2015 FC 350 Repair

PIONEERING SINCE 1903
REPAIR MANUAL2015
FC 350 EU
®
Art. no. 340301 Sen Husqvarna
MOTORCYCLES
INTRODUCTION 1
Read this repair manual carefully and thoroughly before beginning work.
The vehicle will only be able to meet the demands placed on it if the specified service work is performed regularly and properly.
This repair manual was written to correspond to the latest state of this model series. We reserve the right to make changes in the
interest of technical advancement without updating this repair manual at the same time.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified
here. It is assumed that the repair work will be performed by a fully trained mechanic.
All specifications are non-binding. Husqvarna Motorcycles GmbH specifically reserves the right to modify or delete technical speci
fications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to
adapt these to local conditions, as well as to stop production of a particular model without prior notice. Husqvarna accepts no 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.
© 2016 Husqvarna Motorcycles GmbH, Mattighofen Austria

All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright
owner.
ISO 9001(12 100 6061)

Husqvarna Motorcycles applies quality assurance processes that lead to the highest possible product quality as
defined in the ISO 9001 international quality management standard.
Issued by: TOV Management Service
Husqvarna Motorcycles GmbH

5230 Mattighofen, Austria
I 11111111 1 1111 1111111 1 1111111111111111 1 1 11111111

3403015en
04/2016
TABLE OF CONTENTS 2
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 part 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 the 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 ......................................... 12 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 ........................ 108
12.5 Removing the seat .............................................. 73 16.10 Checking the free travel of foot brake lever...... 110
12.6 Mounting the seat ............................................... 73 16.11 Adjusting the basic position of the foot brake
12.7 Removing the fuel tank ....................................... 73 lever .................................................................. 110
12.8 Installing the fuel tank ......................................... 74 16.12 Checking the rear brake fluid level ................... 111
12.9 Checking the fuel pressure ................................. 75 16.13 Adding rear brake fluid ..................................... 111
12.10 Changing the fuel pump ..................................... 77 16.14 Changing the rear brake fluid ........................... 112
12.11 Changing the fuel filter ........................................ 78 17 ENGINE ......................................................................... 115
12.12 Changing the fuel screen .................................... 81 17.1 Removing the engine ........................................ 115
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 Removing the clutch push rod ..................... 126
13.4 Installing the start number plate ......................... 83 17.3.3 Removing the spacer ................................... 126
14 WHEELS .......................................................................... 84 17.3.4 Draining the engine oil.................................. 126
14.1 Checking the tire air pressure ............................. 84 17.3.5 Removing the oil filter................................... 127
14.2 Checking the tire condition................................. 84 17.3.6 Removing the spark plug ............................. 127
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 starter motor ......................... 128
14.5 Front wheel ......................................................... 85 17.3.9 Positioning the engine at ignition top dead
14.5.1 Removing the front wheel .............................. 85 center ........................................................... 128
14.5.2 Installing the front wheel ................................ 86 17.3.10 Removing the timing chain tensioner ........... 129
14.5.3 Removing the brake disc of the front 17.3.11 Removing the camshaft ............................... 129
brake .............................................................. 87 17.3.12 Removing the cylinder head......................... 130
14.5.4 Installing the brake disc of the front brake ..... 87 17.3.13 Removing the piston .................................... 130
14.5.5 Changing the front wheel bearing .................. 87 17.3.14 Removing the rotor....................................... 131
14.6 Rear wheel .......................................................... 88 17.3.15 Removing the starter drive ........................... 131
14.6.1 Removing the rear wheel................................ 88 17.3.16 Removing the suction pump ........................ 131
14.6.2 Installing the rear wheel.................................. 89 17.3.17 Removing the water pump wheel................. 132
14.6.3 Removing the brake disc of the rear brake .... 90 17.3.18 Removing the clutch cover........................... 133
14.6.4 Installing the brake disc of the rear brake ...... 90 17.3.19 Removing the clutch discs ........................... 133
14.6.5 Checking the chain tension ............................ 90 17.3.20 Removing the outer clutch hub .................... 133
14.6.6 Adjusting the chain tension ............................ 91 17.3.21 Removing the shift shaft............................... 134
14.6.7 Checking the chain, rear sprocket, engine 17.3.22 Removing the shift drum locating unit ......... 134
sprocket, and chain guide .............................. 91 17.3.23 Removing the locking lever .......................... 134
14.6.8 Checking for chain dirt accumulation ............ 93 17.3.24 Removing the force pump ............................ 134
14.6.9 Cleaning the chain.......................................... 93 17.3.25 Removing the primary gear .......................... 135
14.6.10 Changing the drivetrain kit ............................. 94 17.3.26 Removing the timing chain ........................... 135
14.6.11 Changing the rear wheel bearing ................... 95 17.3.27 Removing the spacer ................................... 136
15 WIRING HARNESS, BATTERY ........................................ 98 17.3.28 Removing the left section of the engine
15.1 Changing the main fuse ...................................... 98 case .............................................................. 136
15.2 Removing the battery.......................................... 98 17.3.29 Removing the shift rails ................................ 137
15.3 Installing the battery ........................................... 99 17.3.30 Removing the shift drum .............................. 137
15.4 Recharging the battery ....................................... 99 17.3.31 Removing the shift forks .............................. 137
15.5 Checking the charging voltage ......................... 100 17.3.32 Removing the transmission shafts ............... 137
15.6 Checking the open-circuit current .................... 101 17.3.33 Removing the crankshaft ............................. 138
15.7 Checking the capacitor..................................... 101 17.4 Working on individual parts .............................. 138
15.8 Checking the starter relay ................................. 102 17.4.1 Work on the right section of the engine
16 BRAKE SYSTEM ........................................................... 103 case .............................................................. 138
16.1 Checking the front brake linings ....................... 103 17.4.2 Work on the left section of the engine
case .............................................................. 139
16.2 Changing the front brake linings ....................... 103
17.4.3 Work on the clutch cover ............................. 140
16.3 Checking the free travel of the hand brake
lever .................................................................. 104 17.4.4 Checking the oil pressure regulator valve .... 141
16.4 Adjusting the basic position of the hand 17.4.5 Checking the lubrication system .................. 142
brake lever ........................................................ 105 17.4.6 Removing the crankshaft bearing inner
16.5 Checking the brake fluid level of the front race .............................................................. 143
brake ................................................................. 105 17.4.7 Changing the connecting rod, conrod
16.6 Adding front brake fluid .................................... 106 bearing, and crank pin ................................. 143
16.7 Changing the front brake fluid .......................... 107 17.4.8 Checking the crankshaft run-out at the
bearing pin ................................................... 144
16.8 Checking the rear brake linings ........................ 108
TABLE OF CONTENTS 4
17.4.9 Installing the crankshaft bearing inner 17.5.20 Installing the rotor and ignition pulse
race ............................................................. . 144 generator ...................................................... 173
17.4.10 Measuring the crankshaft end play .............. 145 17.5.21 Installing the piston ...................................... 173
17.4.11 Removing the drive wheel of the balancer 17.5.22 Installing the cylinder head........................... 175
shaft.............................................................. 145 17.5.23 Installing the camshafts................................ 176
17.4.12 Installing the drive wheel of the balancer 17.5.24 Checking the valve timing ............................ 176
shaft.............................................................. 146 17.5.25 Adjusting the valve timing ............................ 176
17.4.13 Cylinder - Nikasil® coating ............................ 146 17.5.26 Installing the timing chain tensioner ............. 178
17.4.14 Checking/measuring the cylinder ................. 146 17.5.27 Checking the valve clearance ...................... 178
17.4.15 Checking/measuring the piston ................... 147 17.5.28 Adjusting the valve clearance....................... 179
17.4.16 Measuring the piston/cylinder mounting 17.5.29 Installing the starter motor ........................... 179
clearance ...................................................... 147
17.5.30 Installing the valve cover .............................. 180
17.4.17 Checking the piston ring end gap ................ 148
17.5.31 Installing the spark plug ............................... 181
17.4.18 Changing the camshaft bearing ................... 148
17.5.32 Installing the oil filter..................................... 181
17.4.19 Checking the camshafts............................... 149
17.5.33 Installing the oil screen ................................. 182
17.4.20 Checking the pivot points of the
17.5.34 Installing the spacer ..................................... 182
camshafts..................................................... 149
17.5.35 Installing the clutch push rod ....................... 183
17.4.21 Removing the valves .................................... 150
17.5.36 Removing the engine from the engine
17.4.22 Checking the valves ..................................... 151
assembly stand ............................................ 183
17.4.23 Checking the valve springs .......................... 151
18 CLUTCH ........................................................................ 184
17.4.24 Checking the valve spring seat .................... 151
18.1 Checking/correcting the fluid level of the
17.4.25 Checking the cam levers .............................. 152 hydraulic clutch................................................. 184
17.4.26 Checking the cylinder head .......................... 152 18.2 Changing the hydraulic clutch fluid .................. 184
17.4.27 Installing the valves ...................................... 152 19 WATER PUMP, COOLING SYSTEM ............................. 186
17.4.28 Checking the freewheel................................ 153 19.1 Cooling system ................................................. 186
17.4.29 Removing the freewheel............................... 154 19.2 Checking the antifreeze and coolant level ........ 186
17.4.30 Installing the freewheel................................. 154 19.3 Checking the coolant level. ............................... 187
17.4.31 Checking the electric starter drive ............... 155 19.4 Draining the coolant .......................................... 187
17.4.32 Checking the timing assembly ..................... 156 19.5 Refilling coolant ................................................ 188
17.4.33 Preparing the timing chain tensioner for 20 LUBRICATION SYSTEM ............................................... 189
installation .................................................... 157
20.1 Oil circuit ........................................................... 189
17.4.34 Checking the clutch ..................................... 157
20.2 Checking the engine oil level ............................ 189
17.4.35 Checking the shift mechanism ..................... 159
20.3 Changing the engine oil and oil filter,
17.4.36 Preassembling the shift shaft ....................... 160 cleaning the oil screen ...................................... 190
17.4.37 Disassembling the main shaft ...................... 160 20.4 Adding engine oil .............................................. 192
17.4.38 Disassembling the countershaft ................... 161 20.5 Checking the engine oil pressure ..................... 192
17.4.39 Checking the transmission ........................... 161 21 IGNITION SYSTEM........................................................ 194
17.4.40 Assembling the main shaft ........................... 162 21.1 Ignition coil - checking the secondary
17.4.41 Assembling the countershaft........................ 163 winding.............................................................. 194
17.5 Engine assembly ............................................... 164 21.2 Checking the spark plug connector.................. 194
17.5.1 Installing the crankshaft ............................... 164 21.3 Alternator - checking stator winding................. 194
17.5.2 Installing the transmission shafts ................. 165 21.4 Removing the stator and ignition pulse
17.5.3 Installing the shift forks ................................ 165 generator........................................................... 195
17.5.4 Installing the shift drum ................................ 165 21.5 Installing the stator and ignition pulse
17.5.5 Installing the shift rails .................................. 166 generator........................................................... 195
17.5.6 Installing the left engine case ....................... 166 22 THROTTLE VALVE BODY ............................................. 196
17.5.7 Installing the spacer ..................................... 167 22.1 Adjusting the idle speed ................................... 196
17.5.8 Installing the timing chain............................. 167 22.2 Executing the initialization run .......................... 196
17.5.9 Installing the primary gear ............................ 167 23 TECHNICAL DATA ........................................................ 197
17.5.10 Installing the force pump.............................. 168 23.1 Engine ............................................................... 197
17.5.11 Installing the suction pump .......................... 168 23.2 Engine tolerance, wear limits ............................ 197
17.5.12 Installing the locking lever ............................ 169 23.3 Engine tightening torques ................................. 198
17.5.13 Installing the shift drum locating unit ........... 169 23.4 Capacities ......................................................... 199
17.5.14 Installing the shift shaft ................................ 170 23.4.1 Engine oil ...................................................... 199
17.5.15 Installing the outer clutch hub ...................... 170 23.4.2 Coolant ......................................................... 199
17.5.16 Installing the clutch discs ............................. 171 23.4.3 Fuel............................................................... 199
17.5.17 Installing the clutch cover ............................ 171 23.5 Chassis ............................................................. 200
17.5.18 Installing the water pump cover ................... 172 23.6 Electrical system ............................................... 200
17.5.19 Installing the starter drive ............................. 172 23.7 Tires .................................................................. 200
23.8 Fork................................................................... 201
TABLE OF CONTENTS 5
23.9 Shock absorber ................................................ 201

23.10 Chassis tightening torques ............................... 202
24 CLEANING..................................................................... 203
24.1 Cleaning the motorcycle ................................... 203
25 STORAGE ...................................................................... 204
25.1 Storage ............................................................. 204
25.2 Preparing for use after storage ......................... 204
26 SERVICE SCHEDULE.................................................... 205
26.1 Service schedule............................................... 205
26.2 Service work (as additional order) .................... 206
27 WIRING DIAGRAM ........................................................ 208
27.1 Page 1 of 3 ........................................................ 208
27.2 Page 2 of 3 ........................................................ 210
27.3 Page 3 of 3 ........................................................ 212
28 SUBSTANCES ............................................................... 214
29 AUXILIARY SUBSTANCES ............................................ 215
30 SPECIAL TOOLS ........................................................... 217
31 STANDARDS ................................................................. 230
INDEX .................................................................................... 231
1 MEANS OF REPRESENTATION 6
1.1 S mbols used

The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
X 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.
Indicates the result of a testing step.

»
V
Denotes a voltage measurement.
Denotes a current measurement.

A
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 Re air 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 Safe 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
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.
m
2.3 Degrees of risk and s mbols
Danger
Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.
A
Warning
Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
A 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 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; otherwise, all warranty
claims will be void. No warranty claims can be considered for damage or secondary damage resulting from modifications and/or
alterations to the vehicle.
Additional information on the manufacturer or implied warranty and the procedures involved can be found in the service & warranty
booklet.
3.2 0 erating 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.
401945-10
The type label O is fixed to the front of the steering head.
401946-10
The engine number O is stamped on the left side of the engine under the engine
sprocket.
4.4
·�, @
Fork part number

401949-10
The fork part number O is stamped on the inside of the axle clamp.
401947-10
4.5
The shock absorber part number Ois stamped on the top of the shock absorber
above the adjusting ring on the engine side.
5 MOTORCYCLE 10
5.1 Raising the motorc cle with 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.
- Raise the motorcycle at the frame underneath the engine.

✓ Neither wheel is in contact with the ground.
- Secure the motorcycle against falling over.
I Lift stand (54829055000) (� p. 219)
401942-01
5.2 Removing the motorc�cle 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
Remove the plug-in stand before riding.
402001-10
m
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.
402001-10
5 MOTORCYCLE 11
Press the electric starter button CD.
• Info
I Press the electric starter button for at most 5 seconds. Wait for a least
5 seconds before trying again.
Fl warning lamp lights up briefly as a functional control when starting.
400733-01
5.4 Starting the motorc cle for a check
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. Wait for at least 5 seconds before trying again.
Shift the transmission to idle.

Press the electric starter button CD.
Info
Do not open the throttle.
400733-01
6 FORK, TRIPLE CLAMP 12
Ad"ustin in of the fork
Info
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 counterclockwise by the number of clicks corresponding to the fork type.

Guideline
Compression damping
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce
damping.
Adjusting the rebound dam�ing of the fork
Info
The hydraulic rebound damping determines the fork suspension behavior.
- Turn the red adjusting screw O all the way clockwise.

• Info
I Adjusting screw Ois 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 counterclockwise by the number of clicks corresponding to the fork type.

Guideline
Rebound damping
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce
damping.
6.3 Bleeding the fork legs

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

Preparatory work
- Raise the motorcycle with the lift stand. (il!) p. 10)
- Remove the fork protector. (il!) p. 14)
Main work
- Push dust boot O downward on both fork legs.
• Info
I The dust boots remove dust and coarse dirt particles from the inside fork
tubes. Over time, dirt can penetrate 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 tube of both fork legs.
I Universal oil spray (!!,!I p. 216)
- Press the dust boots back into their normal position.
- Remove excess oil.
Finishing work
- Install the fork protector. (il!) p. 15)
- Remove the motorcycle from the lift stand. (!!,!I p. 10)
6.5 Removin the fork le s

Preparatory work
- Raise the motorcycle with the lift stand. (a p. 10)
- Remove the front wheel. (a 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
Do not pull the hand brake lever if the front wheel has been removed.
M00248-10
- Loosen screwsCD. Take out the left fork leg.

- Unscrew screws C,. Take out the right fork leg.
6.6 Installing the fork legs

Main work
- Position the fork legs.
✓ Bleeder screws O face forward.
• Info
I The rebound damping is located in the right fork leg (red adjusting screw).
The compression damping is located in the left fork leg (white adjusting
screw).
Grooves are milled into the side of the upper end of the fork legs. The sec
ond milled groove (from the top) must be flush with the top edge of the
upper triple clamp.
- Tighten screws @.
Guideline
IScrew, top triple clamp 17 Nm (12.5 lbf ft)
Tighten screws CD.
Guideline
IScrew, bottom triple clamp 12 Nm (8.9 lbf ft)
- Position the brake caliper. Mount and tighten screws C,.

Guideline
Screw, front brake caliper M8 25 Nm Loctite® 243 ™
(18.4 lbf ft)
- Position the brake line and clamp. Mount and tighten screws @t.
M00248-11
Finishing work
- Install the front wheel. (� p. 86)
- Remove screws O on the left fork leg and take off the clamp.
- Remove screws @ on the left fork leg and take off the left fork protector.
Remove screws CD on the right fork leg and take off the right fork protector.
- Position the left fork protector. Mount and tighten screws O.

Guideline
I Remaining screws, chassis I M6 110 Nm (7.4 lbf ft)
- Position the brake line and clamp. Mount and tighten screws 8.
- Position the right fork protector. Mount and tighten screws 8.
Guideline
I Remaining screws, chassis 10 Nm (7.4 lbf ft)
6.9 Performin a fork service

Condition
The fork legs have been removed.
- Disassemble the fork legs. (1!;.!1 p. 15)
- Remove the spring. (a p. 17)
- Disassemble the cartridge. (a p. 18)
- Disassemble the piston rod. (a p. 20)
Disassemble the hydrostop unit. (1!;.!1 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. (a p. 24)
- Assemble the piston rod. (a p. 25)
t 0
t Assemble the cartridge. (a p. 26)
r
ii
• ., 0 - Assemble the fork legs. (� p. 27)
II
' i
�
oo
$0
201926-01
Disassembling the fork legs
Info
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 8
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.
I Clamping stand (T1403S) (lit!I p. 227)
- Remove the screw. Remove adjuster@).
201700-10
- Release screw cap 8.
I Special socket (T14047) (!ill p. 228)
• Info
I The cartridge cannot be taken off yet.
201701-10
- Unclamp the fork leg.
- Push the outer tube down. Drain the fork oil.
- Clamp the fork leg with the axle clamp.

- Release hydrostop unit 0 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.

I Press-out tool (T14051) (� p. 228)
• Info
I Removing the O-ring seat from the cartridge usually requires the applica
tion of force.
- Remove dust boot (3.

- Remove fork protection ring f).
• Info
I The fork protection ring does not necessarily need to be removed for
repair work.
- Remove lock ring @.

• Info
I 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
1 so 0
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 (;).

-
a..
Take off support ring �-
- Take off seal ring
- Take off lock ring @.
- Take off dust boot (D.
- Unclamp the fork leg.
Removing the SRring
Info
Preparatory work
- Disassemble the fork legs. (l!\l p. 15)
Main work
- Pull the spring down. Mount the open end wrench on the hexagonal part.
201722-11
- Clamp the open end wrench in the vise. Release screw cap O but do not
remove it yet.
I Special socket (T14047) (!ill p. 228)
- 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
Info
Preparatory work
- Disassemble the fork legs. (!ill p. 15)
- Remove the spring. (!ill p. 17)
Main work
- Degrease piston rod O and clamp it in the vise.
I Clamping stand (T14049S) (!ill p. 228)
- Remove adjusting tube @. Unscrew spring guide CD.
202480-10
- Remove spring seat 8.
-
(
Pull the piston rod out of the cartridge.
201726-12
- Clamp the tube of the cartridge into a vise.
I Clamping stand (T14049S) (a p. 228)
- Release seal ring retainer 0 and remove with the washer.
- Remove lock ring CD.

- Pull reservoir @ off of the tube.
- @) out of the reservoir.

Pull sleeve
- Remove spring @).
201795-10
- Remove seal rings 6!) and O-ring 4I.
- Remove pilot bushings CB.
Disassembling the cartridge
Info
Preparatory work
- Disassemble the fork legs. (a p. 15)
Main work
j - Degrease piston rod O and clamp it in the vise.
I Clamping stand (T14049S) (a p. 228)
- Remove adjusting tube@. Unscrew spring guide (s).
202480-10
- C,.
t
Remove spring seat
- Pull the piston rod out of the cartridge.
201726-12

I Clamping stand (T14049S) (0 p. 228)
- Release seal ring retainer 0 and remove with the washer.
- Remove lock ring (D.

- Pull reservoir @ off of the tube.
- Pull sleeve @) out of the reservoir.

- Remove spring @).
201795-10
- Remove seal rings � and O-ring 48.
- Remove pilot bushings �.
Disassembling the �iston rod
Info
The steps are identical for both fork legs, except for the hydrostop needle and valve.
Preparatory work
- Remove the spring. (l!\l p. 17)
- Disassemble the cartridge. (l!\l p. 19)
e Main work
Degrease the piston rod.
- Clamp the piston rod with the special tool as far up as possible.
I Clamping stand (T14049S) (l!\l p. 228)
- Release hydrostop needle O and remove it from the piston rod.
✓ The valve 8 usually remains in the hydrostop needle.
e-
• Info
201728-10
I silver hydrostop needle on compression damping side.
@) - red hydrostop needle on rebound damping side.
- Remove the rebound shim stack fD.

- Remove piston 8.
- Remove the compression shim stack@).

- Remove spring.
•I -
-
Remove adapter (3 with spring @ and washer.
Remove spring @).
201788-10
- Remove valve needle 0 from the piston rod.
Info
The adjusting tube can be used for this.
201789-10
Disassembling the h�drostoR 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 8.
- Remove adapter CD.

- Remove hub C, 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 (D.

- Remove washer @.
- Remove O-ring @).
Disassemblin the seal rin retainer
Info
Preparatory work
- Disassemble the fork legs. (1!<,!1 p. 15)
- Remove the spring. (1!<,!1 p. 17)
- Disassemble the cartridge. (1!<,!1 p. 19)
Main work
- Remove pilot bushing supportO.
- Remove O-ring 8 and seal ring CD.
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.
200728-10
- Measure the outside diameter at multiple locations of the inner tube.

Outside diameter of inner tube 47.975 ... 48.005 mm (1.88878...
1.88996 in)
If the measured value is smaller than the specified value:
- Measure the run-out of the inner tube.

I Inner tube run-out I $ 0.20 mm ($ 0.0079 in)
If the measured value is larger than the specified value:
200685-10
- Measure the inside diameter at multiple locations of the outer tube.
I Inside diameter of outer tube I $ 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 G
under sliding layer 0 is visible or the surface
is rough:
- Change the sliding bushings.
�
e 200665-10
- Check the spring length.
Guideline
I Spring length with preload spacer(s) I 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
Assemblin the seal rin retainer
Info
- Mount and grease seal ring O.

I Lubricant (T158) (l!J:!1 p. 215)
- Mount and grease O-ring 8-
1 Lubricant (T158) (l!J:!1 p. 215)
Position pilot bushing support (s).
Assembling the h¥drosto� unit
Info
- Mount and grease O-ring O.

I Lubricant (T158) (l!J:!1 p. 215)
- Mount washer 8.
- Mount shim stack (s) with the smaller washers facing downward.
- Mount the new O-ring on hub C,.

- Mount the hub with washers@).
• Info
I It is possible that only one or no washer is present.
- Mount and tighten adapter (D.

Guideline
I Hydrostop unit adapter I M6x0.5 I 7 Nm (5.2 lbf ft)
- Mount shim stack @ with the smaller washers facing downward.
- Mount and tighten sleeve Q).
Guideline
I Hydrostop unit sleeve I M6x0.5 I 7 Nm (5.2 lbf ft)
- Check distance 8 and total length @) 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:
------0------
- Add or remove washers 0.
201975-10
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.
I Clamping stand (T14049S) (� p. 228)
- Lubricate the O-ring. Mount valve needle O in the piston rod.
I Lubricant (T158) (IOI p. 215)
- Mount spring 8.
- Mount and tighten adapter CD with spring e and washer.
Guideline
I Adapter of piston rod I M6x0.5 112 Nm (8.9 lbf ft)
- Position the spring.

- Mount the compression shim stack 0 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.
I Fork oil (SAE 4) (48601166S1) (� p. 214)
Mount the piston with chamfer G facing down.
- Mount the rebound shim stack (D with the smaller washers facing upward.
201732-11
- 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
I Hydrostop needle on piston rod I M6x0.5 I 7 Nm (5.2 lbf ft)
-0-,
e-
• Info
I silver hydrostop needle on compression damping side.
ti) - red hydrostop needle on rebound damping side.
- Unclamp the piston rod.
Assembling the cartridge
Info
Preparatory work
- Assemble the seal ring retainer. (I!.:! p. 23)
- Assemble the piston rod. (I!.:! p. 25)
Main work
- Mount and grease seal rings O and O-ring @.
I Lubricant (T158) (11,l p. 215)
- Mount and lubricate pilot bushings 8.
I Fork oil (SAE 4) (48601166S1) (a p. 214)
- Check the length of the reservoir spring.

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

- Correct the preload spacers.
- Position the spring with the preload spacers in the reservoir.
201795-11
- Position sleeve C, in the reservoir.
I Clamping stand (T14049S) (I!.:! p. 228)
- Slide reservoir 0 onto the tube.
• Info
I Hold the sleeve in the reservoir to prevent it from sliding out.
Mount lock ring (D.
- Mount seal ring retainer@ with the washer and tighten.

Guideline
Seal ring retainer M23.5x0.75 46 Nm Loctite® 2701 TM
(33.9 lbf ft)
- Unclamp the cartridge.
- Slide piston rod CD into the cartridge.

• Info
I Ensure that the piston ring is seated correctly.
- Mount spring seat @).
- Degrease piston rod CD and clamp in the vise.

I Clamping stand (T14049S) (l!\l p. 228)
- Screw spring guide Ci) 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 4I.

- Unclamp the piston rod. Mount the preload spacer(s).
Assembling the fork legs
Info
When assembling, ensure that the right cartridge is mounted in the corresponding inner tube and the right adjuster is
mounted on the corresponding screw cap.
Compression damping side - screw cap with mark COMP, brake caliper holder, white adjuster.
Rebound damping side - screw cap with mark REB, no brake caliper holder, red adjuster.
Preparatory work
- Assemble the hydrostop unit. (a p. 24)
Main work
- Clamp the inner tube with the axle clamp.
Guideline
I Use soft jaws.
- Mount special tool.
I Protecting sleeve (T1401) (� p. 227)
- Lubricate and mount dust boot O.
201714-10
I Lubricant (T511) (a p. 215)
• Info
I 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 8.

- Lubricate and slide on seal ring @).
• Info
I Mount with the sealing lip facing down and the open side facing up.
- Slide on support ring 8.

- Remove the special tool.
- Grind the edges of the sliding bushings with sandpaper grit 600, clean the bush
ings and lubricate them.
I Fork oil (SAE 4) (48601166S1) (� p. 214)
201715-10
- Slide on the lower sliding bushing 0-
- Mount the upper sliding bushing (D.
Info
Do not use a tool; pull the ends apart slightly by hand.
- Warm the outer tube in area f) of the lower sliding bushing.

Guideline
1 so 0
c (122 °F)
- Slide the outer tube onto the inner tube.
- Hold the lower sliding bushing with the longer section of the special tool.
I Mounting tool (T14040S) (� p. 228)
- Push the sliding bushing all the way into the outer tube.
- Position the support ring.

- Hold the seal ring with the shorter section of the special tool.
I Mounting tool (T14040S) (� p. 228)
- Push the seal ring and support ring all the way into the outer tube.
- Mount lock ring@.
• Info
I The lock ring must engage audibly.
- Mount dust boot O.

- Mount fork protection ring 0.
- Lubricate the O-ring. Slide the cartridge all the way into the fork leg.
I Fork oil (SAE 4) (48601166S1) (� p. 214)
- 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.) (� p. 214)
- Add some of the fork oil while pulling out and pushing in the piston rod numerous
times.
I I
Guideline
Fork oil quantity 510 ml (17.24 fl. oz.)
- Mount and tighten hydrostop unit @.
I I
Guideline
Hydrostop unit M30x1 I 40 Nm (29.5 lbf ft) I
- Clamp the fork vertically.

- Add the remaining quantity of fork oil.
202091-10
- Pull out the piston rod and push it back in numerous times while pressing it to
one side slightly.
✓ Air bubbles emerge and the cartridge is bled.
- Keep bleeding until no more air bubbles emerge.
✓ 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
I Screw cap on piston rod I M8x0.75 18 Nm (13.3 lbf ft)
I Special socket (T14047) (� p. 228)
- Push the outer tube up.

- Clamp the outer tube in the area of the lower triple clamp.
I Clamping stand (T1403S) (� p. 227)
- Tighten screw cap@).
Guideline
I Cartridge on outer tube I M51x1.5 I 40 Nm (29.5 lbf ft) I
201701-11
I Special socket (T14047) (� p. 228)
- Mount the adjuster. Mount and tighten screw @).
I
Guideline
Screw, adjuster
I M4x0.5
1
2.5 Nm
(1.84 lbf ft)
201700-11
Alternative 1
- Turn the adjuster of compression damping G.i) (mark COMP) and the adjuster
of rebound damping 41 (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. (ll!:,!I p. 31)
re
� - Install the lower triple clamp. (ll!:,!I p. 32)
!�
a
> 800010-10
6.24 Removin the lower tri

Preparatory work
- Remove the front wheel. (a p. 85)
- Remove the fork legs. (a p. 13)
- Remove the start number plate. (ll,J p. 82)
- Remove the front fender. (ll,J p. 82)
- Remove the handlebar cushion.
Main work
Take off cable holder O in front of the left radiator.
- Remove screw 8.
- Remove screw 8.
- Take off the upper 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 C,. Remove protective ring@».

- Take off the lower triple clamp with the steering stem.
- Remove the upper steering head bearing.
6.25 Installing the lower tri

Main work
- Clean the bearing and sealing elements, check for damage, and grease.
I High viscosity grease (il!.!J p. 215)
- Insert the lower triple clamp with the steering stem. Mount the upper steering
head bearing.
- Check whether the upper steering head seal O is correctly positioned.
- Slide on protective ring 8 and O-ring @).
- Position the upper triple clamp with the handlebar.

- Mount screw 8 but do not tighten yet.
- Position the fork legs.

✓ Bleeder screws 0 face forward.
• Info
I The rebound damping is located in the right fork leg (red adjusting screw).
The compression damping is located in the left fork leg (white adjusting
screw).
Grooves are milled into the side of the upper end of the fork legs. The sec
ond milled groove (from the top) must be flush with the top edge of the
upper triple clamp.
- Tighten screws (D.

Guideline
I Screw, bottom triple clamp 112 Nm (8.9 lbf ft)
Tighten screw 8.
Guideline
I Screw, top steering head I M20x1.5 12 Nm (8.9 lbf ft)
Mount and tighten screw@.

Guideline
Screw, top steering stem MS 17 Nm Loctite® 243 ™
(12.5 lbf ft)
- Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
- Tighten screws fD.
Guideline
I Screw, top triple clamp 17 Nm(12.5 lbf ft)
- Secure the wiring harness with cable holder@).
- Position the brake caliper. Mount and tighten screws Ci).

Guideline
Screw, front brake caliper MS 25 Nm Loctite® 243 ™
(18.4 lbf ft)
Position the brake line and clamp. Mount and tighten screws 48.
M00248-12
Finishing work
- Install the front fender.(a p. 82)
- Install the start number plate.(� p. 83)
- Install the front wheel.(� 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)
- Remove the motorcycle from the lift stand.(a p. 10)
- Mount the handlebar cushion.
Checking the steering head bearing �la}!
Warning
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components.
- Correct incorrect steering head bearing play immediately.
Info
If the 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
- Raise the motorcycle with the lift stand.(a p. 10)
Main work
- Move the handlebar to the straight-ahead position. Move the fork legs to and fro
in the direction of travel.
I No play should be noticeable in the steering head bearing.
If there is noticeable play present:
- Adjust the steering head bearing play. (Ii!:! 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. (ii!:! p. 35)
- Check the steering head bearing and change if necessary.
Finishing work
- Remove the motorcycle from the lift stand. (I!;! p. 10)
6.27 Changing the steering head bearing

Preparatory work
- Raise the motorcycle with the lift stand. (Ii!:! p. 10)
- Remove the front wheel. (Ii!:! p. 85)
- Remove the fork legs. (� p. 13)
- Remove the start number plate. (a p. 82)
- Remove the front fender. (a p. 82)
- Remove the lower triple clamp. (!i.,!I 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 8 using a suitable tool.

- 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. (l!!l p. 32)
- Install the front fender. (0 p. 82)
- Install the start number plate. (0 p. 83)
- Install the front wheel. (!!:! 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. (0 p. 33)
- Remove the motorcycle from the lift stand. (0 p. 10)
6.28 Adjusting the steering head bearing play

Preparatory work
- Raise the motorcycle with the lift stand. (!!:! p. 10)
Main work
- Loosen screws O.
- Remove screw 8.
- Loosen and retighten screw (s).
Guideline
I Screw, top steering head I M20x1.5 112 Nm (8.9 lbf ft)
- Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses.
- Mount and tighten screw 8.
Guideline
Screw, top steering stem M8 17 Nm Loctite® 243 ™
(12.5 lbf ft)
- Tighten screws O.
Guideline
I Screw, top triple clamp I M8 17 Nm (12.5 lbf ft)
- Check the steering head bearing play. (l!!l p. 33)
Finishing work
- Remove the motorcycle from the lift stand. (l!!l p. 10)
7 HANDLEBAR,CONTROLS 36
7.1 Handlebar osition

On the upper triple clamp, there are two holes at a distance of f) to each other.
I Hole distance A 15 mm (0.59 in)
1
The holes on the handlebar support are placed at a distance of 0 from the center.
I Hole distance B I 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.
800116-10
7.2 Ad"ustin the handlebar osition

- 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 8. Remove the handlebar supports.

- Place the handlebar supports in the required position. Mount and tighten
B00375-10 screws 8-
Guideline
Screw, handlebar support M10 40 Nm Loctite® 243 ™
(29.5 lbf ft)
Info
Position the left and right handlebar supports evenly.
- Position the handlebar.
• Info
I Make sure the cables and wiring are positioned correctly.
- Position the handlebar clamps. Mount and tighten screws O evenly.

Guideline
I Screw, handlebar clamp I 20 Nm (14.8 lbf ft) I
7.3
- Adjust the basic setting of the clutch lever to your hand size by turning adjusting
screw O.
• Info
I 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 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 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
- 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 G.
I Play in throttle cable 13... 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.
I The idle speed must not change.
If the idle speed changes:
- Adjust the play in the throttle cable.(!ill p. 38)
7.6 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 O.
- Loosen nut@. Turn adjusting screw @) in as far as possible.
- Loosen nut 8- Turn adjusting screw 0 so that there is play in the throttle cable
at the throttle grip.
Guideline
I Play in throttle cable 13... 5 mm(0.12 ... 0.2 in)
- Tighten nut 8.
- Press and hold the throttle grip in the closed setting. Turn adjusting screw @) out
until there is no play in the throttle cable 0).
- Tighten nut@.
- Push sleeves O on. Check the throttle grip for smooth operation.
Finishing work
- Check the play in the throttle cable.(� p. 37)
- Mount the seat.(!!:! p. 73)
8 FRAME 39
8.1
- 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
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 O all the way clockwise with a socket wrench.
• Info
I Do not loosen fitting 8.
- 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
I Turn clockwise to increase damping; turn counterclockwise to reduce
damping.
9.2 Adjusting the low-speed compression damping of the shock absorber
A Caution
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 8.
- 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.
Ad"ustin the rebound dam in 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 Measurin rear wheel sa unloaded

Preparatory work
- Raise the motorcycle with the lift stand. (� p. 10)
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 f).
Finishing work
- Remove the motorcycle from the lift stand. (il!]l p. 10)
Checkin the static sag of the shock absorber

- Measure distance f) of rear wheel unloaded. (0 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 0.
e
• Info
I The static sag is the difference between measurements and 0.
- Check the static sag.
I Static sag
13
0 mm (1.18 in)
If the static sag is less or more than the specified value:
- Adjust the spring preload of the shock absorber. (il!]l p. 42)
sag of the shock absorber

- Measure distance O of rear wheel unloaded. (0 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.
✓ The rear wheel suspension levels out.
- Another person now measures the distance between the rear axle and the fixed
point.
- Note down the value as dimension Ci).
Info
e
•
I The riding sag is the difference between measurements and Ci).
- Check the riding sag.

I Riding sag 1100 mm (3.94 in)
If the riding sag differs from the specified measurement:
- Adjust the riding sag. (0 p. 43)
400990-10
9.7 Adjusting the s�ring reload of the shock absorber
A Caution
Info
Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.
Preparatory work
- Raise the motorcycle with the lift stand. (0 p. 10)
- Remove the seat. (0 p. 73)
- Remove the right side cover. (0 p. 72)
- Remove the main silencer. (0 p. 68)
- Remove the shock absorber. (a p. 43)
- After removing the shock absorber, clean it thoroughly.
Main work
- Loosen screw O.
- Turn adjusting ring 8 until the spring is no longer under tension.
I Hook wrench (T106S) (0 p. 225)
- Measure the overall spring length while the spring is not under tension.
- Tighten the spring by turning adjusting ring 8 to measurement •.
Guideline
I Spring preload I 8 mm (0.31 in)
• Info
I 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
I Screw, shock absorber adjusting ring I M5 I 5 Nm (3.7 lbf ft)
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. (0 p. 73)
- Remove the motorcycle from the lift stand. (0 p. 10)
9.8 Adjusting the riding sag

Preparatory work
- Raise the motorcycle with the lift stand. (l!!:!I p. 10)
- Remove the seat. (l!!:!I p. 73)
- Remove the right side cover. (� p. 72)
- Remove the main silencer. (llill p. 68)
- Remove the shock absorber. (0 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 lb/in)
165 lb.)
Weight of rider: 75 ... 85 kg (165... 57 N/mm (325 lb/in)
187 lb.)
B00292-10 Weight of rider: 85... 95 kg (187... 60 N/mm (343 lb/in)
209 lb.)
• Info
I The spring rate is shown on the outside of the spring.
Finishing work
- Install the shock absorber. (11!!:!1 p. 44)
- Install the main silencer. (l!!:!I p. 68)
- Install the right side cover. (l!!:!I p. 73)
- Mount the seat. (0 p. 73)
- Check the static sag of the shock absorber. (0 p. 41)
- Check the riding sag of the shock absorber. (0 p. 42)
- Adjust the rebound damping of the shock absorber. (0 p. 41)
- Remove the motorcycle from the lift stand. (1!;.!1 p. 10)
9.9 Removing the shock absorber

Preparatory work
- Raise the motorcycle with the lift stand. (l!!:!I p. 10)
- Remove the seat. (l!!:!I p. 73)
- Remove the right side cover. (0 p. 72)
- Remove the main silencer. (0 p. 68)
Main work
- Remove screw O.
- Remove fitting 8.
- Press angle lever @) toward the rear.

- Press linkage lever 8 downward.
- Detach springs 0.
I Spring hook (50305017000) (� p. 218)
- Remove screw (D 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.
Main work
- Raise the rear frame slightly and insert the shock absorber from above.
Position the shock absorber.
- Mount and tighten screw O.
Guideline
Screw, top shock M10 60 Nm Loctite® 2701 ™
absorber (44.3 lbf ft)
- Position the rear frame.

- Mount and tighten screws @} on both sides.
Guideline
Screw, subframe M8 30 Nm Loctite® 2701 TM
(22.1 lbf ft)
- Remove screws @) on both sides.
- Mount and tighten screws @) on both sides.
Guideline
Screw, subframe M8 30 Nm Loctite® 2701 TM
(22.1 lbf ft)
- Position the manifold.
- Attach springs C,.
I Spring hook(50305017000)(� p. 218)
Guideline
I Screw, manifold holder 15 Nm(11.1 lbf ft)
- Position the angle lever and linkage lever.

- Mount and tighten fitting Cs}.
Guideline
I Nut, linkage lever to angle lever I M14x1.5 I 80 Nm(59 lbf ft)
- Mount and tighten screw@.
Guideline
Screw, bottom shock M10 60 Nm Loctite® 2701 TM
Finishing work
- Install the main silencer.(� p. 68)
- Install the right side cover.(� p. 73)
- Mount the seat.(� p. 73)
- Remove the motorcycle from the lift stand.(� p. 10)
9.11 Checkin the shock absorber linkage

Preparatory work
- Raise the motorcycle with the lift stand.(� p. 10)
Main work
- Remove screw O.
- Remove screw connection @}.
Info
Raise the wheel slightly to make it easier to remove the screws.
- Remove screw connection CD.

- Take off the angle lever.
@-
-0
303096-10
- Check needle bearing C, and 0 for damage and wear.

If there is damage or wear:
- Change the needle bearing.
- Check spacers (D and @ for damage and wear.
- Change the spacers.
- Check the shaft seal rings for damage and wear.
- Change the shaft seal rings.
- Check dimension 6).

I 54.91... 55.00 mm (2.1618... 2.1654 in)
If dimension 6) is less than the specified value:

- Add the corresponding spacing washers (D.
- Position the angle lever.

- Mount screw connection CD but do not tighten yet.
Guideline
I Nut, linkage lever on swingarm I M14x1.5 I 80 Nm (59 lbf ft)
- Mount screw O but do not tighten yet.

Guideline
Screw, bottom shock M10 60 Nm Loctite® 2701 ™
• Info
I Raise the wheel slightly to make it easier to mount the screw.
- Position the linkage lever.

- Mount and tighten fitting @.
Guideline
I Nut, linkage lever to angle lever I M14x1.5 I 80 Nm (59 lbf ft)
• Info
I Raise the wheel slightly to make it easier to mount the screw.
- Tighten screws O.
Guideline
Screw, bottom shock M10 60 Nm Loctite® 2701 TM
- Tighten fitting (D.
Guideline
I Nut, linkage lever on swingarm I M14x1.5 I 80 Nm (59 lbf ft)
Finishing work
9.12 Servicing the shock absorber
A
Caution
Condition
The shock absorber has been removed.
- Remove the spring. (il!) p. 48)
- Disassemble the damper. (il!) p. 48)
- Disassemble the piston rod. (� p. 49)
- Disassemble the seal ring retainer. (� p. 50)
- Check the damper. (� p. 52)
- Remove the heim joint. (a p. 52)
- Install the heim joint. (a p. 53)
- Assemble the seal ring retainer. (a p. 54)
- Assemble the piston rod. (� p. 55)
- Assemble the damper. (� p. 56)
- Install the spring. (� p. 61)
201457-01
9.13 ring
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.
I Hook wrench (T106S) (� p. 225)
- Remove ring 8.
- Remove spring retainer@) and intermediate washer C,.
- Remove the spring.
9.14 Disassembling the dam�er

Preparatory work
- Remove the spring. (� p. 48)
Main work
- Note down the current state of rebound damping O and compression damp
ing 8.
- Completely open the adjusters of the rebound and compression damping.
- Remove rubber cap@) of the reservoir.

- Open screw C, slowly.
✓ The pressurized nitrogen escapes.
- Remove locking cap Cs,.
-0
'
- Press in seal ring retainer (3 using the special tool.

I Disassembly tool (T1216) (a p. 227)
- Remove lock ring @.
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 Disassemblin iston rod

Preparatory work
- Disassemble the damper. (a p. 48)
Main work
- Clamp the piston rod with the fork in a vise.
Guideline
I Use soft jaws.
- Remove nut O.
- Remove washer 8.
- Remove rebound shim stack 8.

• Info
I Place the rebound shim stack onto a screwdriver and set it down as a unit.
- Remove piston 8.
- Remove compression shim stack 0.

• Info
I Place the compression shim stack onto a screwdriver and set it down as a
unit.
- Remove rebound washer (D.
- Remove seal ring retainer@.

- Remove locking cap@) and rubber buffer@).
9.16 Disassembling the seal ring retainer

Preparatory work
- Remove the spring. (� p. 48)
- Disassemble the damper. (� p. 48)
- Disassemble the piston rod. (� p. 49)
Main work
- Remove spring O.
- Remove O-ring @.
- Remove rebound rubber 8.
201405-10
- Remove centering disk 8.

- Remove seal ring 0.
201406-10
- Remove washer (D for seal ring 0.
- Remove washer @.
- Remove dust boot.
201407-10
9.17 Chan ilot bushin

Preparatory work
- Disassemble the damper. (a p. 48)
- Disassemble the piston rod. (a p. 49)
- Disassemble the seal ring retainer. (a p. 50)
Main work
- Press pilot bushing O out of seal ring retainer 8 with the special tool.
I Press drift (T1504) (a p. 228)
- Slide the new pilot bushing O onto the special tool.

I Press drift (T1504) (l!t!J p. 228)
Position the pilot bushing in the seal ring retainer using the special tool.
I Press drift (T1504) (!!:! p. 228)
- Support seal ring retainer 8 with sleeve f) of the special tool. Press the pilot
bushing all the way in.
I Assembly tool (T150S) (0 p. 229)
- Lubricate the special tool.
Shock absorber fluid (SAE 2.5) (50180751S1) (a p. 214)
Calibration pin (T1205) (I!;! p. 226)
- Support seal ring retainer 8 with sleeve f) of the special tool.
I Assembly tool (T150S) (l!t!J p. 229)
- Press the special tool through the new pilot bushing.
200798-10 I Calibration pin (T1205) (!!:! p. 226)

✓ The pilot bushing is calibrated.
Finishing work
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.
- Check the damper cartridge for damage and wear.
201402-10 If there is damage or 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
I
201403-10
Run-out I s 0.02 mm(s 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.
201404-10
9.19 Removing the heim ·oint

Condition
- Clamp the shock absorber in the vise using soft jaws for protection.
- Remove the collar bushing of the heim joint.
I Pin(T120)(� p. 226)
- 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.
I Pressing tool (T1207S) (il!l p. 226)
- Remove the second lock ring 8.
- Place special tool f) underneath and press out heim joint (D with special
tool@).
Installing the heim joint

- Position the new heim joint O and the special tool into a vise as shown.
Guideline
I Use soft jaws.
I Pressing tool (T1206) (il!l p. 226)
- Press the heim joint all the way in.
- Press the heim joint against the lock ring using the special tool.
- Mount the second lock ring 8.
- Mount seal rings (D on both sides.

- Position both collar bushings 8 and press them in.
9.21
- Mount dust boot O using the special tool.
I Mounting sleeve (T1204) (a p. 226)
- Lubricate the sealing lip of the dust boot.
I
I Lubricant (T625) (l!ll p. 215)
- Mount washer@}.
- Position washer (Don seal ring e.
201409-10
- Grease seal ring 8 and mount with the washer facing downward.
I Lubricant (T511) (l!t!I p. 215)
- Mount centering disk@».
201410-10
- Mount rebound rubber 0).
- Lubricate the groove of the O-ring.
I Lubricant (T158) (I!!:! p. 215)
- Mount O-ring @.
- Mount spring @).
201411-10
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
I Use soft jaws.
0- - Mount rubber buffer O and locking cap 8.
- Position special tool on the piston rod.
I Mounting sleeve (T1215) (a p. 227)
- Grease the dust boot and push seal ring retainer @) onto the piston rod.
- Mount rebound washer 8 with the cut-out facing downward.
/
e
- Mount the compression shim stack 0 with the smaller shims facing downward.
201418-10
- Sand both sides of piston (D on a surface plate using 1200-grit sandpaper.
- Clean the piston.
- Assemble the piston.
Guideline
ViewO Piston from above
ViewC, Piston from below
- Mount the rebound shim stack @ with the smaller shims facing upward.
201420-10
- Mount washer fD with the collar facing downward.
- Grease the thread of the piston rod.

- Mount and tighten nut @).
I I
Guideline
I Nut, piston rod I M16x1 45 Nm (33.2 lbf ft)
9.23 Assemblin
Preparatory work
- Assemble the piston rod. (a p. 55)
Main work
- Lubricate the O-rings of the compression adjuster.
- Lubricate the threads.
- Mount the piston with the spring.
- Mount and tighten the compression adjuster 0-
I I
Guideline
I Compression adjuster I M31x1 45 Nm (33.2 lbf ft)
- Clamp the damper in a bench vise.
Guideline
I Use soft jaws.
- Mount adjusting ring @ with the intermediate washer.
Info
The adjusting ring cannot be mounted after the piston rod is mounted.
- Fill the damper cartridge about half full.

I Shock absorber fluid (SAE 2.5) (50180751S1) (a p. 214)
- Lubricate O-ring (D of the seal ring retainer.
- Mount the piston rod carefully.
Install the seal ring bearer 8 and push it under the ring groove.
Mount lock ring 0.
• 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 (3 of the damper cartridge.

Bleed and fill the damper. (� p. 58)
Fill the damper with nitrogen. (� p. 60)
Mount rubber cap @ of the reservoir.
Alternative 1
Turn adjusting screw Ci) 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 4l& 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@), 0 and Gi) to the position determined during dis
assembly.
Bleeding and filling the damper
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.

I Vacuum pump (T1240S) (l!!ll p. 227)
- 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.

✓ The External tank (D control lever is on Closed, Damper 8 on Vacuum,
and Oil reservoir 0 on Vacuum.
- Operate the On/Off switch (D.
✓ The vacuum pump process starts.
✓ Pressure gauge @ drops to the specified value.
< 0 bar
✓ The vacuum gauge@) falls to the specified value.

4 mbar
- Measure distance f) between the floating piston and reservoir hole with the spe
II• cial tool.
I Depth micrometer (T107S) (0 p. 225)
✓ The floating piston is positioned all the way at the bottom.
201399-10
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
When the pressure gauge reaches the specified value, turn the Damper control
lever C, to Pressure.
Guideline
0 bar
✓ Oil is pumped into the damper.
3 bar
When the pressure gauge reaches the specified value, turn the Damper C, con
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, turn the Oil reservoir 0
control lever to Vacuum.
Guideline
0 bar
Equallze ✓ The vacuum gauge falls to the specified value.
pre•sure
8 mbar
When the vacuum pressure gauge reaches the specified value, turn the Oil reser
voir control lever 0 to Equalize Pressure.
Guideline
8 mbar
0 bar
When the pressure gauge reaches the specified value, turn the Damper control
lever C, to Pressure.
Guideline
0 bar
✓ Oil is pumped into the damper.
3 bar
- When the pressure gauge reaches the specified value, turn the Damper 8 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
✓ The vacuum pump is switched off.
- Slide O-ring 4) to the end of the special tool by the specified value (distance 0
minus specified value).
• Guideline
10 mm
I Depth micrometer (T107S) (� p. 225)

- 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 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.

- Mount and tighten screw@).
Guideline
I Screw, filling port I M10x1 1 Nm (10.3 lbf ft)
1 4
I
9.25 Filling the dam er with nitrogen
- Screw in screw O by approx. 2 rotations but do not tighten.
Info
The piston rod is fully extended.
201396-10
- Clamp the special tool in the vise.
I Nitrogen filling tool (T170S1) (� p. 229)
- Connect the special tool to the pressure regulator of the filling cylinder.
I Filling gas - nitrogen
- Adjust the pressure regulator.
Guideline
201397-10
I Gas pressure I 10 bar (145 psi)
- Position the damper in the special tool.
✓ The hexagonal part of the tap handle O engages in the hexagon socket of
the filling port screw.
- Open filler tap G).

- Fill the damper for at least 15 seconds.
Guideline
I Gas pressure 110 bar (145 psi)
• 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 f).

- Close spigot G) and take the damper out of the special tool.
- Tighten the filling port screw.
Guideline
I Screw, reservoir filling port I 3 Nm (2.2 lbf ft)
- 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.)
Weight of rider: 75 ... 85 kg (165 ... 57 N/mm (325 lb/in)
187 lb.)
209 lb.)
- Mount intermediate washer 8 and spring retainer C,.
- Mount ring C,.
Alternative 1
- Tension the spring to the prescribed amount by turning the adjusting ring.
Guideline
I Spring preload 18 mm (0.31 in)
I Hook wrench (T106S) (� p. 225)

Alternative 2
Warning
- Tension the spring to the amount measured during dismantling by turning the
adjusting ring.
I Hook wrench (T106S) (a p. 225)
- Tighten screw 0.
Guideline
I Screw, shock absorber adjusting ring I M5 I 5 Nm (3.7 lbf ft)
201370-11
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
I Always change a damaged swingarm. Repair of the swingarm is
not authorized by Husqvarna Motorcycles.
500285-01
9.28 Removing the swingarm

Preparatory work
- Remove the rear wheel. (0 p. 88)
Main work
- Take the brake line out of the guide.
- Push the brake caliper forward, remove it, and hang it to the side.
Info
Cover the components to protect them against damage.
- Remove screws O and @.

- Remove the engine sprocket cover.
Remove connecting link CD of the chain.

• Info
I Cover the components to protect them against damage.
Take off the chain.
Remove fitting 8.
Lower the swingarm.
Remove nut 0.
Remove the swingarm pivot.
Remove the swingarm.
Main work
Position the swingarm. Mount the swingarm pivot.
Mount and tighten nut O.
Guideline
Nut, swingarm pivot M16x1.5 100 Nm
(73.8 lbf ft)
Lift the swingarm.

Mount and tighten fitting @.
Guideline
Nut, linkage lever on swingarm M14x1.5 I 80 Nm (59 lbf ft)
Mount the chain.

Connect the chain with connecting link CD.
Guideline
The closed side of the chain joint lock must face in the direction of travel.
- Position the engine sprocket cover and mount it in the holder.

- Mount and tighten screws 8 and C,.
Guideline
Screw, clutch slave cylinder M6 10 Nm (7.4 lbf ft)
Remaining screws, chassis M8 25 Nm (18.4 lbf ft)
- Position the brake caliper and pull it back.
- Position the brake line in the guide.
Finishing work
- Install the rear wheel. (a p. 89)
- Remove the motorcycle from the lift stand. (a p. 10)
Changing the swingarm bearing
Info
These operations are the same on both swingarm bearings.
Preparatory work
- Remove the rear wheel. (� p. 88)
- Remove the swingarm. (a p. 62)
Main work
- Remove outer collar bushings 0-
G01813-10
- Remove bushing 8.
G01814-10
- Remove shaft seal rings (D using a suitable tool.
- Using a suitable tool, press the bearing out from the outside to the inside.
- Press in the new bearing until it is flush using a suitable tool.

- Press in shaft seal rings CD.
- Mount bushing(!}.
G01814-10
- Grease the shaft seal rings.
I Long-life grease (0 p. 215)
•-
J - Position collar bushings O 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. 89)
- Remove the motorcycle from the lift stand. (l!i) p. 10)
10 EXHAUST 67
- Detach springs O.
I Spring hook (50305017000) (� p. 218)
- Remove screw @.
- Take off the manifold.
- Position the manifold.

- Mount screw O but do not tighten yet.
Guideline
I Screw, manifold 115 Nm (11.1 lbf ft) I
- Attach springs @.
I Spring hook (50305017000) (� p. 218)
- Tighten screw O.
Guideline
I Screw, manifold 115 Nm (11.1 lbf ft) I
10 EXHAUST 68
Removin the main silencer
Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
- Allow the exhaust system to cool down before performing any work on the vehicle.
Preparatory work
- Remove the right side cover.(I!!.:! p. 72)
Main work
- Disconnect spring O.
I Spring hook (50305017000) (� p. 218)
Remove screws 8 and take off the main silencer.
10.4
Main work
- Mount the main silencer. Mount screws O but do not tighten yet.
Guideline
I Remaining screws, chassis 10Nm(7.4 lbf ft)
Reconnect spring 8.
- Tighten screws O.
Guideline
I Remaining screws, chassis I10Nm(7.41bf ft)
Finishing work
- Install the right side cover.(ll!:,! p. 73)
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
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
- Remove the right side cover.(ll!:,! p. 72)
- Remove the main silencer. (ll!:,! p. 68)
10 EXHAUST 69
Main work
- Remove all screws on the main silencer.
- Take off silencer cap O and O-ring @.
- Take off outer tube CD and O-ring e.
- Pull glass fiber yarn filling 0 off of inner tube (D.
- Clean the parts that are to be reinstalled.
- Mount the new glass fiber yarn filling 0 on the inner tube.
- Slide O-ring C, and outer tube CD over the glass fiber yarn filling.
- Insert O-ring @ and silencer cap O into the outer tube.
Mount and tighten all screws.
C00494-10
Finishing work
- Install the main silencer.(� p. 68)
- Install the right side cover.(� p. 73)
11 AIR FILTER 70
- Release catch Q, 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 O. Engage the air filter box lid in areas f)
and G).
- Engage tab O.
11.3 Removin 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 f) and detach it at
end G). 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 lnstallin the air filter

Main work
- Mount the clean air filter on the air filter support.
- Grease the air filter in area f).
I Long-life grease (� p. 215)
11 AIR FILTER 71
- Insert both parts together, position them, and fasten them using air filter
holder Oin area C,.
✓ The arrow of marking UP faces up.
• 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.(� 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 box lid.(a p. 70)
- Remove the air filter.(a p. 70)
Main work
- Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.
I Air filter cleaning agent(� p. 215)
• 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.
I Oil for foam air filter(� p. 215)
- Clean the air filter box.
- Clean the intake flange and check it for damage and tightness.
Finishing work
- Install the air filter.(!lll p. 70)
- Install the air filter box lid.(!lll p. 70)
11.6 Sealin the air filter box

Preparatory work
- Remove the air filter box lid.(a p. 70)
Main work
- Seal the air filter box in the marked area 8-
401559-01
Finishing work
- Install the air filter box lid.(!lll p. 70)
12 FUEL TANK, SEAT, TRIM 72
m
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.
- 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.
A
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
- Do not allow fuel to enter the groundwater, the soil, or the sewage system.
- Turn filler cap O counterclockwise and lift it off.
the filler ca
- Mount filler cap O and turn it clockwise until the fuel tank is tightly closed.
Info
Run the fuel tank breather hose 8 without kinks.
Removin
- Remove screw O.
- Pull off the side cover in area f) sideways and remove it toward the rear.
Installing the right side cover

- Position the side cover and engage in area f).
- Mount and tighten screw 0-
Guideline
12.5 Removin the seat

- Remove screws O in the recessed grips on the left and right.
- Lift up the seat at the rear, pull it back and then remove it from above.
12.6 Mountin the seat

- Hook in the front of the seat at the collar bushing of the fuel tank, lower it at the
rear and simultaneously it push forward.
- 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
A
Warning
Preparatory work
- Remove the seat. (� p. 73)
Main work
- Unplug connector O of the fuel pump.
- Thoroughly clean plug-in connection 8 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 f).
I Wash cap set (81212016100)
- Remove the tube from the fuel tank breather.
Remove screws (D with the collar bushing.
- Remove screw C, with the rubber bushing.
- Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank.
m
12.8 lnstallin the fuel tank
Danger
A
Warning
Main work
- Check the throttle cable routing. (!l.,!l 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
I Remaining screws, chassis I10Nm(7.41bf ft)
Mount and tighten screws @} with the collar bushing.

Guideline
I Remaining screws, chassis 10Nm(7.4 lbf ft)
- Plug in connector (D of the fuel pump.

- Remove the wash cap set. Thoroughly clean the 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.
- Lubricate the O-ring and connect plug-in connection 8 of the fuel line.
• Info
I Route the cable and fuel line at a safe distance from the exhaust system.
Finishing work
- Mount the seat. (!l.,!l p. 73)
12.9 Checking the fuel ressure
Danger
A
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 O.
• Info
I Remaining fuel may flow out of the fuel hose.
- Mount special tool 8.

I Pressure tester (61029094000) (a p. 221)
- Mount special tool (D with nozzle code 0,60.
I Testing hose (61029093000) (0 p. 221)
- Position the hose end in a fuel can.
Guideline
I Minimum size, fuel can 110 I (2.6 US gal)
- Connect the diagnostic tool and start it.
- Select the "Function test of fuel pump control" actuator test.
Guideline
I Maximum duration of the actuator test I 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. (0 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. (l!!ll 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
Danger
Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
If any fuel is spilled, wipe it off immediately.
A
Warning
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.
Keep fuels correctly in a suitable canister, and out of the reach of children.
Warning
Preparatory work
Drain the fuel from the fuel tank into a suitable container.
Remove the seat. (ill.,! p. 73)
Remove the fuel tank. (ill.,! p. 73)
Main work
Remove nut O with the gasket.
Remove fuel connection @ with the gasket.
Remove screws fD.

- Pull out the fuel pump.
201990-12
- Position the fuel pump.
- Mount fuel connection fj with the gasket but do not tighten yet.
- Mount and tighten nut O with the gasket.
Guideline
I Nut, fuel pump fastener I M12x1.75 15 Nm (11.1 lbf ft)
- Tighten fuel connection fj.
Guideline
I Fuel port on fuel tank I M8x1.25 110 Nm (7.4 lbf ft)
- Mount and tighten screws (5).
Guideline
I Screw, fuel pump I EJOT I 3 Nm (2.2 lbf ft)
Finishing work
- Install the fuel tank. (a p. 74)
- Mount the seat. (a p. 73)
12.11 Changing the fuel filter
Danger
A
Warning
Warning
Preparatory work
Drain the fuel from the fuel tank into a suitable container.
Remove the seat. (a p. 73)
Remove the fuel tank. (a p. 73)
Main work
Remove nut O with the gasket.
Remove fuel connection 8 with the gasket.
Remove screws 8.
Pull out the fuel pump.

Remove hose clamps C,.
Remove fuel filter 0-
201990-10
- Press lock (D.

- Pull back fuel pump housing @.
- Change fuel screen @).

- Mount the fuel pump housing.
- Mount fuel filter 0.

✓ Arrow 6) points away from the fuel pump.
- Mount hose clamps C,.
I Hose clamp pliers(60029057000)(a p. 221)
- Position the fuel pump.

- Mount fuel connection 8 with the gasket but do not tighten yet.
- Mount and tighten nut O with the gasket.
Guideline
I Nut, fuel pump fastener I M12x1.75 15 Nm(11.1 lbf ft)
- Tighten fuel connection 8.
Guideline
I Fuel port on fuel tank I M8x1.25 10 Nm(7.4 lbf ft)
- Mount and tighten screws (5).
Guideline
I Screw, fuel pump I EJOT I 3 Nm(2.2 lbf ft)
Finishing work
Mount the seat. (� p. 73)
12.12 Changing the fuel screen
Danger
Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
If any fuel is spilled, wipe it off immediately.
A
Warning
Warning
Clean plug-in connection O of the fuel line thoroughly with compressed air.
• Info
I Under no circumstances should dirt enter into the fuel line. Dirt clogs the
injection valve.
Disconnect the plug-in connection of the fuel line.

Pull fuel screen 8 out of the connecting piece.
Insert the new fuel screen all the way into the connecting piece.
Lubricate the 0-ring and connect plug-in connection of the fuel line.
Danger
Always make sure there is sufficient ventilation when running the
engine.
Use an effective exhaust extraction system when starting or running
Start the motor and check the response.

13 MASK, FENDER 82
13.1 Removin the front fender

Preparatory work
- Remove the start number plate.(!,Jl p. 82)
Main work
- Remove screws O and @. Remove the front fender.
Main work
- Position the front fender. Mount and tighten screws O and @.
Guideline
I Remaining screws, chassis 110Nm(7.41bf ft)
Finishing work
- Install the start number plate.(!,Jl p. 83)
- 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 8 in the brake line guide.
14 WHEELS 84
Checkin the tire air ressure
Info
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 11.0 bar (15 psi)
Rear I 1.0 bar (15 psi)
If the tire pressure does not meet specifications:
- Correct the tire pressure.
- Mount the protection cap.
Checking the tire condition
Info
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.
I Minimum tread depth I � 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.
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 several places on the
disk to see if it conforms to measurement f).
• Info
I Wear reduces the thickness of the brake disc around the area used by the
brake linings.
Brake discs - wear limit

Front I 2.5 mm (0.098 in)
Rear I 3.5 mm (0.138 in)
If the brake disc thickness is less than the specified value:
- Change the brake disc.
- Check the front and rear brake discs for damage, cracking and deformation.
If the brake disc shows signs of damage, cracking or deformation:
- Change the brake disc.
Checking s�oke 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.
I 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 5... 6 Nm (3.7 ...
4.4 lbf ft)
Spoke nipple, rear wheel M4.5 5... 6 Nm (3.7 ...
4.4 lbf ft)
I Torque wrench with various accessories in set (58429094000) (� p. 219)

14.5 Front wheel
14.5.1 Removing the front wheel
Preparatory work
- Raise the motorcycle with the lift stand. (� p. 10)
Main work
- Press the brake caliper onto the brake disc by hand in order to push back the
brake pistons.
• Info
I Make sure when pushing back the brake pistons that you do not press the
brake caliper against the spokes.
14 WHEELS 86
- Loosen screw O by several turns.

- Loosen screws@.
- O to push the wheel spindle out of the axle clamp.
Press on screw
- Remove screw O.
- Holding the front wheel, remove the wheel spindle. Take the front wheel out of the
fork.
• Info
I Do not pull the hand brake lever when the front wheel is removed.
Always lay the wheel down in such a way that the brake disc is not dam
aged.
- 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. (I!,) p. 87)
- Clean and grease shaft seal rings O and mating surfaces 6) of the spacers.
I Long-life grease (a p. 215)
- Insert the spacers.
- Position the front wheel and insert the wheel spindle.
✓ The brake linings are correctly positioned.
- Mount and tighten screw@.
Guideline
I Screw, front wheel spindle I M20x1.5 I 35 Nm (25.8 lbf ft) I
- 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. (fl\:! p. 10)
- Operate the front brake and compress the fork a few times firmly.
✓ The fork legs straighten.
- Tighten screws @).
Guideline
I Screw, fork stub
1
15 Nm (11.1 lbf ft) I
14 WHEELS 87
14.5.3 Removing the brake disc of the front brake

Preparatory work
- Remove the front wheel. (0 p. 85)
Main work
- Remove screws 0- Take off the brake disc.
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 O.
Guideline
Screw, front brake disc M6 14 Nm Loctite® 243 ™
(10.3 lbf ft)
Finishing work
- Install the front wheel. (0 p. 86)
14.5.5 Changing the front wheel bearing

Preparatory work
- Remove the front wheel. (0 p. 85)
Main work
- Remove shaft seal rings O and @.
- Press out bearing (D using a suitable tool.
e
• Info
I Spacing tube can be pushed aside.
- Remove the spacing tube.

14 WHEELS 88
- Press out bearing 0 using a suitable tool.

- Press in the new bearing 0 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 8-

- Press in the new bearing CD all the way using a suitable tool.
• Info
- Grease new shaft seal rings @ and O and press in until they are flush.
Finishing work
- Install the front wheel. (� p. 86)
14.6 Rear wheel

14.6.1 Removing the rear wheel
Preparatory work
- Raise the motorcycle with the lift stand. (ll!:!I p. 10)
Main work
Press the brake caliper onto the brake disc by hand in order to push back the
brake piston.
• Info
I Make sure when pushing back the brake piston that you do not press the
- Remove nut O.
- Remove chain adjuster @. Withdraw wheel spindle CD 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.
14 WHEELS 89
- Remove spacers 8.
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.(� p. 95)
- Clean and grease the shaft seal rings O and contact surface 6) of the spacers.
I Long-life grease(� p. 215)
- Insert the spacers.
- Position the rear wheel and insert wheel spindle@.

✓ The brake linings are correctly positioned.
- Put the chain on.
- Position chain adjuster@). Mount nut 8, but do not tighten it yet.

Make sure that chain adjusters@) are fitted correctly on adjusting screws 0.
- Check the chain tension.(!!l p. 90)
- Tighten nut 8.
Guideline
I Nut, rear wheel spindle I M20x1.5 I 80 Nm(59 lbf ft)
• Info
I The wide adjustment range of the chain adjusters(32 mm(1.18 in))
enables different secondary ratios with the same chain length.
Chain adjusters@) can be turned by 180 ° .
- 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
- Remove the motorcycle from the lift stand.(!!l p. 10)
14 WHEELS 90
14.6.3 Removing the brake disc of the rear brake

Preparatory work
Raise the motorcycle with the lift stand. (0 p. 10)
Remove the rear wheel. (0 p. 88)
Main work
Remove screws 0- 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 lbf ft)
Finishing work
Install the rear wheel. (0 p. 89)
Remove the motorcycle from the lift stand. (0 p. 10)
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
Raise the motorcycle with the lift stand. (0 p. 10)
Main work
Pull the chain at the end of the chain sliding component upwards to measure
chain tension f).
• Info
I The lower chain section O must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
I Chain tension I 55 ... 58 mm (2.17 ... 2.28 in)

If the chain tension does not meet specifications:
- Adjust the chain tension. (0 p. 91)
Finishing work
Remove the motorcycle from the lift stand. (� p. 10)
14 WHEELS 91
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
- Raise the motorcycle with the lift stand. (ilill p. 10)
- Check the chain tension. (ilill p. 90)
Main work
- Loosen nut O.
- Loosen nuts@.
- Adjust the chain tension by turning adjusting screws (D left and right.
Guideline
Chain tension I 55... 58 mm (2.17... 2.28 in)
Turn adjusting screws (D 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 f). The rear wheel is then correctly aligned.
- Tighten nuts@.
- Make sure that chain adjusters 8 are fitted correctly on adjusting screws (D.
- Tighten nut 0-
Guideline
I Nut, rear wheel spindle I M20x1.5 I 80 Nm (59 lbf ft)
• Info
I The wide adjustment range of the chain adjusters (32 mm (1.18 in))
enables different secondary ratios with the same chain length.
Chain adjusters 8 can be turned by 180° .
Finishing work
14.6.7 Checking the chain, rear sprocket, engine sprocket, and chain guide
Preparatory work
- Raise the motorcycle with the lift stand. (ilill p. 10)
.. Main work
-
-
Shift gear to neutral.
Check the rear sprocket and engine sprocket for wear.
If the rear sprocket or engine sprocket are worn:
- Change the drivetrain kit. (ilill p. 94)
• Info
I The engine sprocket, rear sprocket, and chain should only be
replaced together.
400227-01
14 WHEELS 92
- Pull at the top part of the chain with the specified weight 6).
Guideline
I Weight, chain wear measurement 110... 15 kg (22 ... 33 lb.)
- Measure distance G) of 18 chain rollers on the lower chain section.
• Info
I Chains do not always wear evenly, which is why the measurement should
be repeated at several locations on the chain.
Maximum distance G) on the longest 272 mm (10.71 in)

part of the chain
If the distance G) is larger than the specified length:

- Change the drivetrain kit. (� p. 94)
l o o--�--0 o l o
• Info
o I When a new chain is mounted, the rear sprocket and engine
sprocket should be changed as well.
2 3 16 17 18 New chains wear more rapidly on old, worn rear sprockets and
400987-10 engine sprockets.
- Check the chain sliding guard for wear.

If the lower edge of the chain pin is at the level of 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.
Guideline
Screw, chain sliding M6 6Nm Loctite® 243 ™
guard (4.4 lbf ft)
- Check the chain sliding piece for wear.

If the lower edge of the chain pin is at the level of 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 chain sliding piece.
Guideline
Screw, chain sliding piece MS 15 Nm
(11 .1 lbf ft)
14 WHEELS 93
- Check the chain guide for wear.
• Info
I The wear can be found on the front of the chain guide.
If the light part of the chain guide is worn:

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

If the chain guide is loose:
- Tighten the chain guide.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
Finishing work
- Remove the motorcycle from the lift stand. (� p. 10)
14.6.8 Checking for chain dirt accumulation

- Check the chain for coarse dirt accumulation.
If the chain is very dirty:
- Clean the chain. (a p. 93)
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.
A
Warning
Warning
regulations.
Info
The service life of the chain depends largely on its maintenance.
Preparatory work
14 WHEELS 94
Main work
- Clean the chain regularly and then treat with chain spray.
I Offroad chain spray (l!!,!J p. 215)
400725-01
Finishing work
14.6.10 Changing the drivetrain kit

Preparatory work
Main work
- Remove screws O and 8.
- Remove the engine sprocket cover.
- Have an assistant operate the rear brake.

- Remove screw @) with washer.
- Remove the rear wheel. (l!!,!J p. 88)
- Remove connecting link C, of the chain.

• Info
I Cover the components to protect them against damage.
- Take off the chain.
- Remove engine sprocket 0.

14 WHEELS 95
- Remove fittings (D. Take off the rear sprocket.

- Position the new rear sprocket. Mount and tighten the fittings.
Guideline
Nut, rear sprocket screw MB 35 Nm Loctite® 2701 TM
(25.8 lbf ft)
- Slide new engine sprocket 0 onto the countershaft.
- Mount the new chain.

- Connect the chain with connecting link C,.
Guideline
- Install the rear wheel. (!1ll p. 89)
- Have an assistant operate the rear brake.

- Mount and tighten screw 8 with washer.
Guideline
Screw, engine sprocket M10 60 Nm Loctite® 2701 TM
(44.3 lbf ft)
- Position the engine sprocket cover.

Guideline
I Screw, clutch slave cylinder 110 Nm (7.4 lbf ft)
- Mount and tighten screw (!}.
Guideline
I Remaining screws, chassis I 25 Nm (18.4 lbf ft) I
Finishing work
14.6.11 Changing the rear wheel bearing

Preparatory work
- Remove the rear wheel. (l!!ll p. 88)
14 WHEELS 96
Main work
Remove shaft seal ring 0-
- Remove lock ring 8.
- Remove shaft seal ring (5).
- Using a suitable tool, press bearing C, out from the inside to the outside.
- Remove spacing tube 0-
- Using a suitable tool, press bearing C) out from the inside to the outside.
- Press new bearing C) all the way in from the outside to the inside.
• Info
- Clean, grease, and mount spacing tube 0.

I Long-life grease (ilill p. 215)
- Press new bearing C, all the way in from the outside to the inside.
• Info
14 WHEELS 97
- Grease new shaft seal ring (D and press it in until it is flush.
- Mount lock ring@.

✓ The lock ring engages audibly.
- Grease new shaft seal ring O and press it in until it is flush.
Finishing work
- Install the rear wheel. (ilill p. 89)
- Remove the motorcycle from the lift stand. (ilill p. 10)
15 WIRING HARNESS, BATTERY 98
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.
- Remove the air filter box lid. (a p. 70)
Main work
- Take off protection caps O.
- Remove the faulty main fuse @.
e.
• Info
I A defective fuse can be identified by the burned-out fuse wire
A spare fuse 8 is located in the starter relay.
- Install a new main fuse.

I Fuse (58011109110) (!i.,!I p. 200)
- Check that the electrical equipment is functioning properly.
• Tip
I Insert the spare fuse so that it is available if needed.
- Mount the protection caps.

- Mount the starter relay onto the holder and lay the cable.
Finishing work
- Install the air filter box lid. (� p. 70)
Removin the batte
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. (!i.,!I 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 (D at the bottom.
- Lift the battery up and out.
Installing the battery

Main work
- Insert the battery into the battery compartment with the terminals facing forward.
I Battery (YTX5L-BS) (i!!l p. 200)
- Reconnect rubber band 0-
e e
• Info
I Contact disks must be mounted under screws and cable sock
ets 0with 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 lbf ft)
___0
__,I A
e o
- Slide positive terminal cover @ over the positive terminal.
- Position the negative cable and mount and tighten the screw.
Guideline
H00387-10
(1.84 lbf ft)
- Slide negative terminal cover (D over the negative terminal.
Finishing work
- Mount the seat. (� p. 73)
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.
- Dispose of batteries at a collection point for used batteries.
Warning
regulations.
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.
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. (� p. 73)
-
Main work
Connect the battery charger to the battery. Set the battery charger.
Battery charger XCharge-professional EU (00029095050) (a p. 217)
Battery charger XCharge-professional US (00029095051) (ll!:!I p. 217)
Battery charger XCharge-professional GB (00029095052) (!!:!I p. 218)
Battery charger XCharge-professional CH (00029095053) (� p. 218)
• Info
311910-10
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
motorcycle is not in use
13 months
-
Finishing work
Mount the seat. (a p. 73)
15.5 Checkin the charging voltage

Condition
The battery must be fully functional and completely charged.
-
Preparatory work
Remove the seat. (a 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
I
5,000 rpm 13.5 ... 15.0 V
1
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. (a p. 194)
If the displayed value is greater than the specified value:
- Change the voltage regulator.
-
Finishing work
Mount the seat. (� p. 73)
15.6 en-circuit current

Preparatory work
- 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.
• Info
I The value of the quiescent current applies only to vehicles in the original
state, i.e. without additional power consumers.
I Maximum open-circuit current I < 1.0 mA

- Disconnect the voltage regulator from the wiring harness and perform the
measurement again.
- Check the capacitor. (@]I p. 101)
Finishing work
- Connect the negative cable of the battery.
- Mount the seat. (@]I p. 73)
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

601204-10 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 Checkin the starter rela

Preparatory work
- Remove the seat. (il!l p. 73)
- Remove the air filter box lid. (il!l p. 70)
Main work
- Disconnect the negative cable of the battery.
- Pull off connector 0-
- Pull back the cover.
Detach cable 8 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.
I Resistance of open circuit I on
If the value displayed does not meet specifications:
- Change the starter relay.
- Mount the starter relay onto the holder and lay the cable.
- Clamp cable 8 on the starter relay.
- Plug in connector O.
Finishing work
- Install the air filter box lid. (il!l p. 70)
- Mount the seat. (il!l p. 73)
16 BRAKE SYSTEM 103
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).
I Minimum thickness 6) I <'= 1 mm (<'= 0.04 in)
If the minimum thickness is less than specified:

- Change the front brake linings. (il!,!l p. 103)
- Check the brake linings for damage and cracking.
If damage or cracking is visible:
- Change the front brake linings. (!el p. 103)
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.
A
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.
A
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
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 O.
- Remove cover 8 with membrane @).
16 BRAKE SYSTEM 104
- 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
I Make sure that you do not press the brake caliper against the spokes
when pushing back the brake pistons.
- Remove cotter pins 8, pull out pin 0, and remove the brake linings.
- Clean the brake caliper and brake caliper support.
- Check that leaf spring (D in the brake caliper and sliding plate @ in the brake
caliper support are seated correctly.
- Insert the new brake linings, insert pin 0, and mount cotter pins 8-
• 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 6).

Guideline
Level O (brake fluid level below 5 mm (0.2 in)
reservoir rim)
I Brake fluid DOT 4 (� p. 214)
Position cover @ with membrane (D.

- Mount and tighten screws O.
Info
Clean up overflowed or spilled brake fluid immediately with water.
.r-----so1900-10
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 105
- Push the hand brake lever forward and check free travel G.
I Free travel of hand brake lever I 2:: 3 mm (2:: 0.12 in)
If the free travel does not meet specifications:
- Adjust the basic position of the hand brake lever. (a p. 105)
16.4 Adjusting the basic �osition of the hand brake lever

Preparatory work
- Check the free travel of the hand brake lever. (a p. 104)
Main work
- Adjust the basic position of the hand brake lever to your hand size by turning
adjusting screw O.
• 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.
Checkin 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.
A
Warning
Preparatory work
- Check the front brake linings. (a p. 103)
Main work
- Check the brake fluid level in level viewer O.
If the brake fluid level has dropped below marking G:
- Add front brake fluid. (a p. 106)
16 BRAKE SYSTEM 106
Adding front brake fluid
Warning
A
Warning
Keep brake fluid out of the reach of children.
Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
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.
A
Warning
Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
Warning
Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable
regulations.
Info
brake fluid.
Preparatory work
Check the front brake linings. (!i.,!I p. 103)
Main work
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Remove screws O.
Remove cover 8 with membrane fD.
Add brake fluid to level f).
Guideline
Level f) (brake fluid level below 5 mm (0.2 in)
reservoir rim)
I Brake fluid DOT 4 (!!J p. 214)

Position the cover with the membrane. Mount and tighten the screws.
Info
.r-----so1900-10
16 BRAKE SYSTEM 107
Changing the front brake fluid
Warning
- Keep brake fluid out of the reach of children.
- Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
- 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
regulations.
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 screws O.
- Remove cover 8 with membrane.
- Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill
with fresh brake fluid.
Bleed syringe (50329050000) (0 p. 218)
Brake fluid DOT 4 (ll!;! p. 214)
- Mount bleeder cover @).
I Bleeder cover (00029013005) (0 p. 217)
Connect the bleeding device.
I Bleeding device (00029013100) (ll!;! p. 217)
- Open shut-off valve C,.

• Info
I Follow the operating instructions of the bleeding device.
- Ensure that the filling pressure is correctly set at pressure gauge f). If neces
sary, adjust the filling pressure at pressure regulator G).
Guideline
I Filling pressure I 2 ... 2.5 bar (29... 36 psi)
16 BRAKE SYSTEM 108
- Pull off protection cap @) of the brake caliper bleeder screw. Connect the hose
of the bleeder bottle.
I Bleeding device (00029013100) (il<ll p. 217)
Open bleeder screw (3 by approx. one half turn.
• Info
I Bleed until fresh brake fluid emerges from the bleeder bottle hose without
bubbles.
- Tighten the bleeder screw.

- Close shut-off valve 8.
- 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.
- Disconnect the bleeding device. Remove the bleeder cover.
- Add brake fluid to level (9.
Guideline
Level (9 (brake fluid level below con- 5 mm (0.2 in)
tainer rim)

- Position the cover with the membrane. Mount and tighten the screws.
• Info
�-----309386-10
I Clean up overflowed or spilt brake fluid immediately with water.
- Check the hand brake lever for a firm pressure point.
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 f).
I Minimum thickness f) I� 1 mm (� 0.04 in)
If the minimum thickness is less than specified:

- Change the rear brake linings. (� p. 108)
- Check the brake linings for damage and cracking.
If damage or cracking is visible:
- Change the rear brake linings. (!!:!I p. 108)
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 109
A
Warning
A
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
Remove cotter pins CD. pull out pin e. and remove the brake linings.
Clean the brake caliper and brake caliper support.
Check that leaf spring 0

in the brake caliper and sliding plate (D 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 110
- Insert the new brake linings, insert pin 8, and mount cotter pins (D.
• Info
I 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
- Add brake fluid to level f).

Mount and tighten screw cap O with membrane 8 and the O-ring.
• Info
I Clean up overflowed or spilled brake fluid immediately with water.
Checkin 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.
O.
l
- Disconnect spring
- Move the foot brake lever back and forth between the end stop and the contact
to the foot brake cylinder piston and check free travel f).
Guideline
I Free travel at foot brake lever 13... 5 mm (0.12... 0.2 in)
If the free travel does not meet specifications:
- Adjust the basic position of the foot brake lever. (I!\:! p. 110)
402026-10
- Reconnect spring O.
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 111
- O.
Detach spring
Loosen nut 8 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 8
and turn screw (D accordingly.
• Info
I The range of adjustment is limited.
Turn push rod Ci) accordingly until you have free travel f). If necessary, adjust
the basic position of the foot brake lever.
I 13 ...
Guideline
Free travel at foot brake lever 5 mm (0.12... 0.2 in)
- Hold push rod Ci) and tighten nut 8.
I
Guideline
Remaining nuts, chassis 10 Nm (7.4 lbf ft)
- Hold screw (D and tighten nut@.
I
Guideline
Nut, foot brake lever stop I 20 Nm (14.8 lbf ft) I
- Attach spring O.
Checking the rear brake fluid level
Warning
A
Warning
Preparatory work
- Check the rear brake linings. (� p. 108)
Main work
- Stand the vehicle upright.
- Check the brake fluid level in the viewer O.
If the brake fluid level drops below marking f):
- Add rear brake fluid. (� p. 111)
Adding rear brake fluid
Warning
16 BRAKE SYSTEM 112
A
Warning
A
Warning
Warning
regulations.
Info
brake fluid.
Preparatory work
Check the rear brake linings. (� p. 108)
Main work
Stand the vehicle upright.
Remove screw cap O with membrane fj and the O-ring.
Add brake fluid to level f).
Mount and tighten the screw cap with the membrane and O-ring.
Info
Changing the rear brake fluid
Warning
Warning
regulations.
16 BRAKE SYSTEM 113
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 O 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.
Bleed syringe (50329050000) (� p. 218)
Brake fluid DOT 4 (� p. 214)
- Mount bleeder cover @.

I Bleeder cover (00029013006) (� p. 217)
- Connect the bleeding device.
I Bleeding device (00029013100) (� p. 217)
- Open shut-off valve 8.

• Info
I Follow the operating instructions of the bleeding device.
- Ensure that the filling pressure is correctly set at pressure gauge 6). If neces
sary, adjust the filling pressure at pressure regulator G,.
Guideline
I Filling pressure I 2... 2.5 bar (29... 36 psi)
- Pull off protection cap C, of the bleeder screw. Connect the hose of the bleeder
bottle.
I Bleeding device (00029013100) (� p. 217)
- Open bleeder screw 0 by approx. one-half turn.
• Info
I Bleed until fresh brake fluid emerges from the bleeder bottle hose without
bubbles.
- Tighten the bleeder screw.

- Close shut-off valve 8.
- 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.
- Disconnect the bleeding device. Remove the bleeder cover.
16 BRAKE SYSTEM 114
- Stand the vehicle upright.

- Add brake fluid to level (9.
I Brake fluid DOT 4 (a p. 214)
- Fit and tighten the screw cap with the membrane and 0-ring.
• Info
- Check the foot brake lever for a firm pressure point.

17 ENGINE 115
17.1 Removin the engine

Preparatory work
- Drain the coolant. (a p. 187)
- Remove the seat. (a p. 73)
- Remove the fuel tank. (il!JJ p. 73)
- Remove the right side cover. (il!ll p. 72)
- Remove the main silencer. (il!ll p. 68)
Main work
- Pull EFI control unit O from the holder and hang it to one side.
- Remove the cable tie(s) and expose the cable.

- Disconnect plug-in connector 8.
- Disconnect plug-in connectors 8.
Loosen hose clip 8.

17 ENGINE 116
Unplug connector C,.
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@).
I Spring hook (50305017000) (I!:! p. 218)
17 ENGINE 117
Remove screw C&.

Take off the manifold.
Loosen hose clip 49.

Pull off the radiator hose.
Loosen hose clip �.

Pull off the radiator hose.
Push back protection cap G).

Unplug connector 4D.
Disconnect spark plug connector 48.
Remove screw 4D.

17 ENGINE 118
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
I Do not kink the clutch line.
Do not activate the clutch lever while the slave cylinder of the clutch is
removed.
Activate the foot brake lever.

Loosen screw G).
Info
The help of an assistant is useful in this step.
Remove the connecting link of the chain.

Take off the chain.
Remove screw G).

Take off the engine sprocket.
Remove screw @D.

Take off the shift lever.
17 ENGINE 119
Loosen hose clip G,.

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 the positive cable and hang it to one side.
Remove fittings �.
Take off the engine braces.
Remove spring �.
Remove nut�-
Remove the swingarm pivot.
Pull the swingarm slightly toward the rear.
Remove screws fl).

17 ENGINE 120
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.
Main work
Position the engine in the frame.
• Info
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.

I I
Guideline
Engine carrying screw M10 60 Nm (44.3 lbf ft)
Position the swingarm.

Insert the swingarm pivot.
Mount and tighten nut 8.
Guideline
Nut, swingarm pivot M16x1.5 100 Nm
(73.8 lbf ft)
Tighten screws O.
I I
Guideline
I Engine carrying screw M10 60 Nm (44.3 lbf ft)
Mount spring CD.
Position the engine braces.

Mount and tighten screws C,.
Guideline
Screw, engine brace M8 33 Nm Loctite® 2701 TM
(24.3 lbf ft)
17 ENGINE 121
Position the positive cable on the starter motor.

Mount and tighten the nut.
Guideline
I Remaining nuts, chassis M6 10 Nm (7.4 lbf ft)
Position protection cap 0.
Position the vent hose and mount hose clamp (D.

Position the throttle valve body.
Tighten hose clip@.
Position the shift lever.

Mount and tighten screw (D with the washers.
Guideline
Screw, shift lever M6 14 Nm Loctite® 243 ™
(10.3 lbf ft)
Slide on the engine sprocket with the collar facing the engine.
Mount screw Q) with the washer but do not tighten yet.
Guideline
(44.3 lbf ft)
Mount the chain.

Connect the chain with connecting link CD.
Guideline
Activate the foot brake lever.

Tighten screw Q).
Guideline
(44.3 lbf ft)
• Info
17 ENGINE 122
Position the clutch slave cylinder with the gasket.

Mount and tighten screws G,.
Guideline
I Screw, clutch slave cylinder M6 10 Nm (7.4 lbf ft)
Mount the cable tie(s).
Position the engine sprocket cover.

Mount and tighten screw CB.
Guideline
I Screw, clutch slave cylinder M6 10 Nm (7.4 lbf ft)
Mount and tighten screw 48.

Guideline
Remaining screws, chassis M8 I 25 Nm (18.4 lbf ft) I
Plug in spark plug connector 4D.
Plug in connector 48.

Mount the protection cap.
Mount the radiator hose.

Position and tighten hose clip G's).
17 ENGINE 123
-
m.
Mount the radiator hose.
- Position and tighten hose clip
- Feed in the manifold.

- Mount screw Qi) but do not tighten yet.
Guideline
I Screw, manifold holder 15 Nm (11.1 lbf ft)
- Mount springs 41).

I Spring hook (50305017000) (!!l p. 218)
- Tighten screw Qi).
Guideline
I Screw, manifold holder 15 Nm (11.1 lbf ft)
- Position the shock absorber.

- Mount and tighten screw �-
Guideline
Screw, top shock M10 60 Nm Loctite® 2701 ™
- Remove the locking piece and position the subframe.
• Info
I Watch out for the intake flange.
- Mount and tighten screw a..

Guideline
Screw, subframe MS 30 Nm Loctite® 2701 TM
(22.1 lbf ft)
- Remove screw fl>.
- Mount and tighten screw fl>.
Guideline
Screw, subframe MS 30 Nm Loctite® 2701 TM
(22.1 lbf ft)
- Repeat the operation on the opposite side.
17 ENGINE 124
Route the cable without tension and secure with cable clamps.
Plug in connector@).
Position and tighten hose clip�-
Connect plug-in connector�

Connect plug-in connectors �.
Route the cable without tension and secure with cable tie(s).
Mount EFI control unit �.

17 ENGINE 125
- Attach negative cable fl!).

Guideline
(1.84 lbf ft)
• Info
I Contact disk O must be mounted between screw @D and cable lug Cii)
with the claws facing down.
- Remove filler plug G and add engine oil.

I Engine oil 11.0 I (1.1 qt.) I Engine oil (SAE 10W/50) (a p. 214)
- Mount and tighten filler plug G.
Finishing work
- Install the main silencer. (a p. 68)
- Install the right side cover. (a p. 73)
- Install the fuel tank. (a p. 74)
- Mount the seat. (!!:! p. 73)
- Remove the motorcycle from the lift stand. (!!:! p. 10)
- Refill the coolant. (a p. 188)
- Execute the initialization run. (a p. 196)
- Go for a short test ride.
- Read out the fault memory using the Husqvarna diagnostics tool.
- Check the engine for leak tightness.
- Check the engine oil level. (a p. 189)
- Check the coolant level. (a p. 187)
17.3 Engine disassembl

17.3.1 Preparations
- Mount the special tool on the engine mounting block.
Engine fixing arm (77229002000) (a p. 222)
Engine assembly stand (61229001000) (a p. 221)
- Mount the engine on the special tool.
• Info
I Work with an assistant or a motorized hoist.
17 ENGINE 126
17.3.2 Removing the clutch push rod

- Remove clutch push rod O.
17.3.3 Removing the spacer

- Remove spacer O of the countershaft.
- Remove O-ring.
17.3.4 Draining the engine oil

Remove plug O with oil screen and the O-rings.
- Remove the oil drain plug @ with the magnet and seal ring.
Remove oil drain plug 8 with the O-ring.

- Completely drain the engine oil.
17 ENGINE 127
17.3.5 Removing the oil filter

- Remove screws O. Remove the oil filter cover@ with the O-ring.
- Pull oil filter (D out of the oil filter housing.

I Circlip pliers reverse (51012011000) (� p. 219)
17.3.6 Removing the spark plug

- Remove the spark plug using special tool O.
I Spark plug wrench (77229172000) (� p. 225)
17.3.7 Removing the valve cover

- Remove screws O.
- Remove the valve cover with the valve cover seal.
- Remove the spark plug shaft insert.

17 ENGINE 128
17.3.8 Removing the starter motor

- Remove screws O and take off cover @.
- Take off the gasket.
- Remove torque limiter (D.
- Remove screws 8.
- Remove the alternator cover.
- Remove screws 0 and take off the starter motor.
17.3.9 Positioning the engine at ignition top dead center

- Turn the crankshaft counterclockwise until markings O on the cylinder head are
located flush above the flat areas Ce) of the camshafts.
17 ENGINE 129
- Remove screw O.
• Info
I Check through the hole whether the position notch of the crankshaft is
visible.
- Mount and tighten screw O without the washer.
17.3.10 Removing the timing chain tensioner

- Loosen screw O.
- Remove screw(!} with the seal ring.
- Pull out timing chain tensioner CD. Remove O-ring e.
17.3.11 Removing the camshaft

- O from the outside to the inside and remove.
8
Loosen screws
- Take off guide rail(!}.
I - Take off the camshaft bearing bridge.
Info
Ensure that the dowel pins remain in place.
- Take the timing chain off the camshaft gear.

- Remove the camshafts.
17 ENGINE 130
17 .3.12 Removing the cylinder head

- Remove nut O with the washer.
G00485-10
- Loosen nuts@ in a crisscross pattern and remove them with the washers.
- Remove the cylinder head.
- 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 0-

- 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 cylinder base gasket@.

17 ENGINE 131
17.3.14 Removing the rotor

- Remove screw O.
- Insert special tool f9 into the crankshaft.

I Protection cap (75029090000) (a p. 222)
Attach special tool CDto the rotor. Hold it tight using the special tool and pull off
the rotor by turning the screw in.
I Extractor (58012009000) (� p. 219)
• Info
I Ensure that the woodruff key remains in place.
17.3.15 Removing the starter drive

- Remove lock ring O.
- Take off the starter idler gear 8 with the washer.
- Take off freewheel gear@.
17.3.16 Removing the suction pump

- Remove screws O.
- Take off oil pump cover@.
17 ENGINE 132
- Remove O-ring CD.
- Take off suction pump C,.
- Remove needle roller@).
17 .3.17 Removing the water pump wheel

- Remove screws O. Take off the water pump cover.
- Remove nut 8.
Take off the two-part water pump impeller CD.
17 ENGINE 133
17 .3.18 Removing the clutch cover

- Remove screws O.
- Take off the clutch cover.
- Remove the clutch cover seal.
17 .3.19 Removing the clutch discs

- Loosen screws O and remove together with the washers and springs.
- Take off the pressure cap.
- Completely remove clutch discs 8.

- Remove pressure piece 8.
17 .3.20 Removing the outer clutch hub

- Bend up the lock washer.
- Hold the inner clutch hub with the special tool. Loosen nut O.
I Clutch holder (59029003100) (� p. 220)
- Remove the nut with the lock washer.
- Take off inner clutch hub 8 and washer@.

• Info
I The washer usually sticks to the inner clutch hub.
- Take off C,.

17 ENGINE 134
- Take off needle bearing 0 and collar sleeve (D.
17.3.21 Removing the shift shaft

Push sliding plate O away from the shift drum locating unit@. Remove shift
shaft8 with the washer.
17.3.22 Removing the shift drum locating unit

- Remove screw O.
Push away locking lever@ from shift drum locating unit 8 and remove the shift
drum locating unit.
- Relieve tension from the locking lever.
17.3.23 Removing the locking lever

- Unscrew O and remove together with locking lever@, washer, sleeve and
spring.
17.3.24 Removing the force pump

- Take off washer@.
Take off oil pump idler gear 8 with the washer.
17 ENGINE 135

- Take off washer@).
- Remove oil pump gear (D.
- Remove pin@.
- Remove screws @).
- Take off the oil pump cover.
- Remove pin@).
- Push oil pump shaft Gi) inward and take it out of the engine from the ignition
side.
- Remove force pump 48.
17.3.25 Removing the primary gear

Remove nut Q.
• Info
I Left-handed thread!
- Position the special tool in the crankshaft.

I Protection cap (75029090000) (I!!]) p. 222)
- Pull off primary gear 8 using the special tool.
I Extractor (46129021000) (llill p. 218)
- Remove screw 8.
17.3.26 Removing the timing chain
- Remove screws O.
- Remove the timing chain tensioning rail @}.
- Remove the timing chain guide rail@).
17 ENGINE 136
- Remove screw C,.

- Take off balancer shaft 0 with the timing chain and timing chain securing guide.
Info
If the timing chain is going to be used again, mark its direction of travel.
17 .3.27 Removing the spacer

- Remove spacer O of the crankshaft.
17 .3.28 Removing the left section of the engine case

- Remove screws O.
- Tilt the left section of the engine case upward and remove the screw connections
of the engine fixing arm.
- Insert the special tool into the crankshaft.

I Protection cap (75029090000) (a p. 222)
Mount special tool 8 with the appropriate screws.
I Puller (77229048000) (a p. 224)
• Info
I Use the drill hole marked with 772.
- Take off the section of the engine case.
• Info
I Do not subject the section of the engine case to any stress.
The washer of the main shaft usually adheres to the bearing.
- Take off the left section of the engine case.

17 ENGINE 137
17.3.29 Removing the shift rails

- Remove shift rail O together with upper spring 8.
- Remove shift rail @) together with upper spring C, and the lower spring.
17.3.30 Removing the shift drum

- Tilt shift forks O to the side.
• Info
I Do not misplace the shift rollers.
Remove shift drum 8.
17.3.31 Removing the shift forks

- Remove shift forks O.
Info
Do not misplace shift rollers 8.
17.3.32 Removing the transmission shafts

17 ENGINE 138
Pull both transmission shafts 8 out of the bearing seats together.
17.3.33 Removing the crankshaft

Take out crankshaft O.
Take off the right section of the engine case.
17.4 Working on individual arts

17.4.1 Work on the right section of the engine case
Remove all dowels.
O of the crankshaft.
Remove shaft seal ring
Remove nozzle 8.
Remove oil nozzle 8 for conrod bearing lubrication.
Remove screw C,.
Remove oil nozzle for piston cooling.
Remove screws 0- Remove the bearing retainers.
Remove any sealing mass remnants and clean the engine case section
thoroughly.
Warm the engine case section in an oven.
Guideline
1150 °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
306539-10 using a suitable tool.
Blow out oil nozzle (D with compressed air and check that it is clear.
Guideline
Oil nozzle for balancer M4 2Nm Loctite® 243 ™
shaft lubrication (1.5 lbf ft)
Insert the new cold bearings in the bearing seats of the heated section of the
engine case; if necessary, use a suitable press drift to push them all the way in
and make them flush.
• Info
306540-10
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.
17 ENGINE 139
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.
Mount the dowels.

Press in shaft seal ring O of the crankshaft with the open side facing out so it is
flush.
Mount and tighten nozzle@}.
Guideline
Nozzle, crank chamber M4 2Nm Loctite® 243 ™
ventilation (1.5 lbf ft)
Mount and tighten the oil nozzle (s).

Guideline
Oil nozzle for conrod M4 2Nm Loctite® 243 ™
bearing lubrication (1.5 lbf ft)
Mount the oil nozzle for piston cooling.
Mount and tighten screw C,.
Guideline
Screw, oil nozzle for pis M4 2Nm Loctite® 243 ™
ton cooling (1.5 lbf ft)
Position all bearing locks.
Mount and tighten screws 0.
Guideline
Locking screw for bearing M5 6Nm Loctite® 243 ™
(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.
Remove shaft seal ring O of the crankshaft, @} shift shaft and (s) countershaft.
Remove oil nozzle C, for clutch lubrication.
Remove oil nozzle 0 for piston cooling.
Remove screws (D. Remove the bearing retainers.
Remove any sealing mass remnants and clean the engine case section
thoroughly.
Warm the engine case section in an oven.
Guideline
1150 °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.
Insert the new cold bearings in the bearing seats of the heated section of the
engine case; if necessary, use a suitable press drift to push them all the way in
and make them 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.
17 ENGINE 140
- 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.
- Mount the dowels.

- Press in shaft seal ring O of the crankshaft with the open side facing out so it is
flush.
- Press in shaft seal ring @ of the shift shaft so it is flush with the open side facing
in.
- Press in shaft seal ring @) of the countershaft so it is flush with the open side
facing in.
- Mount and tighten oil nozzle C,.
Guideline
Oil nozzle for clutch lubri- M5 6Nm Loctite® 243 ™
cation (4.4 lbf ft)
- Mount and tighten oil nozzle 0.
Guideline
Oil nozzle, piston cooling M5 2 Nm Loctite® 243 ™
(1 .5 lbf ft)
- Position all bearing locks.
- Mount and tighten screws (D.
Guideline
Locking screw for bearing M5 6Nm Loctite® 243 ™
(4.4 lbf ft)
- Blow out the oil channel with compressed air and check that it is clear.
17 .4.3 Work on the clutch cover

- Remove shaft seal ring O.
- Remove lock ring @}.

- Remove shaft seal ring @).
17 ENGINE 141
Press out bearing 8 toward the inside.
Mount lock ring@.

Press the shaft seal ring (5) all the way in from the inside to the outside with the
open side facing in.
Press the new bearing 8 all the way in from the inside to the outside using a
suitable tool.
Press in shaft seal ring O all the way, with the open side facing outward.
Remove lock ring 0.

Remove shaft seal ring (D of the crankshaft.
Press the new shaft seal ring in with the open side facing inward.
• Info
I Press the shaft seal ring inward to the point where the lock ring can be
mounted.
Provide suitable support for the clutch cover while pressing in.
306546-10 Mount lock ring 0.

Blow out the oil channel with compressed air and check that it is clear.
17.4.4 Checking the oil pressure regulator valve

Remove screw plug O with sealing washer@.
Remove pressure spring (5) and ball 8.
�- - 0
8-1
o--8
306542-10
17 ENGINE 142
- Measure the spring length of the oil pressure regulator valve.

Oil pressure regulator valve
Minimum length of pressure spring 23.5 mm (0.925 in)
If the measured value does not meet specifications:
- Change the spring.
- Check ball C, and the sealing seat.
306115-10 - Change the ball and machine the sealing seat.
- Install ball e CD.
and pressure spring
- Mount and tighten screw plug O with sealing washer 8.
Guideline
I Plug, oil pressure regulator valve I M12x1.5 I 20 Nm (14.8 lbf ft) I
c,e--e
8-/
o--•
306542-10
17.4.5 Checking the lubrication system
•✓ ,
✓ 01
305003-10
- Check the internal rotor and external rotor of oil pumps O for damage and wear.
- Change the oil pumps.
- Check oil pump shaft 8 for damage and wear.
- Change the oil pump shaft.
- Check the oil pump cover for damage and wear.
- Change the oil pump cover.
17 ENGINE 143
17.4.6 Removing the crankshaft bearing inner race

- Fix the crankshaft in the vise.
• Info
I Use soft jaws.
- Warm up special tool O.

Guideline
1150 °C (302 °F)
I Tool for inner bearing race (58429037037) (a p. 219)

- Push the warmed up special tool O onto the crankshaft bearing inner race,
press firmly together and pull jointly from the crankshaft.
- Take off the compensating disk.
17.4.7 Changing the connecting rod, conrod bearing, and crank pin
Main work
- Position crankshaft O in the press using special tool @.
I Extrude plate, base (77229009000) (a p. 223)
- Press the crank pin with the special tool out of the upper crank web.
I Pressing tool for crankshaft, complete (75029047000) (a p. 222)
• Info
I Hold the lower crank web.
- Remove the connecting rod.

- Press the crank pin out of the lower crank web.
- Press in the new crank pin @) as far as possible.

✓ Oil hole 9 is aligned with oil hole C,.
X If the oil holes are not correctly aligned, the conrod bearing will not be sup
plied with oil.
- Blow compressed air through the oil channel to check that it is clear.
306571-10
- Mount new connecting rod C,.

Info
Thoroughly oil bearing 0.
17 ENGINE 144
- Position special tool (D on the press.

Pressing tool for crankshaft, complete (75029047000) (a p. 222)
Insert for crankshaft pressing tool (77229008000) (a p. 223)
- Insert the crank web with connecting rod and bearing. Position the second crank
web.
- Position special tool @ with the heel pointing down.

I Insert for crankshaft pressing tool (77229008000) (a p. 223)
Press in the upper crank web as far as possible.
• Info
I The press mandrel must be positioned over the crank pin.
- Take the crankshaft out of the special tool and check that the connecting rod can
move freely.
- Measure axial play (!) between the connecting rod and the crankwebs using the
special tool.
I Feeler gauge (59029041100) (a p. 220)
Connecting rod - axial 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 it so the dimension is equal to the specified value.
Finishing work
- Check the crankshaft run-out at the bearing pin. (a p. 144)
17.4.8 Checking the crankshaft run-out at the bearing pin

- Position the crankshaft on a roller block.
- Turn the crankshaft slowly.
Check the crankshaft run-out on both bearing pins.
I Crankshaft - run-out at bearing pin I :-;; 0.03 mm (:-;; 0.0012 in)
If the crankshaft run-out at the bearing pin is larger than the specification:
- Align the crankshaft.
17.4.9 Installing the crankshaft bearing inner race

Main work
- Fix the crankshaft in the vise.
• Info
I Use soft jaws.
- Slide on compensating disk O.

• Info
306538-10 I The compensating disks have a larger diameter than the crankshaft stub.
Ensure that the compensating disks are centered and fixed with a small
amount of grease.
Add compensating disks equally on both sides.
17 ENGINE 145
- Heat the crankshaft bearing inner race in special tool 8 and mount together.
Guideline
1120 °C(248 °F)
I Tool for inner bearing race(58429037037)(!!JJ p. 219)

- Ensure that the new crankshaft bearing inner race is flush.
• Info
I After replacing the crankshaft bearings, the crankshaft end play must be
measured.
Finishing work
- Measure the crankshaft end play.(!!ll p. 145)
17.4.10 Measuring the crankshaft end play

- Insert the crankshaft into the right section of the engine case.
• Info
I Do not forget the fitted bushings.
- Mount the left section of the engine case.

- Mount and tighten screws.
Guideline
I Screw, engine case I M6 10 Nm(7.4 lbf ft)
- Mount the dial gauge support on the engine case and measure and note down
the crankshaft end play.
Guideline
I Crankshaft - axial play I 0.50... 0.60 mm(0.0197... 0.0236 in)
- Remove the crankshaft.
- Remove the crankshaft bearing inner race.(� p. 143)
- Calculate the thickness of the compensating disks.
- Add or remove compensating disks equally on both sides.
• Info
I If the axial play is too small, remove compensating disks.
If the axial play is too large, add compensating disks.
- Install the crankshaft bearing inner race.(� p. 144)
17.4.11 Removing the drive wheel of the balancer shaft

- Position the balancer shaft in the press with special tool 0-
1 Separator plate(77229032000) (!!ll p. 224)
- Mount special tool 8.
I Protection cap(77229031000)(!!JJ p. 224)
- Press out the drive wheel of the balancer shaft.
17 ENGINE 146
17.4.12 Installing the drive wheel of the balancer shaft

- Ensure that woodruff key O is seated properly.
- Warm drive wheel @ of the balancer shaft and push it onto the balancer shaft.
Guideline
1100 °C (212 °F)
303077-10
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.
306549-10
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 0- and 0-axes using
a micrometer to identify oval wear.
'--
Guideline
Cylinder - drill hole diameter
Size I 88.000... 88.012 mm (3.46456 ...
3.46503 in)
Size II 88.012 ... 88.025 mm (3.46503 ...
3.46554 in)
• Info
I The cylinder size O is marked on the cylinder collar.
- Using a straightedge and the special tool, check the sealing area of the cylinder
head for distortion.
I Feeler gauge (59029041100) (� p. 220)
Cylinder/cylinder head - distortion of s; 0.10 mm (::. 0.0039 in)
sealing area
- Change the cylinder.
305004-10
17 ENGINE 147
17.4.15 Checking/measuring the piston

- Use the special tool to measure clearance t) of the piston rings in the piston ring
groove.
e-• Guideline
I Piston ring - groove clearance I $ 0.08 mm ($ 0.0031 in)
+ I Feeler gauge (59029041100) (� p. 220)
If play t) is larger than the specified value:
- Change the piston and piston rings.
400995-10 - Check/measure the cylinder. (� p. 146)
- 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
305017-10 I 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:
- Change 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:
- Change the connecting rod and piston pin.
- Measure the piston at the piston skirt, at right angles to the piston pin, at a
distance C,.
Guideline
Distance 0 27 mm (1.06 in)
Piston - diameter
Size I 87.955... 87.965 mm (3.46279 ...
3.46318 in)
Size II 87.965... 87.975 mm (3.46318...
3.46358 in)
• Info
I The piston size O is marked on the side of the piston.
17.4.16 Measuring the piston/cylinder mounting clearance
- Check/measure the cylinder. (I!!',!! p. 146)
- Check/measure the piston. (I!!',!! 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.
306549-10
17 ENGINE 148
Guideline
Piston/cylinder - mounting clearance
Size I 0.035... 0.057 mm (0.00138 ...
0.00224 in)
Size II 0.037 ... 0.060 mm (0.00146 ...
0.00236 in)
Wear limit 0.070 mm (0.00276 in)
17.4.17 Checking the piston ring end gap

- Remove the piston ring from the piston.
- Place the piston ring in the cylinder and align with the piston.
Guideline
I Below the upper edge of the cylinder 1 20 mm (0.79 in)
- Measure end gap G with a feeler gauge.
Guideline
I
Piston ring - end gap
I
306113-10 Compression ring $ 0.40 mm ($ 0.0157 in)
Oil scraper ring $ 0.80 mm ($ 0.0315 in)
If the end gap is greater than the specified measurement:
- Check/measure the cylinder. (0 p. 146)
If 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 Changing the camshaft bearing

- Clamp special tool O into a vise.
I Adjustment bush bridge (77229050044) (0 p. 224)
- Mount the camshaft on the special tool.
- Remove screw 8.
306550-10
- Pull camshaft gear (D off of the camshaft.
e I Extractor, camshaft gear (77229001044) (I!!:! p. 222)
I -
-
Remove bearing
Oil the new bearing
C,.
C, and push it onto the camshaft.
I Lubricated with engine oil
- Degrease the cone of the camshaft and camshaft gear.
- Mount camshaft gear (D.
306552-10
- Mount screw 8 but do not tighten yet.
Guideline
Screw, camshaft drive M12x1 70 Nm Loe-
sprocket (51.6 lbf ft) tite® 243 ™ /cone
degreased
- Repeat these steps for the second camshaft.
17 ENGINE 149
17.4.19 Checking the camshafts

- Check the camshaft for damage and wear.
- Change the camshaft.
- If the surface of the cams is damaged, check the oil supply to the
camshaft and cam lever.
- Measure the cams of the camshaft.
Camshaft - cam height
Exhaust 36.15... 36.35 mm (1.4232...
1.4311 in)
Intake 36.32... 36.52 mm (1.4299...
1.4378 in)
- Change the camshaft.
- Check the autodecompressor for damage and wear.
- Change the exhaust camshaft.
- Slide the camshaft bearing to the camshaft gear.
- Pull lever O away from camshaft and release it.
If the lever does not return to its original position:
- Change the exhaust camshaft.
306551-10
17.4.20 Checking the pivot points of the camshafts

- Check the pivot points of the camshafts.
- Change the cylinder head with the camshaft bearing bridge.
- Position the camshafts.

✓ The valves are not activated.
- Insert the Plastigauge clearance gauge in area f).
I Plastigauge clearance gauge (60029012000) (� p. 220)
306563-10
- Position camshaft bearing bridge O. Mount and tighten the screws.
Guideline
Screw, camshaft bearing M7x1 14 Nm Lubricated with
bridge (10.3 lbf ft) engine oil
• Info
I Ensure that the dowel pins are seated properly.
Do not turn the camshaft.
17 ENGINE 150
Remove camshaft bearing bridge O

again. Compare the Plastigauge clearance
gauge with the specifications on the packaging.
Guideline
Camshaft bearing - sleeve bearing
Radial clearance 0.020... 0.054 mm (0.00079 ...
0.00213 in)
• Info
I The width of the Plastigauge clearance gauge is a measure of the bearing
play.
Take off the camshafts and clean the parts.
17 .4.21 Removing the valves

Remove screw plugs O with the O-ring.
Screw appropriate screw 8 into the cam lever shaft.
Hold cam levers fD and remove the cam lever shaft.
• Info
I If the cam levers will continue to be used, note down their installation posi
tion.
Take the shims from the valve spring retainers and put them aside corresponding
to their installation position.
306566-10
Pre-tension the valve spring using the special tool.

Valve spring mounter (59029019000) (� p. 220)
Insert for valve spring lever (77229060000) (l!!;!l p. 225)
Remove the valve keys and unload the valve spring.
306567-10
Remove the valve spring retainer and valve springs.

Mark the valve spring according to its normal built-in position.
Pull the valve down out of the valve guide.
Remove valve stem seal C, with the special tool.
I Pliers for valve stem seals (77229010000) (l!!;!l p. 223)
Remove valve spring seat 0.

306568-10
17 ENGINE 151
••
Mark the valves corresponding to their installation position.
Info
--
E"I// £V1)",
I Place the valves in a carton corresponding to their installation position and
label them.
300117-10
17.4.22 Checking the valves

Check the valve plate for run-out.
Valve - run-out
At the valve plate :,; 0.05 mm (:,; 0.002 in)
- Change the valve.
200193-10
Check sealing seat 6) on the valve.

Valve - sealing seat width
Intake 1.40 mm (0.0551 in)

Exhaust 1.40 mm (0.0551 in)
If the sealing seat is not centered on the valve seat or deviates from the speci
fication:
302809-10
Rework the valve seat.
17.4.23 Checking the valve springs

Check the valve springs for breakage and wear (visual check).
• Info
I Intake valves are marked with a green color coding.
Exhaust valves are marked with a brown color coding.
If the valve spring is broken or worn:

- Change the valve spring.
Measure the length of the valve springs.
305015-10
Valve spring
Minimum length of intake valve I 41.20 mm (1.622 in)
Minimum length of exhaust valve I 41.10 mm (1.6181 in)
- Change the valve springs.
17.4.24 Checking the 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.
I Valve spring seat - thickness I 1.40... 1.60 mm (0.0551 ... 0.063 in)
305014-10
17 ENGINE 152
- Change the valve spring seat.
17.4.25 Checking the cam levers

- Check the cam levers and cam lever shafts for damage and wear.
- Change the cam levers and/or cam lever shafts.
302718-10
17.4.26 Checking the cylinder head

- Check valve guides O using the special tool.
I Limit plug gauge (77229026000) (0 p. 223)
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:
302805-10 - Change the cylinder head.
- Using a straightedge and the special tool, check the sealing area of the cylinder
for distortion.
I Feeler gauge (59029041100) (� p. 220)
Cylinder/cylinder head - distortion of :5 0.10 mm (:5 0.0039 in)
sealing area
- Change the cylinder head.
- Check sealing seat t) of the valves.

Intake 1.40 mm (0.0551 in)

Exhaust 1.40 mm (0.0551 in)
- Rework the valve seat.
302808-10
- Blow compressed air through all oil holes and check that they are clear.
17.4.27 Installing the valves

- Position valve spring seat 0- Mount valve stem seal@.
- Mount the valve corresponding to its installation position.
- Mount the valve spring with the tighter coil facing downward according to the
built-in position.
• Info
I Intake valves are marked with a green color coding.
Exhaust valves are marked with a brown color coding.
- Mount the valve spring retainers.

17 ENGINE 153
Pre-tension the valve spring using the special tool.

Valve spring mounter (59029019000) (� p. 220)
Insert for valve spring lever (77229060000) (� p. 225)
Mount valve keys (D.
• Info
I When mounting the valve keys, ensure that they are seated properly; it is
recommended to adhere the valve keys to the valves with a small amount
of grease.
Position cam levers C, in the positions they had before they were removed.
Mount the cam lever shafts.
Remove screw 0-
Mount and tighten screw plugs (D.
Guideline
I Screw plug, cam lever axis M10x1 10 Nm (7.4 lbf ft)
Place the shims in the valve spring retainers corresponding to their installation
position.
306570-10
17.4.28 Checking the freewheel

Insert freewheel gear O into the freewheel hub, turning the freewheel gear clock
wise; do not wedge.
Check the locking action of starter wheel O.
If the freewheel gear does not turn clockwise or if it does not lock counter
clockwise:
- Change the free wheel.
302804-10
17 ENGINE 154
17.4.29 Removing the freewheel

,.
�
-
!
- 1.
,f_ 1"],.! ,: , , · '\.
I ·
'. ' -✓ "'' '

I ' ·, l'\, ►
� •-�� I:•: I
- Press expansion ring fj together with suitable pliers and take off.
- Take freewheel 8 out of the primary gear.
308684-10
17.4.30 Installing the freewheel

- Thoroughly oil all parts.
- Slide freewheel O into the primary gear.
Info
Note the direction of rotation.
308684-11
- Mount spreader ring @.
308685-10
17 ENGINE 155
- Ensure that all lugs of the expansion ring pass through slots 6) of the freewheel
and engage in groove C, of the primary gear.
- Mount lock ring 6).
17.4.31 Checking the electric starter drive
e
·-•
0 0
I
305006-10
- 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 8 for damage and wear.
- Change the torque limiter.
- Check the gear mesh and bearing of freewheel gear 6) for damage and wear.
- Change the freewheel gear or bearing.
- Check freewheel C, for damage and wear.
- Change the free wheel.
- Check the gear mesh of starter motor 0 for damage and wear.
- Change the starter motor.
17 ENGINE 156
- Change O-ring CD 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.
17.4.32 Checking the timing assembly
-Q)
305007-10
- Check timing chain sprocket O for damage and wear.

- Change the timing chain sprocket.
- Check the timing chain tensioning rail 8 for damage and wear.
- Replace the timing chain tensioning rail.
- Check the timing chain guide rail (D for damage and wear.
- Replace the timing chain guide rail.
- Check the timing chain securing guide 8 for damage and wear.
- Replace the timing chain securing guide.
- Check camshaft gears 0 for damage and wear.
- Change the camshaft gears.
- Check timing chain CD for damage and wear.
- Replace the timing chain.
- Let the timing chain hang down freely. Check the timing chain links for smooth operation.
,, The chain links no longer align in a straight line:
- Replace the timing chain.
17 ENGINE 157
17.4.33 Preparing the timing chain tensioner for installation

- Press the timing chain tensioner together completely.
• Info
I 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. This ensures that, when pressed in, the piston cannot go in all the way.
I I
Guideline
Thickness of the compensating disks 2... 2.5 mm (0.08 ... 0.098 in)
- Release the timing chain tensioner.
✓ The detent mechanism engages and the piston remains in place.
Final position of the piston after 3 mm (0.12 in)
engagement
200172-10
Info
This position is necessary for installation.
If the timing chain tensioner is now pressed again and is only extended
a maximum of half way (it is prevented from extending completely). This
locks the detent mechanism and the timing chain tensioner can no longer
be squeezed together. This function is necessary in order to ensure suffi
cient timing chain tension even at low oil pressures.
17.4.34 Checking the clutch
306555-10
- Check pressure piece O for damage and wear.

- Change the pressure piece.
- Check axial bearing 8 for damage and wear.
- Change the axial bearing.
- Place push rod @) on a level surface and check for run-out.
17 ENGINE 158
If there is run-out:
- Change the push rod.
- Check the length of clutch springs 8.
I Clutch spring - length I� 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.
- Change the pressure cap.
- Check the thrust surfaces of the clutch facing discs in the outer clutch hub (3 for wear.
I Contact surface of clutch facing discs in outer clutch hub I� 0.5 mm(� 0.02 in)
If the contact surface exhibits significant wear:
- Change the clutch facing discs and the outer clutch hub.
- Check needle bearing @ and collar sleeve CD for damage and wear.
- Change the needle bearing and collar sleeve.
- Check intermediate clutch discs @) and G, for damage and wear.
If the intermediate clutch discs are not even or are pitted:
- Change all intermediate clutch discs.
- Check clutch facing discs Qi) for discoloration and scoring.
If there is discoloration or scoring:
- Change all clutch facing discs.
- Check the thickness of clutch facing discs Qi).
I Clutch facing discs - thickness of total package I � 26.4 mm(� 1.039 in)
If the clutch facing discs do not meet specifications:
- Change all clutch facing discs.
- Check disc 48 for damage and wear.
- Change the disc.
- Check the inner clutch hub � for damage and wear.
- Change the inner clutch hub.
- Check sleeve 4D for damage and wear.
- Change the sleeve.
17 ENGINE 159
17.4.35 Checking the shift mechanism
•-,�
306554-10
- Check shift forks O on disc 6) for damage and wear (visual check).
- Change the shift fork.
- Check shift grooves @) of shift drum @ for wear.
If the shift groove is worn:
- Change the shift drum.
- Check the seating of the shift drum in the grooved ball bearings @).
If the shift drum is not correctly seated:
- Change the shift drum and/or the grooved ball bearing.
- Check grooved ball bearing @) for smooth operation and wear.
If the grooved ball bearings are stiff or worn:
- Change the grooved ball bearing.
- Check the shift rollers for damage and wear.
- Change the shift rollers.
- Check the springs of shift rails 8 for damage and wear.
If the spring is damaged or worn:
- Change the spring of the shift rail.
- Check the shift rails 8 for run-out on a flat surface.
If there is run-out:
- Change the shift rail.
- Check the shift rails for scoring, wear and smooth operation in the shift forks.
If scoring or wear is present or of the shift fork is stiff:
- Change the shift rail.
- Check sliding plate 0 for wear on contact areas 0.
If the sliding plate is worn:
- Change the sliding plate.
- Check return surface ti) 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:
17 ENGINE 160

- Preassemble the shift shaft. (� p. 160)
- Check clearance O 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
17.4.36 Preassembling the shift shaft

- Secure the short end of the shift shaft in the bench vise.
I
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 C,, with the offset end facing
upward, over the spring guide and lift the offset end over abutment bolt @).
305010-10
- Mount washer (D.
17.4.37 Disassembling the main shaft
306556-10
- Secure the main shaft with the toothed end facing downward in the vise.
Guideline
Use soft jaws.
- Remove stop disk O and second-gear fixed gear @.
- Remove fourth-gear idler gear @) and needle bearing C,.
- Remove stop disk 0.
- Remove third-gear sliding gear@.
- Remove lock ring fD.
- Remove stop disk @).
- Remove fifth-gear idler gear G).
17 ENGINE 161
- Remove needle bearing G,.

17.4.38 Disassembling the countershaft
306558-10
- Fix the countershaft in the vise with the toothed end facing downward.
Guideline
Use soft jaws
- Remove stop disk O and first-gear idler gear @.
- Remove needle bearing fs) and stop disk C,.
- Remove fifth-gear sliding gear 0.
- Remove stop disk @.
- Remove third-gear idler gear fD and needle bearing@).
- Remove stop disk Gi).
- Remove lock ring G,.
- Remove fourth-gear sliding gear 48.
- Remove stop disk 4D.
- Remove second-gear idler gear e and needle bearing 4D).
17.4.39 Checking the transmission
Condition
The transmission has been disassembled.
17 ENGINE 162
306561-10
- Check needle bearings O for damage and wear.

- Change the needle bearings.
- Check the pivot points of main shaft 8 and countershaft @) for damage and wear.
- Change the main shaft and/or countershaft.
- Check the tooth profiles of main shaft 8 and countershaft 8 for damage and wear.
- Change the main shaft and/or countershaft.
- Check the pivot points of idler gears 8 for damage and wear.
- Change the gear wheel pair.
- Check the shift dogs of idler gears 8 and sliding gears @) for damage and wear.
- Check the tooth faces of idler gears 8, sliding gears @), and fixed gear (3 for damage and wear.
- Check the tooth profiles of sliding gears 0 for damage and wear.
- Check sliding gears 0 for smooth operation in the profile of main shaft 8.
If the sliding gear is stiff:
- Change the sliding gear or the main shaft.
- Check sliding gears 0 for smooth operation in the profile of countershaft C,.
If the sliding gear is stiff:
- Change the sliding gear or the countershaft.
- Check stop disks @ for damage and wear.
- Change the stop disks.
- Use new lock rings C, with every repair.
17.4.40 Assembling the main shaft
Info
Use new lock rings with every repair.
17 ENGINE 163
Preparatory work
- Check the transmission. (0 p. 161)
- Carefully lubricate all parts before assembling.
Main work
306557-10
- Secure the main shaft with the toothed end facing downward in the vise.
Guideline
Use soft jaws
- Mount needle bearing O.
- Mount fifth-gear idler gear@.
- Mount stop disk (D and lock ring 8.
- Mount third-gear sliding gear 0.
- Mount lock ring (D and stop disk @.
- Mount needle bearing @).
- Mount fourth-gear idler gear 0.
- Mount second-gear fixed gear Gi) and stop disk 48.
- Finally, check all gear wheels for smooth operation.
17.4.41 Assembling the countershaft
• Info
I Use new lock rings with every repair.
Preparatory work
- Check the transmission. (0 p. 161)
- Carefully lubricate all parts before assembling.
17 ENGINE 164
Main work
306559-10
- Fix the countershaft in the vise with the toothed end facing downward.
Guideline
Use soft jaws
- Mount needle bearing O and second-gear idler gear 8 onto the countershaft with the protruding collar facing downward.
- Mount stop disk (D and lock ring 8.
- Mount fourth-gear sliding gear 0 with the shift groove facing upward.
- Mount lock ring (D and stop disk @.
- Mount needle bearing G) and third-gear idler gear @) with the shift dogs facing upward.
- Mount stop disk GD and lock ring 41.
- Mount fifth-gear sliding gear � with the shift groove facing downward.
- Mount stop disk G).
- Mount needle bearing • and first-gear idler gear 48.
- Mount stop disk 41).
- Finally, check all gear wheels for smooth operation.
17.5 Engine assembl

17.5.1 Installing the crankshaft
- Position the right section of the engine case in the engine work stand.
- Oil the bearing.
I Engine oil (SAE 1 0W/50) (a p. 214)
Push crankshaft O into the bearing seat.

17 ENGINE 165
17.5.2 Installing the transmission shafts

- Oil the bearing.
- Slide both transmission shafts O into the bearing seats together.
- Mount lock ring@.
17.5.3 Installing the shift forks

- Shift fork O has a smaller inside diameter; mount this in the shift groove of the
main shaft.
- Mount shift fork@ in the lower shift groove of the countershaft.
- Mount shift fork fD in the upper shift groove of the countershaft.
0- - Slide on shift rollers 8.
Tip
Fix the shift rollers in the shift forks with grease.
17.5.4 Installing the shift drum

- Push shift drum O into the bearing seat.
- Put shift forks@ in the shift drum.
Info
Do not misplace the shift rollers.
17 ENGINE 166
17.5.5 Installing the shift rails

- Install shift rail O together with upper spring 8 and the lower spring.
- Install shift rail (D together with upper spring C,.
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.
I Loctite® 5910
- Mount the left section of the engine case. If necessary, strike it lightly with a rub
ber mallet and turn the transmission shafts.
• Info
I Do not use the screws to pull the two sections of the engine case
together.
- Mount screws O but do not tighten yet.

Guideline
I Screw, engine case I M6x55 10 Nm (7.4 lbf ft)
- Mount screws 8 but do not tighten yet.
I I I
Guideline
Screw, engine case M6x65 10 Nm (7.4 lbf ft)
- Mount screws (D and tighten all screws in a crisscross pattern.
Guideline
I Screw, engine case I M6x85 10 Nm (7.4 lbf ft)
- Mount the screw connection of the engine fixing arm.
17 ENGINE 167
17.5.7 Installing the spacer

- Grease the shaft seal ring.
- Mount spacer 0-
17.5.8 Installing the timing chain

- Mount balancer shaft O with the timing chain and timing chain securing guide.
• Info
I If the timing chain was used before, ensure it is running in the correct
direction.
Mount and tighten screw 8.

Guideline
Screw, timing chain M6 10 Nm Loctite® 243 ™
securing guide (7.4 lbf ft)
- Position timing chain guide rail 8.
- Mount and tighten screw C,.
Guideline
Screw, timing chain guide M6 10 Nm Loctite® 243 ™
rail (7.4 lbf ft)
- Position timing chain tensioning rail 0-
- Mount and tighten screw (D.
Guideline
Screw, timing chain ten M8 15 Nm Loctite® 243 ™
sioning rail (11.1 lbf ft)
17.5.9 Installing the primary gear

- Position primary gear 0-
✓ Markings f) and G) are aligned.
- Set the crankshaft to top dead center and lock it with screw 8.
- Mount and tighten nut fD.
Guideline
Nut, primary gear M18LHx1.5 100 Nm Loctite® 243 ™
(73.8 lbf ft)
17 ENGINE 168
17.5.10 Installing the force pump

- Oil the oil pump shaft, internal rotor and external rotor before assembly.
I Engine oil (SAE 10W/50) (a p. 214)
- Position force pump 0-
✓ The rounded side of the force pump faces the engine case.
- Mount the oil pump shaft 8 from the ignition side.
- Mount pin@).
- Position the oil pump cover.

✓ Marking 6) faces upward.
- Mount and tighten screws C,.
Guideline
Screw, oil pump cover MS 6Nm Loctite® 243 ™
(4.4 lbf ft)
- Insert pin 0.
- Position oil pump gear (D.
- Mount washer@.
- Mount lock ring C,.
- Crank the oil pump gear and ensure that it can move easily.
- Mount oil pump idler gear 0 with the washer.

- Mount washers (i).
Mount lock ring 48.
17.5.11 Installing the suction pump

- Insert needle roller O.
17 ENGINE 169
- 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 C,.

- Mount and tighten screws 0.
Guideline
Screw, oil pump cover M5 6Nm Loctite® 243 ™
(4.4 lbf ft)
17.5.12 Installing the locking lever

- Mount locking lever O with the washer, sleeve and spring.
- Mount and tighten screw @.
Guideline
Screw, locking lever M5 6Nm Loctite® 243 ™
(4.4 lbf ft)
17.5.13 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
I The flat areas of the shift drum locating unit are not symmetric.
- Relieve tension from the locking lever.

- Mount and tighten screw (D.
Guideline
Screw, shift drum locating M6 10 Nm Loctite® 243 ™
(7.4 lbf ft)
17 ENGINE 170
17.5.14 Installing the shift shaft

Slide shift shaftO with the washer into the bearing seat.
Push sliding plate 8 away from the shift drum locating unit 8. Insert the shift
shaft all the way.
Let the sliding plate engage in the shift drum locating unit.
- Shift through the transmission.
17.5.15 Installing the outer clutch hub

- Mount collar sleeve O and needle bearing 8.
- Slide the outer clutch hub 8 onto the gearbox main shaft. Turn the oil pump
gear until the gear of the outer clutch hub meshes.
- Slide on washer 8 and inner clutch hub 0-
Position the new lock washer and mount nut Q). Tighten the nut, holding the
inner clutch hub with a special tool.
Guideline
Nut, inner clutch hub M18x1.5 100 Nm Loctite® 243 ™
(73.8 lbf ft)
I Clutch holder (59029003100) (!!:! p. 220)

- Secure the nut with the lock washer.
17 ENGINE 171
17.5.16 Installing the clutch discs

- Thoroughly oil the clutch facing discs.
I Engine oil (SAE 10W/50) (a p. 214)
- Insert the intermediate clutch disc.
Guideline
I Thickness 11 mm (0.04 in)
- Place the clutch facing and intermediate discs into the outer clutch hub.
- Insert the intermediate clutch disc.
Guideline
I Thickness 11 mm (0.04 in)
- Mount pressure piece O.
- Position the pressure cap. Mount screws 8 with the washers and springs.
Tighten the screws in a crisscross pattern.
Guideline
I Screw, clutch spring 10 Nm (7.4 lbf ft)
17.5.17 Installing the clutch cover

Prepare the tool (special screw):
-,1 -
A conventional screw is required.
�I - Cut screw Q to length f).
•
Guideline
e I Screw I M6x70
I Length e I 60 mm (2.36 in)
Cut a slot into the top end of the screw.

304820-10
- Mount and hand-tighten screw 0-
- Put on the clutch cover gasket.
• Info
- Position the clutch cover.
• Info
I Ensure that the shaft seal rings of the water pump and the crankshaft are
not damaged.
- Remove screw O.
17 ENGINE 172
- Mount screws 8 b ut do not tighten yet.

Guideline
IScrew, clutch cover I
M6x25 110Nm(7.4 lbfft)
- Mount screws (D b ut do not tighten yet.
Guideline
IScrew, clutch cover I
M6x45 110Nm(7.4 lbfft)
- Tighten all screws in a crisscross pattern.
Guideline
IScrew, clutch cover 10Nm(7.4 lbfft)
17.5.18 Installing the water pump cover

- Mount the two-part water pump impeller O.
Mount and tighten nut 8.
Guideline
Nut, water-pump wheel M6 5Nm Loctite® 243 ™
(3.7 lbfft)
- Mount the water pump cover with the seal ring.
• Info
- Mount screw (D with the seal ring b ut to not tighten yet.
Guideline
IScrew, water pump cover I
M6x25 I10Nm(7.41bfft)
- Mount screw 8 b ut do not tighten yet.
Guideline
IScrew, water pump cover I M6x25 10Nm(7.4 lbfft)
Guideline
- Tighten screws (D and 8.
Guideline
17.5.19 Installing the starter drive

- Position freewheel gear O.
17 ENGINE 173
- Mount the starter idler gear 8 with the washer.

- Mount lock ring fD.
17.5.20 Installing the rotor and ignition pulse generator

- Ensure that the woodruff key is seated properly. Mount the rotor.
• Info
I To simplify installation, turn the starter idler gear counterclockwise.

Guideline
Rotor screw M10x1 70 Nm Thread, oiled with
(51.6 lbf ft) engine oil/cone
degreased
17.5.21 Installing the piston

- Shift the joint of the piston rings by 120° .
- Place the special tool on the oiled piston. Compress the piston rings using the
special tool.
I Piston ring mounting tool (60029015000) (E.,!1 p. 221)
✓ The piston rings are pushed together all the way.
302642-10
- Position the piston on the cylinder using the special tool.
- Push the piston carefully into the cylinder from above.
Info
The piston rings should not catch or they will be damaged.
303078-10
- Ensure that piston mark O faces the exhaust side.
302641-10
17 ENGINE 174
Apply a thin layer of sealing compound in area G).

I Loctite® 5910
Place the cylinder base gasket on.
Info
Ensure that the dowel pins are seated properly.
Cover the engine case opening with a cloth. Thread the timing chain through the
chain shaft. Mount the piston pin.
• Info
I In order to present them more clearly, the following steps are shown with a
removed piston.
Position the piston pin retainer.
Insert the special tool and press it forcefully to the piston.

Turn the special tool clockwise, thereby pushing the piston pin retainer into the
groove.
I Insertion for piston ring lock (77229030000) (l!ill p. 223)
Ensure that the piston pin retainer is seated properly on both sides.
Remove the cloth.

Keep the timing chain taut. Push the cylinder down carefully and let the dowel
pins engage.
17 ENGINE 175
17.5.22 Installing the cylinder head

- Position cylinder head gasket Q.
• Info
- Put the cylinder head in place.
- Mount nuts @ with the washers and tighten in a crisscross pattern.

Guideline
Nut, cylinder head M10x1.25 Tightening Thread, oiled with
sequence: engine oil/cone
Tighten diag- greased
onally.
1st tightening
stage
10 Nm
(7.4 lbf ft)
2nd tighten-
ing stage
30 Nm
(22.1 lbf ft)
3rd tightening
stage
50 Nm
(36.9 lbf ft)
I Graduated disc (60029010000) (� p. 220)

- Mount and tighten nut 8.
Guideline
Nut, cylinder head M6 10 Nm Lubricated with
(7.4 lbf ft) engine oil
G00485-11
17 ENGINE 176
17.5.23 Installing the camshafts

- Pull up the timing chain and insert intake camshaft O.
- Place the timing chain over the camshaft gear of the intake camshaft.
✓ Markings f) are aligned with the flat areas of the camshaft.
✓ Lock ring G) engages in groove(!).
- Ensure that bleeder@ are seated properly.
- Slip in exhaust camshaft (D.
- Place the timing chain over the camshaft gear and position the camshaft in the
bearing seat.
✓ Markings f) are aligned with the flat areas of the camshaft.
✓ Lock ring G) engages in groove(!).
- Clean all oil nozzles thoroughly and blow out with compressed air.
- Mount the camshaft bearing bridge.
• Info
- Position guide rail C,.

- Mount screws 0 and tighten from the inside to the outside.
Guideline
17.5.24 Checking the valve timing

Condition
Camshaft gears were not loosened.
- Mount the special tool and tension the timing chain.
I Insert, timing chain tensioner (77229035000) (i!!ll p. 224)

- Position special tool O.
I Adjustment bush bridge (77229050044) (i!!ll p. 224)
- Check the valve timing.
The special tool must be in full contact with the flat areas.
If the special tool is not in full contact:
- Take off the special tool.
- Remove the camshaft. (� p. 129)
- Pull the camshaft gears off the camshafts.
- Adjust the valve timing. (� p. 176)
Adjustment bush bridge (77229050044) (� p. 224)
Insert, timing chain tensioner (77229035000) (0 p. 224)
17.5.25 Adjusting the valve timing

Condition
Camshaft gears were loosened.
17 ENGINE 177
- Mount special tool O and tension the timing chain.

I Insert, timing chain tensioner (77229035000) (0 p. 224)
- Remove screws 8.
- Position the special tool.

I Adjustment bush bridge (77229050044) (l!!l p. 224)
✓ The valves are not activated.
✓ The special tool must be in full contact with the flat areas of the cam shafts.
Guideline
Screw, special tool, M7x1 10 Nm Lubricated with
adjustment bush bridge (7.4 lbf ft) engine oil
• Info
I Tighten the screws of the exhaust camshaft first.
- Tighten screws C,.

Guideline
Screw, camshaft drive M12x1 70 Nm Loe-
sprocket (51.6 lbf ft) tite® 243 ™/cone
degreased
- Remove screws (D.

I Adjustment bush bridge (77229050044) (� p. 224)

Guideline
17 ENGINE 178
- Remove special tool O.

I Insert, timing chain tensioner (77229035000) (0 p. 224)
17.5.26 Installing the timing chain tensioner

- Position timing chain tensioner O and insert it with new O-ring @.
- Mount and tighten screw plug CD with the seal ring.

Guideline
I Plug, timing chain tensioner I M24x1.5 I 40 Nm (29.5 lbf ft) I
- Remove screw C,.
- Press the timing chain tensioner toward the timing chain using special tool 0-
1 Release device for timing chain tensioner (61229021000) (0 p. 222)
✓ The timing chain tensioner unlocks.
- Mount and tighten screw C,.
Guideline
Screw, unlocking of timing chain ten M10x1 10 Nm (7.4 lbf ft)
sioner
17.5.27 Checking the valve clearance

- Remove screw O.
- Crank over the engine repeatedly.
17 ENGINE 179
- Position the engine at ignition top dead center.

✓ Markings G on the cylinder head are flush above the flat areas C, of the
camshafts.
- Check the valve clearance at all valves between the camshaft and cam levers.
Guideline
Valve clearance
Intake at: 20 °c (68 °F) I 0.10... 0.15 mm(0.0039... 0.0059 in)
Exhaust at: 20 °C(68 °F) I 0.13... 0.18 mm(0.0051... 0.0071 in)
I Feeler gauge(59029041100)(a p. 220)
If the valve clearance does not meet specifications:
- Adjust the valve clearance.(!l;!l p. 179)
- Mount and tighten screw O with the washer.
Guideline
I Screw plug, crankshaft location 10Nm(7.4 lbf ft)
17.5.28 Adjusting the valve clearance

Main work
- Remove the timing chain tensioner.(� p. 129)
- Remove the camshaft.(a p. 129)
- Raise cam levers O.
- Correct the shims according to the findings from checking the valve clearance.
- Install the camshafts.(a p. 176)
- Install the timing chain tensioner.(!l;!l p. 178)
Finishing work
- Check the valve clearance.(� p. 178)
17.5.29 Installing the starter motor

- Grease the O-ring. Position the starter motor.
- Mount screws O but do not tighten yet.
Guideline
I Screw, starter motor I10Nm(7.41bf ft)
17 ENGINE 180
- Position the gasket.
• Info
- Position the alternator cover.

- Mount and tighten screws @.
Guideline
I Screw, alternator cover 10 Nm (7.4 lbf ft)
- Position torque limiter (D.
- Position the gasket.
• Info
Position the cover.

Mount and tighten screws •.
Guideline
I Screw, cover of torque limiter I M6x50 110 Nm (7.4 lbf ft)
Guideline
I Screw, cover of torque limiter I M6x25 10 Nm (7.4 lbf ft)
- Tighten screws O.
Guideline
I Screw, starter motor 10 Nm (7.4 lbf ft)
17.5.30 Installing the valve cover

- Grease the O-rings and mount the spark plug shaft insert.
17 ENGINE 181
- Apply a thin layer of sealing compound in area 6).

I Loctite® 5910
- Position the valve cover with the gasket.

- Mount and tighten screws O.
Guideline
I Screw, valve cover I 8 Nm (5.9 lbf ft)
17.5.31 Installing the spark plug

- Mount and tighten the spark plug with special tool O.
I
Guideline
Spark plug
I M1 Ox1
1
10... 12 Nm
(7.4 ... 8.9 lbf ft)
I Spark plug wrench (77229172000) (I!!:!! p. 225)
17.5.32 Installing the oil filter

- Tilt the motorcycle to one side and fill the oil filter housing to about ½ 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 8-
Guideline
I Screw, oil filter cover 110 Nm (7.4 lbf ft)
17 ENGINE 182
17.5.33 Installing the oil screen

Mount and tighten screw plug O with the O-ring.
Guideline
I Oil drain plug I M14x1.5 15 Nm (11.1 lbf ft)
- Mount and tighten the oil drain plug fj with the magnet and the new seal ring.
I I
Guideline
I Oil drain plug with magnet I M12x1.5 20 Nm (14.8 lbf ft)
- 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 (D with the O-ring.

Guideline
I Screw plug, oil screen I M20x1.5 15 Nm (11.1 lbf ft)
17.5.34 Installing the spacer

- Grease the shaft seal ring before mounting.
- Position the O-ring. Mount spacer O with the bevel facing inward.
17 ENGINE 183
17.5.35 Installing the clutch push rod

- Mount clutch push rod O.
17.5.36 Removing the engine from the engine assembly stand

- Remove the screw connection from the special tool.
I Engine fixing arm (77229002000) (8 p. 222)
- Remove the engine from the engine assembly stand.
Info
Work with an assistant or a motorized hoist.
18 CLUTCH 184
Checkin /correctin the fluid level of the h draulic clutch
Info
The fluid level rises with increased wear of the clutch lining discs.
- Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
- Remove screws O.
- Remove cover 8 with membrane CD.
- Check the fluid level.
I Fluid level below container rim I 4 mm (0.16 in)
If the fluid level does not meet specifications:
- Correct the fluid level of the hydraulic clutch.
I Brake fluid DOT 4 (!,JI p. 214)

- Position the cover with the membrane. Mount and tighten the screws.
Info
Clean up overflowed or spilt brake fluid immediately with water.
18.2 Changing the hydraulic clutch fluid
Warning
regulations.
- Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
- Remove screws O.
- Remove cover 8 with membrane CD.
- Fill bleeding syringe 8 with the appropriate hydraulic fluid.

Bleed syringe (50329050000) (0 p. 218)
Brake fluid DOT 4 (ll!;! p. 214)
- Mount bleeding syringe 8 on bleeder screw 0 using a fitting hose piece.
- Only loosen bleeder screw 0 on the clutch slave cylinder to the point where fill-
ing is possible.
• Info
Avoid contact between brake fluid and painted parts. Brake fluid attacks
paint!
Use only clean brake fluid from a sealed container!
- Inject the liquid into the system until it escapes from hole (D of the master cylin-
der without bubbles.
- To prevent overflow, drain fluid occasionally from the master cylinder reservoir.
- Remove the bleeding syringe. Mount and tighten screws bleeder screw.
- Correct the fluid level of the hydraulic clutch.
Guideline
I Fluid level below container rim 14 mm (0.16 in)
18 CLUTCH 185
Position the cover with the membrane. Mount and tighten the screws.
19 WATER PUMP, COOLING SYSTEM 186
Water pump O in the engine circulates the coolant.

The pressure resulting from the warming of the cooling system is regulated by a valve
in radiator cap 8. This ensures that operating the vehicle at the specified coolant
temperature will not result in a risk of malfunctions.
1120 °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.
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.
A
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.
1-25 ... -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.
400243-10
Coolant level f) above the radiator 10 mm (0.39 in)
fins
If the coolant level does not match the specified value:
- Correct the coolant level.
I Coolant (� p. 214)
Mount the radiator cap.
Checking the coolant level
Warning
A
Warning
Condition
The engine is cold.
Stand the motorcycle upright on a horizontal surface.
Remove the radiator cap.
Check the coolant level in the radiator.
Coolant level f) above the radiator 10 mm (0.39 in)

fins
If the coolant level does not match the specified value:
- Correct the coolant level.
400243-10 I Coolant (� p. 214)

Mount the radiator cap.
Draining the coolant
Warning
A
Warning
Condition
The engine is cold.
- Position the motorcycle upright.

- Place a suitable container under the water pump cover.
- Remove screw O. Take off radiator cap fj.
- Completely drain the coolant.
- Mount and tighten screw O with a new seal ring.
Guideline
I Screw, water pump cover 10 Nm (7.4 lbf ft)
Refilling coolant
Warning
- Keep coolant out of the reach of children.
- Do not allow coolant to come into contact with the skin, the eyes and clothing.
- 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.
- Make sure that screw O is tightened.

- Position the motorcycle upright.
- Pour coolant in up to measurement 6) above the radiator fins.
Guideline
I Dimension e over the radiator fins 110 mm (0.39 in)
I Coolant I 0.95 I (1 qt.) I Coolant (� p. 214)

- Mount the radiator cap.
- Take a short test ride.
- Check the coolant level. (� p. 187)
20 LUBRICATION SYSTEM 189
20.1 Oil circuit
401052-60
Oil screen
2 Force pump
3 Oil pressure regulator valve
4 Oil filter
5 Oil nozzle for conrod bearing lubrication
6 Oil nozzle for cam lever lubrication
7 Oil nozzle, piston cooling
8 Oil nozzle for alternator cooling
9 Oil nozzle for clutch lubrication
10 Suction pump
11 Oil channel, transmission lubrication
12 Timing chain tensioner
Checking the engine oil level
Info
The engine oil level can be checked when the engine is cold or warm.
Preparatory work
- Stand the motorcycle upright on a horizontal surface.
Condition
The engine is cold.
- Check the engine oil level.
I The engine oil level reaches the middle of sight glass G.

If the engine oil does not reach the middle of the sight glass:
- Add engine oil. (0 p. 192)
Condition
The engine is at operating temperature.
- 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 the middle of the level viewer G and the
upper edge of the level viewer G).
If the engine oil does not reach the middle of the level viewer 6):
- Add engine oil. (a p. 192)
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.
- In the event of scalding, rinse the area affected immediately with lukewarm water.
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.
Info
Do not remove screws 8 on both sides.
- Remove screw plug CD with oil screen e.

- Thoroughly clean the parts and sealing surfaces.
- Position oil screen 8 with the O-rings on 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 CD with the O-ring.

Guideline
I Screw plug, oil screen I M20x1.5 15 Nm (11.1 lbf ft)
- Mount and tighten the oil drain plug O with the magnet and a new seal ring.
I I
Guideline
I Oil drain plug with magnet I M12x1.5 20 Nm (14.8 lbf ft)
C00785-10
- Remove screws 0. Remove the oil filter cover with the 0-ring.
Pull oil filter (s) out of the oil filter housing.

I Circlip pliers reverse (51012011000) (l!!l p. 219)
- Thoroughly clean the parts and sealing surfaces.
- Lay the motorcycle on its side and fill the oil filter housing to about ½ full with
engine oil.
- Fill the oil filter with engine oil and place it in the oil filter housing.
Oil the 0-ring of the oil filter cover and mount it with the oil filter cover @.
- Mount and tighten the screws.
Guideline
I Screw, oil filter cover 10 Nm (7.4 lbf ft)
- Stand the motorcycle upright.
- Remove the oil filler plug @) with the 0-ring from the clutch cover and fill up with
engine oil.
I Engine oil 11.0 I (1.1 qt.) I Engine oil (SAE 10W/50) (l!!l p. 214)
• Info
I Too little engine oil or poor-quality engine oil results in premature wear to
the engine.
m
- Install and tighten the oil filler plug with 0-ring.
Danger
engine.
- Start the engine and check that it is oil-tight.

Finishing work
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.
I Engine oil (SAE 10W/50) (ll!:!l p. 214)
• Info
I For optimal performance of the engine oil, do not mix different types of
engine oil.
If appropriate, change the engine oil.
m
- Install and tighten the oil filler plug with O-ring.
Danger
engine.
- Start the engine and check that it is oil-tight.
Checking the engine oil ressure
Warning
Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden.
- Wear suitable protective clothing and safety gloves.
- In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
regulations.
Main work
- Remove screw O.
I
0
- Position the special tool. Mount and tighten the banjo bolt.
Guideline
I Banjo bolt I M10x1 I 8 Nm (5.9 lbf ft)
I Oil pressure adapter (77329006000) (ll!:!l p. 225)

- Connect the pressure tester to the special tool without the T-plate.
I Pressure tester (61029094000) (llill p. 221)
- Check the engine oil level. (llill p. 189)
401095-01
Danger
engine.
- Start the engine and let it warm up.

- Check the engine oil pressure.
Engine oil pressure
Engine oil temperature: 80 °C 0.35 bar (5.1 psi)
(176 °F)
Engine speed: 1,600 rpm
Engine oil temperature: 80 °c 2.2 bar (32 psi)
(176 °F)
Engine speed: 6,000 rpm
If the measured value is less than the specification:
- Change the oil filter. Check the oil pumps for wear. Check all oil holes for
free flow.
- Switch off the engine.
Warning
Danger of burns Some vehicle components get very hot when the
machine is driven.
- Wear appropriate protective clothing and safety gloves. In case of
burns, rinse immediately with lukewarm water.
- Remove the special tools.

Guideline
Screw, unlocking of timing chain ten M10x1 10 Nm (7.4 lbf ft)
sioner
Finishing work
21 IGNITION SYSTEM 194
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.
0 Ignition coil cylinder 1 pin 2 (-) - Ignition coil cylinder 1 pin 3
Ignition coil
Secondary winding resistance at: 11.075 ... 15.525 kn
1
20 °C (68 °F)
If the displayed value does not correspond to specifications:
- Change the ignition coil.
601750-10
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

1 Resistance at: 20 °c (68 °F) 3.75 ... 6.25 kn
- Change the spark plug connector.
2 601170-10
21.3 Alternator - checking stator winding

Condition
The alternator is disconnected.
Stator winding - checking the resistance
0 Alternator, connector CR pin 1 - Alternator, connector CR pin 1
Alternator
Resistance of stator winding at: 1.19 ... 1.61n
1
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 (-)
I Resistance
If the displayed value does meet specifications:
- Change the stator.
21 IGNITION SYSTEM 195
21.4 Removin ulse generator
-'
Condition
The alternator cover has been removed.
- Remove screw O.
- Remove retaining bracket.
- Remove screw 8.
, � ,I �
- . -. " - Remove cable support sleeve 8 from the alternator cover.
_·., ,
\
.
, .. - Remove the stator and ignition pulse generator from the alternator cover.
2_� <i_--2
306640-10
21.5
- Blow out oil nozzle O with compressed air and check that it is clear.
Guideline
Oil nozzle for alternator M4 2Nm Loctite® 243 ™
cooling (1 .5 lbf ft)
306641-10
- Position the stator and ignition pulse generator in the alternator cover.
Guideline
IScrew, stator I I
4 Nm (3 lbf ft) Loctite® 2701 TM
- Position retaining bracket.
- Mount and tighten screws C,.
Guideline
306640-11 Screw, crankshaft posi M5 6Nm Loctite® 243 ™
tion sensor (4.4 lbf ft)
- Position cable support sleeve C, in the alternator cover.
22 THROTTLE VALVE BODY 196
- Run the engine until warm.

- Set the desired idle speed by turning the idle speed adjusting screw Q.
Guideline
I Idle speed I 2,250... 2,350 rpm
• Info
I Turning counterclockwise lowers the idle speed.
Turning clockwise raises the idle speed.
22.2 Executing the initialization run

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

Guideline
I Coolant temperature I < 25 °C (< 77 °F)
- Let the engine idle until it reaches the specified temperature.
Guideline
I Coolant temperature I 80... 90 °C (176... 194 °F)
• Info
I Do not operate the throttle grip during the initialization process.
- 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.
23 TECHNICAL DATA 197
23.1 Engine
Design 1-cylinder 4-stroke engine, water-cooled
Displacement 349.7 cm3(21.34 cu in)
Stroke 57.5 mm(2.264 in)
Bore 88 mm(3.46 in)
Compression ratio 13,65:1
Idle speed 2,250 ... 2,350 rpm
Control DOHC, four valves controlled via cam lever, drive via timing
chain
Valve diameter, intake 36.3 mm(1.429 in)
Valve diameter, exhaust 29.1 mm(1.146 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) 0.13 ... 0.18 mm(0.0051... 0.0071 in)
Crankshaft bearing 2 cylinder bearings
Conrod bearing Plain bearing
Piston pin bearing Bearing bush
Pistons Forged light alloy
Piston rings 1 compression ring, 1 oil scraper ring
Engine lubrication Pressure circulation lubrication with two Eaton pumps
Primary transmission 24:73
Clutch Multidisc clutch in oil bath/hydraulically activated
Gearbox 5-gear, claw shifted
Transmission ratio
1st gear 14:28
2nd gear 16:26
3rd gear 18:24
4th gear 21:24
5th gear 22:21
Alternator 12V, 66W
Ignition Contactless controlled fully electronic ignition with digital igni-
tion adjustment
Spark plug NGK LMAR9Al-8
Spark plug electrode gap 0.8 mm(0.031 in)
Cooling Water cooling, permanent circulation of coolant by water pump
Starting aid Electric starter
23.2 Engine tolerance, wear limits

Camshaft bearing - sleeve bearing
Radial clearance 0.020 ... 0.054 mm(0.00079... 0.00213 in)
Wear limit 0.065 mm(0.00256 in)
Valve spring
Minimum length of intake valve 41.20 mm(1.622 in)
Minimum length of exhaust valve 41.10 mm(1.6181 in)
Intake 1.40 mm(0.0551 in)
Exhaust 1.40 mm(0.0551 in)
Valve - run-out
At the valve plate s: 0.05 mm(S: 0.002 in)
At the valve stem s: 0.05 mm(S: 0.002 in)
Valve spring seat - thickness 1.40... 1.60 mm(0.0551... 0.063 in)
Cylinder/cylinder head - distortion of sealing area :5 0.10 mm (:5 0.0039 in)

Piston - diameter
Size I 87.955 ... 87.965 mm (3.46279 ... 3.46318 in)
Size II 87.965... 87.975 mm (3.46318 ... 3.46358 in)
Cylinder - drill hole diameter
Size I 88.000... 88.012 mm (3.46456 ... 3.46503 in)
Size II 88.012... 88.025 mm (3.46503 ... 3.46554 in)
Piston/cylinder - mounting clearance
Size I 0.035 ... 0.057 mm (0.00138 ... 0.00224 in)
Size II 0.037 ... 0.060 mm (0.00146... 0.00236 in)
Piston ring - end gap
Compression ring :,; 0.40 mm (:5 0.0157 in)
Oil scraper ring :5 0.80 mm (:5 0.0315 in)
Connecting rod - axial play of lower conrod bearing 0.20 ... 0.45 mm (0.0079 ... 0.0177 in)
Crankshaft - run-out at bearing pin :5 0.03 mm (:5 0.0012 in)
Crankshaft - axial play 0.50... 0.60 mm (0.0197 ... 0.0236 in)
Clutch facing discs - thickness of total package ;:: 26.4 mm (;,: 1.039 in)
Clutch spring - length ;:: 38.5 mm (;,: 1.516 in)
Contact surface of clutch facing discs in outer clutch hub :5 0.5 mm (:5 0.02 in)
Oil pressure regulator valve
Minimum length of pressure spring 23.5 mm (0.925 in)
Shift shaft - sliding plate/shift quadrant clearance 0.40 ... 0.80 mm (0.0157... 0.0315 in)
23.3 Engine ti htening tor ues

Nozzle, crank chamber ventilation M4 2 Nm (1.5 lbf ft) Loctite® 243 ™
Oil nozzle for alternator cooling M4 2 Nm (1.5 lbf ft) Loctite® 243 ™
Oil nozzle for balancer shaft lubrica- M4 2 Nm (1.5 lbf ft) Loctite® 243 ™
tion
Oil nozzle for conrod bearing lubrica- M4 2 Nm (1.5 lbf ft) Loctite® 243 ™
tion
Screw, oil nozzle for piston cooling M4 2 Nm (1.5 lbf ft) Loctite® 243 ™
Screw, stator M4 4 Nm (3 lbf ft) Loctite® 2701 TM
Locking screw for bearing M5 6 Nm (4.4 lbf ft) Loctite® 243 ™
Oil channel screw plug in alternator M5 1.2 Nm (0.89 lbf ft) Loctite® 648 ™
cover
Oil nozzle for cam lever lubrication M5 3 Nm (2.2 lbf ft) Loctite® 243 ™
Oil nozzle for clutch lubrication M5 6 Nm (4.4 lbf ft) Loctite® 243 ™
Oil nozzle, piston cooling M5 2 Nm (1.5 lbf ft) Loctite® 243 ™
Screw, bearing bolt, oil pump idler M5 6 Nm (4.4 lbf ft) Loctite® 243 ™
gear
Screw, crankshaft position sensor M5 6 Nm (4.4 lbf ft) Loctite® 243 ™
Screw, locking lever M5 6 Nm (4.4 lbf ft) Loctite® 243 ™
Screw, oil pump cover M5 6 Nm (4.4 lbf ft) Loctite® 243 ™
Nut, cylinder head M6 10 Nm (7.4 lbf ft) Lubricated with engine oil
Nut, water-pump wheel M6 5 Nm (3.7 lbf ft) Loctite® 243 ™
Screw, alternator cover M6 10 Nm (7.4 lbf ft) -
Screw, clutch cover M6 10 Nm (7.4 lbf ft) -
Screw, clutch slave cylinder M6 10 Nm (7.4 lbf ft) -
Screw, clutch spring M6 10 Nm (7.4 lbf ft) -
Screw, cover of torque limiter M6 10 Nm (7.4 lbf ft) -
Screw, engine case M6 10 Nm (7.4 lbf ft) -
Screw, exhaustflange M6 10 Nm (7.4 lbfft) Loctite® 243 ™

Screw, oilfilter cover M6 10 Nm (7.4 lbfft) -
Screw, shift drum locating M6 10 Nm (7.4 lbfft) Loctite® 243 ™
Screw, shift lever M6 14 Nm (10.3 lbfft) Loctite® 243 ™
Screw, starter motor M6 10 Nm (7.4 lbfft) -
Screw, timing chain guide rail M6 10 Nm (7.4 lbfft) Loctite® 243 ™
Screw, timing chain securing guide M6 10 Nm (7.4 lbfft) Loctite® 243 ™
Screw, valve cover M6 8 Nm (5.9 lbfft) -
Screw, water pump cover M6 10 Nm (7.4 lbfft) -
Stud, cylinder head M6 10 Nm (7.4 lbfft) -
Screw, camshaft b earing b ridge M7x1 14 Nm (10.3 lbfft) Lub ricated with engine oil
Screw plug, crankshaft location MB 10 Nm (7.4 lbfft) -
Screw, timing chain tensioning rail MB 15 Nm (11.1 lbfft) Loctite® 243 ™
Screw, engine sprocket M10 60 Nm (44.3 lbfft) Loctite® 2701 TM
Plug, oil channel M10x1 15 Nm (11.1 lbfft) Loctite® 243 ™
Rotor screw M10x1 70 Nm (51.6 lbfft) Thread, oiled with engine
oil/cone degreased
Screw plug, cam lever axis M10x1 10 Nm (7.4 lbfft) -
Screw, unlocking of timing chain ten- M10x1 10 Nm (7.4 lbfft) -
sioner
Spark plug M10x1 10 ... 12 Nm (7.4... 8.9 lbfft) -
Nut, cylinder head M10x1.25 Tightening sequence: Thread, oiled with engine
Tighten diagonally. oil/cone greased
1st tightening stage
10 Nm (7.4 lbfft)
2nd tightening stage
30 Nm (22.1 lbfft)
3rd tightening stage
50 Nm (36.9 lbfft)
Stud, cylinder head M10x1.25 20 Nm (14.8 lbfft) Loctite® 243 ™
Screw, camshaft drive sprocket M12x1 70 Nm (51.6 lbfft) Loctite® 243 ™ /cone
degreased
Engine coolant temperature sensor M12x1.5 12 Nm (8.9 lbfft) -
Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbfft) -
Plug, oil pressure regulator valve M12x1.5 20 Nm (14.8 lbfft) -
Oil drain plug M14x1.5 15 Nm (11.1 lbfft) -
Nut, inner clutch hub M18x1.5 100 Nm (73.8 lbfft) Loctite® 243 ™
Nut, primary gear M18LHx1.5 100 Nm (73.8 lbfft) Loctite® 243 ™
Screw plug, oil screen M20x1.5 15 Nm (11.1 lbfft) -
Plug, timing chain tensioner M24x1.5 40 Nm (29.5 lbfft) -
Screw, alternator cover M24x1.5 18 Nm (13.3 lbfft) -
23.4 Ca acities
23.4.1 Engine oil
I Engine oil 11.0 I (1.1 qt.) I Engine oil (SAE 10W/50) (a p. 214)
23.4.2 Coolant
I Coolant I 0.95 I (1 qt.) I Coolant (a p. 214)
23.4.3 Fuel
Totalfuel tank capacity, 7.5 I (1.98 US gal) Super unleaded (ROZ 95/RON 95/PON 91) (0 p. 214)
approx.
23.5 Chassis
Frame Central tube frame made of chrome molybdenum steel tubing
Fork WP Suspension Up Side Down 4860 MXMA 4CS
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 14:50
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)
Seat height, unloaded 992 mm (39.06 in)
Ground clearance, unloaded 375 mm (14.76 in)
Weight without fuel, approx. 106.4 kg (234.6 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.)
23.6 Electrical s�stem

Battery YTX5L-BS Battery voltage: 12 V
Nominal capacity: 4 Ah
Maintenance-free
Fuse 58011109110 10 A
Fl warning lamp LED
23.7 Tires
Front tires Rear tires
80/100- 21 51M TT 110/90- 19 62M 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
23.8 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 lb/in)
Weight of rider: 75 ... 85 kg (165 ... 187 lb.) 4.8 N/mm (27.4 lb/in)
Weight of rider: 85... 95 kg (187... 209 lb.) 5.0 N/mm (28.6 lb/in)
Fork length 940 mm (37.01 in)
Air chamber length 68 mm (2.68 in)
I Oil capacity per fork leg I 665 ml (22.48 fl. oz.) I Fork oil (SAE 4) (48601166S1) (l!!l p. 214)
23.9 Shock absorber

Shock absorber part number 18.18.70.57
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 preload 8 mm (0.31 in)
Spring rate
Weight of rider: 65 ... 75 kg (143 ... 165 lb.) 54 N/mm (308 lb/in)
Spring length 260 mm (10.24 in)
Gas pressure 10 bar (145 psi)
Static sag 30 mm (1.18 in)
Riding sag 100 mm (3.94 in)
Fitted length 490 mm (19.29 in)
I Shock absorber oil I Shock absorber fluid (SAE 2.5) (50180751S1) (l!!l p. 214)
23.10 Chassis tightening tor ues

Screw, pressure regulator EJOT PT® K60x25-Z 3 Nm (2.2 lbf ft) -
Spoke nipple, front wheel M4.5 5... 6 Nm (3.7 ... 4.4 lbf ft) -
Spoke nipple, rear wheel M4.5 5... 6 Nm (3.7... 4.4 lbf ft) -
Screw, battery terminal M5 2.5 Nm (1.84 lbf ft) -
Screw, intake air temperature sensor M5 2 Nm (1.5 lbf ft) -
Screw, shock absorber adjusting ring M5 5 Nm (3.7 lbf ft) -
Remaining nuts, chassis M6 10 Nm (7.4 lbf ft) -
Remaining screws, chassis M6 10 Nm (7.4 lbf ft) -
Screw, ball joint of push rod on foot M6 10 Nm (7.4 lbf ft) Loctite® 243 ™
brake cylinder
Screw, chain sliding guard M6 6 Nm (4.4 lbf ft) Loctite® 243 ™
Screw, electric starter cable connec- M6 4 Nm (3 lbf ft) -
tion
Screw, front brake disc M6 14 Nm (10.3 lbf ft) Loctite® 243 ™
Screw, rear brake disc M6 14 Nm (10.3 lbf ft) Loctite® 243 ™
Screw, throttle grip M6 5 Nm (3.7 lbf ft) -
Fuel connection on fuel tank M8 10 Nm (7.4 lbf ft) -
Nut, foot brake lever stop M8 20 Nm (14.8 lbf ft) -
Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft) Loctite® 2701 ™
Nut, rim lock M8 12 Nm (8.9 lbf ft) -
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft) -
Screw, chain sliding piece M8 15 Nm (11.1 lbf ft) -
Screw, engine brace M8 33 Nm (24.3 lbf ft) Loctite® 2701 TM
Screw, fork stub M8 15 Nm (11.1 lbf ft) -
Screw, front brake caliper M8 25 Nm (18.4 lbf ft) Loctite® 243 ™
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) -
Screw, manifold holder M8 15 Nm (11.1 lbf ft) -
Screw, subframe M8 30 Nm (22.1 lbf ft) Loctite® 2701 TM
Screw, top steering stem M8 17 Nm (12.5 lbf ft) Loctite® 243 ™
Screw, top triple clamp M8 17 Nm (12.5 lbf ft) -
Engine carrying screw M10 60 Nm (44.3 lbf ft) -
Screw, bottom shock absorber M10 60 Nm (44.3 lbf ft) Loctite® 2701 TM
Screw, handlebar support M10 40 Nm (29.5 lbf ft) Loctite® 243 ™
Screw, top shock absorber M10 60 Nm (44.3 lbf ft) Loctite® 2701 TM
Nut, fuel pump M12 15 Nm (11.1 lbf ft) -
Nut, frame to linkage lever M14x1.5 80 Nm (59 lbf ft) -
Nut, linkage lever on swingarm M14x1.5 80 Nm (59 lbf ft) -
Nut, linkage lever to angle lever M14x1.5 80 Nm (59 lbf ft) -
Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) -
Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft) -
Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft) -
Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) -
Screw-in nozzles, cooling system M20x1.5 12 Nm (8.9 lbf ft) Loctite® 243 ™
24 CLEANING 203
24.1 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.
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.
1///11111111111111� 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.
401061-01
After rinsing the motorcycle with a gentle spray of water, allow it to dry
thoroughly.
Remove the plug from the exhaust system.
Warning
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. 93)
Treat bare metal parts (except for brake discs and the exhaust system) with a
corrosion inhibitor.
I Preserving materials for paints, metal and rubber (0 p. 216)
Treat all plastic parts and powder-coated parts with a mild cleaning and care
agent.
25 STORAGE 204
Storage
Warning
Info
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.(I!!:! p. 203)
1111 ►
Change the engine oil and oil filter, clean the oil screen.(I!!:! p. 190)
Check the antifreeze and coolant level.(I!!:! p. 186)
Check the tire air pressure.(0 p. 84)
Remove the battery.(0 p. 98)
401058-01
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 the lift stand.(� 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.
25.2 Prer,aring for use after storage

Install the battery.(� p. 99)
Remove the motorcycle from the lift stand.(I!!:! p. 10)
Perform checks and maintenance work when preparing the vehicle for use.
Make a test ride.
401059-01
26 SERVICE SCHEDULE 205
26.1 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 diagnostics tool. 0 • I • •
Check and charge the battery. I I • I • •
Check the front brake linings.(l!!ll p. 103) I I • I • •
Check the rear brake linings.(l!!ll p. 108) I I • I • •
Check the brake discs.(� p. 84) I I • I • •
Check the brake lines for damage and leakage. I I • I • •
Check the rear brake fluid level.(� p. 111) I I • I • •
Check the free travel of the foot brake lever.(� p. 110) I I • I• •
Check the frame and swingarm. I I • I• •
Check the swingarm bearing. I I I •
Check the heim joints at the top of the shock absorber. I I • I • •
Check the shock absorber linkage.(� p. 45) I
• I I
• •
Check the tire condition.(l!!ll p. 84) • I
0 • •
Check the tire air pressure.(� p. 84) • I
0 • •
Check the wheel bearing for play. • I • •
• I • •
I I
Check the wheel hubs.
Check the rim run-out. • I
0 • •
Check the spoke tension.(� p. 85) • I
0 • •
Check the chain, rear sprocket, engine sprocket, and chain guide.(� p. 91) • I• •
Check the chain tension.(� p. 90) 0 • I• •
Grease all moving parts(e.g., hand lever, chain, ...) and check for smooth operation. • I• •
I I • I• •
I I
Check/correct the fluid level of the hydraulic clutch.(� p. 184)
Check the brake fluid level of the front brake.(� p. 105) I I • I• •
Check the free travel of the hand brake lever.(� p. 104) • I• •
Check the steering head bearing play.(l!!ll p. 33) 0 • I• •
Check the valve clearance. 0 I •
Check the clutch. I •
I •
I I
I I
Change the shaft seal rings of the water pump.
Change the engine oil and oil filter, clean the oil screen.(l!!ll p. 190) 0 • I • •
Check all hoses(e. g. fuel, cooling, bleeding, drainage) and sleeves for tearing, leaks and incorrect routing. 0 • I • •
Check the antifreeze and coolant level.(� p. 186) 0 • I • •
Check the cables for damage and routing without sharp bends. • I • •
Check that the cables are undamaged, routed without sharp bends and set correctly. 0 • I • •
Clean the air filter and air filter box.(� p. 71) • I • •
Change the glass fiber yarn filling of the main silencer.(� p. 68) I•
Check the screws and nuts for tightness. 0 • I• •
Change the fuel screen.(l!!ll p. 81) 0 • I• •
Check the fuel pressure.(� p. 75) • I• •
Check idle. 0 • I• •
Final check: Check the vehicle for safe operation and take a test ride. 0 • I• •
Read out the fault memory after the test ride using the Husqvarna Motorcycles diagnostics tool. 0 • I• •
Make the service entry in Husqvarna Dealer.net and in the service booklet. 0 • I• •
o One-time interval
• Periodic interval
26 SERVICE SCHEDULE 206
26.2 Service work as additional order

Annually
Every 50 operating hours - corresponds to about 350 liters of fuel (92.5 US gal)
II
Once after 20 operating hours
Once after 10 operating hours I
Change the front brake fluid.(� p. 107) I I ••
Change the rear brake fluid.(� p. 112) I I I I I
Change the hydraulic clutch fluid.(� p. 184) I I I I I ••
Grease the steering head bearing.(� p. 31) I I
I I I
Perform a fork service.(� p. 15) 0
• I I
Service the shock absorber.(a p. 47) 0
•I I
I I•
I
Change the spark plug and spark plug connector. I I I
Change the piston. I I I I • I •
Check/measure the cylinder. I I I I • I •
Check the cylinder head. I I I I • I •
Change the valves, valve springs and valve spring seats. I I I I I•
Check the camshaft and cam lever. I I I I • I•
Change the connecting rod, conrod bearing, and crank pin. I I I I I•
Check the transmission and shift mechanism. I I I I I •
Check the oil pressure regulator valve. I I I I I •
Change the suction pump. I I I I I•
Check the pressure pump and lubrication system. I I I I I•
Replace the timing chain. I I I I I•
Check the timing assembly. I I I I • I •
Change all engine bearings. I I I I I •
o One-time interval
• Periodic interval
207
�"
' ,
CII I 11 l j 4 0 0
""
I
(\J
I
(\J
-©
11
l�
-X16
II I I II ,�
1 l
1 {"
j'
l5 ::0 ::0 � � ::0 ::0 ls�
•
l X7
l.x19 IC
FC/2 'iBR/4
N
N
EB/4
�S/2
�s,K/4
-TI0nt1@·�• ·<WB
N
-C10 -S21 -M10 L:n-J·G10�

G]
�1-1 �1AP/6 E-1 ,,!:!, U w u@
1 --..
_ 1
-X295
i l"' r·- -
- MBIK/4
I
-1 AS/2
If
- � EB/4
- FC/2 3
�BR/4 -X17 EZ/ -X1
1-X7 -X19 -X18
i
1
.co
l
� � �0
� 1
<cc
l ;
l5
'5
j j
-X302
<-
C, I
-cc-
C,
z
('I)
0
....
�---------------------------------------------------------�-----+-------l>a /2.F1
�----------------------------------------------------------------__,.>-----l>b /2.F1
ml
G)
� if 1F
.... FC 350 2014-2015

1/3
� ....: Hu�rna·
C\I C\I
27 WIRING DIAGRAM 209
Components:
A11 EFI control unit
C10 Capacitor
G10 Battery
G20 Alternator
K10 Starter relay with main fuse
K30 Power relay
M10 Starter motor
T20 Voltage regulator
S21 Electric starter button
X295 Diagnostics connector
I I I I I
.. . , I
0 1 2 3 4 5 6 7 8
""
(\J
"'�
I
� � (\J
-©
w,,�
A /3.A1 A
l
'
loma
i 1
, @I @I
- o D "'
�
-X16 �
-X16 -X16 -X16 -X16 -X16
I
m I
t ��i � 9'
:0 1 DD
I
B B
I/
-
I
�
I I
� I
t l�� 9'
1 9'
11..
:0 ii
C j-xs -X2 C
.,,ru
�" �"
-BF/1 NCX/2
(; I/ - N AT/2 j
NDQ/2 M
GA/3
-BA/1 NCW/2
--
""®
-S20�- ·'30 -P25
� �
:::t 0 �
-X295 �
�N � AP/6 -X301
E-1 r,7
�-
\n
�-
-CW/2
W M
D -CX/2 -X3 -XS D
-X2 D G
i r
l
•
<cc
:0 0 0 0 DD D
- -X300 �
<-
C,
E E
C
-cc-
C,
z
('I)
0
"'
G)
- /1.FB a.
/1.FB b.
�
g,.
� 0. F F
"' ® FC 350 2014-2015 I

�
C\I "' Hu5<Mlrna'
1 2 I 3 I 4 5 I 6 I 7 I 8
I 2/3
Components:
M13 Fuel pump
M51 Injection valve (cylinder 1)
P25 Fl warning lamp (MIL)
R30 CAN bus terminating resistor
S20 Kill switch
X295 Diagnostics connector
,..
n
.. . ,
('II 1 2 3 4 5 6 7 8
co
0
('II
"" I
(\J
0
I
Al IA
(\J
�•
-©
°'� ° ' "'
i-X16 i-X16
° '�
i-X16
l�
4 ii ii '1 tj
i .,,,,�
•1DTI� iDTI� , or,� ,me iome
---l
-X16 -X16 -X16 ,-X16 -X16 .-X16 -X16
I--
sl
�
I
-9
'5 il.
I
I l
I
� %
I
.I [
I
"
I
'5
I
il
I Is
i:: {·1 ;·1

�"
�
t, t
-9
'5 il.
+M/3
1.x1s
H:
l.x13
i
t11 -X10
J;: ..,,m
I_
.,,.
e
X6 tv12
{om +P/6 {cM/2
�
·
M
�" LtiJ �" �

'
_,,, l+J
f
{AM/3
6
f {o�
3
5
{AX/2 f {AP/6
4 {cM/2
I( (
( (
�DV/2 -X12
X13
:E
·
1
<cc
I 1
_5::c _5::c '5 ::0I .5 il
<-
C,
-cc-
C,
z ....o
('I)
('I)
, 1-
1·
G)
�
C\I
('I)
�
Hu�rna'
®
T
FC 350 2014-2015
T T T T
1 T
r 3/3
Components:
810 Throttle position sensor circuit A
812 Intake air temperature sensor
821 Engine coolant temperature sensor (cylinder 1)
826 Rollover sensor
837 Crankshaft position sensor
841 Manifold absolute pressure sensor (cylinder 1)
R51 Ignition coil (cylinder 1)
S51 Map switch for ride mode (optional)
S55 Map-Select switch (optional)
Cable colors:
bl Black
br Brown
bu Blue
gn Green
gr Gray
lbu Light blue
or Orange
pk Pink
pu Violet
rd Red
wh White
ye Yellow
28 SUBSTANCES 214
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(a p. 230)
- SAE(� p. 230)(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.
I Synthetic engine oil
Bel-Ray®
- Works Thumper Racing Synthetic Ester 4T
Fork oil SAE 4 48601166S1

- SAE(a p. 230)(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 50180751S1

- SAE(I!!:! p. 230)(SAE 2.5)
Guideline
- Use only oils that comply with the specified standards(see specifications on the container) and that exhibit the corresponding
properties.
Su�er 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 % (E10 fuel) is safe to use.
Info
Do not use fuel containing methanol(e. g. M15, M85, M100) or more than 10 % ethanol(e. g. E15, E25, E85, E100).
29 AUXILIARY SUBSTANCES 215
Air filter cleaning agent

Bel-Ray®
- Foam Filter Cleaner & Degreaser
Hi h viscosity rease
SKF®
- LGHB2
rease
Bel-Ray®
- Waterproof Grease
Lubricant (T158)
Lubcon®
- Turmogrease® PP 300
Lubricant (T511)
Lubcon®
- Turmsilon® GTI 300 P
Lubricant (T625)
Molykote®
- 33 Medium
Lubricant (I152)
Bel-Ray®
- Molylube® Anti-Seize
Lubricant (I159)
Bel-Ray®
- MC-11®
Offroad chain s�ra}'

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

Bel-Ray®
- Foam Filter Oil
29 AUXILIARY SUBSTANCES 216
Preserving materials for aints, metal and rubber

Bel-Ray®
- Silicone Detailer & Protectant Spray
Universal oil s ray

Bel-Ray®
- 6 in 1
30 SPECIAL TOOLS 217
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
Art. no.: 00029095052
H01065-01
Batte rofessional CH
Art. no.: 00029095053
H01065-01
Extractor
Art. no.: 46129021000
46129021000
H01519-01
Spring hook
Art. no.: 50305017000
50305017000
H00973-01
Bleed s�ringe
Art. no.: 50329050000
50329050000
H00565-01
Circli liers reverse

Art. no.: 51012011000
51012011000
H00572-01
Lift stand
Art. no.: 54829055000
54829055000
H00974-01
Extractor
Art. no.: 58012009000
58012009000
H00592-01
Tool for inner bearing race

Art. no.: 58429037037
58429037037
H00596-01
Torgue wrench with various accessories in set

Art. no.: 58429094000
58429094000
H00606-01
Clutch holder
Art. no.: 59029003100
59029003100
H00609-01
Valve s
Art. no.: 59029019000
2x£
59029019000
H00610-01
Feeler
Art. no.: 59029041100
c:;?7
59029041100
H00616-01
Graduated disc
Art. no.: 60029010000
2x£
60029010000
H00625-01
Plastigauge clearance gauge

Art. no.: 60029012000
60029012000
H00627-01
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£
D61029094000
H00660-01
Engine assembly stand

Art. no.: 61229001000
61229001000
H00662-01
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
Extractor, camshaft gear

Art. no.: 77229001044
77229001044
H00747-01
Engine fixing arm

Art. no.: 77229002000
2x£
�
77229002000
H00748-01
Insert for crankshaft tool

Art. no.: 77229008000
®B
77229008000
H00750-01
Extrude late, base

Art. no.: 77229009000
77229009000
H00751-01
Pliers for valve stem seals

Art. no.: 77229010000
77229010000
H00752-01
Limit plug gauge

Art. no.: 77229026000
77229026000
H00753-01
Insertion for �iston ring lock

Art. no.: 77229030000
77229030000
H00754-01
Protection ca
Art. no.: 77229031000
77229031000
H00755-01
Art. no.: 77229032000
77229032000
H00756-01
Insert, timin chain tensioner

Art. no.: 77229035000
77229035000
H00757-01
Puller
Art. no.: 77229048000
77229048000
H00758-01
Adjustment bush bridge

Art. no.: 77229050044
2x&.£
77229050044
H00759-01
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
Hook wrench
Art. no.: T106S
T106S
H00841-01
De�th micrometer
Art. no.: T107S
T107S
H00842-01
Pin
Art. no.: T120
T120
H00844-01
Mountin sleeve
Art. no.: T1204
T1204
H00878-01
Calibration pin
Art. no.: T1205
T1205
H00879-01
Pressing tool
.& Art. no.: T1206
T1206
H00880-01
Pressing tool
.&.& Art. no.: T1207S
��
T1207S
H00881-01
Mounting sleeve
Art. no.: T1215
T1215
H00886-01
Disassembl tool
Art. no.: T1216
CJ T1216
H00887-01
Vacuum pump
Art. no.: T1240S
�
T1240S
H00890-01
Protecting sleeve
Art. no.: T1401
6Y T1401
H00894-01
Clam�ing 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
Clampin 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
Assembl tool
Art. no.: T150S
T150S
H00852-01
Art. no.: T170S1

2x.&.3x.£.
T170S1
H00855-01
31 STANDARDS 230
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. 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 231
cleaning ................................. 93
'A
Chain guide
'Accessories ................................. 8 checking ................................. 91
'Air filter Chain tension
cleaning ................................. 71 adjusting ................................. 91
Installing ................................. 70 checking ................................. 90
removing ................................ 70
Charging voltage
'Air filter box checking ................................ 100
cleaning ................................. 71
Chassis number .............................. 9
sealing .................................. 71
Cleaning .................................. 203
'Air filter box lid
Clutch
installing ................................. 70
checking/correcting the fluid level .............. 184
removing ................................ 70
fluid, changing ............................ 184
'Alternator
Clutch lever
stator winding, checking 194
basic position, adjusting ...................... 36
'Antifreeze
Compression damping
checking ................................ 186
fork, adjusting ............................. 12
'Auxiliary substances ........................... 8
B shock absorber, adjusting ..................... 40
Battery Compression damping, low-speed
installing ................................. 99 shock absorber, adjusting ..................... 40
recharging ............................... 99 Coolant
removing ................................ 98 antifreeze and coolant level, checking 186
Brake disc checking the level 187
front brake, installing ........................ 87 draining ................................ 187
front brake, removing ........................ 87 refilling ................................. 188
rear brake, installing ......................... 90 Cooling system ............................. 186
rear brake, removing 90 Cylinder - Nikasil® coating ..................... 146
Brake discs
D
checking ................................. 84
Drivetrain kit
Brake fluid
changing ................................ 94
front brake, adding ......................... 106
front brake, changing ....................... 107 E
rear brake, adding ......................... 111 Engine
rear brake, changing 112 installing 120
Brake fluid level removing 115
front brake, checking 105 Engine - work on individual parts
rear brake, checking ........................ 111 cam levers, checking ....................... 152
Brake linings camshaft bearing, changing .................. 148
front brake, checking ....................... 103 camshafts, checking 149
of front brake, changing ..................... 103 clutch cover ............................. 140
of rear brake, changing ...................... 108 clutch, checking .......................... 157
rear brake, checking ........................ 108 connecting rod, conrod bearing and crank pin, changing 143
countershaft, assembling .................... 163
C
countershaft, disassembly 161
Capacitor crankshaft bearing inner race, installing 144
checking 101 crankshaft bearing inner race, removing .......... 143
Capacity crankshaft end play, measuring ................ 145
coolant .............................. 188, 199 crankshaft run-out, checking at bearing pin ........ 144
Engine oil ........................ 125, 191, 199 cylinder - Nikasil® coating ................... 146
fuel ................................... 199 cylinder head, checking ..................... 152
Cartridge cylinder, checking/measuring ................. 146
fork legs, assembling ........................ 26 drive wheel of balancer shaft, removing .......... 145
fork legs, disassembling .................... 18-19 electric starter drive, checking ................. 155
freewheel, checking 153
Chain
freewheel, installing ........................ 154
checking ................................. 91
INDEX 232
freewheel, removing ........................ 154 valve cover, installing ....................... 180

ignition pulse generator, installing .............. 195 valve timing, adjusting ...................... 176
ignition pulse generator, removing .............. 195 valve timing, checking 176
left engine case section 139 water pump cover, installing 172
lubrication system, checking .................. 142 Engine disassembly
main shaft, assembling ...................... 162 camshaft, removing ........................ 129
main shaft, disassembling .................... 160 clutch cover, removing ...................... 133
oil pressure regulator valve, checking ............ 141 clutch discs, removing ...................... 133
piston ring end gap, checking ................. 148 clutch push rod, removing .................... 126
piston, checking/measuring 147 crankshaft, removing ....................... 138
piston/cylinder, mounting clearance measuring ..... 147 cylinder head, removing ..................... 130
pivot points of camshafts, checking ............. 149 draining the engine oil ...................... 126
right engine case section .................... 138 engine case, left, removing ................... 136
shift mechanism, checking ................... 159 engine, positioning at ignition top dead center ...... 128
shift shaft, preassembling .................... 160 force pump, removing 134
stator, installing ........................... 195 locking lever, removing ...................... 134
stator, removing .......................... 195 oil filter, removing ......................... 127
timing assembly, checking ................... 156 outer clutch hub, removing ................... 133
timing chain tensioner, preparing for installation 157 piston, removing .......................... 130
transmission, checking ...................... 161 preparations ............................. 125
valve spring seat, checking ................... 151 primary gear, removing ...................... 135
valve springs, checking 151 rotor, removing ........................... 131
valves, checking 151 shift drum locating unit, removing .............. 134
valves, installing 152 shift drum, removing 137
valves, removing 150 shift forks, removing 137
Engine - work on the individual parts shift rails, removing 137
drive wheel of the balancer shaft, installing 146 shift shaft, removing ........................ 134
Engine assembly spacer, removing ....................... 126, 136
camshafts, installing ........................ 176 spark plug, removing ....................... 127
clutch cover, installing ...................... 171 starter drive, removing ...................... 131
clutch discs, installing ...................... 171 starter motor, removing 128
clutch push rod, installing .................... 183 suction pump, removing ..................... 131
crankshaft, installing ........................ 164 timing chain tensioner, removing ............... 129
cylinder head, installing 175 timing chain, removing ...................... 135
engine, removing from the engine assembly stand ... 183 transmission shafts, removing ................. 137
force pump, installing ....................... 168 valve cover, removing ....................... 127
left engine case, installing .................... 166 water pump impeller, removing ................ 132
locking lever, installing ...................... 169 Engine number ............................... 9
oil filter, installing .......................... 181 Engine oil
oil screen, installing ........................ 182 adding ................................. 192
outer clutch hub, installing ................... 170 changing 190
piston, installing ........................... 173
Engine oil level
primary gear, installing ...................... 167
checking ................................ 189
rotor, installing ............................ 173
shift drum locating unit, installing ............... 169 Engine oil pressure
shift drum, installing 165 checking ................................ 192
shift forks, installing ........................ 165 Engine sprocket
shift rails, installing ......................... 166 checking ................................. 91
shift shaft, installing ........................ 170 F
spacer, installing ....................... 167, 182 Figures ..................................... 8
spark plug, installing ....................... 181
Filler cap
starter drive, installing ...................... 172
closing .................................. 72
starter motor, installing ...................... 179
opening ................................. 72
suction pump, installing ..................... 168
timing chain tensioner, installing ............... 178 Foot brake lever
timing chain, installing ...................... 167 basic position, adjusting ..................... 110
transmission shafts, installing ................. 165 free travel, checking 110
valve clearance, adjusting 179 Fork legs
valve clearance, checking .................... 178 assembling ............................... 27
INDEX 233
bleeding ................................. 12
cartridge, assembling ........................ 26
Idle speed
cartridge, disassembling .................... 18-19
adjusting 196
checking ................................. 22
compression damping, adjusting ................ 12 Ignition coil
disassembling ............................. 15 secondary winding, checking 194
dust boots, cleaning ......................... 13 Implied warranty .............................. 8
fork service, performing ...................... 15 Initialization run
hydrostop unit, assembling .................... 24 executing ............................... 196
hydrostop unit, disassembling .................. 21
L
installing ................................. 14
piston rod, assembling ....................... 25 Lower triple clamp
piston rod, disassembling ..................... 20 installing ................................. 32
rebound damping, adjusting ................... 12 removing ................................ 31
removing ................................ 13 M
seal ring retainer, assembling .................. 23
Main fuse
seal ring retainer, disassembling ................ 22
changing ................................ 98
spring, removing ........................... 17
Main silencer
Fork part number ............................. 9
glass fiber yarn filling, changing ................. 68
Fork protector installing ................................. 68
installing ................................. 15 removing ................................ 68
removing ................................ 14
Manifold
Fork service, performing ....................... 15 installing ................................. 67
Frame removing ................................ 67
checking ................................. 39 Motorcycle
Front fender cleaning ................................ 203
installing ................................. 82 lift stand, removing from ...................... 10
removing 82 raising with lift stand ........................ 10
Front wheel 0
installing ................................. 86 Oil circuit 189
removing ................................ 85
Oil filter
Fuel filter changing 190
changing ................................ 78
Oil screen
Fuel pressure cleaning 190
checking ................................. 75
Open-circuit current
Fuel pump checking ................................ 101
changing ................................ 77
Operating substances .......................... 8
Fuel screen
p
changing ................................ 81
Piston rod
Fuel tank
installing ................................. 74 fork legs, assembling ........................ 25
removing 73 fork legs, disassembling ...................... 20
Fuse Play in throttle cable

main fuse, changing ......................... 98 adjusting ................................. 38
Preparing for use
H
after storage ............................. 204
Hand brake lever
R
basic position, adjusting 105
free travel, checking ........................ 104 Rear sprocket
Handlebar position ........................... 36

checking ................................. 91
adjusting ................................. 36 Rear wheel
Hydrostop unit
installing ................................. 89
fork legs, assembling ........................ 24 removing ................................ 88
fork legs, disassembling ...................... 21 Rebound damping
fork, adjusting ............................. 12
shock absorber, adjusting ..................... 41
INDEX 234
Riding sag Steering head bearing

adjusting ................................. 43 changing ................................ 34
Right side cover greasing ................................. 31
installing ................................. 73 Steering head bearing play
removing ................................ 72 adjusting ................................. 35
checking ................................. 33
s
Storage ................................... 204
Seal ring retainer
fork legs, assembling ........................ 23 Swingarm
fork legs, disassembling ...................... 22 checking ................................. 62
installing 63
Seat
removing ................................ 62
mounting ................................ 73
removing ................................ 73 Swingarm bearing
changing ................................ 64
Service schedule ......................... 205-206
Servicing the shock absorber ................... 47 iT
Shock absorber Technical data

compression damping, high- speed, adjusting ....... 40 capacities ............................... 199
compression damping, low- speed, adjusting ........ 40 chassis ................................. 200
damper, assembling ......................... 56 chassis tightening torques ................... 202
damper, bleeding and filling ................... 58 electrical system .......................... 200
damper, checking .......................... 52 engine ................................. 197
damper, disassembling ....................... 48 engine- tolerance, wear limits ................. 197
damper, filling with nitrogen ................... 60 engine tightening torques .................... 198
heim joint, installing ......................... 53 fork ................................... 201
heim joint, removing ......................... 52 shock absorber ........................... 201
installing ................................. 44 tires ................................... 200
pilot bushing, changing ....................... 51 Throttle cable play
piston rod, assembling ....................... 55 checking ................................. 37
piston rod, disassembling ..................... 49
Throttle cable routing
rebound damping, adjusting ................... 41
checking ................................. 37
removing ................................ 43
riding sag, checking ......................... 42 Tire air pressure
seal ring retainer, assembling .................. 54 checking ................................. 84
seal ring retainer, disassembling ................ 50 Tire condition
shock absorber, servicing ..................... 47 checking ................................. 84
spring preload, adjusting ..................... 42 Type label ................................... 9
spring, installing ............................ 61
w
spring, removing ........................... 48
Warranty .................................... 8
static sag, checking ......................... 41
Wheel bearing
Shock absorber linkage
changing, rear ............................. 95
checking ................................. 45
front, changing ............................ 87
Spare parts .................................. 8
Wiring diagram .......................... 208-213
Spark plug connector page1 of3 .............................. 208
checking ................................ 194 page2 of3 210
Spoke tension page3 of3 .............................. 212
checking ................................. 85
Work rules .................................. 7
Spring
fork legs, removing ......................... 17
Start number plate
installing ................................. 83
removing ................................ 82
Starter relay
checking ................................ 102
Starting.................................... 10
for checking .............................. 11
PIONEERING SINCE 1903
I 11111111 1 1111 1111111 1 1111111111 111111 1 1 11111111

3403015en
04/2016
®
Husqvarna MOTORCYCLES
StallhofnerstraBe 3 5230 Mattighofen Austria
www.husqvarna-motorcycles.com llmi LZZa" O
fiiiHiAvl
· �
__ ,, __,
Photo: Mitterbauer,

2015 FC 350 Repair

Uploaded by

Copyright:

Available Formats

2015 FC 350 Repair

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

2015 FC 350 Repair

Uploaded by

Copyright:

Available Formats

PIONEERING SINCE 1903

© 2016 Husqvarna Motorcycles GmbH, Mattighofen Austria

ISO 9001(12 100 6061)

Husqvarna Motorcycles GmbH

I 11111111 1 1111 1111111 1 1111111111111111 1 1 11111111

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

23.9 Shock absorber ................................................ 201

1.1 S mbols used

X 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.

Indicates the result of a testing step.

Denotes a current measurement.

1.2 Formats used

Name® Identifies a protected name.

Brand ™ Identifies a trademark.

2.1 Re air Manual

2.2 Safe advice

2.4 Work rules

3.1 Manufacturer and im lied warran

3.2 0 erating and auxiliary substances

3.3 Spare parts, accessories

4.1 Chassis number

The type label O is fixed to the front of the steering head.

Fork part number

5.1 Raising the motorc cle with the lift stand

- Raise the motorcycle at the frame underneath the engine.

5.2 Removing the motorc�cle from the lift stand

- Remove the motorcycle from the lift stand.

- Remove plug-in stand O.

Press the electric starter button CD.

5.4 Starting the motorc cle for a check

Shift the transmission to idle.

Ad"ustin in of the fork

- Turn the white adjusting screw O all the way clockwise.

- Turn counterclockwise by the number of clicks corresponding to the fork type.

Adjusting the rebound dam�ing of the fork

- Turn the red adjusting screw O all the way clockwise.

- Turn counterclockwise by the number of clicks corresponding to the fork type.

6.3 Bleeding the fork legs

6.4 Cleaning the dust boots of the fork legs

6.5 Removin the fork le s

- Loosen screwsCD. Take out the left fork leg.

6.6 Installing the fork legs

- Position the brake caliper. Mount and tighten screws C,.

- Position the left fork protector. Mount and tighten screws O.

6.9 Performin a fork service

Disassembling the fork legs

- Clamp the fork leg with the axle clamp.

- Remove the cartridge from the fork leg.

- Remove dust boot (3.

- Remove lock ring @.

- Warm the outer tube in area G) of the lower sliding bushing.

- Remove the upper sliding bushing@).

- Take off the lower sliding bushing (;).

Removing the SRring

- Pull the spring down. Remove the open end wrench.

Disassemblin the cartrid e

- Remove lock ring CD.

- @) out of the reservoir.