pressure cap.

  • Page 137: Removing The Shift Shaft

    ENGINE Bend up the lock washer. Hold the inner clutch hub with the special tool. Loosen nut Clutch holder (51129003000) (� p. 225) Remove the nut with the lock washer. Take off inner clutch hub and washer • Info The washer usually sticks to the inner clutch hub. Take off clutch basket Take off needle bearing and collar sleeve@.

  • Page 138: Removing The Locking Lever

    ENGINE 17.3.23 Removing the locking lever Unscrew and remove together with locking lever washer, sleeve and spring. 17.3.24 Removing the force pump Remove lock ring Take off washer Take off oil pump idler gear with the washer. Remove lock ring Take off washer Remove oil pump gear (D.

  • Page 139: Removing The Primary Gear

    ENGINE 17 .3.25 Removing the primary gear Remove nut • Info Left-handed thread! Position the special tool in the crankshaft. Protection cap (75029090000) (� p. 228) Pull off primary gear using the special tool. Extractor (46129021000) (llt!l p. 224) Remove screw 17.3.26 Removing the timing chain Remove screws...

  • Page 140: Removing The Shift Rails

    ENGINE Insert the special tool into the crankshaft. Protection cap (75029090000) p. 228) Mount special tool @ with the appropriate screws. Puller (77229048000) p. 229) • Info Use the drill hole marked with 772. Take off the section of the engine case. •...

  • Page 141: Removing The Shift Forks

    ENGINE 17 .3.31 Removing the shift forks Remove shift forks Info Do not misplace shift rollers 17.3.32 Removing the transmission shafts Remove lock ring Pull both transmission shafts out of the bearing seats together. 17.3.33 Removing the crankshaft Take out crankshaft Take off the right section of the engine case.

  • Page 142: Working On Individual Parts

    ENGINE 17.4 Working on individual arts Work on the right section of the engine case 17.4.1 Remove all dowels. Remove shaft seal ring of the crankshaft. Remove nozzle Remove oil nozzle for conrod bearing lubrication. Remove screw Remove oil nozzle for piston cooling. Remove screws@).

  • Page 143: Work On The Left Section Of The Engine Case

    ENGINE Guideline Screw, oil nozzle for pis­ Loctite ® ™ ton cooling (1 .5 lbf ft) Position all bearing locks. Mount and tighten screws Guideline Locking screw for bearing Loctite ® ™ (4.4 lbf ft) Blow out the oil channel with compressed air and check that it is clear. 17.4.2 Work on the left section of the engine case Remove all dowels.

  • Page 144: Work On The Clutch Cover

    ENGINE Guideline Oil nozzle, piston cooling 2 Nm Loctite ® ™ (1 .5 lbf ft) Position all bearing locks. Mount and tighten screws Guideline Locking screw for bearing Loctite ® ™ (4.4 lbf ft) Blow out the oil channel with compressed air and check that it is clear. 400996-01 17.4.3 Work on the clutch cover...

  • Page 145: Checking The Oil Pressure Regulator Valve

    ENGINE Press the new bearing all the way in from the inside to the outside using a suitable tool. Press in shaft seal ring all the way, with the open side facing outward. Remove lock ring Remove shaft seal ring of the crankshaft.

  • Page 146: Checking The Lubrication System

    ENGINE Install ball and pressure spring Mount and tighten screw plug with sealing washer Guideline Plug, oil pressure regulator valve M12x1.5 20 Nm (14.8 lbf ft) o--8 306542-10 17.4.5 Checking the lubrication system • ✓ ✓ 305003-10 Check the internal rotor and external rotor of oil pumps for damage and wear.

  • Page 147: Installing The Crankshaft Bearing Inner Race

    ENGINE 17.4.7 Installing the crankshaft bearing inner race Main work Fix the crankshaft in the vise. • Info Use soft jaws. Slide on compensating disk Info • The compensating disks have a larger diameter than the crankshaft stub. 306538-10 Ensure that the compensating disks are centered and fixed with a small amount of grease.

  • Page 148: Checking The Crankshaft Run-Out At The Bearing Pin

    ENGINE Mount new connecting rod Info Thoroughly oil bearing Position special tool on the press. Pressing tool for crankshaft, complete (75029047000) (l!!ll p. 228) Insert for crankshaft pressing tool (77729008000) p. 230) Insert the crank web with connecting rod and bearing. Position the second crank web.

  • Page 149: Measuring The Crankshaft End Play

    ENGINE 17.4.10 Measuring the crankshaft end play Insert the crankshaft into the right section of the engine case. • Info Do not forget the fitted bushings. Mount the left section of the engine case. Mount and tighten screws. Guideline Screw, engine case 10 Nm (7.4 lbf ft) Mount the dial gauge support on the engine case and measure and note down the crankshaft end play.

  • Page 150: Cylinder - Nikasil Coating

    ENGINE 17.4.13 Cylinder - Nikasil coating ® ® is a surface protection layer for a coating procedure developed by Mahle. Nikasil 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 ®...

  • Page 151: Measuring The Piston/Cylinder Mounting Clearance

    ENGINE Check the piston rings for damage. If the piston ring is damaged: Change the piston ring. • Info 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: Change the piston pin.

  • Page 152: Checking The Camshafts

    ENGINE cylinder wear lies within the specified tolerance: Replace the piston ring. Mount the piston ring with the marking facing toward the piston head. 17.4.18 Checking the camshafts Check the camshaft for damage and wear. there is damage or wear: Change the camshaft.

  • Page 153: Removing The Valves

    ENGINE Take off the camshafts and clean the parts. 17 .4.20 Removing the valves Remove screw plugs with the O-ring. Screw appropriate screw into the cam lever shaft. Hold cam levers and remove the cam lever shaft. • Info If the cam levers will continue to be used, note down their installation posi­ tion.

  • Page 154: Checking The Valves

    ENGINE 17.4.21 Checking the valves Check the valve plate for run-out. Valve - run-out At the valve plate s; 0.05 mm (s; 0.002 in) If the measured value does not meet specifications: Change the valve. 200193-10 Check sealing seat on the valve. Valve - sealing seat width Intake 1 .40 mm (0.0551 in)

  • Page 155: Checking The Cam Levers

    ENGINE 17.4.24 Checking the cam levers Check the cam levers and cam lever shafts for damage and wear. If there is damage or wear: Change the cam levers and/or cam lever shafts. 302718-10 17.4.25 Checking the cylinder head Check valve guides using the special tool.

  • Page 156: Checking The Freewheel

    ENGINE Pre-tension the valve spring using the special tool. Valve spring mounter (59029019000) (� p. 226) Insert for valve spring lever (77229060000) (� p. 230) Mount valve keys (D. • Info When mounting the valve keys, ensure that they are seated properly; it is recommended to adhere the valve keys to the valves with a small amount of grease.

  • Page 157: Removing The Freewheel

    ENGINE 17 .4.28 Removing the freewheel Remove lock ring � 1"],.! ,: , , · I · ' - ✓ "'' ► l'\, I ' ·, •-�� � I:•: Press expansion ring together with suitable pliers and take off. Take freewheel out of the primary gear.

  • Page 158: Checking The Electric Starter Drive

    ENGINE Ensure that all lugs of the expansion ring pass through slots of the free wheel and engage in groove of the primary gear. Mount lock ring 6) . 17.4.30 Checking the electric starter drive ·-• 305006-10 Check the gear mesh and bearing of starter idler gear for damage and wear.

  • Page 159: Checking The Timing Assembly

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

  • Page 160: Preparing The Timing Chain Tensioner For Installation

    ENGINE 17.4.32 Preparing the timing chain tensioner for installation Press the timing chain tensioner together completely. • Info This requires some force, as the oil must be pressed out. Release the timing chain tensioner. ✓ Without pressure, the timing chain tensioner expands fully. Place two compensating disks or similar aids next to the timing chain tensioner piston.
  • Page 161 ENGINE If there is run-out: Change the push rod. Check the length of clutch springs I� Clutch spring - length 38.5 mm(� 1.516 in) If the clutch spring length is less than the specified value: Change all clutch springs. Check the thrust face of pressure cap Ci) for damage and wear. If there is damage or wear: Change the pressure cap.

  • Page 162: Checking The Shift Mechanism

    ENGINE 17.4.34 Checking the shift mechanism • � 306554-10 Check shift forks on disc for damage and wear (visual check). If there is damage or wear: Change the shift fork. Check shift grooves of shift drum @ for wear. If the shift groove is worn: Change the shift drum.

  • Page 163: Preassembling The Shift Shaft

    ENGINE Change the sliding plate. Preassemble the shift shaft. (� p. 161) Check clearance between the sliding plate and the shift quadrant. Shift shaft - sliding plate/shift quad­ 0.40 ... 0.80 mm (0.0157 ... 0.0315 in) rant clearance If the measured value does not meet specifications: Change the sliding plate.

  • Page 164: Disassembling The Countershaft

    ENGINE Remove needle bearing 17.4.37 Disassembling the countershaft 306558-10 Secure the countershaft with the toothed end facing downward in the bench vise. Guideline Using soft jaws Remove stop disk and first-gear idler gear Remove needle bearing and stop disk Remove fifth-gear sliding gear Remove lock ring (D.

  • Page 165: Assembling The Main Shaft

    ENGINE 306561-10 Check needle bearings for damage and wear. If there is damage or wear: Change the needle bearings. Check the pivot points of main shaft and countershaft for damage and wear. If there is damage or wear: Change the main shaft and/or countershaft. Check the tooth profiles of main shaft and countershaft for damage and wear.

  • Page 166: Assembling The Countershaft

    ENGINE Preparatory work Check the transmission. p. 162) Carefully lubricate all parts before assembling. Main work 306557-10 Secure the main shaft with the toothed end facing downward in the bench vise. Guideline Using soft jaws Mount needle bearing Mount fifth-gear idler gear@. Mount stop disk and lock ring Mount third-gear sliding gear...

  • Page 167: Engine Assembly

    ENGINE Main work 306559-10 Secure the countershaft with the toothed end facing downward in the bench vise. Guideline Using soft jaws Mount needle bearing and the second-gear idler gear onto the countershaft with the protruding collar facing down. Mount stop disk (D and lock ring Mount the fourth-gear sliding gear with the shift groove facing up.

  • Page 168: Installing The Transmission Shafts

    ENGINE 17.5.2 Installing the transmission shafts Oil the bearing. Slide both transmission shafts into the bearing seats together. Mount lock ring @ . 17.5.3 Installing the shift forks Shift fork has a smaller inside diameter; mount this in the shift groove of the main shaft.

  • Page 169: Installing The Shift Rails

    ENGINE 17.5.5 Installing the shift rails Install shift rail together with upper spring and the lower spring. Install shift rail (D together with upper spring 17.5.6 Installing the left engine case Mount the dowels. Degrease the sealing area. Apply the sealing compound to the left section of the engine case.

  • Page 170: Installing The Spacer

    ENGINE 17.5.7 Installing the spacer Grease the shaft seal ring. Mount spacer 17.5.8 Installing the timing chain Mount balancer shaft with the timing chain and timing chain securing guide. • Info If the timing chain was used before, ensure it is running in the correct direction.

  • Page 171: Installing The Force Pump

    ENGINE 17.5.10 Installing the force pump Oil the oil pump shaft, internal rotor and external rotor before assembly. Engine oil (SAE 1 0W/50) p. 220) Position force pump ✓ The rounded side of the force pump faces the engine case. Mount the oil pump shaft from the ignition side.

  • Page 172: Installing The Locking Lever

    ENGINE Position suction pump ✓ The rounded sides of the external rotor face the engine case. Crank the oil pump gear wheel and ensure that it can move easily. Mount O-ring (D . Position the oil pump cover Mount and tighten screws Guideline Screw, oil pump cover Loctite...

  • Page 173: Installing The Shift Shaft

    ENGINE 17 .5.14 Installing the shift shaft Slide shift shaft with the washer into the bearing seat. Push sliding plate away from the shift drum locating unit Insert the shift shaft all the way. Let the sliding plate engage in the shift drum locating unit. Shift through the transmission.

  • Page 174: Installing The Clutch Discs

    ENGINE Mount sleeves@. 17.5.16 Installing the clutch discs Thoroughly oil the clutch facing discs. Engine oil (SAE 1 0W/50) (� p. 220) Insert the intermediate clutch disc. Guideline mm (0.04 in) Thickness Place the clutch facing and intermediate discs into the outer clutch hub. Insert the intermediate clutch disc.

  • Page 175: Installing The Water Pump Cover

    ENGINE Put on the clutch cover gasket. • Info Ensure that the dowel pins are seated properly. Position the clutch cover. • Info Ensure that the sha ft seal rings o f the water pump and the cranksha ft are not damaged.
  • Page 176 ENGINE 17.5.19 Installing the starter drive Position freewheel gear Mount the starter idler gear @ with the washer. Mount lock ring 17.5.20 Installing the rotor and ignition pulse generator Ensure that the woodruff key is seated properly. Mount the rotor. •...
  • Page 177 ENGINE Ensure that piston marking faces the exhaust side. Thinly apply sealing compound to area@). Loctite 5910 ® Position the cylinder base gasket. Info • Ensure that the dowel pins are seated properly. Cover the engine case opening with a cloth. Feed the timing chain through the chain shaft.

  • Page 178: Installing The Cylinder Head

    ENGINE Remove the cloth. Keep the timing chain taut. Press the cylinder down carefully and bring dowel pins into contact. 17.5.22 Installing the cylinder head Position cylinder head gasket • Info Ensure that the dowel pins are seated properly. Put the cylinder head in place. Mount nuts @ with the washers and tighten in a crisscross pattern.

  • Page 179: Installing The Camshafts

    ENGINE 17.5.23 Installing the camshafts Pull up the timing chain and insert the intake camshaft Place the timing chain over the camshaft gear of intake camshaft. ✓ Marking is positioned and is aligned with the edge of the cylinder head. Ensure that bleeder is correctly positioned.

  • Page 180: Checking The Valve Clearance

    ENGINE Press the timing chain tensioner toward the timing chain using special tool Ci). Release device for timing chain tensioner (61229021000) (lliJJ p. 228) ✓ The timing chain tensioner unlocks. Mount and tighten screw Guideline M10x1 Screw, unlocking of timing chain ten­ 10 Nm (7.4 lbf ft) sioner 17.5.25...

  • Page 181: Installing The Starter Motor

    ENGINE Raise cam levers Correct the shims according to the findings from checking the valve clearance. Install the camshafts. p. 177) Install the timing chain tensioner. p. 177) Finishing work Check the valve clearance. p. 178) 17.5.27 Installing the starter motor Grease the O-ring.

  • Page 182: Installing The Valve Cover

    ENGINE Tighten screws Guideline Screw, starter motor 110Nm(7.41bf ft) 17.5.28 Installing the valve cover Grease O-rings and mount spark plug shaft insert Position gasket Apply a thin layer of sealing compound in area f). Loctite ® 5910 Position the valve cover with the gasket. Mount and tighten screws Guideline Screw, valve cover...

  • Page 183: Installing The Spark Plug

    ENGINE Installing the spark plug 17.5.29 Mount and tighten the spark plug with special tool Guideline Spark plug M10x1 10 ... 12 Nm (7.4 ... 8.9 lbf ft) Spark plug wrench (77229172000) (llt!l p. 230) 17.5.30 Installing the oil filter Tilt the motorcycle to one side and fill the oil filter housing to about ½...

  • Page 184: Installing The Spacer

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

  • Page 185: Clutch

    CLUTCH Checkin /correctin the fluid level of the h draulic clutch Warning Brake fluid causes skin irritation. Skin irritation Keep brake fluid out of the reach of children. Wear suitable protective clothing and safety glasses. Do not allow brake fluid to come into contact with the skin, the eyes or clothing. Consult a doctor immediately if brake fluid has been swallowed.
  • Page 186 CLUTCH Fill bleeding syringe with the appropriate hydraulic fluid. Bleed syringe (50329050000) (ll!;!l p. 225) Brake fluid DOT 4 (ll!;!l p. 220) Mount bleeding syringe 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.

  • Page 187: Water Pump, Cooling System

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

  • Page 188: Checking The Coolant Level

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

  • Page 189: Refilling With Coolant

    WATER PUMP, COOLING SYSTEM Position the motorcycle upright. Place a suitable container under the water pump cover. Remove screw Take off radiator cap fj. Completely drain the coolant. Mount and tighten screw with a new seal ring. Guideline Screw, water pump cover 10 Nm (7.4 lbf ft) Refilling with coolant Warning...

  • Page 190: Lubrication System

    LUBRICATION SYSTEM 20.1 Oil circuit 401533-60 Oil screen Force pump Oil pressure regulator valve Oil filter Oil nozzle for conrod bearing lubrication Oil nozzle for cam lever lubrication Oil nozzle, piston cooling Oil nozzle for alternator cooling Oil nozzle for clutch lubrication Suction pump Oil channel, transmission lubrication Timing chain tensioner...

  • Page 191: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen

    LUBRICATION SYSTEM If the engine oil does not reach the middle of level viewer 6): Add engine oil. p. 191) Changing the engine oil and oil filter, cleaning the oil screen Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden. Wear suitable protective clothing and safety gloves.
  • Page 192 LUBRICATION SYSTEM Remove screws Remove the oil filter cover with the 0-ring. Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) (l!!l p. 225) Completely drain the engine oil. Thoroughly clean the parts and sealing surfaces. Lay the motorcycle on its side and fill the oil filter housing to about ½...

  • Page 193: Adding Engine Oil

    LUBRICATION SYSTEM 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 with the O-ring from the clutch cover. Add the same engine oil that was used when the motor was changed. �...
  • Page 194 LUBRICATION SYSTEM 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.

  • Page 195: Ignition System

    IGNITION SYSTEM 21.1 Ignition coil - checking the seconds winding Condition Ignition coil cylinder 1 is disconnected. Spark plug connector cylinder 1 has been removed. Ignition coil cylinder 1 - check the secondary winding resistance Measure the resistance between the specified points. Ignition coil cylinder 1 pin 2 (-) - Ignition coil cylinder 1 pin 3 Ignition coil Secondary winding resistance at:...

  • Page 196: Removing The Stator And Ignition Pulse Generator

    IGNITION SYSTEM 21.4 Removin ulse generator Condition The alternator cover has been removed. Remove screw Remove retaining bracket. Remove screw Remove cable support sleeve from the alternator cover. Remove the stator and ignition pulse generator from the alternator cover. 21.5 Blow out oil nozzle with compressed air and check that it is clear.

  • Page 197: Electric Starter

    ELECTRIC ST ARTER 22.1 Checkin the starter motor Condition The starter motor has been removed. Connect the negative cable of a 12 volt power supply to the housing of the starter motor. Connect the positive cable of the power supply briefly with the connec­ of the starter motor.

  • Page 198: Throttle Valve Body

    THROTTLE VALVE BODY 23.1 Ad"ustin the idle s eed Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and 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. Warning Danger of accidents The engine may go out spontaneously if the idle speed is set too low.
  • Page 199 THROTTLE VALVE BODY As soon as the specified temperature is reached, switch off the ignition. • Info If the initialization is not completed or the initialization process is inter­ rupted, the entire process must be restarted.

  • Page 200: Technical Data

    TECHNICAL DATA 24.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 249.91 cm (15.2505 cu in) Stroke 52.3 mm (2.059 in) Bore 78 mm (3.07 in) Compression ratio 13.9:1 Idle speed 2,250 ... 2,350 rpm Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 32.5 mm (1.28 in)

  • Page 201: Engine Tightening Torques

    TECHNICAL DATA Piston - diameter Size I 77.955 ... 77.965 mm (3.06909 ... 3.06948 in) Size II 77.965 ... 77.975 mm (3.06948 ... 3.06988 in) Cylinder - drill hole diameter Size I 78.000 ... 78.012 mm (3.07086 ... 3.07133 in) Size II 78.012 ...

  • Page 202: Capacities

    TECHNICAL DATA Screw, shi f t lever 14 Nm (10.3 lbf ft) ® Loctite ™ Screw, starter motor 10 Nm (7.4 lbfft) Screw, timing chain guide rail 10 Nm (7.4 lbf ft) ® Loctite ™ Screw, timing chain securing guide 10 Nm (7.4 lbf ft) ®...

  • Page 203: Chassis

    Front tires Rear tires 80/100 - 21 51M TT 100/90 - 19 57M TT Dunlop Geomax MX52F Dunlop Geomax MX52 The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: www.husqvarna-motorcycles.com...

  • Page 204: Fork

    TECHNICAL DATA Fork 24.8 Fork part number 24.18. 70.55 Fork Up Side Down 4860 MXMA 4CS WP Suspension 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...

  • Page 205: Chassis Tightening Torques

    TECHNICAL DATA 2 0 3 24.10 Chassis tightening tor ues ® Screw, air filter box lid EJOT PT K60x20-Z 3 Nm (2.2 lbf ft) ® Screw, pressure regulator EJOT PT K60x25-Z 3 Nm (2.2 lbf ft) Spoke nipple, front wheel M4.5 6 Nm (4.4 lbf ft) Spoke nipple, rear wheel...

  • Page 206: Cleaning/Protective Treatment

    CLEANING/PROTECTIVE TREATMENT 25.1 Cleanin the motorc cle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.

  • Page 207: Storage

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

  • Page 208: Service Schedule

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

  • Page 209: Service Work (As Additional Order)

    SERVICE SCHEDULE 27 .2 Service work as additional order Annually Every 100 operating hours - corresponds to about 700 liters of fuel (185 US gal) Every 50 operating hours - corresponds to about 350 liters of fuel (92.5 US gal) Every 40 operating hours - corresponds to about 280 liters of fuel (74 US gal) Once after 20 operating hours Once after 10 operating hours...

  • Page 210: Fc 250 Eu)

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  • Page 211: Wiring Diagram

    WIRING DIAGRAM Components: A 11 EFI control unit Capacitor Battery Alternator Starter relay with main fuse Power relay Starter motor Voltage regulator Electric starter button X295 Diagnostics connector...

  • Page 212: Fc 250 Eu)

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  • Page 213 WIRING DIAGRAM Components: A 11 EFI control unit Fuel pump Injection valve (cylinder 1) warning lamp (MIL) CAN bus terminating resistor Kill switch X295 Diagnostics connector...

  • Page 214: Fc 250 Eu)

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  • Page 215 WIRING DIAGRAM Components: A 11 EFI control unit Throttle position sensor circuit A Intake air temperature sensor Engine coolant temperature sensor (cylinder 1) Rollover sensor Crankshaft position sensor Manifold absolute pressure sensor (cylinder 1) Ignition coil (cylinder 1) switch for ride mode (optional) Map-Select switch (optional) Cable colors:...

  • Page 216: Fc 250 Us)

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  • Page 217 WIRING DIAGRAM Components: A 11 EFI control unit Capacitor Battery Alternator Starter relay with main fuse Power relay Starter motor Voltage regulator Electric starter button X295 Diagnostics connector...

  • Page 218: Fc 250 Us)

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  • Page 219 WIRING DIAGRAM Components: A 11 EFI control unit Fuel pump Injection valve (cylinder 1) warning lamp (MIL) CAN bus terminating resistor Kill switch X295 Diagnostics connector...

  • Page 220: Fc 250 Us)

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  • Page 221 WIRING DIAGRAM Components: A 11 EFI control unit Throttle position sensor circuit A Intake air temperature sensor Engine coolant temperature sensor (cylinder 1) Rollover sensor Crankshaft position sensor Manifold absolute pressure sensor (cylinder 1) Ignition coil (cylinder 1) Map-Select Switch for ride mode (optional) Map-Select switch (optional) Cable colors:...

  • Page 222: Substances

    SUBSTANCES Brake fluid DOT 4 Standard/classification Guideline Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the cor- responding properties. Recommended supplier ® Bel-Ray Super DOT 4 Brake Fluid Coolant Guideline Only use high quality coolant with corrosion inhibitor for aluminum motors (even in countries with high temperatures).

  • Page 223: Auxiliary Substances

    AUXILIARY SUBSTANCES Air filter cleaning agent Recommended supplier ® Bel-Ray Foam Filter Cleaner & Degreaser Hi h viscosity rease Recommended supplier ® LGHB2 rease Recommended supplier ® Bel-Ray Waterproof Grease Lubricant (T158) Recommended supplier ® Lubcon ® Turmogrease PP 300 Lubricant (T511) Recommended supplier ®...
  • Page 224 AUXILIARY SUBSTANCES Preserving materials for aints, metal and rubber Recommended supplier ® Bel-Ray Silicone Detailer & Protectant Spray Universal oil s ray Recommended supplier ® Bel-Ray 6 in 1...

  • Page 225: Special Tools

    SPECIAL TOOLS Bleeder cover Art. no.: 00029013005 00029013005 H00504-01 Bleeder cover Art. no.: 00029013006 00029013006 H00505-01 Bleedin device Art. no.: 00029013100 00029013100 H00518-01 Battery charger XCharge-professional EU Art. no.: 00029095050 H01065-01 Batte� charger XCharge-�rofessional US Art. no.: 00029095051 H01065-01...
  • Page 226 SPECIAL TOOLS Art. no.: 00029095052 H01065-01 Batte rofessional CH Art. no.: 00029095053 H01065-01 Tachometer Art. no.: 45129075000 45129075000 H00525-01 Extractor Art. no.: 46129021000 46129021000 H01519-01 S�ring hook Art. no.: 50305017000 50305017000 H00973-01...
  • Page 227 SPECIAL TOOLS Bleed s ringe Art. no.: 50329050000 50329050000 H00565-01 Circli liers reverse Art. no.: 51012011000 51012011000 H00572-01 Clutch holder Art. no.: 51129003000 51129003000 H00575-01 Extractor Art. no.: 58012009000 58012009000 H00592-01 Tool for inner bearing race Art. no.: 58429037037 58429037037 H00596-01...
  • Page 228 SPECIAL TOOLS Tor ue wrench with various accessories in set Art. no.: 58429094000 ..flt#'� �� 58429094000 H00606-01 Valve s Art. no.: 59029019000 2x.£. 59029019000 H00610-01 Feeler Art. no.: 590290411 00 c:;?7 59029041100 H00616-01 Graduated disc Art. no.: 60029010000 2x£ 60029010000 H00625-01 Plastigauge clearance gauge Art.
  • Page 229 SPECIAL TOOLS Piston ring mountin tool Art. no.: 60029015000 60029015000 H00628-01 Hose clam liers Art. no.: 60029057000 60029057000 H00650-01 Testin hose Art. no.: 61029093000 61029093000 H00659-01 Pressure tester Art. no.: 61029094000 4x £ 61029094000 H00660-01 Engine assembly stand Art. no.: 61229001000 61229001000 H00662-01...
  • Page 230 SPECIAL TOOLS Release device for timing chain tensioner Art. no.: 61229021000 61229021000 H00675-01 Pressin tool for crankshaft, com lete Art. no.: 75029047000 ©' 75029047000 H00714-01 Protection cap Art. no.: 75029090000 75029090000 H00726-01 Separator plate Art. no.: 77029009001 � 77029009001 H00738-01 Engine fixing arm Art.
  • Page 231 SPECIAL TOOLS Pliers for valve stem seals Art. no.: 77229010000 77229010000 H00752-01 Limit Art. no.: 77229026000 77229026000 H00753-01 Protection cap Art. no.: 77229031000 77229031000 H00755-01 Separator plate Art. no.: 77229032000 77229032000 H00756-01 Puller Art. no.: 77229048000 2x.£. � 77229048000 H00758-01...
  • Page 232 SPECIAL TOOLS Insert for valve s lever Art. no.: 77229060000 77229060000 H00760-01 Art. no.: 77229172000 77229172000 H00761-01 Oil pressure adapter Art. no.: 77329006000 77329006000 H00764-01 Insert for crankshaft pressing tool Art. no.: 77729008000 77729008000 H00779-01 Insertion tool for �iston ring lock Art.
  • Page 233 SPECIAL TOOLS Lift stand Art. no.: 81329955100 81329955100 H00985-01 Hook wrench Art. no.: T106S T106S H00841-01 Depth micrometer Art. no.: T107S T107S H00842-01 Art. no.: T120 T120 H00844-01 Mounting sleeve Art. no.: T1204 T1204 H00878-01...
  • Page 234 SPECIAL TOOLS Calibration in Art. no.: T1205 T1205 H00879-01 Pressin tool Art. no.: T1206 & � T1206 H00880-01 Pressin tool Art. no.: T1207S &.& <:))� T1207S H00881-01 Mounting sleeve Art. no.: T1215 T1215 H00886-01 Disassembly tool Art. no.: T1216 T1216 H00887-01...
  • Page 235 SPECIAL TOOLS Vacuum Art. no.: T1240S � T1240S H00890-01 Protectin sleeve Art. no.: T1401 cs)) T1401 H00894-01 Clampin stand Art. no.: T1403S ❖ 2x£ T1403S H00896-01 Mounting tool Art. no.: T14040S � T14040S H00922-01 S�ecial socket Art. no.: T14047 � T14047 H00923-01...
  • Page 236 SPECIAL TOOLS Clam ing stand Art. no.: T14049S 2x£ T14049S H00924-01 Press-out tool Art. no.: T14051 T14051 H00926-01 Press drift Art. no.: T1504 T1504 H00899-01 Assembly tool Art. no.: T150S .&& T150S H00852-01 Nitrogen filling tool Art. no.: T170S1 �! 2x.£3x£...

  • Page 237: Standards

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

  • Page 238: Index

    INDEX cleaning ....... . . 95 Chain guide 'Accessories ....... . . 8 checking .
  • Page 239 INDEX left engine case section ..... 141 Engine disassembly lubrication system, checking ....144 camshaft, removing .
  • Page 240 INDEX compression damping, adjusting ....12 Initialization run disassembling ......15 executing .
  • Page 241 INDEX Seat Swingarm mounting ........ 73 checking ......... 62 removing ........ 73 installing removing ....... . 62 .
  • Page 242 I 1 1 11 1 11 1 1 1 1 11 1 1 1 111 1 11 1 1 1 1 111 1 11 1 1 1 1 1 1 1 11 1 I I I I I I II I I II 3403012en 06/2016 ® Husqvarna llmi Husqvarna Motorcycles GmbH StallhofnerstraBe 3 5230 Mattighofen Austria fiiiHiAv � LZZa" ·...

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