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Husqvarna FE 350 2016 Repair Manual
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Husqvarna FE 350 2016 Repair Manual

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PIONEERING SINCE 1903
REPAIR MANUAL2016
FE 350
FE 350 S
®
Husqvarna
Art. no. 3403027en
MOTORCYCLES

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Summary of Contents for Husqvarna FE 350 2016

  • Page 1 PIONEERING SINCE 1903 REPAIR MANUAL2016 FE 350 FE 350 S ® Husqvarna Art. no. 3403027en MOTORCYCLES...
  • Page 3 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.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 6.15 Disassembling the seal ring MEANS OF REPRESENTATION ......7 retainer ..........26 Symbols used ........7 6.16 Checking the fork legs ......26 1 .2 Formats used ........7 6.17 Assembling the seal ring retainer ..28 SAFETY ADVICE ..........
  • Page 5 TABLE OF CONTENTS Adjusting the riding sag ...... 53 12.6 Mounting the seat ....... 97 Removing the shock absorber .... 54 12.7 Removing the fuel tank ....... 98 9.10 Installing the shock absorber ....55 12.8 Installing the fuel tank ....... 100 9.11 Checking the shock absorber 12.9...
  • Page 6 TABLE OF CONTENTS 15.3 Checking the starter relay ....143 18.3.9 Removing the torque limiter ..184 15.4 Removing the battery ......143 18.3.10 Positioning the engine at ignition top dead center ....184 15.5 Installing the battery ......144 18.3.11 Removing the timing chain 15.6...
  • Page 7 TABLE OF CONTENTS 18.4.12 18.5.12 Installing the drive wheel of the Installing the locking lever .... 234 balancer shaft ....... 206 18.5.13 Installing the shift drum locating 18.4.13 Cylinder - Nikasil ® coating .... 206 unit ..........234 18.4.14 Checking/measuring the 18.5.14 Installing the shift shaft ....
  • Page 8 TABLE OF CONTENTS IGNITION SYSTEM ........265 30.2 Page 2 of 8 (EU) ........ 294 30.3 Page 3 of 8 (EU) ........ 296 22.1 Ignition coil - checking the 30.4 Page 4 of 8 (EU) ........ 298 secondary winding ......265 30.5 Page 5 of 8 (EU) ........

  • Page 9: Means Of Representation

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

  • Page 10: Safety Advice

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

  • Page 11: Important Notes

    3 IMPORTANT NOTES Manufacturer and im�lied warran The work prescribed in the service schedule must be carried out by an authorized Husqvarna Motorcycles workshop only and confirmed both in the customer's Service & Warranty Booklet and in the Husqvarna Motor­...

  • Page 12: Serial Numbers

    4 SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right. 401945-10 e label (FE EU/ AU FE 350 S US) (FE EU/AU) Type label is fixed to the front of the steering head. 401946-10 (FE 350 SUS) Type label...

  • Page 13: Key Number (Fe Eu/Au, Fe 350 S Us)

    4 SERIAL NUMBERS Ke� number (FE EU/ AU, FE 350 S US) {FE EU/AU) The key number for the steering lock is stamped onto the key connector. 402247-10 ,r,r {FE 350 5 US) Key number for the ignition and steering lock is indicated on the KEYCODECARD.

  • Page 14: Shock Absorber Article Number

    4 SERIAL NUMBERS Shock absorber article number Shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side.

  • Page 15: Motorcycle

    5 MOTORCYCLE Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle can roll away or fall over. Park the vehicle on a firm and level surface. Raise the motorcycle at the frame underneath the engine. Lift stand (81329955100) (!,) p.

  • Page 16: Starting The Motorcycle For A Check

    5 MOTORCYCLE Raise the motorcycle off of the stand and secure the stand with the rubber band Shift transmission to neutral. (FE 350 SUS) Turn the key in the ignition lock to the position 0. Turn the emergency OFF switch to the position 0. (FE AU) Turn the emergency OFF switch to the position 0.

  • Page 17: Fork, Triple Clamp

    6 FORK, TRIPLE CLAMP Adjusting the com�ression dam ing of the fork Info The hydraulic compression damping determines the fork suspension behavior. Turn the white adjusting screw all the way clockwise. Info The adjusting screw is located at the upper end of the left fork leg.

  • Page 18: Bleeding The Fork Legs

    6 FORK, TRIPLE CLAMP Info Turn clockwise to increase damping; turn counter­ clockwise to reduce damping. Bleeding the fork legs Preparatory work Raise the motorcycle with a lift stand. p. 13) Main work Release bleeder screws ✓ Any excess pressure escapes from the interior of the fork.

  • Page 19: Removing The Fork Legs

    6 FORK, TRIPLE CLAMP Finishing work Install the fork protector. (llill p. 19) Remove the motorcycle from the lift stand. (llill p. 13) Removing the fork legs Preparatory work Remove the headlight mask with the headlight. (llill p. 113) Raise the motorcycle with a lift stand. (llill p.
  • Page 20 6 FORK, TRIPLE CLAMP Info The compression damping is located in left fork COMP (white adjusting screw). The rebound damping is located in right fork leg REB (red adjusting screw). Grooves are milled into the side of the upper end of the fork legs.

  • Page 21: Removing The Fork Protector

    6 FORK, TRIPLE CLAMP Remove screws and take off the clamp. Remove screws on the left fork leg. Take off the fork pro- tector. Remove screws on the right fork leg. Take off the fork protector. Installing the fork �rotector Position the fork protector on the left fork leg.

  • Page 22: Disassembling The Fork Legs

    6 FORK, TRIPLE CLAMP Disassembling the fork legs Info The operations are the same on both fork legs. Condition The fork legs have been removed. Note down the current state of rebound damping (red adjuster on the right fork leg). Note down the current state of compression damping (white adjuster on the left fork leg).
  • Page 23 6 FORK, TRIPLE CLAMP Clamp the fork leg with the axle clamp. Release hydrostop unit and remove it. Info Do not use an impact wrench. Place a pan underneath since oil will run out. Remove the cartridge from the fork leg. Pressing tool (T14051) (�...

  • Page 24: Removing The Spring

    6 FORK, TRIPLE CLAMP Remove upper sliding bushing Info Without using a tool, pull the stack slightly apart by hand. Take off lower sliding bushing Take off support ring 41). Take off seal ring Take off lock ring@. Take off dust boot Cs). Unclamp the fork leg.

  • Page 25: Disassembling The Cartridge

    6 FORK, TRIPLE CLAMP Disassembling the cartridge Info The procedures are the same on both fork legs. Preparatory work Disassemble the fork legs. p. 20) Remove the spring. p. 22) Main work Degrease piston rod and clamp using the special tool. Clamping stand (T14049S) (�...

  • Page 26: Disassembling The Piston Rod

    6 FORK, TRIPLE CLAMP Pull sleeve out of the reservoir. Remove spring@) with preload spacers@). R00028-10 Remove seal rings Ci) and O-ring Remove pilot bushings«&. • R00029-10 Disassembling the �iston rod Info The steps are identical for both fork legs, except for the hydrostop needle and valve. Preparatory work Disassemble the fork legs.

  • Page 27: Disassembling The Hydrostop Unit

    6 FORK, TRIPLE CLAMP Remove compression shim stack@). Remove the spring. R00031-10 Remove adapter with spring @. Remove spring @. Remove valve needle from the piston rod. Info The adjusting tube can be used for this. Disassembling the hydrostop unit Info The procedures are the same on both fork legs.

  • Page 28: Disassembling The Seal Ring Retainer

    6 FORK, TRIPLE CLAMP Remove adapter Remove hub Remove O-ring from the hub. Remove shim stack C). Remove washer @. Remove O-ring Disassembling the seal ring retainer Info The steps are identical for both fork legs. Preparatory work Disassemble the fork legs. (!i.,!I p.
  • Page 29 6 FORK, TRIPLE CLAMP Check the inner tube and axle clamp for damage. If there is damage: Change the inner tube. B03581-10 Measure the outside diameter at multiple locations of the inner tube. Outside diameter of inner 47.975 ... 48.005 mm tube (1 .88878 ...

  • Page 30: Assembling The Seal Ring Retainer

    6 FORK, TRIPLE CLAMP Check the spring length. Guideline Spring length with preload 475 mm (18.7 in) spacer(s) If the measured value is larger than the specified value: Reduce the thickness of the preload spacers. If the measured value is smaller than the specified value: •...

  • Page 31: Assembling The Piston Rod

    6 FORK, TRIPLE CLAMP Mount washer (3 and shim stack @. Info Note the setting list. Mount sleeve@. Turn hydrostop unit and clamp sleeve @with special tool. Clamping stand (T1202S) p. 367) Tighten sleeve@. Guideline 6 Nm (4.4 lbf ft) Hydrostop unit M6x0.5 sleeve...

  • Page 32: Assembling The Cartridge

    6 FORK, TRIPLE CLAMP Grind the piston on both sides on a surfacing plate using 1200 grit sandpaper. Clean the piston. Lubricate the piston ring. I Fork oil (SAE 4) (48601166S1) (11\:! p. 352) Mount the piston with chamfer facing down. Mount rebound shim stack with the smaller shims facing upward.
  • Page 33 6 FORK, TRIPLE CLAMP Main work Mount and grease seal rings and O-ring @. Lubricant (T158) (� p. 354) Mount and lubricate pilot bushings Fork oil (SAE 4) (48601166S1) (� p. 352) R00029-11 Check the length of the reservoir spring. Guideline Reservoir spring length with 46 mm (1.81 in)

  • Page 34: Assembling The Fork Legs

    6 FORK, TRIPLE CLAMP Clamp piston rod with the special tool. I Clamping stand (T14049S) (I!!,! p. 370) Mount spring guide � all the way on. Info The nut must be firmly tightened against the stop by hand. Do not use a tool. Mount adjusting tube 202480-11 Unclamp the piston rod.
  • Page 35 6 FORK, TRIPLE CLAMP Sand the edges of the sliding bushings with 600 grit sandpa­ per; then clean and grease the bushings. Fork oil (SAE 4) (48601166S1) (llill p. 352) 201715-10 Push on lower sliding bushing Mount upper sliding bushing Q). Info Without using a tool, pull the stack slightly apart by hand.
  • Page 36 6 FORK, TRIPLE CLAMP Mount dust boot Mount fork protector ring G). Grease the O-ring. I Fork oil (SAE 4) (48601166S1) (ll!:!l p. 352) Slide the cartridge all the way into the fork leg. Turn the fork. Have the entire filling quantity of fork oil available. Oil capacity per fork 630 ml Fork oil (SAE 4)
  • Page 37 6 FORK, TRIPLE CLAMP Pull out the piston rod and push it back in numerous times while pressing it to one side slightly. ✓ Air bubbles emerge and the cartridge is bled. Keep bleeding until no more air bubbles emerge. ✓...

  • Page 38: Lubricating The Steering Head Bearing

    6 FORK, TRIPLE CLAMP Alternative 1 Turn the adjuster for rebound damping � (mark REB) and the adjuster for compression damping (mark COMP) clockwise all the way. Turn counterclockwise by the number of clicks corre­ sponding to the fork type. Guideline Rebound damping Comfort...

  • Page 39: Removing The Lower Triple Clamp

    6 FORK, TRIPLE CLAMP 6.23 Removing the lower tri�le clam� Preparatory work Remove the headlight mask with the headlight. (� p. 113) Raise the motorcycle with a lift stand. (� p. 13) Remove the front wheel.(� p. 121) Remove the fork legs. (�...

  • Page 40: Installing The Lower Triple Clamp

    6 FORK, TRIPLE CLAMP 6.24 Installing the lower tri�le clam� Main work Clean the bearing and sealing elements, check for damage, and grease. I High viscosity grease (I!!:! p. 354) Position the lower triple clamp with the steering stem. Mount the upper steering head bearing.
  • Page 41 6 FORK, TRIPLE CLAMP (FE EU/AU, FE 350 US) Tighten screws (D. Guideline Screw, bottom 15 Nm (11.1 lbf ft) triple clamp (FE 350 SUS) Tighten screws (D. Guideline Screw, bottom 15 Nm (11.1 lbf ft) triple clamp Tighten screw Guideline Screw, top steering M20x1 .5...

  • Page 42: Checking The Play Of The Steering Head Bearing

    6 FORK, TRIPLE CLAMP (FE 350 SUS) Tighten screws (3. Guideline Screw, top triple 17 Nm (12.5 lbf ft) clamp Secure the wiring harness with cable holder@). Position the brake caliper. Mount and tighten screws Gi) with the washers. Guideline Screw, front 25 Nm (18.4 lbf ft) ®...

  • Page 43: Changing The Steering Head Bearing

    6 FORK, TRIPLE CLAMP Main work Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. Play should not be detectable on the steering head bear­ ing. If there is detectable play: Adjust the steering head bearing play.

  • Page 44: Adjusting The Steering Head Bearing Play

    6 FORK, TRIPLE CLAMP Remove upper bearing ring with special tool@. Tool bracket (58429089000) (I!!;! p. 359) Pressing tool (58429092000) (� p. 359) Press the new bearing ring up to the stop with special tool@). Tool bracket (58429089000) (� p. 359) Pressing tool (58429091000) p.
  • Page 45 6 FORK, TRIPLE CLAMP Main work (FE EU/ AU, FE 350 US) Loosen screws Remove screw Loosen and retighten screw Guideline Screw, top steering M20x1 .5 12 Nm (8.9 lbf ft) head Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses.

  • Page 46: 7 Handlebar,Controls

    7 HANDLEBAR,CONTROLS Handlebar �osition On the upper triple clamp, there are two holes at a distance to each other. 1 15 mm (0.59 in) I Hole distance The holes on the handlebar supports are placed at a distance from the center. 3.5 mm (0.138 in) I Hole distance The handlebar supports can be mounted in four different posi­...

  • Page 47: Adjusting The Basic Position Of The Clutch Lever

    7 HANDLEBAR,CONTROLS Info Make sure the gap width is even. 7 .3 Adjustin the basic position of the clutch lever Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw • Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar.

  • Page 48: Checking The Play In The Throttle Cable

    7 HANDLEBAR,CONTROLS (FE 350 SUS) Check the throttle cable routing. Both throttle cables must be routed to the throttle valve body side by side behind the handlebars and above the fuel tank bearing. If the throttle cable is not routed as specified: Correct the throttle cable routing.

  • Page 49: Adjusting The Play In The Throttle Cable

    7 HANDLEBAR,CONTROLS Adjusting the �la� in the throttle cable Preparatory work Remove the seat. (� p. 97) Remove the fuel tank. (� p. 98) Check the routing of the throttle cable. (� p. 45) Main work Move the handlebar to the straight-ahead position. Push back sleeves Loosen nut Turn adjusting screw@) in as far as possi-...

  • Page 50: Frame

    If the frame exhibits cracks or deformation due to a mechanical impact: Change the frame. • Info Always replace a frame that has been damaged due to a mechanical impact. Repair of the frame is not authorized by Husqvarna 401799-01 Motorcycles.

  • Page 51: Shock Absorber, Swingarm

    9 SHOCK ABSORBER, SWINGARM Adjusting the high-s eed com�ression dam�ing of the shock absorber Caution Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incor­ rectly. The shock absorber is filled with highly compressed nitrogen. Please follow the description provided.

  • Page 52: Adjusting The Rebound Damping Of The Shock Absorber

    9 SHOCK ABSORBER, SWINGARM Turn adjusting screw clockwise with a screwdriver up to the last perceptible click. Info Do not loosen fitting@! Turn counterclockwise by the number of clicks correspond­ ing to the shock absorber type. Guideline Compression damping, low-speed Comfort 20 clicks Standard...

  • Page 53: Measuring Rear Wheel Sag Unloaded

    9 SHOCK ABSORBER, SWINGARM Measuring rear wheel sag unloaded Preparatory work Raise the motorcycle with a lift stand. p. 13) Main work Measure the distance - as vertically as possible - between the rear axle and a fixed point such as a mark on the side cover.

  • Page 54: Checking The Riding Sag Of The Shock Absorber

    9 SHOCK ABSORBER, SWINGARM Checking the riding sag of the shock absorber Measure distance of rear wheel unloaded.(� p. 51) With another person holding the motorcycle, the rider, wear­ ing full protective clothing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down a few times.

  • Page 55: Adjusting The Riding Sag

    9 SHOCK ABSORBER, SWINGARM Main work Loosen screw Turn adjusting ring until the spring is no longer under ten- sion. Hook wrench (T1 06S) p. 367) Measure the overall spring length while the spring is not under tension. Tighten the spring by turning adjusting ring to measure­...

  • Page 56: Removing The Shock Absorber

    9 SHOCK ABSORBER, SWINGARM Main work Choose and mount a suitable spring. Guideline Spring rate Weight of rider: 65 ... 51 N/mm (291 lb/in) 75 kg (143 ... 165 lb.) Weight of rider: 75 ... 54 N/mm (308 lb/in) 85 kg (165 ... 187 lb.) Weight of rider: 85 ...

  • Page 57: Installing The Shock Absorber

    9 SHOCK ABSORBER, SWINGARM Installing the shock absorber Main work Carefully position the shock absorber into the vehicle from above. Finishing work Install the manifold. (� p. 85) Mount the seat. (� p. 97) Install the main silencer. (� p. 87) Install the right side cover.
  • Page 58 9 SHOCK ABSORBER, SWINGARM 303096-10 @» Check needle bearings for damage and wear. If there is damage or wear: Change the needle bearings. Check spacers and @ for damage and wear. If there is damage or wear: Change the spacers. Check the shaft seal rings for damage and wear.

  • Page 59: Servicing The Shock Absorber

    9 SHOCK ABSORBER, SWINGARM Mount screw but do not tighten yet. Guideline M 1 0 60 Nm (44.3 lbf ft) Screw, bottom ® Loctite 2701 shock absorber • Info Raise the wheel slightly to be able to mount the screw more easily.

  • Page 60: Removing The Spring

    9 SHOCK ABSORBER, SWINGARM Remove the spring. (!!',! p. 58) Disassemble the damper. (!!',! p. 59) Disassemble the piston rod. (!!',! p. 60) Disassemble the seal ring retainer.(!!',! p. 61) Check the damper. p. 63) Remove the heim joint. p. 64) Install the heim joint.

  • Page 61: Disassembling The Damper

    9 SHOCK ABSORBER, SWINGARM 9.14 Disassembling the dam er Preparatory work Remove the spring. (� p. 58) Main work Note down the current state of rebound damping compression damping Completely open the adjusters of the rebound and compres­ sion damping. Remove rubber cap of the reservoir.

  • Page 62: Disassembling The Piston Rod

    9 SHOCK ABSORBER, SWINGARM Remove the piston rod. Remove adjusting ring with the intermediate washer. Drain the oil. Remove compression adjuster@). Remove the spring and piston. 9.15 Disassembling the piston rod Preparatory work Remove the spring. (� p. 58) Disassemble the damper. (�...

  • Page 63: Disassembling The Seal Ring Retainer

    9 SHOCK ABSORBER, SWINGARM Remove rebound shim stack Info Place the rebound shim stack onto a screwdriver and set it down as a unit. Remove piston Remove compression shim stack • Info Place the compression shim stack onto a screwdriver and set it down as a unit.

  • Page 64: Changing The Pilot Bushing

    9 SHOCK ABSORBER, SWINGARM Remove centering disk Remove seal ring 201406-10 Remove washer for seal ring Remove washer @. Remove dust boot. 201407-10 9.17 Changing the ilot bushing Preparatory work Remove the spring. (!!.!I p. 58) Disassemble the damper. (!!.!I p.

  • Page 65: Checking The Damper

    9 SHOCK ABSORBER, SWINGARM Lubricate the special tool. Shock absorber fluid (SAE 2.5) (50180751 S1) (!!l p. 353) Calibrating unit (T1205) (l!,JI p. 368) Support seal ring retainer @} with sleeve of the special tool. Mounting tool (T150S) (l!,JI p. 371) Press the special tool through the new pilot bushing.

  • Page 66: Removing The Heim Joint

    9 SHOCK ABSORBER, SWINGARM Check the piston rings for damage and wear. If damage or a bronze-colored surface is visible: Change the piston. 201404-10 9.19 Removin the heim joint Condition The shock absorber has been removed. Clamp the shock absorber in the vise using soft jaws for pro­ tection.

  • Page 67: Installing The Heim Joint

    9 SHOCK ABSORBER, SWINGARM Installing the heim joint Position the new heim joint and the special tool into a vise as shown. Guideline Use soft jaws. Pressing tool (T1206) (� p. 368) Press the heim joint all the way in. Press the heim joint against the lock ring using the special tool.

  • Page 68: Assembling The Piston Rod

    9 SHOCK ABSORBER, SWINGARM Mount washer Position washer on seal ring 201409-10 Grease seal ring and mount with the washer facing down­ ward. I Lubricant (T14034) p. 354) Mount centering disk 201410-10 Mount rebound rubber (D. Grease the 0-ring groove. I Lubricant (T158) p.
  • Page 69 9 SHOCK ABSORBER, SWINGARM Mount rebound washer with the cut-out facing down­ ward. Mount the compression shim stack with the smaller shims facing downward. 201418-10 Sand both sides of piston on a surface plate using 1200- grit sandpaper. Clean the piston. Assemble the piston.

  • Page 70: Assembling The Damper

    9 SHOCK ABSORBER, SWINGARM Grease the thread of the piston rod. I Lubricant (T152) (� p. 354) Mount and tighten nut Q). Guideline I Nut, piston rod M16x1 45 Nm (33.2 lbf ft) 201422-10 9.23 Assemblin the damper Preparatory work Assemble the seal ring retainer.
  • Page 71 9 SHOCK ABSORBER, SWINGARM Install the seal ring bearer and push it under the ring groove. Mount lock ring • Info Do not scratch the inner surface. Pull out the piston rod so that the seal ring retainer rests against the lock ring. Mount locking cap (3 of the damper cartridge.

  • Page 72: Bleeding And Filling The Damper

    9 SHOCK ABSORBER, SWINGARM Turn counterclockwise by the number of clicks corre­ sponding to the shock absorber type. Guideline Rebound damping Comfort 20 clicks Standard 18 clicks Sport 16 clicks Alternative 2 Warning Modifications to the sus­ Danger of accident pension setting may seriously alter the handling characteristic.
  • Page 73 9 SHOCK ABSORBER, SWINGARM Clamp the control lever as shown in the figure. ✓ The External tank control lever is Closed, Damper on Vacuum, Oil reservoir on Vacuum. Operate the On/Off switch (D. ✓ The vacuum pump process starts. ✓ Pressure gauge @ drops to the specified value. <...
  • Page 74 9 SHOCK ABSORBER, SWINGARM When the pressure gauge reaches the specified value, turn Oil reservoir control lever to Vacuum. Guideline 0 bar ✓ The vacuum gauge falls to the specified value. mbar When the vacuum pressure gauge reaches the specified value, turn the control lever Oil reservoir...

  • Page 75: Filling Damper With Nitrogen

    9 SHOCK ABSORBER, SWINGARM Info The floating piston must be positioned at exactly this point when the rod is fully extended; otherwise, damage will occur during compression of the shock absorber. Remove the special tool. Remove adapter from connection of the vacuum pump.

  • Page 76: Installing The Spring

    9 SHOCK ABSORBER, SWINGARM Info Watch the pressure regulator dial. Ensure that the damper is filled to the specified pres­ sure. Screw the filling port shut with tap handle f). Close spigot and take the damper out of the special tool. Tighten the filling port screw.

  • Page 77: Checking The Swingarm

    9 SHOCK ABSORBER, SWINGARM Alternative 2 Warning Modifications to the sus­ Danger of accident 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...
  • Page 78 9 SHOCK ABSORBER, SWINGARM Main work (FE EU/AU, FE 350 US) Move the swingarm up and down. there is detectable play: Change the swingarm bearing. (il,Jl p. 79) Move the swingarm from one side to the other. there is detectable play: Change the swingarm bearing.

  • Page 79: Removing The Swingarm

    9 SHOCK ABSORBER, SWINGARM 9.29 Removing the swingarm Preparatory work Raise the motorcycle with a lift stand. p. 13) Remove the rear wheel. p. 125) Main work Take the brake line out of the guide. Push the brake caliper forward, slip it out, and hang it to the side.

  • Page 80: Installing The Swingarm

    9 SHOCK ABSORBER, SWINGARM C, . Remove fitting Lower the swingarm. Remove nut Remove the swingarm pivot. Take off the swingarm. Main work Position the swingarm. Mount the swingarm pivot. Mount and tighten nut Guideline I Nut, swingarm pivot M 16x1 .5 100 Nm (73.8 lbf ft) Lift the swingarm.

  • Page 81: Changing The Swingarm Bearing

    9 SHOCK ABSORBER, SWINGARM Position the engine sprocket cover and mount in the holder. Mount and tighten screws Guideline Screw, clutch slave 10 Nm (7.4 lbf ft) cylinder Mount and tighten screws (3. Guideline Remaining screws, 25 Nm (18.4 lbf ft) chassis Position the brake caliper and pull it back.
  • Page 82 9 SHOCK ABSORBER, SWINGARM Left swingarm bearing Remove collar bushings R02757-10 Remove bushing R02758-10 Remove shaft seal rings (D using a suitable tool. Remove stop disks Press out bearing using a suitable tool. Using a suitable tool, press in new bearing Position stop disks Press in shaft seal rings (D .
  • Page 83 9 SHOCK ABSORBER, SWINGARM Grease the shaft seal rings. I Long-life grease (!ill p. 354) Position collar bushings with the shoulder facing inward. R02763-10 Right swingarm bearing Remove collar bushings (D. R02760-10 Remove bushing @. R02761-10 Remove shaft seal rings using a suitable tool.
  • Page 84 9 SHOCK ABSORBER, SWINGARM Mount bushing@. R02761-10 Grease the shaft seal rings. Long-life grease (� p. 354) Position collar bushings with the shoulder facing inward. R02764-10 Finishing work Install the swingarm. (� p. 78) Install the rear wheel. (� p. 126) Remove the motorcycle from the lift stand.

  • Page 85: Exhaust

    EXHAUST Removing the manifold 10.1 Preparatory work Raise the motorcycle with a lift stand. p. 13) Remove the seat. p. 97) Remove the right side cover. (!,JI p. 96) Remove the main silencer. (!i.,!I p. 87) Main work Remove screw cap Remove screw @.
  • Page 86 10 EXHAUST Remove screws on both sides. Loosen screws on both sides. Remove screw @. Raise the rear frame slightly and lower the shock absorber. Remove springs I Spring hook (50305017000) (!!l p. 357)

  • Page 87: Installing The Manifold

    EXHAUST (EU) Remove screw Disconnect plug-in connector Qi) of the lambda sensor and remove the cable binder. Take off the manifold. (FE AU, FE US) Remove screw Take off the manifold. Main work Position the manifold and mount springs Spring hook (50305017000) (�...
  • Page 88 10 EXHAUST Lift the rear frame slightly and position the shock absorber. Mount and tighten screw (D. Guideline Screw, top 60 Nm (44.3 lbf ft) ® Loctite 2701 shock absorber Position the rear frame. Mount and tighten screws on both sides. Guideline Screw, sub­...

  • Page 89: Removing The Main Silencer

    EXHAUST Info Raise the wheel slightly to be able to mount the screw more easily. (EU) Connect plug-in connector of the lambda sensor, route the cable without tension, and secure with a new cable tie. Install the fuel tank. (l!!ll p.

  • Page 90: Changing The Glass Fiber Yarn Filling In The Main Silencer

    10 EXHAUST Finishing work Install the right side cover. (� p. 96) Changing the glass fiber yarn filling in the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. Allow the exhaust system to cool down before performing any work on the vehicle. Info Over time, the fibers of the glass fiber yarn escape and the damper "burns"...
  • Page 91 EXHAUST (FE US) Remove screws of connecting cap Remove connecting cap with the perforated pipe, 0- ring (D, and glass fiber yarn filling Remove screws and silencer cap with 0-ring Remove screws and insert together with insulat- ing pad Gi). Remove the insulating pad from the insert.

  • Page 92: Spark Arrestor, Cleaning

    10 EXHAUST s�ark arrestor, cleaning Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. Allow the exhaust system to cool down before performing any work on the vehicle. Info Soot particles accumulate on the screen of the spark arrestor over time. This changes the performance characteristics.
  • Page 93 EXHAUST Finishing work Install the main silencer. (ilill p. 87) Install the right side cover. (l!li p. 96)

  • Page 94: 11 Air Filter

    11 AIR FILTER Release catch pull the air filter box lid sideways in areas t) and and remove toward the rear. Position the air filter box cover and catch Engage the air filter box cover in areas t) and Engage catch 11.3 Removin the air filter Note...

  • Page 95: Installing The Air Filter

    11 AIR FILTER 11.4 Installing the air filter Main work Mount the clean air filter on the air filter support. Grease the air filter in area 6). Long-life grease p. 354) Insert both parts together, position them, and secure them using air filter holder in area ✓...

  • Page 96: Sealing The Air Filter Box

    11 AIR FILTER Finishing work Install the air filter. (ilill p. 93) Install the air filter box cover. (ilill p. 92) 11.6 Sealing the air filter box Preparatory work Remove the air filter box cover. (ilill p. 92) Main work Seal the air filter box in the marked area t).

  • Page 97: Fuel Tank, Seat, Trim

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

  • Page 98: Closing The Filler Cap

    12 FUEL TANK, SEAT, TRIM Closing the filler ca� (EU) Mount the filler cap and turn clockwise until the release button locks in place. Info Run the fuel tank breather hose @} without kinks. (FE AU, FE US) Mount the filler cap and turn clockwise until the release button locks in place.

  • Page 99: Removing The Seat

    FUEL TANK, SEAT, TRIM 12.5 Removing the seat Remove screws Raise the rear of the seat, push the seat back, and lift it off. 12.6 Mounting the seat Mount the front of the seat on the collar bushing of the fuel tank, lower the seat at the rear while pushing it forward.

  • Page 100: Removing The Fuel Tank

    12 FUEL TANK, SEAT, TRIM 12.7 Removing the fuel tank Danger Fuel is highly flammable. Fire hazard The fuel in the fuel tank expands when warm and can escape if overfilled. Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. Switch off the engine for refueling.
  • Page 101 FUEL TANK, SEAT, TRIM (FE EU/AU) Disconnect the connector of the horn. Remove screws (i) with the collar bushings and horn. (FE 350 US) Remove screws (i) with the collar bushings. (FE 350 SUS) Remove screws (i) with the collar bushings and horn. Remove screw with the rubber bushing.

  • Page 102: Installing The Fuel Tank

    12 FUEL TANK, SEAT, TRIM Installing the fuel tank 12.8 Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. Switch off the engine for refueling.

  • Page 103: Changing The Fuel Screen

    FUEL TANK, SEAT, TRIM (FE 350 US) Position the collar bushings, and mount and tighten screws @ . Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis (FE 350 SUS) Position the collar bushings and horn, and mount and tighten screws @ . Guideline Remaining screws, 10 Nm (7.4 lbf ft)
  • Page 104 12 FUEL TANK, SEAT, TRIM Warning Fuel is poisonous and a health hazard. Danger of poisoning Avoid skin, eye and clothing contact with fuel. Immediately consult a doctor if you swallow fuel. Do not inhale fuel vapors. In case of skin contact, rinse the affected area with plenty of water. Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.

  • Page 105: Changing The Fuel Filter

    FUEL TANK, SEAT, TRIM 12.10 Changing the fuel filter Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. Switch off the engine for refueling.
  • Page 106 12 FUEL TANK, SEAT, TRIM Remove hose clamps Remove fuel filter 305315-10 Press locking mechanism C). Pull back fuel pump housing 305317-10 Change fuel screen Mount the fuel pump housing. Mount the new fuel filter ✓ Arrow points away from the fuel pump. Mount hose clamps I Hose clamp plier (60029057000) (i!,Jl...

  • Page 107: Changing The Fuel Pump

    FUEL TANK, SEAT, TRIM Guideline Fuel connection on 10 Nm (7.4 lbf ft) fuel pump Mount and tighten screws Guideline I EJOT PT Screw, fuel pump 2.3 Nm (1.7 lbf ft) ® 305314-10 Finishing work Install the fuel tank. (� p.
  • Page 108 12 FUEL TANK, SEAT, TRIM Main work Remove nut with the gasket. Remove fuel connection with the gasket. 305313-10 Remove screws Pull out the fuel pump. 305314-10 Position the fuel pump. Mount fuel connection with the gasket but do not tighten yet.

  • Page 109: Checking The Fuel Pressure

    FUEL TANK, SEAT, TRIM 12.12 Checking the fuel �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.

  • Page 110: Removing The Activated Charcoal Filter (Fe 350 S Us)

    12 FUEL TANK, SEAT, TRIM Select the actuator "Function test of fuel pump control" test. Guideline Maximum duration of the 3 min actuator test Check the fuel pressure with the filler cap closed. Fuel pressure When the fuel pump is 3.35 ...

  • Page 111: Installing The Activated Charcoal Filter (Fe 350 S Us)

    FUEL TANK, SEAT, TRIM Detach hoses Remove the activated charcoal filter. Push back hose clamp Pull off the hose. Remove fitting Take off the retaining bracket. Installing the activated charcoal filter {FE 350 S US) Main work Position the retaining bracket. Mount and tighten fittings Guideline Screw, engine...
  • Page 112 12 FUEL TANK, SEAT, TRIM Mount hoses Position the activated charcoal filter. Mount rubber band Finishing work Install the fuel tank. (� p. 100) Mount the seat. (� p. 97)

  • Page 113: 13 Mask, Fender

    13 MASK, FENDER 13.1 Removing front fender Preparatory work Remove the headlight mask with the headlight. (� p. 113) Main work (FE EU/ AU, FE 350 US) Remove screws Take off the front fender. (FE 350 SUS) Remove screws Take off the front fender.

  • Page 114: Installing Front Fender

    13 MASK, FENDER Main work (FE EU/AU, FE 350 US) Position front fender. Mount and tighten screws and fj . Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis (FE 350 SUS) Position front fender. Mount and tighten screws and fj . Guideline Remaining screws, 10 Nm (7.4 lbf ft)

  • Page 115: Removing The Headlight Mask With The Headlight

    13 MASK, FENDER 13.3 Removing the headlight mask with the headlight (FE EU/AU) Press and hold the kill switch (?9 while the engine is idling until the engine stops. (FE 350 US) Press and hold the kill switch (?9 while the engine is idling until the engine stops.

  • Page 116: Installing The Headlight Mask With The Headlight

    13 MASK, FENDER (FE 350 SUS) and wiring harness @} . Detach brake line Release rubber bands (5) . Slide the headlight mask up and swing it forward. Detach plug-in connectors and take off the headlight mask with the headlight. 13.4 Installing the headlight mask with the headlight Main work...
  • Page 117 13 MASK, FENDER (FE 350 US) Connect plug-in connector Position the headlight mask and secure it with rubber bands @ . ✓ The holding lugs engage in the fender. Position brake line and wiring harness in the brake line guide. (FE 350 SUS) Connect plug-in connectors Position the headlight mask and secure it with rubber...
  • Page 118 13 MASK, FENDER Position brake line and wiring harness in the brake line guide. K00261-10 Finishing work Check the headlight setting. p. 169)

  • Page 119: 14 Wheels

    Checking the tire condition Info Only mount tires approved and/or recommended by Husqvarna Motorcycles. Other tires could have a negative effect on handling characteristics. The type, condition, and air pressure of the tires all have a major impact on the handling of the motorcy­...

  • Page 120: Checking The Wheel Bearing For Play

    DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manufacture. Husqvarna Motorcycles recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear.

  • Page 121: Checking The Brake Discs

    14 WHEELS Place a load on the front of the vehicle. ✓ The rear wheel is not in contact with the ground. Move the rear wheel from side to side. Info Hold the swingarm to check it. If there is detectable play: Change the rear wheel bearing.

  • Page 122: Checking The Rim Run-Out

    14 WHEELS Strike each spoke briefly using a screwdriver blade. Info The frequency of the sound depends on the spoke length and spoke diameter. If you hear different tone frequencies from different spokes of equal length and diameter, this is an indica­ tion of different spoke tensions.

  • Page 123: Front Wheel

    14 WHEELS Check for lateral and radial run-out of the rims. Lateral runout Outside the rim joint < 1 .8 mm (< 0.071 in) Radial runout Outside the rim joint < 1.8 mm (< 0.071 in) If the measured value is greater than the specified value: Center the rim.

  • Page 124: Installing The Front Wheel

    14 WHEELS Warning Damaged brake discs reduce Danger of accidents the braking effect. Always lay the wheel down in such a way that the brake disc is not damaged. Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork. Info Do not pull the hand brake lever when the front wheel is removed.

  • Page 125: Changing The Front Brake Disc

    14 WHEELS Operate the front brake and compress the fork a few times firmly. ✓ The fork legs straighten. Tighten screws (D. Guideline Screw, fork stub Nm (11.1 lbf ft) 14.7.3 Changing the front brake disc Info If the brake discs are changed, the brake linings must also be changed. Preparatory work Raise the motorcycle with a lift stand.
  • Page 126 14 WHEELS Press out bearing using a suitable tool. • Info Spacing tube can be pushed aside. Remove the spacing tube. Press out bearing using a suitable tool. Press in new bearing all the way using a suitable tool. Info Only press the bearing in via the outer ring otherwise the bearing will be damaged when it is pressed in.

  • Page 127: Rear Wheel

    14 WHEELS Rear wheel 14.8 14.8.1 Removing the rear wheel Preparatory work Raise the motorcycle with a lift stand. (� p. 13) Main work (FE EU/ AU, FE 350 US) Press the brake caliper onto the brake disc by hand in order to push back the brake piston.

  • Page 128: Installing The Rear Wheel

    14 WHEELS (FE 350 SUS) Press the brake caliper onto the brake disc by hand in order to push back the brake piston. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.
  • Page 129 14 WHEELS Main work Check the wheel bearing for damage and wear. If the wheel bearing is damaged or worn: Change the rear wheel bearing. (I!!;,! p. 136) Clean and grease shaft seal rings and contact surface of the spacers. Long-life grease (I!!;,! p.

  • Page 130: Changing The Rear Brake Disc

    14 WHEELS Position chain adjuster 6) . Mount nut but do not tighten it yet. Make sure that chain adjusters 6) are fitted correctly on adjusting screws Check the chain tension. (!l;!l p. 129) Tighten nut Guideline M20x1 .5 80 Nm (59 lbf ft) Info The wide adjustment range of the chain adjusters (32 mm (1.26 in)) enables different secondary...

  • Page 131: Checking The Chain Tension

    14 WHEELS Finishing work Install the rear wheel. (llill p. 126) Remove the motorcycle from the lift stand. (llill p. 13) 14.8.4 Checking the chain tension Warning Incorrect chain tension damages components and results in accidents. Danger of accidents If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly.
  • Page 132 14 WHEELS Main work (FE EU/AU, FE 350 US) Loosen nut Loosen nuts @ . Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 55 ... 58 mm (2.17 ... 2.28 in) Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks...

  • Page 133: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    14 WHEELS Info The wide adjustment range of the chain adjusters (32 mm (1 .26 in)) enables different secondary ratios with the same chain length. ° Chain adjusters can be turned by 180 Finishing work Remove the motorcycle from the lift stand. p.
  • Page 134 14 WHEELS Check the chain sliding guard for wear. If the lower edge of the chain pins is in line with or below the chain sliding guard: Change the chain sliding guard. Check that the chain sliding guard is firmly seated. If the chain sliding guard is loose: Tighten the screws on the chain sliding guard.

  • Page 135: Checking For Chain Dirt Accumulation

    14 WHEELS (FE EU/AU, FE 350 US) Check that the chain guide is firmly seated. If the chain guide is loose: Tighten the screws on the chain guide. Guideline Remaining 10 Nm screws, chassis (7.4 lbf ft) Remaining nuts, 10 Nm chassis (7.4 lbf ft) (FE 350 SUS)

  • Page 136: Changing The Drivetrain Kit

    14 WHEELS Info The service life of the chain depends largely on its maintenance. Preparatory work Raise the motorcycle with a lift stand. (!!:!J p. 13) Main work Rinse off loose dirt with a soft jet of water. Clean chain and apply chain spray. I Offroad chain spray (!!:!J p.
  • Page 137 14 WHEELS Remove engine sprocket (FE EU/ AU, FE 350 US) Remove fittings Cs) . Take the rear sprocket. Position the new rear sprocket. Mount and tighten the fittings. Guideline Nut, rear 35 Nm (25.8 lbf ft) ® Loctite 2701 sprocket screw (FE 350 SUS)

  • Page 138: Changing The Rear Wheel Bearing

    14 WHEELS Have an assistant operate the rear brake. Mount and tighten screw (D with the washer. Guideline Screw, engine 60 Nm (44.3 lbf ft) ® Loctite 2701 sprocket Position the engine sprocket cover. Mount and tighten screw Guideline Screw, clutch slave 10 Nm (7.4 lbf ft) cylinder Mount and tighten screw...
  • Page 139 14 WHEELS Using a suitable tool, press bearing out from the inside to the outside. Remove spacing tube Using a suitable tool, press bearing (D out from the inside to the outside. Check spacer washer @ for damage and wear. If the spacer washer is damaged or worn: Replace the spacer washer.
  • Page 140 14 WHEELS Mount lock ring@. ✓ The lock ring engages audibly. Grease new shaft seal ring and press it in until it is flush. (FE 350 5 US) Remove shaft seal ring Remove lock ring 4i}. Remove shaft seal ring (s). Using a suitable tool, press bearing out from the inside to the outside.
  • Page 141 14 WHEELS Position spacer washer @. Press new bearing all the way in from the outside to the inside. Info Only press the bearing in via the outer ring oth­ erwise the bearing will be damaged when it is pressed in. Clean, grease, and mount spacing tube I Long-life grease (Ii!:!

  • Page 142: 15 Wiring Harness, Battery

    15 WIRING HARNESS, BATTERY Changing the fuses of individual �ower consumers Info The fuse box containing the fuses of individual power consumers is located under the seat. Preparatory work (FE EU/AU) Press and hold the kill switch (5<:) while the engine is idling until the engine stops.
  • Page 143 15 WIRING HARNESS, BATTERY Replace the spare fuse in the fuse box so that it is available if needed. Check that the power consumer is functioning properly. Close the fuse box cover. (FE 350 SUS) Open fuse box cover Remove the defective fuse. Guideline Fuse - 10 A - EFI control unit...

  • Page 144: Changing The Main Fuse

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

  • Page 145: Checking The Starter Relay

    15 WIRING HARNESS, BATTERY 15.3 Checking the starter rela� Preparatory work (FE EU/AU) Press and hold the kill switch � while the engine is idling until the engine stops. (FE 350 US) Press and hold the kill switch � while the engine is idling until the engine stops.

  • Page 146: Installing The Battery

    15 WIRING HARNESS, BATTERY (FE 350 US) Press and hold the kill switch � while the engine is idling until the engine stops. (FE 350 SUS) While the engine is idling, turn the key in the ignition lock to the position �- Remove the seat.

  • Page 147: Recharging The Battery

    Warning Environmental hazard Batteries contain environmentally-hazardous materials. Do not dispose of batteries as household waste. Return batteries to your authorized Husqvarna Motorcycles dealer or dispose of them at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 148: Checking The Charging Voltage

    15 WIRING HARNESS, BATTERY Alternative 3 CH battery charger XCharge-professional (00029095053) p. 357) • Info Follow the instructions of the charger and the manual. Disconnect the battery charger after charging the battery. Guideline The charging current, charging voltage, and charging time must not be exceeded.
  • Page 149 15 WIRING HARNESS, BATTERY (FE 350 SUS) While the engine is idling, turn the key in the ignition lock to the position (5Q_ Remove the seat. (� p. 97) Main work Disconnect the negative cable of the battery. Measure the current between battery ground (-) and the neg­ ative cable.

  • Page 150: 16 Brake System

    16 BRAKE SYSTEM Checking the front brake linings Warning Worn-out brake linings reduce the braking effect. Danger of accidents Ensure that worn-out brake linings are replaced immediately. Check the brake linings for minimum thickness I Minimum thickness I � 1 mm (� 0.04 in) If the minimum thickness is less than specified: Change the front brake linings.
  • Page 151 Brake linings which have not been approved alter the braking efficiency. Danger of accidents Not all brake linings are tested and approved for Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 152 16 BRAKE SYSTEM Check that leaf spring (3 in the brake caliper and sliding plate @ in the brake caliper support are seated correctly. Insert the new brake linings, insert pin and mount cotter pins • Info Always change the brake linings in pairs. Operate the hand brake lever repeatedly until the brake lin­...

  • Page 153: Checking The Free Travel Of The Hand Brake Lever

    BRAKE SYSTEM Info Clean up overflowed or spilled brake fluid immedi­ ately with water. Checking the free travel of the hand brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. Set the free travel on the hand brake lever in accordance with the specification.

  • Page 154: Adjusting Free Travel Of Hand Brake Lever (Fe Eu/Au, Fe 350 S Us)

    16 BRAKE SYSTEM Adjusting free travel of hand brake lever (FE EU/ AU, FE 350 S US) Check the free travel of the hand brake lever. (!lll p. 151) Adjust the free travel of the hand brake lever with adjusting screw Info Turn the adjusting screw clockwise to reduce free...

  • Page 155: Adding Front Brake Fluid

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

  • Page 156: Changing The Front Brake Fluid

    16 BRAKE SYSTEM Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilled brake fluid immedi­ ately with water. (FE 350 SUS) Move the brake fluid reservoir mounted on the handlebar to a horizontal position. Remove screws Remove cover with membrane...
  • Page 157 BRAKE SYSTEM (FE EU/AU, FE 350 US) Move the brake fluid reservoir mounted on the handlebar to a horizontal position. Cover painted parts. Remove screws Take off cover with the membrane. Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid.
  • Page 158 16 BRAKE SYSTEM Disconnect the bleeding device. Remove the bleeder cover. Add brake fluid to level (!). Guideline 5 mm (0.2 in) Level (!) Brake fluid DOT 4 (ilel p. 352) Position the cover with the membrane. Mount and tighten the screws.

  • Page 159: Checking The Rear Brake Linings

    BRAKE SYSTEM Pull off protection cap of the brake caliper bleeder screw. Connect the bleeder bottle hose. I Bleeding device (00029013100) (I!!:! p. 356) Open bleeder screw by approx. one half turn. • Info Drain until fresh brake fluid emerges in the bleeder bottle hose without bubbles.

  • Page 160: Changing The Rear Brake Linings

    Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for Husqvarna motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 161 BRAKE SYSTEM Stand the vehicle upright. Remove screw cap with membrane and the 0-ring. Press the brake caliper onto the brake disc by hand in order to push back the brake piston and ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suction if it does.

  • Page 162: Checking The Free Travel Of Foot

    16 BRAKE SYSTEM Add brake fluid to level f). I Brake fluid DOT 4 (I!\',! p. 352) Mount screw cap with membrane and O-ring. Info Clean up overflowed or spilled brake fluid immediately with water. Checking the free travel of foot brake lever Warning The brake system fails in the event of overheating.

  • Page 163: Adjusting The Basic Position Of The Foot Brake Lever

    BRAKE SYSTEM Adjusting the basic �osition of the foot brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.

  • Page 164: Adding Rear Brake Fluid

    16 BRAKE SYSTEM Stand the vehicle upright. Check the brake fluid level in level viewer lf the brake fluid level has dropped below marking Add rear brake fluid. (� p. 162) Addin rear brake fluid Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail. If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.

  • Page 165: Changing The Rear Brake Fluid

    BRAKE SYSTEM Main work Stand the vehicle upright. Remove screw cap with membrane f!} and the 0-ring. Add brake fluid to level fj. Brake fluid DOT 4 (!ill p. 352) Mount the screw cap with the membrane and the 0-ring. Info Clean up overflowed or spilled brake fluid immediately with water.
  • Page 166 16 BRAKE SYSTEM Cover the painted parts. Remove screw cap with membrane and the O-ring. Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid. Syringe (50329050000) (� p. 358) Brake fluid DOT 4 (�...
  • Page 167 BRAKE SYSTEM Stand the vehicle upright. Correct the brake fluid up to marking (!). Brake fluid DOT 4 (Ii!:! p. 352) Fit and tighten plug with oil screen and 0-ring. Info Clean up overflowed or spilt brake fluid immediately with water. Check the foot brake lever for a firm pressure point.

  • Page 168: Lighting System, Instruments

    LIGHTING SYSTEM, INSTRUMENTS 17.1 Adjusting the combination instrument Condition The motorcycle is stationary. Press and hold both buttons for 3 - 5 seconds. ✓ The Setup menu is displayed. The display flashes. UNIT ____ ,�_ I _L Press one of the buttons to select for the speed in kilo­...

  • Page 169: Adjusting The Kilometers Or Miles

    17 LIGHTING SYSTEM, INSTRUMENTS Switching off the service interval display Press and hold the left button. ✓ appears on the display. 401914-01 Adjustin the kilometers or miles Info If the unit is changed, the value ODO is retained and converted accordingly. Condition The motorcycle is stationary.

  • Page 170: Setting The Wheel Circumference

    LIGHTING SYSTEM, INSTRUMENTS 17.4 Setting the wheel circumference Condition The motorcycle is stationary. Preparatory work Disconnect speedometer connector CZ. Main work Press both buttons for 3 - 5 seconds. ✓ The Setup menu is displayed. The UNIT display flashes. ____ ,�_1_1, . ✓...

  • Page 171: Checking The Headlight Setting

    17 LIGHTING SYSTEM, INSTRUMENTS Switching off the service interval display Press and hold the left button. ✓ appears on the display. 401914-01 Checkin the headli Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight.
  • Page 172 LIGHTING SYSTEM, INSTRUMENTS (FE 350 SUS) Loosen screw Adjust the headlight range by pivoting the headlight. Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with driver (instruc­ tions on how to apply the mark: Checking the headlight setting).

  • Page 173: 18 Engine

    18 ENGINE 18.1 Removing the engine Preparatory work Remove the engine guard. p. 48) Drain the coolant. p. 257) Raise the motorcycle with a lift stand. p. 13) Remove the right side cover. (Ii.,! p. 96) Remove the main silencer. (Ii.,! p.
  • Page 174 18 ENGINE Push back hose clamp off the vent hose. Pull Remove screws Loosen screw (D. Repeat these steps on the opposite side. Swing up the subframe and secure it. Remove screw @. Swing back the shock absorber. Remove springs I Spring hook (50305017000) p.
  • Page 175 18 ENGINE Remove screw Take off the manifold. Push back the cover. Remove nut Ci). Take off the cable. Loosen hose clip Pull off the radiator hose. G>. Disconnect spring Remove screw 41). Remove screw Take off the engine sprocket cover.
  • Page 176 18 ENGINE Remove the connecting link of the chain. Take off the chain. Remove screws Take off the clutch slave cylinder and hang it to one side. Info Do not kink the clutch line. Do not activate the clutch lever while the clutch slave cylinder is removed.

  • Page 177: Installing The Engine

    18 ENGINE Remove fittings ... Take off the engine braces. Remove nut Remove the swingarm pivot. Pull the swingarm toward the rear slightly. Remove screws @). Lift out the engine sideways. Info The help of an assistant is useful in this step. Ensure that the motorcycle is sufficiently secured against falling over.
  • Page 178 18 ENGINE Mount screws but do not tighten yet. Guideline Engine attachment 60 Nm (44.3 lbf ft) bolt Position the swingarm. Mount the swingarm pivot. Mount nut but do not tighten it yet. Guideline Nut, swingarm pivot M 16x1 .5 1100 Nm (73.8 lbf ft) Position the engine braces.
  • Page 179 18 ENGINE Plug in connector (D. Position the protection cap. Plug in connector@. Plug in connector Mount the spark plug connector. Position the clutch slave cylinder with the gasket. Mount and tighten screws 6). Guideline Screw, clutch slave 10 Nm (7.4 lbf ft) cylinder Mount the chain.
  • Page 180 18 ENGINE Mount the radiator hose. Position and tighten hose clip Position the cable. Mount and tighten nut�­ Position the cover. Position the manifold and mount springs I Spring hook (50305017000) (� p. 357) Mount and tighten screw •. Guideline Remaining screws, 25 Nm (18.4 lbf ft) chassis...
  • Page 181 18 ENGINE Remove the locking piece and position the subframe. Info Watch out for the intake flange. Mount and tighten screws G). Guideline Screw, sub­ 35 Nm (25.8 lbf ft) Loctite ® 2701 frame Remove screw Mount and tighten screw Guideline Screw, sub­...
  • Page 182 256) Execute the initialization run. (l!!J p. 274) Finishing work Take a test ride. Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. Check the engine for leak tightness. Check the engine oil level. (l!!J p. 259) Check the coolant level.

  • Page 183: Engine Disassembly

    18 ENGINE Install the engine guard. (I!:! p. 48) 18.3 Engine disassembly 18.3.1 Preparations Mount the special tool on the engine assembly stand. Holder and fitting for work stand (77229002000) (I!:! p. 363) Engine work stand (80329001000) (I!:! p. 366) Mount the engine on the special tool.

  • Page 184: Removing The Oil Filter

    18 ENGINE Remove oil drain plug with the magnet. Completely drain the engine oil. 18.3.5 Removing the oil filter Remove screws Remove the oil filter cover with the O-ring. Pull oil filter out of the oil filter housing. I Lock ring plier (51012011000) (ll!:!l p.

  • Page 185: Removing The Valve Cover

    18 ENGINE 18.3.7 Removing the valve cover Remove screws Remove the valve cover with the valve cover seal. Remove the spark plug shaft insert. 18.3.8 Removing the alternator cover Remove screws Remove the alternator cover. Take off the alternator cover gasket ✓...

  • Page 186: Removing The Torque Limiter

    18 ENGINE 18.3.9 Removing the torque limiter Remove torque limiter 18.3.10 Positioning the engine at ignition top dead center Turn the crankshaft counterclockwise until markings the cylinder head are located flush above the flat areas the camshafts. Remove screw with the washer. Info Check through the hole whether the position notch of the crankshaft is visible.

  • Page 187: Removing The Camshaft

    18 ENGINE Pull out timing chain tensioner (5). Remove O-ring G00422-10 18.3.12 Removing the camshaft Loosen screws from the outside to the inside and remove. Take off guide rail@}. Take off the camshaft bearing bridge. Take the timing chain off the camshaft gear. Remove the camshafts.

  • Page 188: Removing The Piston

    18 ENGINE Remove cylinder head gasket 18.3.14 Removing the piston Push the cylinder upward. Info Only push the cylinder as far up as necessary to take the piston pin out. Remove the piston pin retainer Remove the piston pin. Take off the cylinder and piston. Push the piston upward out of the cylinder.
  • Page 189 18 ENGINE Insert special tool into the crankshaft. Protection cap (75029090000) (� p. 362) Attach special tool to the rotor. Hold it tight using the special tool and pull off the rotor by turning the screw in. Puller (58012009000) (� p.

  • Page 190: Removing The Suction Pump

    18 ENGINE Remove screws @. Take off the starter motor. 18.3.16 Removing the suction pump Remove screws Take off oil pump cover Remove O-ring Remove suction pump Remove needle roller...

  • Page 191: Removing The Water Pump Wheel

    18 ENGINE 18.3.17 Removing the water pump wheel Remove screws Take off the water pump cover. Remove nut @}. Take off the two-part water pump impeller@). 18.3.18 Removing the clutch cover Remove screws Take off the clutch cover. Remove the clutch cover seal. 18.3.19 Removing the clutch discs Remove screws...

  • Page 192: Removing The Clutch Basket

    18 ENGINE Take off spring washer (5). Take off pretension ring Take off pressure cap Completely remove clutch disc pack 0). Remove clutch pressure piece@. 18.3.20 Removing the clutch basket Bend open lock washer. Hold the inner clutch hub with the special tool. Loosen Holding wrench (51129003000) (l!!:!l p.

  • Page 193: Removing The Shift Shaft

    18 ENGINE Take off inner clutch hub@ and washer (5). Info The washer usually sticks to the inner clutch hub. Take off clutch basket Take off needle bearing and collar sleeve C). 18.3.21 Removing the shift shaft Push sliding plate away from the shift drum locating unit @.

  • Page 194: Removing The Locking Lever

    18 ENGINE 18.3.23 Removing the locking lever Unscrew and remove together with locking lever@, washer, sleeve and spring. 18.3.24 Removing the force pump Remove lock ring Take off washer@. Take off oil pump idler gear with the washer. Remove lock ring Take off washer Take off oil pump gear wheel (D.

  • Page 195: Removing The Primary Gear

    18 ENGINE 18.3.25 Removing the primary gear Remove nut Info Left-handed thread! Take off primary gear@. 18.3.26 Removing the timing chain Remove screws Remove the timing chain tensioning rail Remove the timing chain guide rail (D. Remove screw Take off balancer shaft with the timing chain and timing chain securing guide.

  • Page 196: Removing The Left Section Of The Engine Case

    18 ENGINE 18.3.28 Removing the left section of the engine case Remove screws Tilt the left section of the engine case upward and remove the screw connections of the engine fixing arm. Insert the special tool into the crankshaft. I Protection cap (75029090000) (�...

  • Page 197: Removing The Shift Drum

    18 ENGINE Remove shift rail together with upper spring and the lower spring. 18.3.30 Removing the shift drum Tilt shift forks to the side. Info • Do not misplace the shift rollers. Remove shift drum 18.3.31 Removing the shift forks Remove shift forks Info Do not misplace shift rollers...

  • Page 198: Removing The Crankshaft

    18 ENGINE Pull both transmission shafts out of the bearing seats together. 18.3.33 Removing the crankshaft Take out crankshaft Take off the right section of the engine case. Working on individual �arts 18.4 18.4.1 Work on the right section of the engine case Remove all dowels.
  • Page 199 18 ENGINE Blow out oil nozzle with compressed air and check that it is clear. Guideline Oil nozzle for 2 Nm (1.5 lbf ft) ® Loctite ™ balancer shaft lubrication Insert the new cold bearings into the bearing seats of the hot engine case section and, if necessary, use a suitable press drift to push the bearing all the way to the stop or so that it is 308660-10...

  • Page 200: Working On The Left Section Of The Engine Case

    18 ENGINE Blow out the oil channel with compressed air and check that • it is clear. Working on the left section of the engine case 18.4.2 Remove all dowels. Remove shaft seal ring of the shift shaft and of the countershaft.

  • Page 201: Work On The Clutch Cover

    18 ENGINE Press in shaft seal ring of the countershaft so it is flush with the open side facing in. Mount and tighten oil nozzle (D. Guideline Oil nozzle, pis­ 2 Nm (1.5 lbf ft) Loctite ® ™ ton cooling Position all bearing retainers.
  • Page 202 18 ENGINE Press out bearing toward the inside. Mount lock ring Press the shaft seal ring all the way in from the inside to the outside with the open side facing in. G00445-10 Press the new bearing all the way in from the inside to the outside using a suitable tool.

  • Page 203: Checking The Oil Pressure Regulator Valve

    18 ENGINE Remove shaft seal ring of the crankshaft. Press the new shaft seal ring all the way in with the open side facing outward. • Info Provide suitable support for the clutch cover while pressing in. Mount lock ring Blow out the oil channel with compressed air and check that it is clear.

  • Page 204: Checking The Lubrication System

    18 ENGINE 18.4.5 Checking the lubrication system • ✓ ✓ 305003-10 Check the internal rotor and external rotor of oil pumps for damage and wear. If there is damage or wear: Change the oil pumps. Check oil pump shaft @} for damage and wear. If there is damage or wear: Change the oil pump shaft.

  • Page 205: Installing The Crankshaft Bearing Inner Race

    18 ENGINE 18.4.7 Installing the crankshaft bearing inner race Fix the crankshaft in the vise. • Info Use soft jaws. Slide on the compensating disk. Heat the crankshaft bearing inner race in special tool mount together. Guideline 1120 oc (248 OF) Puller (58429037037) (!ill p.
  • Page 206 18 ENGINE Press in the new crank pin as far as possible. ✓ Oil hole is aligned with oil hole G). X If the oil holes are not correctly aligned, the conrod bear­ ing will not be supplied with oil. Blow compressed air through the oil channel to check that it is clear.

  • Page 207: Checking The Crankshaft Run-Out At The Bearing Pin

    18 ENGINE 18.4.9 Checking the crankshaft run-out at the bearing pin Position the crankshaft on a roller block. Turn the crankshaft slowly. Check the crankshaft run-out on both bearing pins. Crankshaft - run-out at � 0.03 mm (� 0.0012 in) bearing pin If the crankshaft run-out at the bearing pin is larger than the specification:...

  • Page 208: Removing The Drive Wheel Of The Balancer Shaft

    18 ENGINE 18.4.11 Removing the drive wheel of the balancer shaft Position the balancer shaft in the press with special tool 1 Separator plate (77229032000) p. 364) Mount special tool I Protection cap (77229031000) p. 364) Press out the drive wheel of the balancer shaft. 18.4.12 Installing the drive wheel of the balancer shaft Ensure that woodruff key...

  • Page 209: Checking/Measuring The Piston

    18 ENGINE Info The cylinder size is marked on the cylinder collar. Using a straightedge and the special tool, check the sealing area of the cylinder head for distortion. Feeler gauge (59029041100) (� p. 360) Cylinder/cylinder head - dis- :;; 0.10 mm (:;; 0.0039 in) tortion of sealing area If the measured value does not meet specifications: Change the cylinder.

  • Page 210: Measuring The Piston/Cylinder Mounting Clearance

    18 ENGINE Measure the piston at the piston skirt, at right angles to the piston pin, at a distance Guideline 27 mm (1 .06 in) Distance Piston - diameter Size I 87.965 ... 87.975 mm (3.46318 ... 3.46358 in) Size II 87.976 ...

  • Page 211: Changing The Camshaft Bearing

    18 ENGINE Mount the piston ring with the marking facing toward the pis­ ton head. 18.4.18 Changing the camshaft bearing Clamp special tool into a vise. Adjustment bush bridge (77229050044) p. 365) Mount the camshaft on the special tool. Remove screw 308666-10 Pull camshaft gear off of the camshaft.

  • Page 212: Checking The Pivot Points Of The Camshafts

    18 ENGINE 18.4.20 Checking the pivot points of the camshafts Check the pivot points of the camshafts. If there is damage or wear: Change the cylinder head with the camshaft bearing bridge. 308668-10 Position the camshafts. ✓ The valves are not activated. Insert the Plastigauge clearance gauge in area f).

  • Page 213: Removing The Valves

    18 ENGINE 18.4.21 Removing the valves Remove screw plugs with the O-ring. Screw appropriate screw @ into the cam lever shaft. Hold cam levers and remove the cam lever shaft. Info If the cam levers will continue to be used, note down their installation position.

  • Page 214: Checking The Valves

    18 ENGINE 18.4.22 Checking the valves Check the valve plate for run-out. Valve - run-out At the valve plate :!> 0.05 mm (:!> 0.002 in) If the measured value does not meet specifications: Change the valve. 200193-10 Check sealing seat on the valve.

  • Page 215: Checking The Cam Levers

    18 ENGINE 18.4.25 Checking the cam levers Check the cam levers and cam lever shafts for damage and wear. If there is damage or wear: Change the cam levers and/or cam lever shafts. 302718-10 18.4.26 Checking the cylinder head Check valve guides using the special tool.

  • Page 216: Installing The Valves

    18 ENGINE 18.4.27 Installing the valves Position valve spring seat Mount valve stem seal @. Mount the valve corresponding to its installation position. Mount the valve spring with the tighter coil facing downward. Mount the valve spring retainers. 302712-11 Pre-tension the valve spring using the special tool. Valve spring mounter (59029019000) p.

  • Page 217: Checking The Freewheel

    18 ENGINE 18.4.28 Checking the freewheel Insert freewheel gear into the freewheel hub, turning the freewheel gear clockwise; do not wedge. Check the locking action of starter wheel If the freewheel gear does not turn clockwise or if it does not lock counterclockwise: Change the free wheel.

  • Page 218: Installing The Freewheel

    18 ENGINE 18.4.30 Installing the freewheel Thoroughly oil all parts. Slide freewheel into the primary gear. Info Note the direction of rotation. Mount spreader ring 308677-10 Ensure that all lugs of the expansion ring pass through slots of the freewheel and engage in groove of the primary gear.

  • Page 219: Checking The Electric Starter Drive

    18 ENGINE 18.4.31 Checking the electric starter drive ·-• 305006-10 Check the gear mesh and bearing of starter idler gear for damage and wear. If there is damage or wear: Change the starter idler gear. Check the gear mesh and bearing of torque limiter @} for damage and wear. If there is damage or wear: Change the torque limiter.

  • Page 220: Checking The Timing Assembly

    18 ENGINE 18.4.32 Checking the timing assembly 305007-10 Check timing chain sprocket for damage and wear. If there is damage or wear: Change the timing chain sprocket. Check the timing chain tensioning rail for damage and wear. If there is damage or wear: Replace the timing chain tensioning rail.

  • Page 221: Preparing The Timing Chain Tensioner For Installation

    18 ENGINE 18.4.33 Preparing the timing chain tensioner for installation Press the timing chain tensioner together completely. Info This requires some force, as the oil must be pressed out. Release the timing chain tensioner. ✓ Without pressure, the timing chain tensioner expands fully.

  • Page 222: Checking The Clutch

    18 ENGINE 18.4.34 Checking the clutch 304690-10 Check clutch push rod for damage and wear. If there is damage or wear: Change the clutch push rod. Place clutch push rod on a flat surface and check for run-out. If there is run-out: Change the clutch push rod.

  • Page 223: Checking The Shift Mechanism

    18 ENGINE If there is damage or wear: Change the clutch facing discs and the clutch basket. Check needle bearing and collar sleeve for damage and wear. If there is damage or wear: Change the needle bearing and collar sleeve. Check intermediate discs for damage and wear.

  • Page 224: Preassembling The Shift Shaft

    18 ENGINE Check the shift rollers for damage and wear. If there is damage or wear: Change the shift rollers. Check the springs of shift rails for damage and wear. If the spring is damaged or worn: Change the spring of the shift rail. Check the shift rails for run-out on a flat surface.

  • Page 225: Disassembling The Main Shaft

    18 ENGINE 18.4.37 Disassembling the main shaft 305011-10 Secure the main shaft with the toothed end facing downward in the vise. Guideline I Use soft jaws. Remove stop disk and 2nd-gear fixed gear Remove 5th-gear idler gear and needle bearing Remove stop disk Remove lock ring (D.

  • Page 226: Disassembling The Countershaft

    18 ENGINE 18.4.38 Disassembling the countershaft 305012-10 Secure the countershaft in the bench vise with the toothed end facing downward. Guideline Use soft jaws. Remove stop disk and first-gear idler gear Remove needle bearing (D. Remove stop disk Remove sixth-gear sliding gear Remove stop disk (D.
  • Page 227 18 ENGINE 305013-10 Check needle bearings for damage and wear. If there is damage or wear: Change the needle bearings. Check the pivot points of main shaft and countershaft (D for damage and wear. If there is damage or wear: Change the main shaft and/or countershaft.

  • Page 228: Assembling The Main Shaft

    18 ENGINE Use new lock rings with every repair. 18.4.40 Assembling the main shaft Info Use new lock rings with every repair. Preparatory work Carefully lubricate all parts before assembling. Check the transmission. (llill p. 224) 305011-11 Main work Secure the main shaft in the vise with the gear teeth facing downward. Guideline Use soft jaws.

  • Page 229: Assembling The Countershaft

    18 ENGINE 18.4.41 Assembling the countershaft Info Use new lock rings with every repair. Preparatory work Carefully lubricate all parts before assembling. Check the transmission. p. 224) 305012-11 Main work Secure the countershaft in the bench vise with the toothed end facing downward. Guideline I Use soft jaws.

  • Page 230: Engine Assembly

    18 ENGINE 18.5 Engine assembl� 18.5.1 Installing the crankshaft Position the right section of the engine case in the engine work stand. Oil the bearing. Push crankshaft into the bearing seat. 18.5.2 Installing the transmission shafts Oil the bearing. Slide both transmission shafts into the bearing seats together.

  • Page 231: Installing The Shift Forks

    18 ENGINE 18.5.3 Installing the shift forks Shift fork has a smaller inside diameter; mount this in the shift groove of the main shaft. •- Mount shift fork @ in the lower shift groove of the counter­ shaft. Mount shift fork in the upper shift groove of the counter­...

  • Page 232: Installing The Left Engine Case

    18 ENGINE Install shift rail (D together with upper spring 18.5.6 Installing the left engine case Mount the dowels. Degrease the sealing area. Apply sealing compound to the left section of the engine case. I Loctite 5910 ® Mount the left section of the engine case. If necessary, strike it lightly with a rubber mallet and turn the transmission shafts.

  • Page 233: Installing The Spacer

    18 ENGINE 18.5.7 Installing the spacer Grease the shaft seal ring. Mount spacer 18.5.8 Installing the timing chain Mount balancer shaft with the timing chain and timing chain securing guide. Info If the timing chain was used before, ensure it is run­ ning in the correct direction.

  • Page 234: Installing The Primary Gear

    18 ENGINE 18.5.9 Installing the primary gear Position primary gear ✓ The wide tooth of the primary gear engages in the wide recess of the crankshaft. ✓ Markings and G) are aligned. Set the crankshaft to top dead center and lock it with screw@}.

  • Page 235: Installing The Suction Pump

    18 ENGINE Mount oil pump idler gear with the washer. CD) . Mount washers G, . Mount lock ring 18.5.11 Installing the suction pump Insert needle roller Position suction pump ✓ The rounded sides of the external rotor face the engine case.

  • Page 236: Installing The Locking Lever

    18 ENGINE 18.5.12 Installing the locking lever Mount locking lever with the washer, sleeve and spring. Mount and tighten screw@. Guideline Screw, locking 6 Nm (4.4 lbf ft) ® lever Loctite ™ 18.5.13 Installing the shift drum locating unit Push away locking lever from the shift drum locating unit and position the shift drum locating unit Info...

  • Page 237: Installing The Clutch Discs

    18 ENGINE Slide the clutch basket onto the gearbox main shaft. Turn the oil pump gear until the gear teeth of the clutch basket mesh. Slide on washer and inner clutch hub Position the new lock washer and mount nut 0). Tighten the nut, holding the inner clutch hub with a special tool.
  • Page 238 18 ENGINE Mount pretension ring (D with marking Top facing up. Position spring washer Position spring retainer with marking I. Mount screws (D and tighten in a crisscross pattern. Guideline I Screw, clutch spring 6 Nm (4.4 lbf ft)

  • Page 239: Installing The Clutch Cover

    18 ENGINE Using a straightedge and the special tool, check the spring washer for distortion. Feeler gauge (59029041100) (llill p. 360) Spring washer distortion 0 ... 0.10 mm (0 ... 0.0039 in) If the specified value is not reached: Remove screws and mount the spring retainer with marking II.

  • Page 240: Installing The Water Pump Cover

    18 ENGINE Position the clutch cover. Info Ensure that the shaft seal rings of the water pump and the crankshaft are not damaged. Remove screw Mount screw with the washer but do not tighten yet. Guideline Screw, clutch cover M6x25 10 Nm (7.4 lbf ft) Mount screws but do not tighten yet.

  • Page 241: Installing The Starter Drive

    18 ENGINE 18.5.19 Installing the starter drive Grease the O-ring of the starter motor. Position the starter motor. Mount screws but do not tighten yet. Guideline Screw, starter motor 10 Nm (7.4 lbf ft) Mount gasket Position the inside alternator cover. Mount and tighten screws Guideline Screw, inside alter­...

  • Page 242: Installing The Piston

    18 ENGINE Mount the starter idler gear with the washer. Mount lock ring Position the rotor. • Info Ensure that the woodruff key is seated properly. Mount and tighten screw (D. Guideline Rotor screw M10x1 70 Nm (51.6 lbf ft) Thread, oiled with engine oil/cone degreased...
  • Page 243 18 ENGINE Ensure that piston mark faces the exhaust side. 308657-10 Apply a thin layer of sealing compound in area Loctite 5910 ® Place the cylinder base gasket on. Info Ensure that the dowel pins are seated properly. Cover the engine case opening with a cloth. Thread the tim­ ing chain through the chain shaft.

  • Page 244: Installing The Cylinder Head

    18 ENGINE Insert the special tool and press it forcefully to the piston. Turn the special tool clockwise, thereby pushing the piston pin retainer into the groove. I Insertion for piston ring lock (77229030000) (i!!ll p. 364) Ensure that the piston pin retainer is seated properly on both sides.

  • Page 245: Installing The Camshafts

    18 ENGINE Guideline Nut, cylinder M10x1 .25 Tightening sequence: Tighten diagonally. head 1st tightening stage 10 Nm (7.4 lbf ft) 2nd tightening stage 30 Nm (22.1 lbf ft) 3rd tightening stage 50 Nm (36.9 lbf ft) Thread, oiled with engine oil/cone greased Mount and tighten nut with the washer.

  • Page 246: Checking The Valve Timing

    18 ENGINE Position guide rail Mount screws and tighten from the inside to the outside. Guideline Screw, M7x1 14 Nm (10.3 lbf ft) Lubricated with engine camshaft bearing bridge 18.5.23 Checking the valve timing Condition Camshaft gears were not loosened. Mount the special tool and tension the timing chain.
  • Page 247 18 ENGINE Remove screws @. Position the special tool. Adjustment bush bridge (77229050044) (� p. 365) ✓ The valves are not activated. ✓ The special tool must be in full contact with the flat areas of the cam shafts. Mount and tighten screws@). Guideline Screw, special M7x1...

  • Page 248: Installing The Timing Chain Tensioner

    18 ENGINE Mount and tighten screws Guideline Screw, M7x1 14 Nm (10.3 lbf ft) Lubricated with engine camshaft bearing bridge Remove special tool I Insert for timing chain tensioner (77229035000) (� p. 365) • 18.5.25 Installing the timing chain tensioner Preparatory work Prepare the timing chain tensioner for installation.

  • Page 249: Checking The Valve Clearance

    18 ENGINE Guideline Screw, unlocking M10x1 8 Nm (5.9 lbf ft} of timing chain ten- sioner 18.5.26 Checking the valve clearance Remove screw Crank over the engine repeatedly. Position the engine at ignition top dead center. ✓ Markings on the cylinder head are flush above the flat areas G) of the camshafts.

  • Page 250: Adjusting The Valve Clearance

    18 ENGINE 18.5.27 Adjusting the valve clearance Main work Remove the timing chain tensioner. p. 184) Remove the camshaft. (ll!,!l p. 185) Raise cam levers Correct the shims according to the findings from checking the valve clearance. Install the camshafts. p.

  • Page 251: Installing The Valve Cover

    18 ENGINE Mount screw with the seal ring and tighten all screws in a crisscross pattern. Guideline Screw, alternator M6x25 6 Nm (4.4 lbf ft) cover 18.5.30 Installing the valve cover Grease the O-rings and mount the spark plug shaft insert. Apply a thin layer of sealing compound in area 6).

  • Page 252: Installing The Oil Filter

    18 ENGINE 18.5.32 Installing the oil filter Tilt the motorcycle to one side and fill the oil filter housing to about ½ full with engine oil. Insert oil filter into the oil filter housing. Oil the O-ring of the oil filter cover. Mount oil filter cover Mount and tighten screws Guideline...

  • Page 253: Installing The Spacer

    18 ENGINE 18.5.34 Installing the spacer Grease the shaft seal ring before mounting. Position the O-ring. Mount spacer with the bevel facing inward. 18.5.35 Installing the clutch push rod Mount clutch push rod Removing the engine from the engine assembly stand 18.5.36 Remove the screw connection from the special tool.

  • Page 254: 19 Clutch

    19 CLUTCH Checking/correcting the fluid level of the h draulic clutch Warning Brake fluid causes skin irritation. Skin irritation Keep brake fluid out of the reach of children. Wear suitable protective clothing and safety glasses. Do not allow brake fluid to come into contact with the skin, the eyes or clothing. Consult a doctor immediately if brake fluid has been swallowed.

  • Page 255: Changing The Hydraulic Clutch Fluid

    19 CLUTCH (FE 350 SUS) Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. Remove screws with membrane @ . Remove cover Check the fluid level. Fluid level below container 4 mm (0.16 in) If the fluid level does not meet specifications: Correct the fluid level of the hydraulic clutch.
  • Page 256 19 CLUTCH (FE 350 SUS) Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. Remove screws Remove cover with membrane Fill bleeding syringe with the appropriate hydraulic fluid. Syringe (50329050000) (ll!:!l p. 358) Brake fluid DOT 4 (ll!:!J p.

  • Page 257: 20 Water Pump, Cooling System

    20 WATER PUMP, COOLING SYSTEM 20.1 Cooling s�stem Water pump in the engine circulates the coolant. The water flow through the radiator is controlled as a function of the coolant temperature. The cooling system is divided into two circuits. In the warming-up phase of the engine, the coolant flows through the small cooling circuit.

  • Page 258: Checking The Coolant Level

    20 WATER PUMP, COOLING SYSTEM Stand the motorcycle upright on a horizontal surface. Remove the radiator cap. Check the antifreeze in the coolant. I -25 ... -45 °C (-13 ... -49 °F) If the antifreeze in the coolant does not match the speci­ fied value: Correct the antifreeze in the coolant.

  • Page 259: Draining The Coolant

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

  • Page 260: Refilling Coolant

    20 WATER PUMP, COOLING SYSTEM Refilling coolant Warning Coolant is toxic and a health hazard. Danger of poisoning Keep coolant out of the reach of children. Do not allow coolant to come into contact with the skin, the eyes and clothing. Consult a doctor immediately if coolant is swallowed.

  • Page 261: Lubrication System

    LUBRICATION SYSTEM 21.1 Oil circuit 401362-60 Oil screen Force pump Oil pressure regulator valve Oil filter Oil nozzle, conrod lubrication Oil nozzle for cam follower lubrication Oil nozzle, piston cooling Oil nozzle for alternator cooling Oil nozzle for clutch lubrication Suction pump Oil channel, transmission lubrication Timing chain tensioner...

  • Page 262: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen

    LUBRICATION SYSTEM Info After switching off the engine, wait one minute before checking the level. The engine oil is at a level between lower edge middle of the level viewer. If the engine oil is not at a level between lower edge and middle of the level viewer:...
  • Page 263 LUBRICATION SYSTEM Position oil screen with the O-rings on a pin wrench. Position the pin wrench through the drilled hole of the screw plug in the opposite section of the engine case. Push the oil screen all the way into the engine case. Mount and tighten screw plug with the O-ring.

  • Page 264: Adding Engine Oil

    LUBRICATION SYSTEM Remove the oil filler plug @ with the 0-ring from the clutch cover and fill up with engine oil. Engine oil 1.0 I (1.1 qt.) Engine oil (SAE 1 0W/50) p. 352) • Info Too little engine oil or poor-quality engine oil results in premature wear to the engine.

  • Page 265: Checking The Engine Oil Pressure

    LUBRICATION SYSTEM Main work Remove oil filler plug with the O-ring from the clutch cover. Fill engine oil to the middle of the level viewer. Engine oil (SAE 1 0W/50) (� p. 352) • Info For optimal performance of the engine oil, do not mix different types of engine oil.
  • Page 266 LUBRICATION SYSTEM Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. Always make sure there is sufficient ventilation when running the engine. Use an effective exhaust extraction system when starting or running the engine in an enclosed space.

  • Page 267: 22 Ignition System

    22 IGNITION SYSTEM 22.1 Ignition coil - checking the seconda� winding Condition Ignition coil cylinder 1 is disconnected. Spark plug connector cylinder 1 has been removed. Ignition coil cylinder 1 - check the secondary winding resistance Measure the resistance between the specified points. Ignition coil cylinder 1 pin (-) - Ignition coil cylin­...

  • Page 268: Removing The Stator And Ignition Pulse Generator

    22 IGNITION SYSTEM Stator winding, measurement II - check the resistance Measure the resistance between the specified points. Stator, connector pin 1 - Stator, connector Alternator Resistance of stator 0.368 ... 0.552 Q winding at: 20 °c (68 °F) If the value displayed does not meet specifications: Change the stator.

  • Page 269: Installing The Stator And Ignition 30.11 Pulse Generator

    22 IGNITION SYSTEM Remove screws Remove the stator and ignition pulse generator from the alternator cover. 305321-10 22.5 lnstallin the stator and i nition pulse enerator Blow out oil nozzle with compressed air and check that it is clear. Guideline Oil nozzle for 2 Nm (1 .5 lbf ft) ®...

  • Page 270: 23 Cylinder Head

    23 CYLINDER HEAD 23.1 Checking the valve clearance Preparatory work (FE EU/AU, FE 350 US) Remove the seat. (lll:!l p. 97) Remove the fuel tank. (lll:!l p. 98) (FE 350 SUS) Remove the seat. (lll:!l p. 97) Remove the fuel tank. (lll:!l p.
  • Page 271 23 CYLINDER HEAD Remove gasket Remove screw Gi). Turn the crankshaft counterclockwise until markings the cylinder head are flush with the flat areas of the camshafts. Info Make sure that the crankshaft is at top dead center. Remove screw Remove washer �. Look through the hole to check that the position notch of the crankshaft is visible.
  • Page 272 23 CYLINDER HEAD Remove screw Crank the engine several times. Check the valve clearance and correct it if necessary. Mount and tighten screw with washer Guideline Screw plug, 10 Nm (7.4 lbf ft) crankshaft location Mount and tighten screw Guideline Screw, alternator M24x1.5 18 Nm (13.3 lbf ft)

  • Page 273: Adjusting The Valve Clearance

    23 CYLINDER HEAD Position the engine braces. Mount and tighten fittings (D. Guideline 33 Nm (24.3 lbf ft) Screw, engine brace ® Loctite 2701 Position the radiator on the right. Mount and tighten screws Mount right radiator shield Mount and tighten the spark plug with special tool (D. Guideline Spark plug M10x1...
  • Page 274 23 CYLINDER HEAD Remove the timing chain tensioner. p. 184) Remove the camshaft. p. 185) Main work Swing up cam lever Correct the shims based on the results of the valve clearance check. Finishing work Install the camshafts. p. 243) Install the timing chain tensioner.

  • Page 275: 24 Electric Starter

    24 ELECTRIC STARTER 24.1 Checking the starter motor Condition The starter motor has been removed. Connect the negative cable of a 12 volt power supply to the housing of the starter motor. Connect the positive cable of the power supply briefly to connector of the starter motor.

  • Page 276: 25 Throttle Valve Body

    25 THROTTLE VALVE BODY Adjusting the idle s�eed Warning The engine may go out spontaneously if the idle speed is set too low. Danger of accidents Set the idle speed to the specified value. Danger Exhaust gases are toxic and Danger of poisoning inhaling them may result in unconsciousness and death.
  • Page 277 25 THROTTLE VALVE BODY Start the engine without operating the throttle grip. Guideline Coolant temperature < 25 °C (< 77 °F) Let the engine idle until it reaches the specified temperature. Guideline Coolant temperature so ... 90 °c (176 ... 194 °F) •...

  • Page 278: 26 Technical Data

    26 TECHNICAL DATA 26.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 349.7 cm (21.34 cu in) Stroke 57.5 mm (2.264 in) Bore 88 mm (3.46 in) Compression ratio 12.3:1 Idle speed 1,950 ... 2,050 rpm Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 36.3 mm (1.429 in)

  • Page 279: Tolerance, Engine Wear Limits

    26 TECHNICAL DATA 26.2 Tolerance, engine wear limits Valve - run-out At the valve plate :'> 0.05 mm (:'> 0.002 in) Valve spring Minimum length 42.00 mm (1.6535 in) Valve - sealing seat width Intake 1 .40 mm (0.0551 in) Exhaust 1.40 mm (0.0551 in) Valve spring seat - thickness...
  • Page 280 26 TECHNICAL DATA Screw, oil nozzle for piston cool- 2 Nm (1 .5 lbf ft} Loctite ® ™ Locking screw for bearing 6 Nm (4.4 lbf ft) Loctite ® ™ Oil channel screw plug in alterna- 1.2 Nm (0.89 lbf ft) ®...

  • Page 281: Capacities

    26 TECHNICAL DATA Screw, timing chain tensioning rail 15 Nm (11.1 lbfft) Loctite ® ™ Screw, engine sprocket 60 Nm (44.3 lbf ft) ® Loctite 2701 ™ Plug, oil channel M10x1 15 Nm (11.1 lbfft) ® Loctite ™ Rotor screw M10x1 70 Nm (51.6 lbf ft) Thread, oiled with engine oil/cone...

  • Page 282: Fuel

    26 TECHNICAL DATA 26.4.3 Fuel Total fuel tank capacity, approx. (FE EU/AU) Super unleaded (ROZ 95/RON 95/PON 91) (l!!ll p. 353) I 9.5 I (2.51 US gal) Total fuel tank capacity, approx. (FE US) Super unleaded (ROZ 95/RON 95/PON 91) (�...

  • Page 283: Electrical System

    110/100 - 18 64M TT Dunlop GEOMAX AT81 F Dunlop GEOMAX AT81 The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: www.husqvarna-motorcycles.com 26.8 Fork Fork part number 24.18. 7P.67...

  • Page 284: Shock Absorber

    26 TECHNICAL DATA Weight of rider: 65 ... 75 kg (143 ... 165 lb.) 4.2 N/mm (24 lb/in) Weight of rider: 75 ... 85 kg (165 ... 187 lb.) 4.4 N/mm (25.1 lb/in) Weight of rider: 85 ... 95 kg (187 ... 209 lb.) 4.6 N/mm (26.3 lb/in) Fork length 932 mm (36.69 in)
  • Page 285 26 TECHNICAL DATA Screw, shock absorber adjusting 5 Nm (3. 7 lbf ft) ring Screw, spoiler on fuel tank M5x12 1 .5 Nm (1.11 lbf ft) (FE 350 US) Nut, cable on starter motor 4 Nm (3 lbf ft) Remaining nuts, chassis 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) Remaining screws, chassis...
  • Page 286 26 TECHNICAL DATA Screw, top shock absorber 60 Nm (44.3 lbf ft) 2701 TM ® Loctite 15 Nm (11.1 lbf ft) Nut, fuel pump fixation Nut, angle lever on swingarm M14x1.5 80 Nm (59 lbf ft) Nut, frame on linkage lever M14x1.5 80 Nm (59 lbf ft) Nut, linkage lever on angle lever...

  • Page 287: 27 Cleaning, Care

    27 CLEANING, CARE 27.1 Cleaning the motorc}!cle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.

  • Page 288: Checks And Maintenance Steps For Winter Operation

    27 CLEANING, CARE Treat bare metal (except for brake discs and the exhaust sys­ tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber (� p. 355) Treat all plastic parts and powder-coated parts with a mild cleaning and care product. (FE EU/AU, FE 350 SUS) Grease steering lock.

  • Page 289: 28 Storage

    O ... 35 °C (32 ... 95 °F) tery without direct sunshine Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info Husqvarna Motorcycles recommends raising the motorcycle. Raise the motorcycle with a lift stand. (� p. 13) Preferably cover the vehicle with a tarp or similar cover that is permeable to air.

  • Page 290: Preparing For Use After Storage

    28 STORAGE 28.2 Pre�aring for use after storage Remove the motorcycle from the lift stand. (� p. 13) Install the battery. (� p. 144) Perform checks and maintenance measures when preparing for use. Take a test ride. 401059-01...

  • Page 291: 29 Service Schedule

    Every 30 operating hours/after every race Every 15 operating hours Once after 1 operating hour • • Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. • • Check that the electrical equipment is functioning properly. • •...

  • Page 292: Service Work (As Additional Order)

    Final check: Check the vehicle for roadworthiness and take a test ride. • • • • Read out the fault memory after the test ride using the Husqvarna Motorcycles diagnostics tool. Make the service entry in the Husqvarna Motorcycles Dealer.net and in the Service and War- ranty Booklet.
  • Page 293 29 SERVICE SCHEDULE...
  • Page 294 � " " " " " " u� " " } x 4 � B A F/4 �l -M10 -K10 � -G10 -521 /""' ...J n � · ,.,. I � ,',!, - X 4 � " -X300 -" w�rd�a /2.E1 <( ,..

  • Page 295: 30 Wiring Diagram

    30 WIRING DIAGRAM Components: Battery Starter relay with main fuse Electric starter system E-tip switch...

  • Page 296: Eu)

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  • Page 297 30 WIRING DIAGRAM Components: A 11 EFI control unit Radiator fan temperature switch Fuse Fuse Fuse Alternator Light relay Power relay Radiator fan Voltage regulator X295 Diagnostics connector...

  • Page 298: Eu)

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  • Page 299 30 WIRING DIAGRAM Components: A 11 EFI control unit Low beam, high beam Speedometer Horn Parking light Light switch, horn button, kill switch...

  • Page 300: Eu)

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  • Page 301 30 WIRING DIAGRAM Components: Front brake light switch Rear brake light switch License plate lamp Brake/tail light...

  • Page 302: Eu)

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  • Page 303 30 WIRING DIAGRAM Components: Turn signal relay Turn signal indicator lamp Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right S2 5 Turn signal switch...

  • Page 304: Eu)

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  • Page 305 30 WIRING DIAGRAM Components: A 11 EFI control unit Fuel level sensor Lambda sensor (cylinder 1) Fuse Speedometer...

  • Page 306: Eu)

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  • Page 307 30 WIRING DIAGRAM Components: A 11 EFI control unit Front wheel speed sensor Fuel pump Injection valve (cylinder 1) CAN-bus terminating resistor 1 Speedometer X295 Diagnostics connector...

  • Page 308: Eu)

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  • Page 309 30 WIRING DIAGRAM Components: A 11 EFI control unit Throttle position sensor Intake air temperature sensor Coolant temperature sensor (cylinder 1) Rollover sensor Crankshaft position sensor Induction manifold pressure sensor (cylinder 1) Ignition coil (cylinder 1) Map-Select switch for ride mode (optional) Map-Select switch for basic position (optional) Cable colors:...

  • Page 310: Fe Au)

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  • Page 311 30 WIRING DIAGRAM Components: Battery Starter relay with main fuse Electric starter system Emergency OFF switch, tip switch...

  • Page 312: Fe Au)

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  • Page 313 30 WIRING DIAGRAM Components: A 11 EFI control unit Radiator fan temperature switch Fuse Fuse Fuse Alternator Light relay Power relay Radiator fan Voltage regulator X295 Diagnostics connector...

  • Page 314: Fe Au)

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  • Page 315 30 WIRING DIAGRAM Components: A 11 EFI control unit Low beam, high beam Speedometer Horn Parking light Light switch, horn button, kill switch S2 3 Emergency OFF switch, tip switch...

  • Page 316: Fe Au)

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  • Page 317 30 WIRING DIAGRAM Components: Front brake light switch Rear brake light switch License plate lamp Brake/tail light...

  • Page 318: Fe Au)

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  • Page 319 30 WIRING DIAGRAM Components: Turn signal relay Turn signal indicator lamp Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right S2 5 Turn signal switch...

  • Page 320: Fe Au)

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  • Page 321 30 WIRING DIAGRAM Components: A 11 EFI control unit Fuel level sensor Fuse Speedometer...

  • Page 322: Fe Au)

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  • Page 323 30 WIRING DIAGRAM Components: A 11 EFI control unit Front wheel speed sensor Fuel pump Injection valve (cylinder 1) Speedometer CAN-bus terminating resistor 1 X295 Diagnostics connector...

  • Page 324: Fe Au)

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  • Page 325 30 WIRING DIAGRAM Components: A 11 EFI control unit Throttle position sensor Intake air temperature sensor Coolant temperature sensor (cylinder 1) Rollover sensor Crankshaft position sensor Induction manifold pressure sensor (cylinder 1) Ignition coil (cylinder 1) Map-Select switch for ride mode (optional) Map-Select switch for basic position (optional) Cable colors:...

  • Page 326: Fe 350 Us)

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  • Page 327 30 WIRING DIAGRAM Components: Battery Starter relay with main fuse Electric starter system E-tip switch...

  • Page 328: Fe 350 Us)

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  • Page 329 30 WIRING DIAGRAM Components: A 11 EFI control unit Radiator fan temperature switch (optional) Fuse Fuse Fuse Alternator Light relay Power relay Radiator fan (optional) Voltage regulator X295 Diagnostics connector...

  • Page 330: Fe 350 Us)

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  • Page 331 30 WIRING DIAGRAM Components: A 11 EFI control unit Low beam Parking light Tail light Kill switch Light switch...

  • Page 332: Fe 350 Us)

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  • Page 333 30 WIRING DIAGRAM Components: A 11 EFI control unit Fuel level sensor Fuse Speedometer...

  • Page 334: Fe 350 Us)

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  • Page 335 30 WIRING DIAGRAM Components: A 11 EFI control unit Front wheel speed sensor Fuel pump Injection valve (cylinder 1) Speedometer CAN-bus terminating resistor 1 X295 Diagnostics connector...

  • Page 336: Fe 350 Us)

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  • Page 337 30 WIRING DIAGRAM Components: A 11 EFI control unit Throttle position sensor Intake air temperature sensor Coolant temperature sensor (cylinder 1) Rollover sensor Crankshaft position sensor Induction manifold pressure sensor (cylinder 1) Ignition coil (cylinder 1) Map-Select switch for ride mode (optional) Map-Select switch for basic position (optional) Cable colors:...

  • Page 338: Fe 350 S Us)

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  • Page 339 30 WIRING DIAGRAM Components: Fuse Battery Starter relay with main fuse Electric starter system Ignition lock S2 3 Emergency OFF switch, tip switch...

  • Page 340: Fe 350 S Us)

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  • Page 341 30 WIRING DIAGRAM Components: A 11 EFI control unit Radiator fan temperature switch Fuse Fuse Alternator Light relay Power relay Radiator fan Voltage regulator X295 Diagnostics connector...

  • Page 342: Fe 350 S Us)

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  • Page 343 30 WIRING DIAGRAM Components: A 11 EFI control unit Low beam, high beam Horn High beam indicator lamp Parking light S2 9 Light switch, horn button, turn signal switch...

  • Page 344: Fe 350 S Us)

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  • Page 345 30 WIRING DIAGRAM Components: Front brake light switch Rear brake light switch License plate lamp Brake/tail light...

  • Page 346: Fe 350 S Us)

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  • Page 347 30 WIRING DIAGRAM Components: Turn signal relay Turn signal switch Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right S2 9 Light switch, horn button, turn signal switch...

  • Page 348: Fe 350 S Us)

    -A11 -P13 "' /7.A2 -© /7.A4 CY/3 1 CY/3 }' " " -X15 -X15 CZ/3 � CZ/3 ]°'� -X60 -X60 " " � • - < & � J� -X29 FJ/2 "W 17.07 rr.D7 " " " O'------t>h /7.E1 <( <( �...
  • Page 349 30 WIRING DIAGRAM Components: A 11 EFI control unit Fuel level sensor Fuse Speedometer...

  • Page 350: Fe 350 S Us)

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  • Page 351 30 WIRING DIAGRAM Components: A 11 EFI control unit Front wheel speed sensor Fuel pump Evaporate emission control valve Injection valve cylinder 1 Speedometer CAN-bus terminating resistor 1 X295 Diagnostics connector...

  • Page 352: Fe 350 S Us)

    -A11 · '" '" "" -© "" ' " " l · 1" '" ' 1""' 1 1° 1 " 1 " 1 " 1 " 1""" -X15 - X 15 -X15 -X15 - X15 -X15 -X15 -X15 -X15 -X15 "...
  • Page 353 30 WIRING DIAGRAM Components: A 11 EFI control unit Throttle position sensor Intake air temperature sensor Coolant temperature sensor (cylinder 1) Rollover sensor Crankshaft position sensor Induction manifold pressure sensor (cylinder 1) Ignition coil (cylinder 1) Map-Select switch for ride mode (optional) Map-Select switch for basic position (optional) Cable colors:...

  • Page 354: Substances

    SUBSTANCES Brake fluid DOT 4 Standard/classification Guideline Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corresponding properties. Recommended supplier ® Bel-Ray Super DOT 4 Brake Fluid Coolant Guideline Only use high-grade, silicate-free coolant with corrosion inhibitor additive for aluminum motors. Low grade and unsuitable antifreeze causes corrosion, deposits and frothing.
  • Page 355 31 SUBSTANCES Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification p. 372) (SAE 2.5) Guideline Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification DIN EN 228 (ROZ 95/RON 95/PON 91) Guideline...

  • Page 356: 32 Auxiliary Substances

    32 AUXILIARY SUBSTANCES Air filter cleaning agent Recommended supplier ® Bel-Ray Foam Filter Cleaner & Degreaser High viscosi't}f grease Recommended supplier ® LGHB 2 Long-life grease Recommended supplier ® Bel-Ray Waterproof Grease Lubricant (I158) Recommended supplier Lubcon ® ® Turmogrease PP 300 Lubricant 14034...
  • Page 357 32 AUXILIARY SUBSTANCES Oil for foam air filter Recommended supplier ® Bel-Ray Foam Filter Oil Preserving materials for �aints metal and rubber Recommended supplier ® Bel-Ray Silicone Detailer & Protectant Spray Universal oil s�ra}! Recommended supplier ® Bel-Ray 6 in 1...

  • Page 358: 33 Special Tools

    33 SPECIAL TOOLS Bleeder cover Art. no.: 00029013005 00029013005 H00504-01 Bleeder cover Art. no.: 00029013006 00029013006 H00505-01 Bleeding device Art. no.: 00029013100 00029013100 H00518-01 EU batte charger XCharge- rofessional Art. no.: 00029095050 Feature EU safety plug Nominal voltage 230 V Mains fuse Power cable length 5 m (16 ft)
  • Page 359 33 SPECIAL TOOLS US batterY charger XCharge-�rofessional Art. no.: 00029095051 Feature US plug Nominal voltage 120 V Mains fuse 32 A Power cable length 5 m (16 ft) approx. Charger cable 5 m (16 ft) H01065-01 length approx. e-professional Art. no.: 00029095052 Feature UK safety plug Nominal voltage...
  • Page 360 33 SPECIAL TOOLS S�ringe Art. no.: 50329050000 50329050000 H00565-01 Lock ring �lier Art. no.: 51012011000 51012011000 H00572-01 Holding wrench Art. no.: 51129003000 51129003000 H00575-01 Puller Art. no.: 58012009000 58012009000 H00592-01...
  • Page 361 33 SPECIAL TOOLS Puller Art. no.: 58429037037 Feature Inside diameter I 37.5 mm (1.476 in) 58429037037 H00596-01 Tool bracket Art. no.: 58429089000 58429089000 H00603-01 Pressing tool Art. no.: 58429091000 ® 58429091000 H00604-01 Pressing tool Art. no.: 58429092000 ® 58429092000 H00605-01...
  • Page 362 33 SPECIAL TOOLS Torgue wrench set Art. no.: 58429094000 Feature Torque 3 ... 15 Nm (2.2 ... 11 .1 lbf ft) Open ended bit 3.9 mm (0.154 in) Open ended bit 4.9 mm (0.193 in) Open ended bit 5.5 mm (0.217 in) Open ended bit 6.8 mm (0.268 in) 58429094000...
  • Page 363 33 SPECIAL TOOLS Piston ring mounting tool Art. no.: 60029015000 Feature Height 80 mm (3.15 in) 57 ... 125 mm (2.24 ... 4.92 in) Diameter 60029015000 H00628-01 Hose clamR Rlier Art. no.: 60029057000 60029057000 H00650-01 Testing hose Art. no.: 61029093000 �...
  • Page 364 33 SPECIAL TOOLS Release device for timing chain tensioner Art. no.: 61229021000 61229021000 H00675-01 Crankshaft ressing tool Art. no.: 75029047000 75029047000 H00714-01 Protection ca� Art. no.: 75029090000 75029090000 H00726-01 Puller Art. no.: 77229001044 � 77229001044 H00747-01...
  • Page 365 33 SPECIAL TOOLS Holder and fitting for work stand Art. no.: 77229002000 2x£ 77229002000 H00748-01 Crankshaft �ressing tool insert Art. no.: 77229008000 77229008000 H00750-01 Se�arator late Art. no.: 77229009000 77229009000 H00751-01 Valve stem seals lier Art. no.: 77229010000 77229010000 H00752-01...
  • Page 366 33 SPECIAL TOOLS Limit �lug gauge Art. no.: 77229026000 Feature I Diameter 5.55 mm (0.2185 in) 77229026000 H00753-01 Insertion for �iston ring lock Art. no.: 77229030000 77229030000 H00754-01 Protection ca� Art. no.: 77229031000 77229031000 H00755-01 Art. no.: 77229032000 77229032000 H00756-01...
  • Page 367 33 SPECIAL TOOLS Insert for timing chain tensioner Art. no.: 77229035000 77229035000 H00757-01 Puller Art. no.: 77229048000 77229048000 H00758-01 Adjustment bush bridge Art. no.: 77229050044 2x&.£ 77229050044 H00759-01 Insert for valve s ring lever Art. no.: 77229060000 77229060000 H00760-01...
  • Page 368 33 SPECIAL TOOLS S�ark �lug wrench with link Art. no.: 77229172000 Feature Drive 3/8 in Hexagonal part 14 mm (0.55 in) Length 130 mm (5.12 in) 77229172000 H00761-01 Oil ressure ada�ter Art. no.: 77329006000 77329006000 H00764-01 Engine work stand Art. no.: 80329001000 80329001000 H01047-01 Lift stand...
  • Page 369 33 SPECIAL TOOLS Hook wrench Art. no.: T106S Feature Diameter I 68 ... 75 mm (2.68 ... 2.95 in) T106S H00841-01 De�th micrometer Art. no.: T107S T107S H00842-01 Drift Art. no.: T120 Feature Diameter I 8 mm (0.31 in) T120 H00844-01 Clam ing stand Art.
  • Page 370 33 SPECIAL TOOLS Mounting sleeve Art. no.: T1204 Feature I Diameter 25.5 ... 30.5 mm (1 .004 ... 1 .201 in) T1204 H00878-01 Calibrating unit Art. no.: T1205 Feature I Diameter 1 18 mm (0.71 in) T1205 H00879-01 Pressing tool Art.
  • Page 371 33 SPECIAL TOOLS Mounting sleeve Art. no.: T1215 Feature Diameter 1 18 mm (0.71 in) T1215 H00886-01 Pressing tool Art. no.: T1216 Feature Diameter 13 8 ... 49 mm (1.5 ... 1.9 3 in) T1216 H00887-01 Vacuum um� Art. no.: T1240S �...
  • Page 372 33 SPECIAL TOOLS Clam�ing stand Art. no.: T1403S .&. Feature Diameter 48 mm (1.89 in) Diameter 60 mm (2.36 in) T1403S H00896-01 Mounting tool Art. no.: T14040S Feature I Diameter 48 mm (1.89 in) � T14040S H00922-01 Mounting tool Art. no.: T14047 &...
  • Page 373 33 SPECIAL TOOLS Pressing tool Art. no.: T14051 Feature Diameter I 50 mm (1 .97 in) T14051 H00926-01 Pressing tool Art. no.: T1504 Feature Diameter 118 mm (0.71 in) T1504 H00899-01 Mounting tool && Art. no.: T150S �c0 T150S H00852-01 Filling tool Art.

  • Page 374: Standards

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

  • Page 375: 35 List Of Abbreviations

    35 LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 376: Index

    INDEX Capacity ......9 Accessories coolant ....... 258, 279 Activated charcoal filter Engine oil ....180, 262, 279 installing ......109 fuel ......
  • Page 377 INDEX Engine - working on the individual parts clutch, checking ....220 Engine countershaft, assembling ... . . 227 installing countershaft, disassembling .
  • Page 378 INDEX engine oil, draining ....181 cartridge, disassembling ....23 engine, positioning at ignition top dead center 184 checking .
  • Page 379 INDEX Headlight Open-circuit current light range, adjusting checking ......146 Headlight adjustment Operating substances ....checking .
  • Page 380 INDEX piston rod, disassembling ....60 engine tightening torques ... . . 277 removing ......54 fork ......
  • Page 381 I 1 1 11 1 11 1 1 1 1 11 1 1 1 111 1 11 1 1 1 1 111 1 1 1 1 1 1 1 1 1 111 1 I I I I I I II I I II 3403027en 07/2017 ® Husqvarna llmi Husqvarna Motorcycles GmbH StallhofnerstraBe 3 5230 Mattighofen Austria fiiiHiAv � LZZa" ·...

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