PIONEERING SINCE 1903

REPAIR MANUAL2019

401 Svartpilen
(el
Art. no. 3403091 en Husqvarna®
MOTORCYCLES
 INTRODUCTION

Read this repair manual carefully and thoroughly befare beginning work.

The vehicle w ill only be able to meet the demands placed on it if the specified service work is performed regu-
larly 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 t he interest of technical advancement w ithout 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 work-
shop are not specified here. lt is assumed that the repair work will be performed by a fu lly trained mechanic.

AII specifications are non-binding. Husqvarna Motorcycles GmbH specifically reserves the right to modify or
delete t echnical specíficatíons, prices, colors, forms, materials, servíces, 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 liability for delivery options, deviations from figures
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.

© 2018 Husqvarna Motorcycles GmbH , Mattighofen Austria

AII rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only w ith 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.
lssued by: TÜV- Management Service

Husqvarna Motorcycles GmbH

StallhofnerstraBe 3
5230 Mattighofen, Austria

This document is valid for the fol lowing models:

SVARTPILEN 401 EU (F2303S2)
SVARTPILEN 401 US (F2375S2)
SVARTPILEN 401 AR (F2342S2)

lllllll lllll lllll lllll lllll lllll lllll 111111111111111111

3403091en

09/2018
TABLE OF CONTENTS

MEANS OF REPRESENTATION ........................ 7 6.1 o Adjusting steering head bearing

play ..................................................... 36
1 .1 Symbols used ....................................... 7 6.11 Changing the steering head
1 .2 Formats used ......... ............................... 7 bearing ............ ........ .............. ......... ..... 39

2 SAFETY ADVICE ............................................... 8 7 HANDLEBAR, CONTROLS .............................. 41

2.1 Repair Manual. ...................................... 8 7.1 Checking the clutch lever play............ 4 1
2.2 Safety advice ... ..................................... 8 7 .2 Adjust ing p lay in the clutch lever ........ 41
2.3 Degrees of risk and symb ols ................ 8 7.3 Changing the throttle grip ................... 42
2.4 Work rules ............................................. 8
8 FRAME ............................................................ 47
3 IMPORTANT NOTES ......................................... 9
8.1 Changing the footrest bracke t.. .......... 4 7
3.1 Manufacturer and implied warranty ...... 9 8.2 Checkíng the trame ............................. 51
3.2 Fuel, auxiliary substances ... .. ................ 9
9 SHOCK ABSORBER. LINK FORK ................... 52
3.3 Spare parts, accessories ...................... 9
3.4 Figures .................................................. 9 9.1 Measuring the rear wheel dimension
u nload ed ....... .. ....... ............... .............. 52
4 SERIAL NUMBERS ....... .............. ................. .... 1O
9.2 Checking the static sag of the
4.1 Vehícle identiflcatíon number.............. 10 shock absorber ........................... ........ 52
4.2 Type label. ......................................... .. 10 9.3 Adjusting the spring preload of the
4.3 Key number ...... ................................... 11 shock absorber ..... .. ........ .... ... ..... .. . ..... 52
4.4 Engíne number .................................... 11 9.4 Checking the heim joint for play ... ...... 53
9.5 Removing the shock absorber ............ 53
5 MOTORCYCLE ................................................ 12
9 .6 lnstalling the shock absorber .............. 54
5.1 Raísíng the motorcycle with the rear 9. 7 Removing the sp ring ........................... 55
lifting gear ........................................... 12 9.8 lnstalling the spring ......... .............. ...... 56
5.2 Removing the rear of the 9.9 Checking the link fork ......................... 57
motorcycle from the lifting gear .......... 12 9.1O Removing the link fork ........................ 57
5.3 Liftíng the mot orcycle wíth t he front 9.11 lnstalling the link fork .......................... 59
lifting gear ....... .................................... 13 9. 12 C hecking the fork bearing for play ...... 61
5.4 Takíng the motorcycle off the front 9. 13 Changing the fork bearing ... ............... 62
líftíng gear .. ........... ...... ......... ........ ....... 14
5.5 Raising the motorcycle wíth the 10 EXHAUST SYSTEM ......................................... 66
work stand .......................................... 14 10.1 Removing the exhaust system ............ 66
5.6 Removing the motorcycle from the 10.2 lnstalling the exhaust system .............. 67
work stand .. ... .. .. ... .. ... .. .. ... .. . ...... .. .. ... .. 15 10.3 Removing the maín sílencer................ 69
5.7 Startíng ............................................... 16 10.4 lnstalling the maín silencer.................. 70
5.8 Starting the motorcycle to make
checks ...... ...................... ..................... 17 11 AIR FILTER .................. ....... ....... ........ .. ............ 71

6 FORK, TRIPLE CLAMP .............. ..................... 18 11 .1 Changing the air fllter, cleaníng the
aír filter box ......................................... 71
6 .1 Cleaníng the dust boots of the fork
12 FUEL TANK, SEAT, TRIM ................................ 73
legs ·················· ······"· .. ····"·················· 18
6.2 Removíng the fork leg s .................. ..... 18 Openíng fuel tank filler cap ........... ...... 73
12.1
6.3 lnstalling the fork legs ......................... 20 Closing the fuel tank filler cap ............. 74
12.2
6.4 Disassembling the fork legs ................ 22 Removing the passenger seat ............ 74
12.3
6.5 Checking t he fork legs ........................ 24 Mounting the passenger seat ............. 74
12.4
6.6 Assemb ling the fork legs .................... 25 Removing the front rider's seat .......... 75
12.5
6.7 Removing the lower triple clamp ........ 27 Mounting the front rider's seat ........... 75
12.6
6.8 lnstalling the lower t riple clamp .......... 30 Removing the bag carrier ................... 75
12.7
6.9 Checking steering head bearing lnstalling the bag carrier ......... ............ 76
12.8
p lay .................. ................................... 36
12.9 Rem oving t he left side cover ...... ........ 76
12.10 lnstalling the left side cover .. .............. 77

2
 TABLE OF CONTENTS

12.11 Removing the right side cover ............ 78 14 .5 Charging the 12-V battery ................ 121
12.12 lnstalling the right side cover .............. 79 14.6 Checking the charging voltage ......... 122
12.13 Removing the fuel tank ....................... 80 14.7 Checking the open-circuit current.... 123
12.14 lnstalling the fuel tank ......................... 82 14.8 Changing the fuses of individual
12.15 Removing the engine guard ................ 84 power consumers ............................. 123
12.16 lnstalling the engine guard .................. 84
15 BRAKE SYSTEM ......... ............... ................... 125
12.17 Removing front fender ........................ 85
12.18 lnstalling front fender ...... ............... ..... 85 15.1 Checking the front brake linings ....... 125
12.19 Removing the license plate holder...... 86 15.2 Changing the front brake linings ....... 125
12.20 lnstalling the license plate holder ....... 87 15.3 Checking the front brake fluid
12.21 Checking the fuel pressure ................. 89 level ......... ........ ............................... ... 128
12.22 Changing the fuel filter .... ....... ........ ..... 91 15.4 Adding front brake fluid .. .................. 128
12.23 Changing the fuel pump ........ ......... .... 92 15.5 Changing the front brake fluid .......... 130
15.6 Checking the rear brake linings ........ 132
13 WHEELS .......................................................... 95 15.7 Changing the rear brake linings ..... ... 132
13.1 Checking tire pressure ........................ 95 15.8 Checking the free travel of the foot
13.2 Checking the tire condition ................. 95 brake lever ...... ....... .. ..... .. . ........ ...... ... 134
13.3 Checking spoke tension ..................... 96 15.9 Adjust ing t he free travel of the foot
13.4 Checking the brake discs ...... ............. 97 brake lever ...... ...... .. ....... .. .. .... ........ .. . 135
13.5 Checking the rim run-out.. .......... ........ 97 15.1 O Checking t he rear brake f luid level ... 135
13.6 Checking the wheel bearing for 15.11 Adding rear brake fluid ..................... 136
play .......... ........ ........ ....... ................ .... 98 15.12 Changing the rear brake fluid ........... 137
13.7 Front wheel ...... ........ .............. ......... .... 99 16 COMBINATION INSTRUMENT .... .............. ... 139
13.7.1 Removing the front wheel .......... .... 99
13.7.2 lnstalling t he front wheel ... ........ ..... 99 16.1 Combination instrument ....... ............ 139
13.7.3 Changing the front brake disc ...... 100 16.2 Activation and test .. .............. ............ 139
13.7.4 Changing the front wheel 16.3 Warnings ......... .............. ................. ... 140
bearing ........ ...................... ......... .. 101 16.4 lndicator lamps ............. .. .................. 141
13.8 Rear wheel ....... ... .... .. .. ... ... ........ .... .. .. 1 03 16.5 Shift warning light ......... .. .................. 142
13.8.1 Removing the rear wheel. .. ......... .. 103 16.6 Display .... ........ .............. ................. ... 143
13.8.2 lnstalling t he rear wheel..... ... ..... ... 104 16.7 Fuel leve) d isplay ........... ................. ... 143
13.8.3 Changing the rear b rake disc .... ... 105 16.8 Coolant temperature indicator .......... 144
13.8.4 Changing the rear wheel 16.9 Function buttons ..... ...... ................. ... 144
bearing ......................................... 106 16.10 lnfo display ...... ........ ........ ...... ............ 145
13.8.5 Checking the chain tension .......... 109 16.11 000 display .... ........ ...... ................. ... 145
13.8.6 Adjusting the chain tension .......... 11 O 16.11 .1 Fue) Range ......... ....................... ... 145
13.8.7 Checking the chain, rear 16.11 .2 Service........ ........ ...... ................. ... 146
sprocket, and engine sprocket ... .. 111 16.12 TRIP 1 display ........ ........................... 146
13.8.8 Cleaning the chain ............. ........ ... 112 16.12.1 Time Trip 1 ........ ........................... 146
13.8.9 Checking the rear hub damping 16.12.2 Average Speed Trip1 .................... 147
rubber pieces ............. .................. 113 16.12.3 Avg F.C. Trip 1 .. ........................... 147
13.8.10 Opening the chain ...... .................. 11 4 16.13 TRIP 2 display ........ ........................... 147
13.8.11 Riveting the chain ....... .................. 1 14 16.13.1 Tim e Trip 2 ........ ........................... 148
13.8.12 Changing the drivetrain kit ........... 115 16.13.2 Average Speed Trip2 .................... 148
16.13.3 Avg F.C. Trip 2 ............................. 148
14 WIRING HARNESS, BATTERY ...................... 118
16.14 Setting the units ............................. ... 149
14.1 Removing the 12 V battery ............... 118 16.15 Setting the clock ............................... 149
14.2 lnstalling the 12 V battery ..... ......... ... 119 16.16 Adjusting the shift speed RPM1 .... ... 150
14.3 Disconnecting the negative cable 16.17 Adjusting t he shift speed RPM2 .... ... 150
of the 12-V battery ............................ 120 16.18 Setting the service interval
14.4 Connecting the negative cable of display............................................... 151
the 12-V battery ................................ 120

3
TABLE OF CONTENTS

17 LIGHTING SYSTEM, INSTRUMENTS ........... 152 18.4 Working on individual parts ... ........... 185
18.4.1 Working on the left section of
17 .1 Checking the headlight setting ...... ... 152
the engine case ... .............. ........ ... 185
17.2 Adjusting the headlight range ........ ... 152
18.4.2 Working on the right section of
18 ENGINE ................ ........ ........ ...... ................... 154 the engine case ........... ................. 186
18.4.3 Changing the shaft seal ring of
18.1 Removing the engine ..... ................... 154
the water pump ........ ......... ........ ... 187
18.2 lnstalling the engine ....... ................... 160
18.4.4 Checking the radial clearance of
18.3 Engine disassembly ....... ................... 166
lower conrod bearing ................... 188
18.3.1 Preparations ...... ........ ........ ... ...... .. 166
18.4.5 Changing the conrod bearing ....... 189
18.3.2 Draining the engine oil. ................. 166
18.4.6 Changing the balancer shaft
18.3.3 Removing the chain securing
bearing ....... ....... ....... ........ ......... ... 191
guide.... ........ ................................. 167
18.4.7 Work on the cylinder head ....... .... 191
18.3.4 Removing the valve cover ............ 167
18.4.8 Checking t he cylinder head ...... .... 192
18.3.5 Removing the spark plug ............. 168
18.4.9 Checking t he pivot points of the
18.3.6 Removing the clutch cover...... ... .. 168 camshafts........... .......... .. ... ........ .. . 193
18.3.7 Setting the engine to ignition 18.4.1O Checking/measuring the
top dead center......... ... .. ... ......... .. 169 cylinder ....... ........ .......................... 194
18.3.8 Removing the t im ing chain
18.4.1 1 Checking t he piston ring end
tensioner ............ ........ ................. .. 170 gap ............. ........................ .......... 194
18.3 .9 Removing the camshaft ............. .. 170 18.4.12 Checking/measuring the piston ... 195
18.3.10 Removing the cylinder head ......... 171 18.4.13 Checking the piston/cylinder
18.3.11 Removing the piston ... ................. 172 mounting clearance ................... ... 196
18.3.12 Removing the starter motor ......... 172 18.4.14 Checking the oíl pump ..... ......... ... 196
18.3.13 Removing the timing chain ........... 172 18.4.1 5 Checking the oíl pressure
18.3.14 Removing the water pump control valve ........ ....... .................. 197
wheel ... ........ ............................... .. 173 18.4.16 Checking t he clutch ..................... 197
18.3.15 Removing the alternator cover .. ... 173 18.4.17 Checking t he shift mechanism ..... 198
18.3.16 rotor, removing .... ...... ................... 174 18.4.18 Preassembling the shift shaft ....... 200
18.3.17 Removing the starter drive ........... 174 18.4.19 Disassembling the main shaft ...... 200
18.3.18 Removing the drive gear wheel 18.4.20 Disassembling the
of the balancer shaft.. ........ ......... .. 175 countershaft .............................. ... 201
18.3.19 Removing the gear position 18.4.21 Checking t he t ransm ission ........ ... 201
sensor........................ ................... 176 18.4.22 Assembling t he main shaft ....... .... 203
18.3.20 Removing the suction pump ........ 176 18.4.23 Assembling t he countershaft..... ... 203
18.3.21 Removing the clutch basket ......... 177 18.4.24 Checking t he timing assembly ..... 205
18.3 .22 Removing th e primary gear 18.4.25 Changing the stator. ..................... 206
wheel .. ......... ...... ................. .......... 178
18.4.26 Checking t he electric starter
18.3.23 Removing the force pump ............ 179 drive .... .............................. ........ .... 207
18.3.24 Removing the shift shaft.... ........ ... 180 18.4.27 freewheel, checking ..................... 208
18.3.25 Removing the shift drum 18.5 Engine assembly ........................... .... 208
locating ........ ............................... .. 181
18.5.1 lnstalling the crankshaft ............... 208
18.3.26 Removing the locking lever .......... 181
18.5.2 lnstalling the balancer shaft ..... .... 208
18.3 .27 Removing the oíl filter ................... 181
18.5.3 lnstalling the transmission
18.3.28 Removing the left engine case ..... 182
shafts .......... .............. ......... ........ ... 209
18.3.29 Removing the shift rails ................ 183
18.5.4 lnstalling the shift forks ............ .... 209
18.3.30 Removing the shift drum .............. 184
18.5.5 lnstalling the shift drum ..... ....... .... 209
18.3.31 Removing the shift forks .............. 184
18.5.6 lnstalling the shift rails .............. .... 21 O
18.3.32 Removing the t ransmission 18.5.7 lnstalling the left engine case ... .... 21 O
shafts ... ........ ...... ......................... .. 184
18.5.8 lnstalling the oil filter ................. .... 212
18.3.33 Removing the balancer shaft ....... 184
18.5.9 lnstalling the locking lever ........ .... 212
18.3.34 Removing the crankshaft ........... .. 185
18.5.1 O lnstalling the shift drum locating
unit .............. ........ ....................... ... 213

4
 TABLE OF CONTENTS

18.5.11 lnstalling the shift shaft .... ............ 213 22.2 Checking the valve clearance,
18.5.12 lnstalling the oil pump .................. 213 changing the spark plug ............. ... ... 252
18.5.13 lnstalling the primary gear 22.3 Adjusting the valve clearance ..... ... ... 257
wheel .. ......... ....................... .......... 215 22.4 Removing the camshafts .................. 258
18.5.14 lnstalling the clutch basket ........ ... 216 22.5 lnstalling the camshafts .. .................. 258
18.5.15 lnstalling the spacer .......... ........ ... 218
23 LUBRICATION SYSTEM ..... .......................... 260
18.5.16 lnstalling t he suction pump ....... ... 218
18.5.17 lnstalling the gear position 23.1 Oíl círcuít.. ..................... .................... 260
sensor........................................... 2 19 23.2 Checking the engine oil level ............ 260
18.5.18 lnstalling the drive gear wheel of 23.3 Checking the oil pressure ................. 260
the balancer shaft ....... .................. 220 23.4 Changing the engíne oíl and oíl
18.5.19 lnstalling the starter drive ............. 221 filter, cleaníng the oíl screens ........... 262
18.5.20 lnstalling the rotor ....... ...... ............ 221 23.5 Addíng engíne oíl ............ .................. 264
18.5.21 alternator cover, installing ............ 222
24 IGNITION SYSTEM .............. .......................... 265
18.5.22 lnstalling the water pump
cover.... ........ ...... ......... ....... ........... 222 24.1 Alternator - checking the stator
18.5.23 lnstalling the t iming chain ............. 223 winding ............ ........ ......... .............. ... 265
18.5.24 lnstalling the starter motor ........... 223 24.2 Changing the spark plug ................ ... 267
18.5.25 lnstalling the piston .. ................. ... 223 25 THROTTLE VALVE BODY .......................... ... 269
18.5.26 lnstalling the cylinder head ........... 225
18.5.27 lnstalling the camshafts............. ... 226 25.1 Resetting the service display with
Husqvarna Motorcycles
18.5.28 lnstalling t he timing chain
tensioner..................................... .. 227 diagnostics tool.. ............................ ... 269
18.5.29 Checking the val ve clearance ... ... 227 25.2 Performing the initíalization run ........ 269
18.5.30 Adjusting the valve clearance....... 228 26 TECHNICAL DATA ...... ........ ....................... ... 270
18.5.31 lnstalling the clutch cover ............ 229
26.1 Engine ............. ....... ........................... 270
18.5.32 lnstalling the spark plug ............... 230
26.2 Tolerance, engine wear limits ........... 271
18.5.33 lnstalling t he valve cover ... ........... 230
26.3 Engine tightening torques ................. 271
18.5.34 lnstalling the chain securing
26.4 Capacities .............. .......... .............. ... 273
guide.... ........ ....... .......................... 231
26.4.1 Engine oíl .... ....... ........................... 273
18.5.35 lnstalling the oil screen .............. ... 231
26.4.2 Coolant ....... ......... ...................... ... 273
18.5.36 engine, removing from the
engine assembly stand ..... ........... 232 26.4.3 Fuel ..... ........ ......... ........ ................. 273
26.5 Chassis ... ........ ......... ...................... ... 27 4
19 CLUTCH ...... ......... ........ ............... ....... ........... 233 26.6 Electrícal system ..... ......... ................. 27 4
19.1 Checking the clutch ........ .................. 233 26.6.1 Diagnostícs connector .............. ... 275
26.6.2 Front ACC1 and ACC2 ................. 275
20 SHIFT MECHANISM ..... ..... ................. ........ ... 240 26.6.3 ACC2 rear. .. .............. .................... 275
20.1 Adjusting the shift lever ......... ........... 240 26.7 Tires ........ ........ ............... ................... 275
20.2 Programming the gear position 26.8 Fork ......... ........ ............... ................... 276
sensor ...... ........ ....................... .......... 240 26.9 Shock absorber ....... ...... ................... 276
26.1 O Chassis tíghtening torques ............... 276
21 WATER PUMP, COOLING SYSTEM .. ........ ... 241
27 CLEANING/PROTECTIVE TREATMENT ....... 280
21.1 Draining the coolant .......................... 241
21.2 Filling/bleeding the cooling 27.1 Cleaning the motorcycle ................... 280
system ...... ........ ............... .................. 241 27.2 Checks and maintenance steps for
21.3 Changing the coolant ........................ 243 winter operation ...... .......................... 281
21.4 Checking the antifreeze and
28 STORAGE .................... ........ .............. ......... ... 283
coolant level ..... ........ ....... .................. 244
21.5 Checking the coolant level. ............... 246 28.1 Storage ... ........ .............. ................. ... 283
28.2 Preparíng for use after storage ......... 284
22 CYLINDER HEAD ................. ......................... 247

22.1 Checking the valve clearance ........... 247

5
TABLE OF CONTENTS

29 SERVICE SCHEDULE.. ....... ........................... 285

29.1 Additional information ... ................. ... 285

29.2 Required work .. ...... ........ ................. .. 285
29.3 Recommended work ...... ................. .. 286

30 WIRING DIAGRAM ..... ................ ................... 288

30.1 Page 1 of 9 (EU/AR) ....... ................... 288

30.2 Page 2 of 9 (EU/AR) ....... ................... 290
30.3 Page 3 of 9 (EU/AR) ....... ................... 292
30.4 Page 4 of 9 (EU/AR) ....... ................... 294
30.5 Page 5 of 9 (EU/AR) ....... ................... 296
30.6 Page 6 of 9 (EU/AR) ............... ........ ... 298
30.7 Page 7 of 9 (EU/AR) .......................... 300
30.8 Page 8 of 9 (EU/AR) ............... ........ ... 302
30.9 Page 9 of 9 (EU/AR) .......................... 304
30.10 Page 1 of 9 (US) .............. ....... ........ ... 306
30.11 Page 2 of 9 (US) ...... ........ ....... ........ ... 308
30.12 Page3of9(US) ..... ........ ................... 310
30.13 Page4of 9(US) ..... ........ ................... 312
30.14 Page 5 of 9 (US) ..... ........ ................... 314
30.15 Page6of 9(US) ..... ........ ................... 3 16
30.16 Page 7 of 9 (US) ..... ........ ................... 3 18
30.17 Page 8 of 9 (US) ..... ........ ................... 320
30.18 Page 9 of 9 (US) ................................ 322

31 SUBSTANCES ............ .. ...... .. ...... ........ ......... .. 324

32 AUXILIARY SUBSTANCES ............................ 326

33 SPECIAL TOOLS ........................................... 328

34 STANDARDS ........ ........ .............. ................. .. 342

35 INDEX OF SPECIAL TERMS ......................... 343

36 LIST OF ABBREVIATIONS ............................ 344

37 LIST OF SYMBOLS ...... .............. ................... 345

37.1 Yellow and orange symbols .............. 345

37.2 Green and blue symbols ........ ........ ... 345

INDEX .......... ....................................... ................... 346

6
 MEANS OF REPRESENTATION 1

1.1 S mbols used

The meaning of specific symbols is described below.
lndicates an expected reaction (e.g. of a work step ora f unction).
✓
lndícates an unexpected reaction (e.g. of a work step ora function).
X
lndicates a page reference (more information is provided on the specified page).

lndicates information with more details or t ips.

lndicates the result of a testing step.

»
lndicates a voltage measurement.

lndicates a current measurement.

lndicates a resistance measurement.

lndicates the end of an activity including potential rework.

1.2 Formats used

The typographical formats used in this document are explained below.
Proprietary name lndicates a proprietary name.

Name® lndicates a protected name.

Brand™ lndicates a brand available on the open market.

Underlined terms Refer to technical details of the vehicle or indicate technical terms, which
are explained in the glossary.

7
2 SAFETY ADVICE

2.1 Re air Manual

Read this Repair Manual carefully and thoroughly before beginning work. lt contains useful information and tips
to help you repair and service your vehicle.
This manual assumes that the necessary special Husqvarna tools and Husqvarna workplace and workshop
equipment are available.

2.2 Safe advice

A number of safety instructions need to be followed to operate the product described safely. Therefore read
this instruction and all further instructions included carefully. The safety instructions are highlighted in the text
and are referred to at the relevant passages.

lnfo
Various information and warning labels are attached in prominent locations on the product described.
Do not remove any information or warning labels. lf they are missing, you or others may not recognize
dangers and may therefore be injured.

2.3 De rees of risk and s mbols

Danger
ldentifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the
appropriate measures are not taken.

Warning
ldentifies a danger t hat is likely to lead to fatal or serious injury if the appropriate measures are not
taken.

Caution
A ldentifies a danger t hat may lead to minor injuries if the appropriate measures are not t aken.

Note
ldentifies a danger that w ill lead to considerable machina and material damage if the appropriate measures are
not taken.

Note
lndicates a danger that will lead to environmental damage if the appropriate measures are not taken.

2.4 Workrules
Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered
using the number in parentheses. Example: bearing puller (1511201 7000}
During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts,
seals, sealing rings, 0 -rings, pins, and lock washers}.
In the case of certain screws, a screw adhesive (e.g. Loctite®) is required. Observe the manufacturer's instruc-
tions.
After d isassembly, clean the parts that are to be reused and check them for damage and wear. Change dam-
aged or worn parts.
After completing a repair or service work, check the operating safety of the vehicle.

8
 IMPORTANT NOTES 3

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 confirmed both in the customer's Service & Warranty Booklet and in the Husqvarna Motor-
c ycles Dealer.net; otherwise, all manufacturer warranty c laims will be void. Damage or secondary damage
caused by tampering with and/or conversions on the vehicle is not covered by the manufacturer warranty.
Additional information on the manufacturer or manufacturer warranty and the procedures involved can be
found in the Service & Warranty Booklet.

3.2 Fuel, auxiliarY substances

Note
Envíronmenta l hazard lmproper handling of fuel is a danger t o 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) specified in the manual.

3.3 Spare parts, accessoñes

For your own safety, only use spare parts and accessory products that are approved and/or recommended by
Husqvarna Motorcycles and have them installed by an authorized Husqvarna Motorcycles workshop. Husq-
varna Motorcycles accepts no liabílity for other products and any resulting damage or loss.
Certain spare parts and accessory products are specified in parentheses in the descriptions. Your authorized
Husqvarna Motorcycles dealer will be glad to advise you.

The current Husqvarna Motorcycles accessories for your vehicle can be found on the Husqvarna Motorcy-
cles website.
lnternational Husqvarna Motorcycl es website: www.husqvarna-motorcycles.com

3.4 Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, sorne components may be shown d isassembled or may not be shown at all. lt is not
always necessary to disassemble the component to perform the activity in question. Please follow the instruc-
tions in the text.

9
4 SERIAL NUMBERS

4.1 Vehicle identification number

The vehicle identification number O is stamped on the right side
of the steering head.

402408 -10

4.2 T~ label
(EU/AR)
The type label O is on the right of the tram e behind the
steering head.

402 174-10

(US)
The USA t ype label O is on the right of the trame behind the
steering head.

402 174-10

(US)
The Ganada type label 8 is on the left of the trame behind
the steering head.

10
 SERIAL NUMBERS 4

4.3 Ke number
The key number O can be found on the KEYCODECARD.
o lnfo
You need the key number to order aspare key. Keep
KEY
COOE the KEYCODECARD in a safe place.
CARO
o lf at least one ignition key is still available, aspare key can

•
c:::::::::J
:
I ==-~
:=
111111rn1111111111 be produced. lf an ignition key is no longer present , the
entire lock system must be replaced.

F01413•10

4.4 Engine number

The engine number O is stamped on the left side of the engine
under the engine sprocket.

n ~====-,r----1 1

402486-10

11
5 MOTORCYCLE

5.1 Raisin the motore ele with the rear liftin ear

Note
Danger of damage The parked vehicle can roll away or fall over.
- Park the vehicle on a fi rm and leve! surface.

C ondition
Rear wheel is not removed.
- Remove screw O.

- Mount the supports of the lifting gear.

Guideline
1 Screw on left side: M 10x70
- lnsert the adapter in the rear lifting gear.
Retaining adapter (61029955244) (O p . 332)
Rear wheel work stand (6932995500033) (0 p. 338)
- Stand the motorcycle upright, align the lifting gear to the
E0 1138-01 link fork and the adapters, and raise the motorcycle.
Condition
Rear wh eel is removed.
- Remove the license plate holder. (~ p . 86)
- Mount the supports of the lifting gear.
- lnsert the adapter in the rear lifting gear.
Retaining adapter (61029955244) (O p . 332)
Rear wheel work stand (6932995500033) (fi/!I p. 338)
- Stand the motorcycle upright, align the lifting gear to the
link fork and the adapters, and raise the motorcycle.

402346 -0 1

5.2 Removin the rear of the motore ele from the liftin ear

Note
Danger of damage The parked vehicle can roll away or fall over.
- Park the vehicle on a firm and leve! surface.

12
 MOTORCYCLE 5

Condition
Rear wheel was not removed.
Secure the motorcycle against falling over.
Remove the rear lifting gear and lean the vehicle on side
stand O .
- Remove bushings kit.

•1 lnfo
Do not ride with the bushings mounted, as the
402029-10
bushings can collide w ith the main silencer.

Mount and tighten screw @.

Guideline
Screw, license M10x30 45 Nm (33.2 lbf ft)
plate holder Loctite®243™

Condition
Rear wheel was removed.
- Secure the motorcycle against falling over.
Remove the rear lifting gear and lean the vehicle on side
stand O .
- Remove bushings kit .

•
1
lnfo
Do not ride w ith the bushings mounted, as the
402029-10
bushings can collide with the main silencer.

lnstall the license plate holder. (@JI p. 87)

5.3 Lifting the motorc ele with the front lifting gear

Note
Danger of damage The parked vehicle can roll away or fall over.
- Park the vehicle on a firm and level surface.

Preparatory work
- Raise the motorcycle w ith the rear lifting gear. (O p. 12)
Main work
- Move the handlebar to the straight-ahead position. Position
the lifting gear.
Mounting pin (69329965030) (é:.! p. 333)
Front wheel work stand, large (6932996510033) (8 p. 338)

• lnfo
1 Always raise the motorcycle at the rear first.
402345-01
- Lift the motorcycle at the front.
•

13
5 MOTORCYCLE

5.4 Takin the motore ele off the front liftin ear

Note
Danger of damage The parked vehicle can roll away or fall over.
- Park the vehicle on a fi rm and leve! surface.

Main work
- Secure the motorcycle against falling over.
- Remove the front lifting gear.

402777-01

Finishing work
- Remove the rear of the motorcycle from the lifting gear.
(8 p. 12)
41

5.5 Raisin the motore ele with the work stand

Note
Danger of damage The parked vehicle can roll away or fall over.
- Park the vehicle on a f irm and leve! surface.

- Remove the cable t ie.

- Remove nuts O.
- Remove screws 8.
- Remove fitting @) .
- Remove both engine fixing arms.

14
 MOTORCYCLE 5

- Screw in holder of the special tool all the way into the middle
hole. Select the right height and width of the work stand.
1 Work stand (62529055200) (O p. 333)
- Raise the motorcycle.

• lnfo
1 Check that the work stand is properly seated.

•
Removin the motorc ele from the work stand

Note
Danger of damage The parked vehicle can rol! away or fall over.
- Park the vehicle on a firm and leve! surface.

- Secure the motorcycle against falling over.

- Remove the special too!.
1 Work stand (62529055200) (8 p. 333)

- Position both engine fixing arms.

- Mount and tighten screws O.
Guideline
Screw, engine M8 22 Nm (16.2 lbf ft)
bearer Loctite®243™

- Mount and tighten fitting fj.

Guideline
Fitting, engine M10 50 Nm (36.9 lbf ft)
mounting Loctite®243™
bracket

- Mount and tighten nuts C) .

Guideline
1 Nut, radiator l 5 Nm (3.7 lbf ft)
- Mount the cable t ie.
•

15
5 MOTORCYCLE

5.7 Startin

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 effective exhaust extraction when starting or running the engine in an enclosed space.

Caution
A Danger of accídents Electronic components and safety devices will be damaged if the 12-V battery
is discharged or missing.
- Never operate the vehic le with a discharged 12-V battery or without a 12-V battery.

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.

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.

- Unlock the steering.

- Sit on the vehicle, take the weight off of the side stand, and
move it all the way up with your foot.

o ® CD
-
-
Tum the emergency OFF switch to the position O .
Switch on the ignition by turning the ignition key to the posi-
t ion O .
✓ After you switch on the ignition, you can hear the fuel
pump working for about two seconds. The function
B00782-10 check of the combination instrument is run at the same
time.
- Shift the transmission to neutral position.
✓ The green idle indicator lamp N lights up.
✓ The ABS warning lamp lights up and goes back out after
starting off.
- Press the electric starter button ()).

16
 MOTORCYCLE 5

• lnfo
1 Do not press the electric starter button until the com-
bination instrument function check is finished.
When starting, DO NOT open the throttle. lf you open
the throttle during the starting procedure, fuel is not
injected by the engine management system and the
engine cannot start.
Press the starter for a maximum of 5 seconds. Wait for
a least 5 seconds before trying again.
This motorcycle is equipped with a safety starting
system. You can only start the engine if the transmis-
sion is in neutral or if the clutch lever is pulled when
a gear is engaged. lf the side stand is folded out and
you shift into gear and release the clutch, the engine
stops.

41

5.8 Starting the motorcy:cle to make checks

Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and
death.
- Always make sure there is sufficient ventilation when running the engine.
- Use effective exhaust extraction when starting or running the engine ín an enclosed space.

• lnfo
1 Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds before trying again.

- Turn the emergency OFF switch to the position O .

- Shíft the transmission to neutral posítion.
- Switch on the ignition by turning the ignition key to the posi-

o ® 0) -
t ion O .
Press the electric starter button fü

•
1
lnfo
Do not open the throttle.
B00782-10
41

17
6 FORK, TRIPLE CLAMP

6.1 Cleanin the dust boots of the fork le s

Preparatory work
- Raise the motorcycle w ith the rear lifting gear. (~ p. 12)
- Lift the motorcycle w ith the front lifting gear. (i!!J!J p. 13)
Main work
- Push dust boots O of both fork legs downward.
• lnfo
1 The dust boots remove dust and coarse d irt parti-
cles from the inside fork tubes. Over time, dirt can
accumulate behind the dust boots. lf 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 braking effect.
- Always keep the brake discs free of oil and
grease.
- Clean the brake discs with brake cleaner when
necessary.

- Clean and oil the dust boots and inner fork tubes of both fork
legs.
1 Universal oil spray (~ p. 327)
- Press the dust boots back into their installation posit ion.
- Remove excess oil.
Finishing work
- Take the motorcycle off the front lifting gear. (~ p. 14)
- Remove the rear of the motorcycle from the lifting gear.
(!!!:! p . 12)

6.2 Removin the fork le s

Preparatory work
- Raise the motorcycle with the work stand. (O p . 14)
- Clamp down the rear of the vehicle.
- Remove front tender. (8 p. 85)
Main work
- Remove the cable ti e.
- Remove screw O and pull the wheel speed sensor out of
the hole.

18
 FORK, TRIPLE CLAMP 6

- Remove screws 8.
- Press back t he brake linings by slightly tilting the brake
caliper laterally on the brake disc.
- Pull the brake caliper with the spacers carefully back from the
brake disc and hang to the side.

• lnfo
1 Do not operate the hand brake lever if the brake
caliper has been removed.

- Loasen screw @) and screws 8.

Unscrew screw @) a few turns and press your hand on the
screw to push the wheel spindle out of the axle c lamp.
Remove screw @).

Warning
Danger of accidents Reduced braking effect
causad by damaged brake discs.
- Always lay the wheel down in such a way that the
brake discs are not damaged.

- Hold the front wheel and remove the wheel spindle. Take the
front wheel out of the fork.

~v~ - Remove spacers 0.

!ID~ 1 ~QlD
1 1
0 0
-<o~ G03281 -10

- Loasen screws (D . Remove the fork legs from the bottom .

•

19
6 FORK, TRIPLE CLAMP

lnstallin the fork I s

Warning
Danger of accidents Modifications to the suspension setting may seriously alter the handling charac-
teristic.
- Ride slowly to start with after making adjustments to get the feel of the new handling characteristic.

Main work
- Push the fork legs into the triple clamps.
- Align the fork legs in the requ ired position using the fork
rings.

- Tighten screws O.
Guideline
Screw, top triple M8 17 Nm (12.5 lbf ft)
clamp

- Tighten screws 8.
Guideline
Screw, bottom triple M8 12 Nm (8.9 lbf ft)
clamp

- Check the wheel bearing for damage and wear.

» lf the wheel bearing is damaged or worn:
- Change front wheel bearing. (O p. 101)
- Clean and grease shaft seal rings 8 and contact
surfaces f) ot the spacers.
1 Long-lite grease (li!)I p. 326)
- lnsert the spacers.

- Clean the thread of the wheel spindle and screw 8.

- Clean and grease the wheel spindle.
1 Long-lite grease (O p. 326)

- Jack up the front wheel into the fork, position it, and insert
the wheel spindle.
- Mount and tighten screw 8.
Guideline
Screw, tront wheel M8 26 Nm (19.2 lbt ft)
spindle

20
 FORK, TRIPLE CLAMP 6

- Position the brake caliper with the spacers.

• lnfo
1 Ensure that the brake linings are seated properly.

- Mount screws 0 . but do not tighten yet.

Guideline
Screw, front M8x1 30 Nm (22.1 lbf ft)
brake caliper Loctite ®243TM

- Operate the hand brake lever repeatedly until the brake lin-
ings are in contact with the brake disc and there is a pressure
point. Fix the hand brake lever in the activated position.
✓ The brake caliper straightens.
- Tighten screws 0.
Guideline
Screw, front M8x1 30 Nm (22.1 lbf ft)
brake caliper Loctite®243™

- Remove the locking piece of the hand brake lever.

- Position the wheel speed sensor.
- Mount and tighten screw a) .
Guideline
Screw, wheel M6 8 Nm (5.9 lbf ft)
speed sensor Loctite®243Thl

- Route the cable and secure w ith a cable t ie.

- Remove the load from the rear of the vehicle.

- Operate the front brake and compress the fork a few t imes
firmly.
✓ The fork legs straighten.
- Tighten screws O.
Guideline
1 Screw, fork stub 1 15 Nm (11 .1 lbf ft)

Fínishing work
- Remove the motorcycle from the work stand. (O p. 15)
lnstall front fender. (e:! p. 85)

21
6 FORK, TRIPLE CLAMP

6.4 Disassemblin the fork I s

lnfo
The operations are t he same on both fork legs.

Condition
The fork legs have been removed.
- Clamp the fork leg in the area of the lower triple clamp.
1 Clamping stand (T612S) ((1 p. 341)

- Loosen screw cap O.

• lnfo
1 Toe screw cover cannot be removed yet.

- Unclamp the fork leg.

- Drain the fork oil.

- Unclamp the fork leg w ith the axle c lamp.

Guideline
1 Use soft jaws.

- Remove cartridge screw 8 w ith the washer.

lnfo
Place a collecting container underneath as sorne oil
will usually still run out.

- Remove the cartrid ge.

22
 FORK, TRIPLE CLAMP 6

- Remove dust boot @).

- Remove lock ring C,.

• lnfo
1 Toe lock ring has a beveled end where a screwdriver
can be applied.

- Warm up the outside fork tube in area 6) of the lower sliding

bushing.
Guídeline
¡so 0
c (122 º F)
- Pull the outside fork tube off the ínsid e fork tube with a jerk.

• lnfo
1 Lower sliding bushing 0 must be drawn from its
B05072-10
bearing seat.

- Remove upper sliding bushing (¡) .

• lnfo
1 Without using a tool, pull the stack slightly apart by
hand.

- Take off lower sliding bushing 0.

- Take off support ring @.
- Take off seal ring (¡).
- Take off lock ring C,.
- Take off dust boot @).
- Unclamp the fork leg.

23
6 FORK, TRIPLE CLAMP

6.5 Checkin the fork le s

C ondition
The fork legs have been disassembled.
- Check the inside fork tube and the axle clamp for damage.
lf damage is found:
- Change the inside fork tube.

- Measure the outside diameter of the inside fork tube at sev-

era! places.
Outside diameter of the 42.975 ... 43.005 mm
inside fork tube (1.69193 ... 1.69311 in)
lf the measured value is less than the specified value:
- Change the inside fork tube.

- Measure the run-out of t he inside fork tube.

Run-out of the inside fork ~ 0.20 mm (~ 0.0079 in)
tube
lf the measured value is greater than the specified value:
- Change the inside fork tube.

- Check the outside fork tube for damage.

lf damage is found:
- Change the outside fork tube.

804658-10

- Check the surface of the sliding bushings.

lf the dark layer f) is worn off:
- Change the guiding bushes.

201 517-10

24
 FORK, TRIPLE CLAMP 6

6.6 Assemblin the fork le s

• lnfo
1 The operations are t he same on both fork legs.

Preparatory work
- Check the fork legs. (ta!! p . 24)
Mainwork
- Clamp the inside fork tube using the axle clamp.
Guideline
1 Use soft jaws.
- Mount the special tool.
-8 1 Protecting sleeve (T512) (O p. 341)

- Grease and push on dust boot O.

1 Lubricant (T14034) (O p. 326)

• lnfo
1 Always change the dust boot, seal ring, lock ring, and
support ring.
Mount the sealing lip at the bottom.

- Push on lock ring 8.

- Grease and push on seal ring 8.
1 Lubricant (T14034) (l!JI p. 326)
✓ The sealing lip points downward, the open side upward.
- Remove the special tool.
- Push on support ring C,.
- Sand the edges of the sliding bushings with 600 grit sandpa-
per; then clean and grease the bushings.
1 Fork oil (SAE 5) (8 p. 325)

- Push on lower sliding bushing 0.

- Mount upper sliding bushing (D.

• lnfo
1 Without using a tool, pull the stack slightly apart by
hand.

- Warm up the outside fork tube in area 6) of the lower sliding

bushings.
Guideline
1 50 ºC (122 ºF)
- Hold the lower sliding bushing with the longer side of the
special tool.
1 Mounting tool (T528S) (illJ!J p. 341)
- Slide on the outside fork tube.

25
6 FORK, TRIPLE CLAMP

- Press the sliding bushing all the way into the outside fork
tube.
- Position the support ring.
- Hold the seal ring w ith the shorter side of the special tool.
1 Mounting tool (T528S) (19 p. 341)
- Press the seal ring and support ring all the way into the out-
side fork tube.

- Mount lock ring 8.

lnfo
Toe lock ring must engage audibly.

- Mount dust boot O.

- Slide the cartridge into the inside fork tube.

- Mount and tighten cartridge screw @ w ith the washer.

Guideline
1 Screw, cartridge 1 M10x1 .5 1 25 Nm (18.4 lbf ft)

26
 FORK, TRIPLE CLAMP 6

- Clamp the left fork leg vertically.

Guideline
1 Use soft jaws.
- Fill with fork oil.
Fork oíl per fork leg 420 ± 5 mi Fork oíl (SAE 4)
(14.2 (48601166S1}
± 0.17 fl. oz.) (O p. 325)
805077-10
• lnfo
1 After approx. half the oíl capacity has been filled,
close the screw cap of the outside fork tube, unclamp
the fork and bounce a number of times so t hat the
cartridge fills w ith oil. Then add the remaining amount.

- Push the outside fork tube upwards.

- Clamp the fork leg in the area of the lower triple clamp.
1 Clamping stand (T612S) (O p. 341)
- Grease the 0 -ring of the screw cover.
1 Lubricant (T158) ~ p. 326)

Tighten screw cap @) .

Guideline
Screw cap on the M47x1 .5 40 Nm (29.5 lbf ft)
outside fork tube

•
6.7 Removing the lower tri le clamQ
Preparatory work
- Raise the motorcycle with the work stand. (O p . 14)
- Clamp down the rear of the vehicle.
- Remove front tender. (l!t! p. 85)
- Remove the fork legs. (l!'.! p. 18)
Mainwork
- Remove screws O.
- Remove the cover.

27
6 FORK, TRIPLE CLAMP

- Remove screws 8.
- Remove screws 8.
- Swivel the headlight mask forward.

- Expose and disconnect plug-in connector C,.

- Disconnect plug-in connector 0 and expose the cable.
- Take off the headlight mask.

- Remove screws 0 with the handlebar clamps.

- Take off the handlebar and place it at the front.

• lnfo
1 Cover the components to protect them against dam-
age.
Do not kink the cables and lines.

28
 FORK, TRIPLE CLAMP 6

- Remove fittings O with washers @) .

- Take off the handlebar support.

- Remove screw @).

Take off the upper triple clamp.

- Expose the cable.

- Place handlebar on the rear of the fuel tank.

• lnfo
1 Cover the components to protect them against dam-
age.
Do not kink the cables and lines.

- Remove nut G'i) .

1 Groove nut wrench (90129050100) (O p. 336)
- Remove the lower triple clamp w ith the steering stem.

29
6 FORK, TRIPLE CLAMP

- Take off washer 48.

- Remove steering head bearing 48.
•

Main work
- Clean the bearing and sealing elements, check for damage,
and grease.
1 High viscosity grease (~ p. 326}

- Mount upper steering head bearing O.

- Mount washer 8 with the cut-out facing downward.

Alternative 1
A new steering head bearing is used.
- lnsert the lower triple clamp with the steering stem.
✓ Holding lugs f) engage in holes @) .
- Mount and tighten nut @).
Guideline
Nut, steering head M30x1 1st stage
55 Nm (40.6 lbf ft)
2nd stage
(loosen, counter-
clockwise)
2tums
3rd stage
5 Nm (3.7 lbf ft)

1 Groove nut wrench (90129050100) (O p. 336)

Alternative 2
The steering head bearing is used again.
- lnsert the lower triple c lamp with the steering stem.
✓ Holding lugs f) engage in holes @) .
- Mount and tighten nut @).
Guideline
1 Nut, steering head I M30x1 1 5 Nm (3. 7 lbf ft)

1 Groove nut wrench (90129050100) (O p . 336)

- Place handlebar at the front.

30
 FORK, TRIPLE CLAMP 6

lnfo
Cover the components to protect them against
damage.
Do not kink the cables and lines.

- Secure the cable in the bracket.

- Position the upper triple clamp.

✓ Holding lug (9 engages in hole Ci).
- Mount screw 9 , but do not tighten yet.
Guideline
Screw, steering M16 53 Nm (39.1 lbf ft)
head, top Loctite®243™

31
6 FORK, TRIPLE CLAMP

- Push the fork legs into the triple clamps.

- Align the fork legs in the required position using the fork
rings.
- Tighten screws 0.
Guideline
Screw, bottom triple M8 12 Nm (8.9 lbf ft)
c lamp

- Tighten screw 8.
Guideline
Screw, steering M1 6 53 Nm (39.1 lbf ft)
head, top Loctite®243Thl

- Tighten screws Q) .
Guideline
Screw, top triple M8 17 Nm (12.5 lbf ft)
clamp

32
 FORK, TRIPLE CLAMP 6

- Position the handlebar support.

- Mount and t ighten fittings C) with the washers @ .
Guideline
Screw, handlebar M10 20 Nm (14.8 lbf ft)
supp ort

- Position the handlebar with handlebar c lamps.

- Mount and t ighten screws @) .
Guideline
Screw, handle- M8 20 Nm (14.8 lbf ft)
bar clamp Loctite®243™

- Position the headlight mask.

- Route t he cable without tension and join plug-in connec-
tor 41) .
- Join plug-in connector G, and posit ion in the cover.

33
6 FORK, TRIPLE CLAMP

- Swivel the headlight mask upward.

- Mount and tighten screws 49.
Guideline
Screw, headlight fix- M6 7 Nm (5.2 lbf ft)
ation on triple clamp

- Mount and tighten screws 41) .

Guideline
Screw, headlight fix- M6 7 Nm (5.2 lbf ft)
ation on triple clamp

- Position the cover.

- Mount and tighten screws 41) .
Guideline
Remaining screws, M5 5 Nm (3.7 lbf ft)
chassis

- Check the wheel bearing for damage and wear.

lf the wheel bearing is damaged or worn:
- Change front wheel bearing. (8 p . 101)
- Clean and grease shaft seal rings ~ and contact
surfaces O of the spacers.
1 Long-life grease (il!JJ p. 326)
- lnsert the spacers.

- Clean the thread of the wheel spindle and screw 4D.

- Clean and grease the wheel spindle.
1 Long-life grease (il!!J p. 326)
- Jack up the front wheel into the fork, position it , and insert
the wheel spindle.
- Mount and tighten screw 4D.
Guideline
Screw, front wheel M8 26 Nm (19.2 lbf ft)
spindle

34
 FORK, TRIPLE CLAMP 6

- Position the brake caliper with the spacers.

• lnfo
1 Ensure that the brake linings are seated properly.

- Mount screws 4D, but do not tighten yet.

Guideline
Screw, front M8x1 30 Nm (22.1 lbf ft)
brake caliper Loctite ®243TM

- Operate the hand brake lever repeatedly until the brake lin-
ings are in contact with the brake disc and there is a pressure
point. Fix the hand brake lever in the activated position.
✓ The brake caliper straightens.
- Tighten screws 4D.
Guideline
Screw. front M8x1 30 Nm (22.1 lbf ft)
brake caliper Loctite®243™

- Remove the locking piece of the hand brake lever.

- Position the wheel speed sensor.
- Mount and tighten screw Gi).
Guideline
Screw. wheel M6 8 Nm (5.9 lbf ft)
speed sensor Loctite®243Thl

- Route the cable and secure w ith a cable t ie.

- Remove the load from the rear of the vehicle.

- Operate the front brake and compress the fork a few t imes
firmly.
✓ The fork legs straighten.
- Tighten screws 41).
Guideline
1 Screw, fork stub 1 15 Nm (11 .1 lbf ft)

Fínishing work
- Check that the w iring harness, throttle cables, and brake line
have the necessary freedom of movement and are correctly
routed.
Check steering head bearing play. (é:! p. 36)
- Remove the motorcycle from the work stand. (O p. 15)
•

35
6 FORK, TRIPLE CLAMP

Checkin head bearin

Warning
Danger of accidents lncorrect steering head bearing play impairs the handling characteristic and
damages components.
- Correct incorrect steering head bearing play immediately.

lnfo
lf the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the
bearing seats in the trame can become damaged over t ime.

Preparatory work
- Raise the motorcycle w ith the work stand. (í!!!I p. 14)
- Clamp down the rear of the vehicle.
Mainwork
- Move the handlebar to the straight-ahead position. Move the
fork legs to and fro in t he direction of travel.
Play should not be detectable on the steering head bear-
ing.
lf there is detectable play:
- Adjust steering head bearing play. (B p. 36)
- Move the handlebar to and fro over the entire steering range.
lt must be possible to move the handlebar easily over the
entire steering range. There should be no detectable det ent
positions.
lf detent positions are detected:
- Adjust steering head bearing play. (8 p. 36)
- Check the steering head bearing and adjust if neces-
sary.
Finishing work
- Remove the motorcycle from the work stand. (O p . 15)
•
6.10 Adjustlng steerlng head bearing play
Preparatory work
- Raise the motorcycle with the work stand. (8 p . 14)
Main w ork
- Remove screws O with the handlebar clamps.
- Take off the handlebar and place it at the f ront.

• lnfo
1 Cover the components to protect them against dam-
age.
Do not kink the cables and lines.

36
 FORK, TRIPLE CLAMP 6

- Remove fittings 8 with washers (D .

- Take off the handlebar support.

- Loasen screws C,.

- Remove screw 0-

- Tighten nut (!} with the special too( until there is no play in
the steering head bearing.
1 Hook wrench (90129051000) (il!! p. 337)

37
6 FORK, TRIPLE CLAMP

- Using a plastic hammer, tap lightly on the upper triple clamp

to avoid stresses.
- Mount and tighten screw 0.
Guideline
Screw, steering M 16 53 Nm (39.1 lbf ft)
head, top Loctite®243™

- Tighten screws C,.

Guideline
Screw, top triple M8 17 Nm (12.5 lbf ft)
clamp

- Position the handlebar support.

- Mount and tighten fittings 8 with the washers 8.
Guideline
Screw, handlebar M10 20 Nm (14.8 lbf ft)
support

- Position the handlebar with handlebar c lamps.

- Mount and tighten screws O.
Guideline
Screw, handle- M8 20 Nm (14.8 lbf ft)
bar clamp Loctite®243TM

Finishing work
- Check steering head bearing play. (U p. 36)
- Remove the motorcycle from the work stand. (O p . 15)
•

38
 FORK, TRIPLE CLAMP 6

6.11 Chan in the steerin head bearin

Preparatory work
- Raise the motorcycle w ith the work stand. (8 p. 14)
- Clamp down t he rear of the vehicle.
- Remove front tender. (O p. 85)
- Remove the fork legs. (0 p. 18)
- Remove the lower triple clamp. (íil;!J p. 27)
Mainwork
- Remove the lower bearing race O using a suitable tool.

- Press in the new bearing ring ali the way using a suitable tool.

- Remove the upper bearing race 8 using a suitable tool.

- Press in the new bearing ring ali the way using a suitable tool.

39
6 FORK, TRIPLE CLAMP

- Remove lower steering head bearing (s) .

- Remove the seal ring.
- Grease new seal ring and press on all the way with a suitable
tube.
- Mount new bearing.

Q
~¡ -
R03604-10

Finishing work
- lnstall the lower triple clamp. (O p. 30)
- Check that the w iring harness, throttle cables, and brake line
have the necessary freedom of movement and are correctly
routed.
- Check steering head bearing play. (~ p. 36)
- Remove the motorcycle from the work stand. (8 p. 15)
41

40
 HANDLEBAR,CONTROLS 7

7 .1 Checkin the clutch lever la

Note
Clutch damage lf there is no free travel by the clutch lever, the clutch will begin to slip.
- Check the f ree travel of the clutch lever each t ime before using the motorcycle.
- Adjust the free travel of the clutch lever when necessary in accordance with the specification.

- Check the clutch lever for smooth operation.

- Move the handlebar to the straight-ahead position.
- Pull the clutch lever until resistance is perceptible, and deter-
mine the play in the clutch lever G.
1 Clutch lever play 6' 11 ... 3 mm (0.04 ... 0.12 in)
lf the clutch lever play does not meet the specified value:
- Adjust play in the clutch lever. (8 p. 41)
- Move the handlebar to and fro over the entire steering range.
1 The clutch lever play must not change.
lf the clutch lever play changes:
- Check the routing of the clutch cable.
•
7.2 Adjustin lay in the clutch lever
- Move the handlebar to the straight-ahead position.
- Push back sleeve O.
- Loosen lock nut 8 .
- Adjust the play in the clutch level 6' by turning adjusting
screw @).
Guideline
1 Clutch lever play 6' 11 ... 3 mm (0.04 ... 0.1 2 in)
- Tighten lock nut 8.
- Position bellows O .

41
7 HANDLEBAR,CONTROLS

- Remove screws O.
- Remove the cover.

- Remove screws 8 and 8.

- Swivel the headlight mask forward.

- Expose and disconnect plug-in connector 8.

- Disconnect plug-in connector 0 and expose the cable.
- Take off the headlight mask.

- Remove screws (D .
- Take off the cover.

42
 HANDLEBAR,CONTROLS 7

- Detach connector @.

- Remove the cable ties.

- Disconnect plug-in connectors @).

- Expose the cable.

- Loasen screw @).

- Remove the handlebar weight.

- Remove screw Gi).

- Remove screw 48.

R03689· 10

43
7 HANDLEBAR,CONTROLS

- Pull the throttle grip and accelerator position sensor unit from
the handlebar.

- Remove the throttle grip.

lnfo
Push the accelerator position sensor slightly to the
side.

- Position new throttle grip.

- Holding lugs O engage in inner clutch hub (¡) .
• lnfo
1 Push the accelerator position sensor slightly to the
side.

T02027-10

- Position the throttle grip and accelerator position sensor unit

on the handlebar.
✓ Pin (9 engages in hole 0 .

44
 HANDLEBAR,CONTROLS 7

- Mount and tighten screw I>.

Guideline
Screw for throttle M5 1.7 Nm (1 .25 lbf ft)
grip

Mount and tighten screw 8 .

Guideline
Screw for throttle M5 1.7 Nm (1 .25 lbf ft)
R03689-10
grip

- Position handlebar weight.

- Tighten screw 0.
Guideline
Screw, handlebar M6 9 Nm (6.6 lbf ft)
weight

- Route the cables without tension.

- Join plug-in connectors G).

- Secure the plug-in connectors and cables with cable t ies.

- Plug in the connectors O.

45
7 HANDLEBAR,CONTROLS

- Position the cover.

- Mount and tighten screws (!} .
Guideline
Screw, headlight EJOT PT® 2 Nm (1 .5 lbf ft)
mask K50x12

- Position the headlight mask.

- Route the cable without tension and join plug-in connec-
tor0.
- Join plug-in connector C, and position in the cover.

- Position the headlight mask.

- Mount and tighten screws 8.
Guideline
Screw, headlight fix- M6 7 Nm (5.2 lbf ft)
ation on triple clamp

- Mount and tighten screws fj .

Guideline
Screw, headlight fix- M6 7 Nm (5.2 lbf ft)
ation on triple clamp

- Position the cover.

- Mount and tighten screws O.
Guideline
Remaining screws, M5 5 Nm (3.7 lbf ft)
chassis

46
 FRAME 8

8.1 Chan in the footrest bracket

Pre parato ry work
Remove the main silencer. (O p. 69)
- Remove the engine guard. (8 p. 84)
- Raise the motorcycle with the rear lifting gear. (8 p. 12)
- Lift the motorcycle w ith the front lifting gear. (O p. 13)
M ainwo rk
- Secure the engine and link fork against turning using the floor
jack.

• lnfo
1 Cover the components to protect them against dam-
age.

- Remove screws O.
Take off the rear footrest bracket.
- Remove screws @.
- Take off bracket.

- Remove screw 8.
- Hang the shift rod to the side.

- Remove nuts C, with washers.

47
8 FRAME

- Remove fitting 0.
- Remove screw (D.
- Take off the footrest bracket.

- Remove chain guide @.

- Remove screws G) .
- Take the side stand off t he footrest bracket.
- Remove screw 0.
- Take the shift lever off the footrest bracket.
- Position the side stand and shift lever on the new footrest
bracket.
- Mount and tighten screws f¡) .
Guideline
Screw, side M 10 55 Nm (40.6 lbf ft)
stand bracket Loctite®243™

- M ount and tighten screw @).

Guideline
Screw, shift M 10 30 Nm (22.1 lbf ft)
lever Loctite®243™

Position the chain guid e @.

48
 FRAME 8

- Position the footrest bracket.

- Mount and tighten screw C) .
Guideline
Screw, front M 1 Ox 1. 25 44 Nm (32.5 lbf ft)
footrest bracket Loctitee243™

- Adjust adjusting ring ~ with special tool f).

Guideline
Adj usting ring, link M22x1 Tighten and ensure
fork bearing that there is no
play

1 Groove nut wrench (75029034000) (~ p. 333)

✓ The adjusting ring is flush w ith the collar bushing.

- Remove screw G) .

- Remove the spring.

- Remove screw • with retaining bracket and expose cable.
- Remove screw G).
Take the foot brake lever off the footrest bracket.
- Remove screws G,.
- Take the brake cylinder off the footrest bracket.
- Position the brake cylinder and foot brake lever on the new
footrest bracket.
- Mount and tighten screw G) .
Guideline
Screw, foot M10 30 Nm (22.1 lbf ft)
brake lever Loctite®243™

- Mount and tighten screws G,.

Guideline
Remaining screws, M6 1 O Nm (7.4 lbf ft)
chassis

- Position the cable. Mount and tighten screw • with retain -

ing bracket.

49
8 FRAME

Guideline
Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis
- Mount the spring.
- Position the footrest bracket with the spacer.
- Mount and tighten fitting Cs,.
Guideline
Screw, front footrest M10x1.25 49 Nm (36.1 lbf ft)
bracket / engine
bearer

- Mount and tighten screw G>.

Guideline
Screw, front M1 0x1 .25 44 Nm (32.5 lbf ft)
footrest bracket Loctite®243™

- Adjust the adjusting ring with special tool Q.

Guideline
Adjusting ring, link M22x1 Tighten and ensure
fork bearing that there is no
play

1 Groove nut wrench (75029034000) (O p. 333)

✓ The adjusting ring is flush with the collar bushing.

- Mount and tighten nuts C, with the washers.

Guideline
1 Nut, fork pivot 1 M14x1 .5 1 100 Nm (73.8 lbf ft) 1

- Position the shift rod.

- Mount and tighten screw (D.
Guideline
Screw, shift rod M6 8 Nm (5.9 lbf ft)
Loctite®243™

50
 FRAME 8

- Position new rear footrest bracket.

- Mount and t ighten screws O.
Guideline
Screw, pas- M8 22 Nm (16.2 lbf ft)
senger foot rest Loctite®243™
bracket
- Position bracket.
- Mount and tighten screws 8.
Guideline
Remaining screws, M8 25 N m (18.4 lbf ft)
chassis
- Remove the floor jack.
Finishing work
- Take the motorcycle off the front lifting gear. (!El p. 14)
- Remove the rear of the motorcycle trom the lifting gear.
(~ p. 12)
- lnstall t he engine guard. (8 p. 84)
- lnstall t he main silencer. (O p. 70)

8.2 Checking the frame

- Check the trame for cracks and deformation.
lf the trame exhibits cracks or deformation dueto a
mechanical impact :
Change the tram e.

• lnfo
1 Always replace a trame that has been
d amaged due to a m echanical im pact. Repair
R03678•10
of the trame is not authorized by Husqvarna
Motorc ycles.

...

51
9 SHOCK ABSORBER, LINK FORK

9.1 Measurin the rear wheel dimension unloaded

Preparatory work
- Raise the motorcycle w ith the work stand. (O p. 14)
Main work
- Measure the distance - as vertical as possible - between the
rear axle and a fixed point, for example, a mark on the rear
fairing.
- Note down the value as dimension 6) .

Finishíng work
- Remove the motorcycle from the work stand. (O p. 15)
•
Checking the static sag of the shock absorber
- Measure dimension 6) of rear wheel unloaded. (el p. 52)
- 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 @) .

• lnfo
1 The static sag is the difference between measure-
ments 6) and @) .

- Check the static sag.

Guideline
1 Static sag l 13 mm (0.51 in)
•

400989-10

Adjustin the sprin reload of the shock absorber

Warning
Danger of accídents Modifications to the suspension setting may seriously alter the handling charac-
teristic.
- Ride slowly to start with after making adjustments to get the feel of the new handling characteristic.

• lnfo
1 The spring preload defines the initial status of the spring operation on the shock absorber.
The best spring preload setting is achieved when it is set for the weight of the rider and that of any lug-
gage and a passenger, thus ensuring an ideal compromise between handling and stability.

52
 SHOCK ABSORBER, LINK FORK 9

- Set the spring preload by turning adjusting ring O using the

hook wrench and the extension from the tool set.
Guideline
Spring preload
Standard l 5 clicks
Full payload ¡ 10 clicks
• lnfo
1 The spring preload can be set to 1 O different posi-
tions.

•
9.4 Checking the helm joint for P-lay
Preparatory work
- Raise the mot orcycle w ith the work stand. (l!i!J p . 14)
Maín work
- Check the top and bottom heim joints.
Move the link fork up and down.
lf there is detectable play:
- Change shock absorber.

H01902·01

Finishing work
- Remove the motorcycle from the work stand. (D p. 15)
•
9.5 Removing the shock absorber
Preparatory work
- Remove the bag carrier. (G!;! p. 75)
- Remove the passenger seat. (8 p. 7 4)
- Remove the front rider's seat. (O p. 75)
- Remove the left side cover. (O p. 76)
- Raise the mot orcycle w ith the work stand. (O p . 14)
Main work
- Remove screws O with the washers.
- Expose the cable.
- Take off the splash protector.

53
9 SHOCK ABSORBER, LINK FORK

- Remove screw 8.
• lnfo
1 Cover the components to protect them against dam-
age.
Ensure that the chain and brake line are not damaged.

- Remove fitting (D .
- Remove the shock absorberC, toward the rear.

Main work
- Position shock absorber O.
- Mount fitting @ , but do not tighten yet.
Guideline
Screw, bottom M1 0x1 .25 52 Nm (38.4 lbf ft)
shock absorber Loctite®243™

- Lift the link fork.

- Mount and tighten screw (D.
Guideline
Screw, top M1 0x1 .25 52 Nm (38.4 lbf ft)
shock absorber Loctite®243™

- Tighten fitting 8.
Guideline
Screw, bottom M1 0x1 .25 52 Nm (38.4 lbf ft)
shock absorber Loctite®243™

- Position the splash protector.

- Mount and tighten screws C, with the washers.
Guideline
Screw, splash pro- M6 6 Nm (4.4 lbf ft)
tector
- Secure the cable in the holders.

54
 SHOCK ABSORBER, LINK FORK 9

Finishing w ork
- Remove the motorcycle from the work stand. (O p. 15)
- lnstall the left side cover. (li!l!J p. 77)
- Mount the front rider's seat. (~ p. 75)
- Mount the passenger seat. (8 p. 74)
- lnstall the bag carrier. (g p. 76)
..
9.7 Removlng the sprlng
Conditio n
The shock absorber has been removed.
- Clamp the shock absorber into the vise.
Guideline
1 Use soft jaws.
- Note the position of the spring preload.
- Loasen adjusting ring f) using the special tool.

1 Hook wrench (T1068) (O p. 340)

- Clamp the shock absorber into the special tool.

1 Spring compressor (T14050S) (!!;! p. 340)

• lnfo
1 Use the suitable ring of the special tool with the small-
est possible inside diameter.

- Compress the spring.

- Remove spring retainer O.
- Release the spring. Remove the shock absorber from the
special tool.

- Remove washer 8.
- Remove the spring.
..

55
9 SHOCK ABSORBER, LINK FORK

9.8
- Mount the spring.
✓ The tight coil of the spring is mounted in the installation
position at the bottom.
- Position washer O.

- Clamp the shock absorber into the special tool.

1 Spring compressor (T14050S) (8 p. 340)

• lnfo
1 Use the suitable ring of the special tool with the small-
est possible inside diameter.

- Mount spring retainer 8.

✓ The open end is opposite the spring end.
- Release the spring. Remove the shock absorber from the
special tool.
- Clamp the shock absorber into the vise.
Guideline
1 Use soft jaws.

Alternative 1
- Tension the spring to the prescribed position by turning
adjusting ring f.}.
Guideline
Spring preload
Standard l 5 clicks
Full payload 1 10 clicks

1 Hook wrench (T106S) (O p. 340)

Alternative 2

Warning
Danger of accident Modifications to the sus-
pension 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 recom-
mended range.
- Ride slowly to start with after making
adjustments to get the feel of the new
handling characteristic.

56
 SHOCK ABSORBER, LINK FORK 9

- Tension the spring to the position measured during d is-

mantling by turning adjusting ring f).
•
9.9 Checkin the link fork
- Check the link fork for damage, cracking, and deformation.
lf the link fork exhibits damage, cracking, or deformation:
- Change the link fork.

• lnfo
1 Damaged link forks must always be replaced.
Husqvarna Motorcycles does not permit
repairing link forks.
R01993-10
•
9.10 Removing the link fork
Preparatory work
- Remove the license plate holder. (8 p. 86)
- Raise the motorcycle with the work stand. (8 p . 14)
Main work
Remove screws O with the washers.
Take off the splash protector.

- Clamp down the front of the vehicle.

✓ The rear wheel is not in contact with the ground.
- Remove screw 8 and pull wheel speed sensor CD out of
the hole.
Remove nut C, with the washer.
Remove chain adjuster 0.
- Hold the rear wheel and remove wheel spindle (!) with the
washer and chain adjuster @ .
- Push the rear wheel forward as far as possible and take the
chain off the rear sprocket.

Warning
Danger of accidents Damaged brake discs reduce
the braking effect.
- Always lay the wheel down in such a way that the
brake disc is not damaged.

- Pull the rear wheel back and take it out of the link fork.

57
9 SHOCK ABSORBER, LINK FORK

lnfo
Do not operate the foot brake lever when the rear
wheel is removed.

- Remove spacers G,.

'-~o,'
': v

~~
@)
<>~@)
/\
~0? G03285-10

- Expose cable @) and brake line 41!).

- Take off the brake caliper and hang to the side.

• lnfo
1 Cover the components to protect them against dam-
age.

- Hang chain 48 to the side.

• lnfo
1 Cover the components to protect them against dam-
age.

- Remove fitting 49.

- Push the link fork down and away from the shock absorber.

- Remove nut G) with the washer.

- Remove fork pivot 41) with the washer.

58
 SHOCK ABSORBER, LINK FORK 9

- Loosen adjusting rings C8 using the special tool.

1 Groove nut wrench (75029034000) (l!il p. 333)
- Take off the link fork.
41

Main work
- Position the link fork.
- Evenly adjust adjusting rings O on the right and left using
the specíal t ool.
Guideline
Adjusting ring, link M22x1 Tighten and ensure
fork bearing that there is no
play

1 Groove nut wrench (75029034000) (liili p. 333)

✓ The adjusting ring is flush with the collar bushing.

- Mount fork pivot 8 with the washer.

- Mount and t ighten nut (9 with the washer.
Guideline
1 Nut, fork pivot 1 M14x1.5 1 100 Nm (73.8 lbf ft) 1

- Lift the link fork and position shock absorber.

- Mount and tighten f itting C,.
Guideline
Screw, bottom M 10x1 .25 52 Nm (38.4 lbf ft)
shock absorber Loctite®243™

59
9 SHOCK ABSORBER, LINK FORK

- Check the wheel bearing for damage and wear.

lf the wheel bearing is damaged or worn:
- Change the rear wheel bearing. (O p . 106)
- Clean and grease shaft seal rings f) and contact
surfaces (¡) of the spacers.

1 Long-life grease (l!ill p. 326)

- Clean the thread of the wheel spindle and axle nut.
T02204•10 - Clean and grease the wheel spindle.
1 Long-life grease (O p. 326)
- Clean the contact areas on the brake caliper bracket and link
fork.
- lnsert the narrow spacer into the side of the rear sprocket.
- lnsert the wide spacer into the side of the brake disc.
- Position the rear wheel.
✓ The brake linings are correctly positioned.
- Push the rear wheel forward as far as possible and lay the
chain on the rear sprocket.
- Pull the rear wheel back and mount wheel spindle 0 with
the washer and chain adjuster (D .

• lnfo
1 Mount left and right chain adjusters (D in the same
position.

- Mount nut @ with the washer.

Make sure that the chain adj usters are fitted correctly on the
screws.
Tighten nut @.
Guideline
In order for the rear wheel to be correctly aligned, the
markings on the left and right chain adjusters must be in
the same position relative to reference markings 8.
Nut, rear wheel spin- M14x1 .5 90 Nm (66.4 lbf ft)
die

- Position wheel speed sensor G) in the hole.

- Mount and tighten screw @).
Guideline
Screw, wheel M6 8 Nm (5.9 lbf ft)
speed sensor Loctite®243n.o

- Remove load from the front of the vehicle.

60
 SHOCK ABSORBER, LINK FORK 9

- Secure cable G) and brake line 41 in the bracket.

- Position the splash protector.

- Mount and tighten screws 48 w ith the washers.
Guideline
Screw, splash pro- M6 6 Nm (4.4 lbf ft)
tector

Finishing work
- Check the chain tension. (O p . 109)
- Remove the motorcycle from the work stand. (O p. 15)
- lnstall t he license plate holder. (O p. 87)
...
9.12 Checkin the fork bearin
Preparatory work
- Raise the motorcycle with the work stand. (iéll p. 14)
- Place a load on the front of the vehicle.
✓ The rear wheel is not in contact with the ground.
Mainwork
- Move the link fork up and down.
lf there is detectable play:
- Change the fork bearing. (~ p. 62)
- Move the link fork from one side to the other.
lf there is detectable play:
- Change the fork bearing. (ll!l: p. 62)

H01903-01

Finishing work
- Remove the motorcycle from the work stand. (l!!:!l p. 15)
...

61
9 SHOCK ABSORBER, LINK FORK

9.13 Chan in the fork bearin

Preparatory work
- Remove the license plate holder. (8 p. 86)
- Raise the motorcycle w ith the work stand. (IY;!J p. 14)
- Remove the link fork. (8 p. 57)
Left fork bearing
- Remove collar bushings O.

•-~ ~-•
R03807-10

- Remove bushing 8.

R03809-10

- Remove shaft seal rings (9 using a suitable tool.

- Remove stop disks C,.
- Press out bearing 0 using a sultable tool.
- Using a suitable tool, press in new bearing 0.
- Position the stop disks C,.
- Press in shaft seal rings (9.

R03810- 10

62
 SHOCK ABSORBER, LINK FORK 9

- Mount bushing 8.

R03809-10

- Grease the shaft seal rings.

1 Long-life grease (~ p. 326)

O with the shoulder facing

~--
- Position t he collar bushings
inward.

O-i

R03808· 10

Right fork bearing

- Remove collar bushings (D .

C>-1 ,- e>
R03811• 10

63
9 SHOCK ABSORBER, LINK FORK

- Remove bushing @.

o
1

R03813 -10

- Remove shaft seal rings @) using a suitable tool.

- Press out bearing 0 using a suitable tool.
- Using a suitable tool, press in new bearing @).
- Press in shaft seal rings @) .

R03814-10

- Mount bushing @.

R03813-10

- Grease the shaft seal rings.

1 Long-life grease (O p. 326)
- Position the collar bushings (¡} with the shoulder facing
inward.

i-<D

Finishing work
- lnstall the link fork. (8 p. 59)
- Check the chain tension. (~ p . 109)
- Remove the motorcycle from the work stand. (O p. 15)

64
 SHOCK ABSORBER, LINK FORK 9

- lnstall t he license plate holder. (O p. 87)

•

65
1O EXHAUST SYSTEM

10.1 Removin the exhaust s stem

Preparatory work
- Remove the main silencer. (@!!J p. 69)
Main work
- Remove screw O . Remove the clamp.

- Remove screws 8.
- Remove screw 8 .
- Remove t he presilencer in a downward direction.

- Remove screw C,. Remove the clamp.

- Take off the catalytic converter in a downward direction.

66
 EXHAUST SYSTEM 10

- Remove screws 0.
- Remove the cover.
- Hang ignition coil and cable to the side.

- Expose and disconnect plug-in connector (D of the lambda

sensor.

- Remove nuts @.
- Take off the manifold in a forward direction.
...

Mainwork
Position the manifold.
Mount nuts O . but do not tighten yet.
Guideline
1 Nut, exhaust flange I M8 1 8 Nm (5.9 lbf ft)

67
1O EXHAUST SYSTEM

- Route t he cable.
- Join plug- in connector @.

- Position the ignition coil.

- Position the cover.
- Mount and t ighten screw (D.
Guideline
Rem aining screws, M6 10 Nm (7.4 lbf ft)
chassis

- Mount and tighten screw C, with the ground wire.

Guideline
Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis

- Position the catalytic converter with a clamp.

- M ount screw 0 , but do not tighten yet.
Guideline
1 Exhaust clamp 1 - 1 20 Nm (14.8 lbf ft)

68
 EXHAUST SYSTEM 10

- Position the presilencer.

- Mount and t ighten screws (¡) .
Guideline
1Screw, main silencer I M6 1 12 Nm (8.9 lbf ft)
Mount and tighten screw @.
Guideline
1Screw, main silencer I M8 1 23 Nm (17 lbf ft)

- Position the clamp.

- Mount screw Ci), but do not t ighten yet.
Guideline
1 Exhaust c lamp 1 -
1 20 Nm (14.8 lbf ft)

- Tighten nuts O.
Guideline
1 Nut, exhaust flange I M8 1 8 Nm (5.9 lbf ft)

- Tighten screw 0 and Ci) evenly.

Guideline
1 Exhaust c lamp 1 -
1 20 Nm (14.8 lbf ft)

Finishing work
- lnstall the main silencer. (0 p. 70)
.
- Remove screw O . Remove the clamp.

69
1O EXHAUST SYSTEM

- Remove fitting 8.
- Take off the main silencer.
...

- Position the main silencer with the gasket.

- Mount fitting 0 , but do not t ighten yet.
Guideline
1 Screw, main silencer I M8 1 23 Nm (17 lbf ft)

- Position the clamp. Mount and tighten screw 8.

Guideline
1 Exhaust clamp 1 - 1 20 Nm (14.8 lbf ft)
- Tighten fitting O.
Guideline
1Screw, main silencer I M8 1 23 Nm (17 lbf ft)
...

70
 AIR FILTER 11

11.1 Chan in the air filter cleanin the air filter box
Preparatory work
- Remove the passenger seat. (ÉJI p. 7 4)
- Remove the front rider's seat. (8 p. 75)
Main work
- Remove screws O.
- Take off the air filter box cover.

- Push the hold ing lugs forwards.

- Remove the air fi lter.
- Clean the air filter box.

- Position new air fi lter in the guides.

- Engage holding lugs to the rear.

71
11 AIR FILTER

- Mount the air filter box cover.

• lnfo
1 Check that the air filter box cover is correctly seated.

- Mount and tighten screws O.

Guideline
Screw, air filter box M6 3 Nm (2.2 lbf ft)
cover

Finishing work
- Mount the front rider's seat. (!!! p. 75)
- Mount the passenger seat. (Él p. 74)

72
 FUEL TANK, SEAT, TRIM 12

12.1 fuel tank filler ca

~ Danger
t..¡.J 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 viciníty of open flamas or lit cigarettes.
- Switch off the engine for refueling.
- Make sure that no fuel is spilled; particularty not on hot parts of the vehicle.
- lf any fuel is spilled, wipe it off immediately.
- Observe the specifications for refueling.

Warning
Danger of poisoning Fuel is poisonous and a health hazard.
- Avoid skin, eye and clothing contact with fuel.
- lmmediately consulta 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 w ith 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.

Note
Environmental hazard lmproper handling of fuel is a danger t o the environment.
- Do not allow fuel to enter the groundwater, the soil, or the sewage system.

- Lift cover O of the fuel tank filler cap and insert the ignition
key into the lock.

Note
Danger of damage The ignition key may break if over-
loaded.
Damaged ignition keys must be replaced.
Push down on the fuel tank filler cap to take pressure off
the ignition key.

- Turn t he ignition key 90º clockwise.

- Lift the fuel tank filler cap.
...

73
12 FUEL TANK, SEAT, TRIM

Warning
Fire hazard Fuel is highly flammable, toxic and a
health hazard.
- Check that the fuel tank filler cap is locked cor-
rectly after closing.
- Change your clothing if fuel spills on them.
- Rinse the affected area immediately with plenty of
water in the event of contact with the skin.

- Fold down the fuel tank filler cap.

- Turn the ignition key 90º clockwise.
- Push down the fuel tank fil ler cap and turn the ignition key
counterclockwise until the fuel tank filler cap lock engages.
- Remove the ignition key and close the cover.

12.3 assenger seat

- lnsert the ignition key in seat lock O and turn it clockwise.
- Raise the rear of the passenger seat, push it towards the rear,
and lift it off.
- Remove the ignition key from the seat lock.

l
'
H02674-1 0

12.4 erseat
- Attach hooks O on the passenger seat to seat mounting 8
on the subframe, and lower it at the rear while pushing for-
ward.
- Press passenger seat downward until it clicks into place.

Warning
Danger of accidents The seat can come loose
from the anchoring if it is not mounted correctly.
H02675-10 - After assembly, check whether the seat is cor-
rectly locked and cannot be pulled up.

- Finally, check that the passenger seat is correctly mounted.

74
 FUEL TANK, SEAT, TRIM 12

12.5 Removin the front rider's seat

Preparatory work
- Remove the passenger seat. (ÉJI p. 7 4)
Main work
- Raise the rear of the front rider's seat, pull it toward the rear,
and remove it upward.
•

H02676-10

12.6 Mountin the front rider's seat

M ainwork
- Attach the front rider's seat in area 6) and lower at the rear.
- Finally, check that the front rider's seat is correctly mounted.

H02677-10

Finishing work
- Mount the passenger seat. (8 p. 74)

Removing the bag carrier

- Remove screws O with the bushings.
- Take off the bag carrier.

- Remove bushings 8 .
•

75
12 FUEL TANK, SEAT, TRIM

- Mount bushings O.

- Position bag carrier.

- Mount screws 8 with bushings and tighten.
Guideline
1 Screw, bag carrier I M6x45 15Nm (3.7 lbf ft)
•

12.9 Removing the left side cover

Preparatory work
- Remove the bag carrier. (0 p. 75)
- Remove the passenger seat. (8 p. 7 4)
- Remove the front rider's seat. (U p. 75)
Main work
- Remove screw O.

- Remove screw 8.

76
 FUEL TANK, SEAT, TRIM 12

- Pull off holding lug in area 6) .

- Take off the side cover forwards .

lnstalling the left side cover

Main work
- Position the side cover.
✓ Holding lug 6) engages in bracket @) .
- Engage side cover in area C9.

- Mount and tighten screw O.

Guideline
Screw, fuel tank 15Nm (3.7 lbf ft)
.1 bridge

- Mount and tighten screw 8 .

Guideline
1 Screw, front trim 1 M6x15 ¡s Nm (3.7 lbf ft)

77
12 FUEL TANK, SEAT, TRIM

Finíshíng work
- Mount the front rider' s seat. (9 p. 75)
- Mount the passenger seat. (1$ p. 74)
- lnstall the bag carrier. (O p. 76)

12.11 Removing the right side cover

Preparatory work
- Remove the bag carrier. (O p . 75)
- Remove the passenger seat. (a p. 74)
- Remove the front rider's seat. (!!! p. 75)
Main w ork
- Remove screw O.

- Remove screw 8.

- Pull off holding lug in area f) .

- Take off the side cover forwards.

78
 FUEL TANK, SEAT, TRIM 12

12.12 ht side cover

Main work
- Position the side cover.
✓ Holding lug O engages in bracket @) .
- Engage side cover in area (9.

- Mount and tighten screw O.

Guideline
Screw, fuel tank M6 5 Nm (3.7 lbf ft)
bridge

- Mount and tighten screw $ .

Guideline
1 Screw, front trim 1 M6x15 15Nm (3.7 lbf ft)

Finishing work
- Mount the front rider's seat. (8 p. 75)
- Mount the passenger seat. (é:! p. 74)
- lnstall t he bag carrier. (l!! p. 76)
•

79
12 FUEL TANK, SEAT, TRIM

12.13 Removin the fuel tank

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.
- lf any fuel is spilled, wipe it off immediately.
- Observe the specifications for refueling.

Warning
Danger of poisoning Fuel is poisonous and a health hazard.
- Avoid skin, eye and clothing contact with fuel.
- lmmediately consulta 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 w ith 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.

Note
Environmental hazard lmproper handling of fuel is a danger t o the environment.
- Do not allow fuel to enter the groundwater, t he soil, or the sewage system.

Preparatory work
- Remove the bag carrier. (i!l p. 75)
- Remove the passenger seat. (a p. 7 4)
- Remove the front rider's seat. (!! p. 75)
- Remove the left side cover. (l!UII p. 76)
- Remove the right side cover. (!!JI! p. 78)
Main work
- Take off fuel tank cover O.

80
 FUEL TANK, SEAT, TRIM 12

- Pull off air ralease hose 8.

- Pull off overflow hose (s) .
- Expose hoses.

Remove screws C,.

- Remove screw 0.

- Raise the fuel tank.

- Pull off the fuel tank in area f).

- Unplug connector (¡).

81
12 FUEL TANK, SEAT, TRIM

- Disconnect fuel hose connection O.

• lnfo
1 Remaining fuel may flow out of the fuel hose.

- Take off the fuel tank.

..
12.14 lnstalling the fuel tank

m Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank ex.pands 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.
- lf any fuel is spilled, wipe it off immediately.
- Observe the specifications for refueling.

Warning
Danger of poisoning Fuel is poísonous and a health hazard.
- Avoid skin, eye and clothing contact with fuel.
- lmmediately consuit 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 w ith 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 oorrectly in a suitable canister, and out of the reach of children.

Note
Environmental hazard lmproper handling of fuel is a danger to the environment.
- Do not allow fuel to enter the groundwater, the soil, or the sewage system.

Main work
- Plug in fuel hose connection O.

82
 FUEL TANK, SEAT, TRIM 12

- Plug in connector 8.

- Position the fuel tank.

- Mount the fuel tank in area f).

- Mount and tighten screw @).

Guideline
Screw, fuel tank M8x40 21 Nm (15.5 lbf ft)
bridge

- Mount and tighten screws C,.

Guideline
Screw, fuel tank M8x30 26 Nm (19.2 lbf ft)
bridge

- Route hoses.
- Mount vent hose 0.
- Mount overflow hose (D .

83
12 FUEL TANK, SEAT, TRIM

- Position fuel tank cover O.

Finishing work
- lnstall the left side cover. (8 p. 77)
- lnstall the right side cover. (l!:-5 p. 79)
- Mount the front rider' s seat. (a p. 75)
- Mount the passenger seat. (O p. 74)
- lnstall the bag carrier. (~ p. 76)

- Remove screws O.

- Remove screws 8.
- Remove the engine guard.
•

12.16
- Position engine guard. Mount screws O but do not t ighten
yet.
Guideline
Screw, front engine M5x12 5 Nm (3.7 lbf ft)
guard

84
 FUEL TANK, SEAT, TRIM 12

- Mount and tighten screws 8.

Guideline
Screw, rear engine M6x12 10 Nm (7.4 lbf ft)
guard

- Tighten screws O.
Guideline
Screw, front engine M5x12 5 Nm (3.7 lbtft)
guard
41

12.17 Removing front tender

- Remove screws O . Take off the front tender.

- Position front tender. Mount and tighten screws O.

Guideline
Screw, tender on M6 7 Nm (5.2 lbt ft)
axle clamp
41

85
12 FUEL TANK, SEAT, TRIM

- Take the cable out of holders.

- Remove the cable t ie.

- Disconnect plug-in connector O.

- Expose the cable.

- Remove screw @.

86
 FUEL TANK, SEAT, TRIM 12

- Remove nut @.

- Remove screws C) , @) and (i).

- Remove screw @.
- Take off the lícense plate holder.
•

- Position the license plate holder.

- Mount screw O but do not tighten yet.
Guideline
Screw, license M8x20 20 Nm (14.8 lbf ft)
plate holder Loctite®243™

- Mount screw 8 but do not tighten yet.

Guideline
Screw, license pi ate M6 5 Nm (3.7 lbf ft)
holder

- Mount screw @) but do not tighten yet.

Guideline
Screw, license M8x35 25 Nm (18.4 lbf ft)
plate holder Loctite®243™

- Mount and tighten screw C).

87
12 FUEL TANK, SEAT, TRIM

Guideline
Screw, license M 10x30 45 Nm (33.2 lbf ft)
plate holder Loctite®243TM

- Tighten screws O , 8 , and (D .

Guideline
Screw, license M8x20 20 Nm (14.8 lbf ft)
plate holder Loctite®243™
Screw, license M6 5 Nm (3.7 lbf ft)
plate holder
Screw, license M8x35 25 Nm (18.4 lbf ft)
plate holder Loctite®243™

- Mount and tighten nut 0.

Guideline
Rem aining nuts, M5 5 Nm (3.7 lbf ft)
chassis

- Mount and tighten screw (D.

Guideline
Screw, chain M5 7 Nm (5.2 lbf ft)
guard Loctite®243™

- Route the cable without tension.

- Join plug-in connector @.

- Mount the cable t ie.

88
 FUEL TANK, SEAT, TRIM 12

- Secure the cable in the holders.

•

12.21 Checking the fuel P-ressure

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; particularty not on hot parts of the vehicle.
- lf any fuel is spilled, wipe it off immediately.
- Observe the specifications for refueling.

Warning
Danger of poisoning Fuel is poisonous and a health hazard.
- Avoid skin, eye and clothing contact with fuel.
- lmmediately consulta 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.

Condition
The fuel tank is completely full.
Ensure that the battery voltage does not drop below 12.5 V.
The ignition is off.
The diagnostics tool is connected .

89
12 FUEL TANK, SEAT, TRIM

- Disconnect fuel hose connection O.

• lnfo
1 Remaining fuel may flow out of the fuel hose.

- Remove connection 8 from the hose.

1 Pressure testing tool (61029094000) (1!91 p. 332)
8
..
1
- ....

002699-10

- Mount special tool @.

1 Pressure testing tool (61029094000) (8 p. 332)

- Mount special tool C) with nozzle code 0 ,60.

1 Testing hose (61029093000) (ll!! p. 332)
- Position the hose end in a fuel can.
Guideline
1 Minimum size, fuel can 110 1(2.6 US gal)
- Switch the ignition on.
- "Actuator test" > "Exec ute func-
tion test of fuel pump control".
- Check the fuel pressure with the fuel tank filler cap closed.
Fuel pressure
When the fuel pump is 1 3.2 ... 3. 7 bar (46 ... 54 psi)
\
active
lf the specification is not reached:
- Open fuel tank filler cap. (8 p . 73)
- Check the fuel tank breather.

- Check the fuel pressure with the fuel tank filler cap open.
Fuel pressure
When the fuel pump is 1 3.2 ... 3. 7 bar (46 .. . 54 psi)
active
lf the specification is not reached:
- Check that the fuel line is c lear.
- Change the fuel f ilter. (&ll p. 9 1)
- Change the fuel pump _(él p. 92)

90
 FUEL TANK, SEAT, TRIM 12

- Stop the "Function test of fuel pump control" actuator test

by pressing the "Quit" button.
- Remove the special tools.

- Join the fue! hose connection O.

•

12.22 Changlng the fuel fllter

Danger
Fire hazard Fuel is highly flammable.
The fue! in the fue! tank expands when warm and can escape if overfilled.
- Do not refuel the vehicle in the vicinity of open flamas or lit cigarettes.
- Switch off the engine for refueling.
- Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
- lf any fuel is spilled, wipe it off immediately.
- Observe the specifications for refueling.

Warning
Danger of poisoning Fuel is poisonous and a health hazard.
- Avoid skin, eye and clothing contact with fuel.
- lmmediately consulta doctor if you swallow fue!.
- Do not inhale fue! 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 fue! spills on them.
- Keep fuels correctly in a suitable canister, and out of the reach of children.

Note
Environmenta l hazard lmproper handling of fue! is a danger to the environment.
- Do not allow fue! to enter the groundwater, the soil, or the sewage system.

Preparatory work
- Remove the bag carrier. (i!l p. 75)
Remove the passenger seat. (~ p. 74)
- Remove the front rider's seat. (Él p. 75)
Remove the left side cover. (O p. 76)
- Remove the right side cover. (0 p. 78)
- Remove the fuel tank. (8 p. 80)
- Drain the fuel from the fuel tank into a suitable container.

91
12 FUEL TANK, SEAT, TRIM

Main w ork
- Take fuel filter O out of the holder.
- Disconnect fuel hose connectlons f) and @).
- Remove fuel filter.
- Positlon new fuel filter.
✓ Arrow points away from the dlrection of travel.
- Join fuel hose connections f) and @) .
R03753-10
- Position fuel filter O in the holder.
Finishing work
- lnstall the fuel tank. (8 p. 82)
- lnstall the left side cover. (O p. 77)
- lnstall the right side cover. (l!U! p. 79)
- Mount the front rider's seat. (O p. 75)
- Mount the passenger seat. (f!:! p. 74)
- lnstall the bag carrier. (~ p. 76)
•
12.23 Chan

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.
- lf any fuel is spilled, wipe it off immediately.
- Observe the specifications for refueling.

Warning
Danger of poisoning Fuel is poisonous and a health hazard.
- Avoid skin, eye and clothing contact with fuel.
- lmmediately consulta 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 w ith water, and consult a doctor in case of fuel contact with the eyes.
- Change your clothing in case of fuel spílls on them.
- Keep fuels correctly in a suitable canister, and out of the reach of children.

Note
Environmental hazard lmproper handling of fuel is a danger to the environment.
- Do not allow fuel to enter the groundwater, the soil, or the sewage system.

Preparatory work
- Remove the bag carrier. (i!l p. 75)
- Remove the passenger seat. (8 p. 74)
- Remove the front rider's seat. (!! p. 75)
- Remove the left side cover. (lit! p. 76)
- Remove the right side cover. (!!! p. 78}

92