2019 Husqvarna TE 250i - TE300i Service Repair Manual PDF

PIONEERING SINCE 1903
REPAIR MANUAL 2019
TE 250i
TE 300i
Art. no. 3403080en Husqvarna
MOTORCYCLES
INTRODUCTION
Read this repair manual carefully and thoroughly before beginning work.
The vehicle will only be able to meet the demands placed on it if the specified service work is performed regu
larly and properly.
This repair manual was written to correspond to the latest state of this model series. We reserve the right to
make changes in the interest of technical advancement without updating this repair manual at the same time.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a work
shop are not specified here. It is assumed that the repair work will be performed by a fully trained mechanic.
All specifications are non-binding. Husqvarna Motorcycles GmbH specifically reserves the right to modify or
delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior
notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a
particular model without prior notice. Husqvarna accepts no liability for delivery options, deviations from figures
and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment
that does not belong to the regular scope of supply.
© 2018 Husqvarna Motorcycles GmbH, Mattighofen Austria

All rights reserved
Reprinting, including excerpts, and duplication of any kind only with the written consent of the publisher.
ISO 9001(12 100 6061)

Husqvarna Motorcycles applies quality assurance processes that lead to the highest possible
product quality as defined in the ISO 9001 international quality management standard.
Issued by: TUV Management Service
REG.NO. 12 100 6061
Husqvarna Motorcycles GmbH

StallhofnerstraBe 3
5230 Mattighofen, Austria
This document is valid for the following models:

TE 250i EU (F2303S7)
TE 250i US (F2375S7)
TE 300i EU (F2403S7)
TE 300i US (F2475S7)
3403080en
05/2018
TABLE OF CONTENTS
1 MEANS OF REPRESENTATION....................... 7 6.15 Assembling the tap compression.......28

6.16 Assembling the cartridge.....................29
1.1 Symbols used........................................7
6.17 Assembling the fork legs......................32
1.2 Formats used........................................ 7
6.18 Greasing the steering head bearing.... 37
SAFETY ADVICE.............................................. 8 6.19 Removing the lower triple clamp....... 38
6.20 Installing the lower triple clamp......... 39
2.1 Repair manual...................................... 8
6.21 Checking the play of the steering
2.2 Safety advice....................................... 8
head bearing........................................41
2.3 Degrees of risk and symbols............... 8
6.22 Changing the steering head
2.4 Workrules..............................................8
bearing.................................................41
IMPORTANT NOTES........................................ 9 6.23 Adjusting the play of the steering
head bearing........................................43
3.1 Manufacturer and implied warranty.......9
3.2 Operating and auxiliary substances.... 9 7 HANDLEBAR, CONTROLS............................. 44
3.3 Spare parts, accessories.......................9
7.1 Handlebar position...............................44
3.4 Figures................................................. 9
7.2 Adjusting the handlebar position....... 44
SERIAL NUMBERS......................................... 10 7.3 Adjusting the basic position of the
clutch lever...........................................45
4.1 Chassis number................................. 10
7.4 Checking throttle cable routing......... 45
4.2 Type label (All EU models)................. 10
7.5 Checking the play in the throttle
4.3 Engine number................................... 10
cable....................................................46
4.4 Fork article number............................ 10
7.6 Adjusting the play in the throttle
4.5 Shock absorber article number......... 11 cable....................................................46
MOTORCYCLE............................................... 12 7.7 Checking the rubber grip.....................47
7.8 Setting the characteristic map of the
5.1 Raising the motorcycle with a lift
throttle response..................................47
stand.................................................. 12
5.2 Removing the motorcycle from the 8 FRAME........................................................... 49
lift stand............................................. 12
8.1 Removing the engine guard.................49
5.3 Starting the vehicle............................ 12
8.2 Installing the engine guard...................49
5.4 Starting the motorcycle to check the
8.3 Checking the frame..............................49
function.............................................. 13
8.4 Changing the footrests........................49
FORK, TRIPLE CLAMP.................................. 15
9 SHOCK ABSORBER, SWINGARM................. 53
6.1 Adjusting the compression damping
9.1 Adjusting the high-speed
of the fork........................................... 15
compression damping of the shock
6.2 Adjusting the rebound damping of
absorber...............................................53
the fork............................................... 15
9.2 Adjusting the low-speed
6.3 Adjusting the spring preload of the
compression damping of the shock
fork..................................................... 16
absorber...............................................53
6.4 Bleeding the fork legs........................ 16
9.3 Adjusting the rebound damping of
6.5 Cleaning the dust boots of the fork the shock absorber........................ 54
legs.................................................... 17
9.4 Measuring the rear wheel dimension
6.6 Removing the fork protector.............. 18 unloaded..............................................55
6.7 Installing the fork protector................ 18 9.5 Checking the static sag of the
6.8 Removing the fork legs...................... 18 shock absorber....................................55
6.9 Installing the fork legs........................ 19 9.6 Checking the riding sag of the
6.10 Servicing the fork.................................20 shock absorber....................................56
6.11 Disassembling the fork legs.................. 20 9.7 Adjusting the spring preload of the
6.12 Disassembling the cartridge................23 shock absorber.................................. 56
6.13 Disassembling the tap 9.8 Adjusting the riding sag.......................57
compression........................................26 9.9 Removing the shock absorber........... 58
6.14 Checking the fork legs.........................27 9.10 Installing the shock absorber...............59
2
TABLE OF CONTENTS
9.11 Checking the shock absorber 12.8 Installing the fuel tank...................... 103
linkage..................................................61 12.9 Checking the fuel pressure.............. 105
9.12 Servicing the shock absorber..............63 12.10 Changing the fuel screen...................107
9.13 Removing the spring............................64 12.11 Changing the fuel filter.......................108
9.14 Disassembling the damper..................65 12.12 Changing the fuel pump.................. Ill
9.15 Disassembling the piston rod..............66
13 MASK, FENDER............................................ 114
9.16 Disassembling the seal ring
retainer............................................... 67 13.1 Removing front fender.......................114
9.17 Changing the pilot bushing..................68 13.2 Installing front fender....................... 114
9.18 Checking the damper........................ 69 13.3 Removing the headlight mask with
9.19 Removing the heim joint.................... 70 the headlight.................................... 115
9.20 Installing the heim joint...................... 71 13.4 Installing the headlight mask with
9.21 Assembling the seal ring retainer....... 71 the headlight.................................... 115
9.22 Assembling the piston rod................. 72 14 WHEELS....................................................... 117
9.23 Assembling the damper..................... 74
9.24 Bleeding and filling the damper......... 76 14.1 Checking the tire air pressure.......... 117
9.25 Filling damper with nitrogen.............. 79 14.2 Checking the tire condition.............. 117
9.26 Installing the spring..............................80 14.3 Checking the wheel bearing for
9.27 Checking the swingarm.......................81 play.................................................. 118
9.28 Checking the swingarm bearing for 14.4 Checking the brake discs................. 119
play......................................................81 14.5 Checking spoke tension.................. 119
9.29 Removing the swingarm......................82 14.6 Checking the rim run-out................. 120
9.30 Installing the swingarm........................84 14.7 Front wheel...................................... 121
9.31 Changing the swingarm bearing........ 86 14.7.1 Removing the front wheel........... 121
9.32 Checking the heim joint for play........88 14.7.2 Installing the front wheel............. 122
9.33 Changing the heim joint.......................89 14.7.3 Changing the front brake disc..... 122
14.7.4 Changing the front wheel
10 EXHAUST....................................................... 91 bearing........................................ 123
10.1 Removing the main silencer.................91 14.8 Rear wheel....................................... 124
10.2 Installing the main silencer...................91 14.8.1 Removing the rear wheel............. 124
10.3 Removing the manifold........................91 14.8.2 Installing the rear wheel............... 125
10.4 Installing the manifold..........................93 14.8.3 Changing the rear brake disc....... 126
10.5 Changing the glass fiber yarn filling 14.8.4 Checking the chain for dirt.......... 127
in the main silencer..............................94 14.8.5 Cleaning the chain....................... 127
14.8.6 Checking the chain tension......... 128
11 AIR FILTER..................................................... 96
14.8.7 Checking the chain, rear
11.1 Removing the air filter box cover........96 sprocket, engine sprocket, and
11.2 Installing the air filter box cover..........96 chain guide.................................. 128
11.3 Removing the air filter..........................96 14.8.8 Adjusting the chain tension......... 131
11.4 Installing the air filter............................97 14.8.9 Changing the drivetrain kit........... 131
11.5 Cleaning the air filter and air filter 14.8.10 Changing the rear wheel
box..................................................... 97 bearing........................................ 133
11.6 Sealing the air filter box....................... 98 15 WIRINGHARNESS, BATTERY...................... 136
12 FUEL TANK, SEAT, TRIM............................... 99 15.1 Ignition curve plug-in connector...... 136
12.1 Opening the filler cap......................... 99 15.2 Changing the main fuse................... 136
12.2 Closing the filler cap..........................99 15.3 Changing the fuses of individual
12.3 Removing the right side cover......... 100 power consumers............................ 138
12.4 Installing the right side cover........... 100 15.4 Disconnecting the negative cable
12.5 Removing the seat........................... 100 of the battery.................................... 139
12.6 Mounting the seat............................ 101 15.5 Connecting the negative cable of
12.7 Removing the fuel tank.................... 102 the battery........................................ 140
15.6 Removing the battery....................... 140
3
TABLE OF CONTENTS
15.7 Installing the battery..........................141 18.4 Engine disassembly......................... 181

15.8 Recharging the battery.................... 142 18.4.1 Clamping engine into the engine
15.9 Checking the charging voltage........ 143 work stand................................... 181
15.10 Checking the open-circuit current.... 144 18.4.2 Removing the shift lever.............. 181
15.11 Checking the starter relay............... 144 18.4.3 Removing the clutch push rod.... 182
15.12 Diagnostics connector..................... 145 18.4.4 Draining the gear oil..................... 182
18.4.5 Removing the spacer.................. 182
16 BRAKE SYSTEM.......................................... 146
18.4.6 Removing the alternator cover..... 183
16.1 Checking the front brake linings...... 146 18.4.7 Removing the kick starter............ 183
16.2 Changing the front brake linings...... 146 18.4.8 Removing injection valves........... 184
16.3 Checking the free travel of the 18.4.9 Removing the cylinder head........ 184
hand brake lever.............................. 148 18.4.10 Removing the cylinder................. 185
16.4 Adjusting the basic position of the 18.4.11 Removing the piston................... 187
hand brake lever.............................. 149 18.4.12 Removing the water pump
16.5 Checking the front brake fluid cover............................................ 187
level.................................................. 149 18.4.13 Removing the clutch cover.......... 188
16.6 Adding front brake fluid.................. 150 18.4.14 Removing the clutch discs........... 189
16.7 Changing the front brake fluid......... 151 18.4.15 Removing the clutch basket........ 190
16.8 Checking the brake linings of the 18.4.16 Removing the balancer shaft...... 191
rear brake......................................... 153 18.4.17 Removing the kick starter shaft.... 192
16.9 Changing the rear brake linings....... 153 18.4.18 Removing the intermediate kick
16.10 Checking the free travel of the foot starter gear.................................. 192
brake lever....................................... 156 18.4.19 Removing the shift shaft............... 192
16.11 Adjusting the basic position of the 18.4.20 Removing the shift drum
foot brake lever................................ 156 locating unit................................. 193
16.12 Checking the rear brake fluid level... 157 18.4.21 Removing the locking lever......... 193
16.13 Adding rear brake fluid.................... 157 18.4.22 Removing the rotor...................... 193
16.14 Changing the rear brake fluid.......... 158 18.4.23 Removing the starter motor......... 194
17 LIGHTING SYSTEM, INSTRUMENTS.......... 161 18.4.24 Removing the reed valve
housing........................................ 195
17.1 Adjusting the combination 18.4.25 Removing the left engine case
instrument........................................ 161 section......................................... 195
17.2 Setting the kilometers or miles........ 162 18.4.26 Removing the shift rails............... 196
17.3 Setting the clock.............................. 162 18.4.27 Removing the shift drum.............. 196
17.4 Adjusting the wheel 18.4.28 Removing the shift forks.............. 196
circumference.................................. 163 18.4.29 Removing the transmission
17.5 Setting the service display............... 163 shafts........................................... 197
17.6 Changing the headlight bulb............ 164 18.4.30 Removing the crankshaft............ 197
17.7 Changing the turn signal bulb 18.5 Working on individual parts............. 198
(All EU models)................................. 165 18.5.1 Working on the right section of
17.8 Checking the headlight setting........ 165 the engine case........................... 198
17.9 Adjusting the headlight range.......... 166 18.5.2 Working on the left section of
17.10 Changing the combination the engine case........................... 199
instrument........................................ 166 18.5.3 Removing the crankshaft
17.11 Activation......................................... 167 bearing inner race..........................200
18 ENGINE........................................................ 168 18.5.4 Installing the crankshaft bearing
inner race.......................................201
18.1 Cleaning the pressure sensor 18.5.5 Changing the connecting rod,
hose................................................. 168 conrod bearing, and crank pin....201
18.2 Removing the engine....................... 168 18.5.6 Checking the crankshaft run-out
18.3 Installing the engine......................... 175 at the bearing pin..........................203
18.5.7 Checking/measuring the
cylinder..........................................203
4
TABLE OF CONTENTS
18.5.8 Cleaning the pressure sensor 18.6.15 Installing the balancer shaft.........235
cylinder connection.......................204 18.6.16 Installing the clutch basket...........236
18.5.9 Removing the exhaust control....204 18.6.17 Installing the clutch discs...............237
18.5.10 Checking the exhaust control...... 206 18.6.18 Installing the clutch cover............239
18.5.11 Installing the exhaust control....... 207 18.6.19 Installing the water pump
18.5.12 Cylinder - Nikasil® coating........... 210 cover..............................................241
18.5.13 Checking/measuring the piston ... 210 18.6.20 Installing the piston....................... 241
18.5.14 Checking the piston ring end 18.6.21 Installing the cylinder..................... 242
gap................................................211 18.6.22 Checking the X-distance...............244
18.5.15 Measuring the piston/cylinder 18.6.23 Adjusting the X-distance................ 245
mounting clearance.......................212 18.6.24 Adjusting the Z-distance................ 247
18.5.16 Disassemble the reed valve 18.6.25 Installing the cylinder head...........249
housing..........................................212 18.6.26 Installing injection valves................250
18.5.17 Checking the reed valve 18.6.27 Installing the kick starter................250
housing, reed valve and intake 18.6.28 Installing the alternator cover.......250
flange.............................................213 18.6.29 Installing the spacer...................... 251
18.5.18 Assemble the reed valve 18.6.30 Installing the gear oil drain plug ... 251
housing..........................................214
18.6.31 Installing the clutch push rod.......252
18.5.19 Working on the clutch cover.......215
18.6.32 Installing the shift lever.................. 252
18.5.20 Checking the clutch......................218
18.6.33 Removing the engine from the
18.5.21 Preassembling shift shaft............ 219 engine work stand.........................252
18.5.22 Checking the shift mechanism....220
18.5.23 Disassembling the main shaft.....221 19 CLUTCH.........................................................253
18.5.24 Disassembling the 19.1 Checking/correcting the fluid level
countershaft..................................222 of the hydraulic clutch..................... 253
18.5.25 Checking the transmission..........222 19.2 Changing the hydraulic clutch
18.5.26 Assembling the main shaft.......... 224 fluid....................................................254
18.5.27 Assembling the countershaft.......224 19.3 Checking the clutch......................... 255
18.5.28 Checking the kick starter..............226
20 WATER PUMP, COOLING SYSTEM............ 264
18.5.29 Preassembling the kick starter
shaft...............................................226 20.1 Cooling system..................................264
18.5.30 Checking the electric starter 20.2 Checking the antifreeze and
drive...............................................227 coolant level..................................... 264
18.6 Engine assembly..............................228 20.3 Checking the coolant level.................265
18.6.1 Installing the crankshaft................228 20.4 Draining the coolant...........................265
18.6.2 Installing the transmission 20.5 Refilling with coolant..........................266
shafts.............................................229
21 EXHAUST CONTROL................................... 269
18.6.3 Installing the shift forks.................229
18.6.4 Installing the shift drum.................230 21.1 Checking/adjusting the exhaust
18.6.5 Installing the shift rails................. 230 control.............................................. 269
18.6.6 Installing the left engine case
22 LUBRICATION SYSTEM.............................. 272
section...........................................230
18.6.7 Installing the reed valve 22.1 Changing the gear oil.........................272
housing..........................................231 22.2 Checking the gear oil level............... 273
18.6.8 Installing the starter motor........... 232 22.3 Adding gear oil................................. 273
18.6.9 Installing the rotor........................ 233 22.4 Checking 2-stroke oil level............... 274
18.6.10 Installing the locking lever...........233 22.5 Opening 2-stroke oil tank cap......... 274
18.6.11 Installing the shift drum locating 22.6 Closing 2-stroke oil tank cap........... 275
unit.................................................234 22.7 Adding 2-stroke oil.............................275
18.6.12 Installing the shift shaft.................234 22.8 Priming oil pump.............................. 275
18.6.13 Installing the intermediate kick 22.9 Changing the oil pump.......................277
starter gear....................................234
18.6.14 Installing the kick starter shaft....234
5
TABLE OF CONTENTS
23 IGNITION SYSTEM.........................................279 29 SERVICE SCHEDULE................................... 302
23.1 Checking the ignition system...........279 29.1 Additional information........................302

23.2 Ignition coil - checking the primary 29.2 Required work....................................302
winding...............................................280 29.3 Recommended work..........................303
23.3 Checking the spark plug
30 WIRING DIAGRAM....................................... 306
connector...........................................281
23.4 Alternator - checking the stator 30.1 Page 1 of 8 (All EU models)...............306
winding...............................................281 30.2 Page 2 of 8 (All EU models)...............308
23.5 Checking the crankshaft position 30.3 Page 3 of 8 (All EU models)............. 310
sensor................................................282 30.4 Page 4 of 8 (All EU models)...............312
23.6 Changing the spark plug....................283 30.5 Page 5 of 8 (All EU models)...............314
23.7 Changing the spark plug and spark 30.6 Page 6 of 8 (All EU models)............. 316
plug connector...................................284 30.7 Page 7 of 8 (All EU models)............. 318
23.8 Removing the stator...........................284 30.8 Page 8 of 8 (All EU models)...............320
23.9 Installing the stator............................285 30.9 Page 1 of 6 (All US models)...............322
24 ELECTRIC STARTER.................................... 286 30.10 Page 2 of 6 (All US models)..............324
30.11 Page 3 of 6 (All US models)..............326
24.1 Checking the starter motor................286 30.12 Page 4 of 6 (All US models)...............328
25 THROTTLE VALVE BODY............................ 287 30.13 Page 5 of 6 (All US models)..............330
30.14 Page 6 of 6 (All US models)...............332
25.1 Adjusting the idle speed....................287
25.2 Programming ambient pressure...... 287 31 SUBSTANCES.............................................. 334
25.3 Cold start button................................288 32 AUXILIARY SUBSTANCES........................... 336
26 TECHNICAL DATA....................................... 289 33 SPECIAL TOOLS.......................................... 338
26.1 Engine.............................................. 289 34 STANDARDS..................................................353
26.1.1 All TE 250i................................... 289
26.1.2 All TE 300i................................... 289 35 INDEX OF SPECIAL TERMS........................ 354
26.2 Tolerance, engine wear limits.......... 290 36 LIST OF ABBREVIATIONS........................... 355
26.2.1 All TE 250i................................... 290
26.2.2 All TE 300i................................... 290 INDEX................................................................... 356
26.3 Engine tightening torques..................291
26.4 Capacities..........................................293
26.4.1 Gear oil..........................................293
26.4.2 Engine oil.......................................293
26.4.3 Coolant..........................................293
26.4.4 Fuel.............................................. 293
26.5 Chassis..............................................293
26.6 Electrical system................................294
26.7 Tires................................................. 294
26.8 Fork.................................................. 295
26.9 Shock absorber.................................295
26.10 Chassis tightening torques................296
27 CLEANING, CARE........................................ 298
27.1 Cleaning the motorcycle....................298

27.2 Checks and maintenance steps for
winter operation.................................299
28 STORAGE..................................................... 300
28.1 Storage..............................................300
28.2 Preparing for use after storage........301
6
MEANS OF REPRESENTATION 1
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,
Indicates the result of a testing step

»
Indicates a voltage measurement,
Indicates a current measurement,
Indicates a resistance measurement.
Indicates the end of an activity including potential rework,
1.2 Formats used

The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.
Name® Indicates a protected name.
Brand™ Indicates a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which
are explained in the glossary.
7
2 SAFETY ADVICE
2.1 Repair manual

- It is imperative that you read this owner's manual carefully and completely before the start of work. It con
tains useful information and many tips on how to repair and maintain your vehicle.
- This manual assumes that the necessary special Husqvarna tools and Husqvarna workplace and workshop
equipment are available.
2.2 Safety advice

A number of safety instructions need to be followed to operate the product described safely. Therefore read
this instruction and all further instructions included carefully. The safety instructions are highlighted in the text
and are referred to at the relevant passages.
• Info
I Various information and warning labels are attached in prominent locations on the product described.
Do not remove any information or warning labels. If they are missing, you or others may not recognize
dangers and may therefore be injured.
2.3 Degrees of risk and symbols
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the
appropriate measures are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not
taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are
not taken.
Note
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.
2.4 Work rules

Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered
using the number in parentheses. Example: bearing puller (15112017000)
During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts,
seals, sealing rings, O-rings, pins, and lock washers).
In the case of certain screws, a thread locker (e.g. Loctite®) is required. Apply according to the manufacturer's
instructions.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change dam
aged or worn parts.
After completing a repair or service work, check the operating safety of the vehicle.
8
IMPORTANT NOTES 3
3.1 Manufacturer and implied warranty

The work prescribed in the service schedule must be carried out by an authorized Husqvarna Motorcycles
workshop only and confirmed in the customer's Service & Warranty Booklet and in the Husqvarna Motorcy
cles Dealer.net; otherwise, all warranty claims will be void. Damage or secondary damage caused by tamper
ing with and/or conversions on the vehicle are not covered by the warranty.
Additional information on the manufacturer or implied warranty and the procedures involved can be found in
the Service & Warranty Booklet.
3.2 Operating and auxiliary substances
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
- Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Use operating and auxiliary substances in accordance with the Owner's Manual and specification.
3.3 Spare parts, accessories

Only use spare parts and accessories approved and/or recommended by Husqvarna Motorcycles. Husqvarna
Motorcycles accepts no liability for other products and any resulting damage or loss.
The current Husqvarna Motorcycles accessories for your vehicle can be found on the Husqvarna Motorcycles
website.
International Husqvarna Motorcycles website: www.husqvarna-motorcycles.com
3.4 Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not
always necessary to disassemble the component to perform the activity in question. Please follow the instruc
tions in the text.
9
4 SERIAL NUMBERS
4.1 Chassis number

The chassis number o is stamped on the right side of the steer
ing head.
4.2 Type label (All EU models)

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

The engine number o is embossed on the left side of the
engine above the engine sprocket.
4.4 Fork article number

Fork article number O's stamped on the inside of the axle
clamp.
10
SERIAL NUMBERS 4
4.5 Shock absorber article number

Shock absorber article number o is stamped on the top of the
shock absorber above the adjusting ring towards the engine side.
11
5 MOTORCYCLE
5.1 Raising the motorcycle with a lift stand
Note
Danger of damage The parked vehicle can roll away or fall
over.
- Park the vehicle on a firm and level surface.
Raise the motorcycle at the frame underneath the engine.

Lift stand (81329955100) p p. 347)
S Neither wheel is in contact with the ground.
Secure the motorcycle against falling over.
5.2 Removing the motorcycle from the lift stand
Note
Danger of damage The parked vehicle can roll away or fall over.
- Park the vehicle on a firm and level surface.
Remove the motorcycle from the lift stand.

Remove the lift stand.
To park the motorcycle, press side stand O to the ground
with your foot and lean the motorcycle on it.
• Info
I When you are riding, the side stand must be folded up
and secured with the rubber band.
5.3 Starting the vehicle
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and
death.
- Always make sure there is sufficient ventilation when running the engine.
- Use an effective exhaust extraction system when starting or running the engine in an enclosed
space.
Note
Engine damage High revving speed with a cold engine negatively impacts the lifespan of the engine.
- Always run the engine warm at a low speed.
12
MOTORCYCLE 5
- Take the motorcycle off side stand o and secure the side
stand with rubber band
- Shift gear to neutral.
(All EU models)
- Turn the emergency OFF switch to the position O.
Condition
Ambient temperature: < 10 °C (< 50 °F)
- Pull the cold start button fully out and turn it by a Va turn.
• Info
I If the engine is warm, the cold start button must
be deactivated.
Press the electric starter button or push the kick starter

robustly through its full range.
• Info
I Do not open the throttle.
Press the electric starter button for a maximum of
5 seconds. Wait for 30 seconds before a further
attempt at starting.
At temperatures below 15 °C (60 °F), several attempts
at starting may be necessary to warm-up the lithium-
ion battery and thereby increase the starting power.
During the starting process, the malfunction indicator
lamp lights up.
5.4 Starting the motorcycle to check the function
Danger
death.
space.

(All EU models)
Press the electric starter button or push the kick starter
robustly through its full range.
13
5 MOTORCYCLE
• Info
I Press the electric starter button for a maximum of 5
seconds. Wait for 30 seconds before a further attempt
at starting.
At temperatures below 15 °C (60 °F), several attempts
at starting may be necessary to warm-up the lithium-
ion battery and thereby increase the starting power.
During the starting process, the malfunction indicator
lamp lights up.
Do not open the throttle.
14
FORK, TRIPLE CLAMP 6
6.1 Adjusting the compression damping of the fork
• Info
I The hydraulic compression damping determines the fork suspension behavior.
Turn white adjusting screw o clockwise as far as it will go.
• Info
I Adjusting screw o is located at the upper end of the
left fork leg.
The compression damping is located in left fork
leg COM (white adjusting screw). The rebound
damping is located in right fork leg REB (red adjusting
screw).
Turn counterclockwise by the number of clicks correspond

ing to the fork type.
Guideline
Compression damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Info
Turn clockwise to increase damping; turn counter
clockwise to reduce damping.
6.2 Adjusting the rebound damping of the fork
• Info
I The hydraulic rebound damping determines the fork suspension behavior.
Turn red adjusting screw o clockwise as far as it will go.

• Info
I Adjusting screw o is located at the upper end of the
right fork leg.
The compression damping is located in left fork
leg COM (white adjusting screw). The rebound
damping is located in right fork leg REB (red adjusting
screw).

ing to the fork type.
Guideline
Rebound damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
15
6 FORK, TRIPLE CLAMP
• Info
I Turn clockwise to increase damping; turn counter
6.3 Adjusting the spring preload of the fork

Preparatory work
- Raise the motorcycle with a lift stand. ( p. 12)
Main work
- Turn the adjusting wings o counterclockwise all the way.
S The marking +0 aligns with the adjusting wing on both
fork legs.
• Info
I Make the adjustment by hand only. Do not use a tool.
Make the same adjustment on both fork legs.
- Turn the adjusting wings clockwise.

Guideline
Spring preload - Preload Adjuster
Comfort +0
Standard +0
Sport +3
S The adjusting wings engage noticeably at the numerical
values.
• Info
I Adjust the spring preload to the numerical values only
as the preload will not engage between the numerical
values.
Turn clockwise to increase the spring preload; turn
counterclockwise to reduce the spring preload.
Adjusting the spring preload has no influence on the
absorption setting of the rebound.
Basically, however, you should set the rebound damp
ing higher with a higher spring preload.
Finishing work
- Remove the motorcycle from the lift stand. ( p. 12)
6.4 Bleeding the fork legs

Preparatory work
16
Main work
- Release bleeder screws O-
Any excess pressure escapes from the interior of the
fork.
- Tighten the bleeder screws.
Finishing work
- Remove the motorcycle from the lift stand. (83 p. 12)
6.5 Cleaning the dust boots of the fork legs

Preparatory work
- Raise the motorcycle with a lift stand. (83 p. 12)
- Remove the fork protector. (83 p. 18)
Main work
- Push dust boots o of both fork legs downward.
• Info
I The dust boots remove dust and coarse dirt parti
cles from the inside fork tubes. Over time, dirt can
accumulate behind the dust boots. If this dirt is not
removed, the oil seals behind can start to leak.
Warning
Danger of accidents Oil or grease on the brake
discs reduces the braking effect.
- Always keep the brake discs free of oil and
grease.
- Clean the brake discs with brake cleaner when
necessary.
- Clean and oil the dust boots and inner fork tubes of both fork
legs.
Universal oil spray (83 p. 337)
- Press the dust boots back into their installation position.
- Remove excess oil.
Finishing work
- Install the fork protector. ( p. 18)
- Remove the motorcycle from the lift stand. (83 p. 12)
17
6.6 Removing the fork protector

Remove screws o and take off the clamp.
Remove screws © and take off the left fork protector.
Remove screws © and take off the right fork protector.
6.7 Installing the fork protector

Position the fork protector on the left fork leg. Mount and
tighten screws o
Guideline
Remaining screws, M6 10 Nm (7.4 Ibfft)
chassis
Position the brake line, wiring harness, and clamp. Mount and
tighten screws 0
Position the fork protector on the right fork leg. Mount and
tighten screws ©
Guideline
chassis
6.8 Removing the fork legs

Preparatory work
- Remove the headlight mask with the headlight. (IS p. 115)
- Remove the front wheel. ( P- 121)
Main work
- Remove screws o and take off the clamp.
- Remove the cable tie.
- Remove screws 0 and take off the brake caliper.
- Allow the brake caliper and brake line to hang loosely to the
side.
• Info
I Do not pull the hand brake lever when the front wheel
is removed.
18
Loosen screws 0 Remove the left fork leg.

Loosen screws © Remove the right fork leg.
6.9 Installing the fork legs

Main work
- Position the fork legs.
O O S Bleeder screws o are positioned toward the front.
Info
The rebound damping is located in the right fork leg
(red adjusting screw). The compression damping is
located in the left fork leg (white adjusting screw).
Grooves are milled into the side of the upper end of
the fork legs. The second milled groove (from the top)
must be flush with the top edge of the upper triple
clamp.
Tighten screws ©
Guideline
Screw, top triple M8 17 Nm (12.5 Ibfft)
clamp
Tighten screws 0
Guideline
Screw, bottom triple M8 15 Nm (11.1 Ibfft)
clamp
Position the brake caliper, and mount and tighten screws ©

Guideline
Screw, front M8 25 Nm (18.4 Ibfft)
brake caliper Loctite®243™
Mount the cable tie(s).

tighten screws 0
Finishing work
- Install the front wheel. ( p. 122)
- Install the headlight mask with the headlight. (£ p. 115)
- Check the headlight setting. (U p. 165)
19
6.10 Servicing the fork

Condition
The fork legs have been removed.
- Disassemble the fork legs. ( p. 20)
- Disassemble the cartridge. ( p. 23)
- Check the fork legs. (P p. 27)
- Assemble the cartridge. (II p. 29)
- Assemble the fork legs. (P p. 32)
6.11 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 compression
damping o COMP (white adjuster on the left fork leg).
Note down the current state of rebound damping © REB
(red adjuster on the right fork leg).
Open the adjusters of the rebound and compression damp
ing completely.
Clamp the fork leg in the area of the lower triple clamp.
Clamping stand (T1403S) (P p. 351)
Remove screw © . Remove adjuster.
B04521 -10
20
Loosen the screw cover ©.

Ring wrench (T14017) (i! p. 350)
• Info
I The screw cover cannot be removed yet.
Extract the fork leg and push the outer tube downward.
Pull the spring downward and push the open end wrench
onto the hexagonal part.
Hold the hexagonal part and loosen Preload Adjuster with
special tool ©, but do not take it off yet.
Special socket (T14087) (il p. 351)
Pull the spring downward. Remove the open end wrench.

Remove the screw cap.
Remove the spring.

Drain the fork oil.
• Info
I Pull out and push in the piston rod a few times to
pump the cartridge empty.
Clamp the fork leg with the axle clamp.

Guideline
Use soft jaws.
Unscrew and remove compression holder ©.
• Info
I Place a container underneath as oil will run out in
most cases.
21
Remove the cartridge.
B04515-10
Remove dust boot ©

Remove fork protector ring ©.
• Info
I The fork protector ring does not necessarily need to
be removed for repair work.
Remove lock ring ©.
• Info
I The lock ring has a beveled end where a screwdriver
can be applied.
Warm up the outer tube in area © of the lower sliding bush

ing.
Guideline
50 °C (122 °F)
Pull the outer tube from the inner tube with a jerk.
• Info
I Lower sliding bushing © must be pulled from its
bearing seat.
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 ©
Take off seal ring ©
Take off lock ring ©
Take off dust boot ©.
Unclamp the fork leg.
22
6.12 Disassembling the cartridge

Preparatory work
- Disassemble the fork legs. (iS p. 20)
Right cartridge
- Clamp the piston rod with the special tool.
Clamping stand (T14016S) (ES p. 350)
- Remove adjusting tube o

- Remove fluid barrier © from the piston rod.
- Take piston rod © out of the cartridge.
- Take spring seat o and washer © off of the cartridge.
- Degrease the piston rod.

Clamping stand (T14016S) (US p. 350)
- Remove nut ©
- Completely remove shim stack O-
23
- Remove piston ©
- Completely remove shim stack ©
B04530-10
- Remove spring ©
- Warm up the piston rod in area ©.
Guideline
50 °C (122 °F)
- Remove tap rebound ©
- Remove spring ©
- Remove valve © of the rebound damping with the
spring.
- Unclamp the piston rod.
- Remove piston ring ©
Left cartridge
Clamping stand (T14016S) (H p. 350)
- Remove adjusting tube o

- Remove fluid barrier © from the piston rod.
24
- Take piston rod © out of the cartridge.
B04518-10
- Take spring seat © and washer © off of the cartridge.
B04533-10
- Degrease the piston rod.

Clamping stand (T14016S) (iS p. 350)
- Remove piston ring ©
- Warm up the piston rod in area ©

Guideline
50 °C (122 °F)
- Remove piston © with setting needle ©
- Pull setting needle © out of the piston.

- Remove O-rings © and ©
B04536-10
25
Remove spring ©
Unclamp the piston rod.
<D
B04537-10
6.13 Disassembling the tap compression
Info
The procedures are the same on both fork legs.
Preparatory work
- Disassemble the fork legs. ( p. 20)
Main work
- Mount the tap compression on a suitable hexagon socket
and clamp into a vise.
- Remove nut ©
- Remove spring ©
- Remove washer ©
- Remove O-ring ©
- Remove piston ©
- Remove shim stack ©
- Remove O-ring © from the tap compression.

- Extract the tap compression.
26
6.14 Checking the fork legs

Condition
The fork legs have been disassembled.
Check the inner tube and the axle clamp for damage.
» If damage is found:
- Change the inner tube.
Measure the outside diameter of the inner tube in several

places.
Outside diameter of the 47.975 ... 48.005 mm
inner tube (1.88878 ... 1.88996 in)
» If the measured value is less than the specified value:
n B03582-10
Measure the run-out of the inner tube.

£
i Inner tub run-out < 0.20 mm (< 0.0079 in)
» If the measured value is greater than the specified value:
B03583-10
Check the outer tube for damage.

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

» When bronze-colored layer o becomes visible under
gliding layer ©
- Change the guiding bushes.
27
Check the spring length.

Guideline
Spring length with preload 474 mm (18.66 in)
spacer(s)
- Reduce the thickness of the preload spacers.
- Increase the thickness of the preload spacers.
• Info
I There may only be one preload spacer
installed, or none at all.
6.15 Assembling the tap compression
Info
The procedures are the same on both fork legs.
Mount the tap compression on a suitable hexagon socket

and clamp into a vise.
Mount O-ring o
Grease O-ring.
Lubricant (T158) (0 p. 336)
Mount shim stack ©.
• Info
I Mount the smaller shims below.
Mount piston ©
Guideline
View © of piston from above
View © of piston from below
Mount O-ring ©
Grease the piston O-ring.
Mount washer ©
Mount spring © with the tighter coil facing downward.
Mount and tighten nut ©
Guideline
Nut, tap compres M6x0.5 5 Nm (3.7 Ibf ft)
sion
• Info
I Washer © must be free to move against the spring
force.
28
- Extract the tap compression.
6.16 Assembling the cartridge

Right cartridge
- Clamp in the piston rod.
Clamping stand (T14016S) (H p. 350)
— Mount valve O of the rebound damping with the spring

and O-ring.
- Grease the O-ring.
Lubricant (T158) (®3 p. 336)
- Mount spring ©
- Mount and grease O-ring © in tap rebound ©
Lubricant (T158) (81 p. 336)
- Mount and tighten the tap rebound.
Guideline
Tap rebound M9x1 18 Nm (13.3 Ibfft)
Loctite®2701 ™
- Position spring 0
- Mount shim stack 0
• Info
I Mount the smaller shims at the bottom.
- Press the shim stack downward against the spring force.
• Info
I The shim stack must be pressed downward over
the collar.
Mount and lubricate piston ring 0
29
Mount piston © with the piston ring.

Guideline
Mount shim stack ©
• Info
I Align the triangular plate exactly with the piston
opening.
Mount and tighten nut © with the collar facing down

ward.
Guideline
Tap rebound nut M6x0.5 5 Nm (3.7 Ibf ft)
S The lower shim stack is free to move against the
spring force.
Lock the nut by center punching it.
Mount washer © and spring seat ©
Slide piston rod © into the cartridge.
B04532-11
Mount fluid barrier © all the way on.
• Info
I The fluid barrier must be tightened all the way. Do
not use a tool.
Mount adjusting tube © for the rebound damping in the

cartridge.
30
S The adjusting tube protrudes approx. 5 mm (0.197 in)

out of the cartridge and can be pressed in against the
spring force.
X The adjusting tube protrudes more than 7 mm
(0.275 in) from the cartridge and cannot be pressed
in against the spring force.
Left cartridge
- Clamp in the piston rod.
Clamping stand (T14016S) (EJ p. 350)
- Mount spring o
- Mount and lubricate O-ring © for setting needle ©

Lubricant (T158) ((8 p. 336)
Mount and lubricate O-ring Q for piston ©.

Lubricant (T158) p p. 336)
B04551-10
Insert setting needle © in the piston.

Mount and tighten piston ©.
Guideline
Compression M9x1 18 Nm (13.3 Ibfft)
piston Loctite®2701 ™
Mount and lubricate piston ring ©
31
Mount washer © and spring seat ©.
Slide piston rod © into the cartridge.
Mount fluid barrier © all the way on.
• Info
I The fluid barrier must be tightened all the way. Do
not use a tool.
Mount adjusting tube © for the rebound damping in the

cartridge.
S The adjusting tube protrudes approx. 3 mm (0.197 in)
out of the cartridge and can be pressed in against the
spring force.
X The adjusting tube protrudes more than 5 mm
(0.275 in) from the cartridge and cannot be pressed
in against the spring force.
6.17 Assembling the fork legs
Info
The operations are the same on both fork legs.
Preparatory work
- Check the fork legs. (8i p. 27)
- Assemble the tap compression. (BS p. 28)
- Assemble the cartridge. (ES p. 29)
32
Main work
- Clamp the inner tube using the axle clamp.
Guideline
Use soft jaws.
- Mount the special tool.
Protecting sleeve (T1401) (U p. 350)
- Grease and push on dust boot ©

Lubricant (T14034) (d p. 336)
• Info
I Always change the dust boot, seal ring, lock ring, and
support ring.
Mount the sealing lip with the spring expander facing
down.
- Push on lock ring ©

- Grease and push on seal ring ©
Lubricant (T14034) (IS p. 336)
• Info
I Sealing lip downward, open side upward.
Push on support ring ©

Remove the special tool.
Push on lower sliding bushing ©
Mount upper sliding bushing ©
• Info
I Without using a tool, pull the stack slightly apart by
hand.
Warm up the outer tube in area © of the lower sliding bush

ing.
Guideline
50 °C (122 °F)
Push the outer tube on.
Hold the lower sliding bushing with the longer side of the
special tool.
Press the outer tube all the way in.
33
Position the support ring.

Hold the seal ring with the shorter side of the special tool.
Press the outer tube all the way in.
Mount lock ring ©
Info
The lock ring must engage audibly.
B03527-12
Mount dust boot o

Mount fork protector ring ©
Slide the cartridge all the way into the inner tube.
S The hexagonal part of the cartridge engages in the inner
tube guide.
• Info
I When assembling, ensure that the cartridges are not
mixed up.
The cartridges with the holes are installed on the left.
The cartridge without the hole is installed on the right.
34
Mount and tighten tap compression ©

Guideline
Compression damp- M29x1 35 Nm (25.8 Ibfft)
ing fitting
Mount special tool © on the piston rod.

Support tool (T14026S1) (IS p. 350)
• Info
I The special tool must be used to prevent the adjust
ing tube from being lifted and thus to prevent oil from
reaching the piston rod.
Clamp the fork vertically.

Fill with fork oil.
Fork oil per fork leg 642 ± 10 ml Fork oil (SAE 4)
(21.71 (48601166S1)
± 0.34 fl. oz.) (ip p. 335)
• Info
I Pull out the piston rod and push back in a number of
times to bleed the cartridge.
Remove pin © of the special tool.

Support tool (T14026S1) (IS p. 350)
Pull out the piston rod. Mount the spring. Mount the pin
again.
Guideline
Spring rate
Weight of rider: 65 ... 4.0 N/mm (22.8 Ib/in)
75 kg (143 ... 165 lb.)
Weight of rider: 75 ... 4.2 N/mm (24 Ib/in)
85 kg (165 ... 187 lb.)
Weight of rider: 85 ... 4.4 N/mm (25.1 Ib/in)
95 kg (187 ... 209 lb.)
Pull the spring downward.

Support tool (T14026S1) ( p. 350)
Mount screw cap ©
35
• Info
I When assembling, ensure that the screw caps are
mounted correctly.
Rebound damping side - right fork leg, screw cap with
marking REB, red adjuster.
Compression damping side - left fork leg, screw cap
with marking COMP, white adjuster.
Pull the spring downward.

Mount the open end wrench on the hexagonal part.
Hold the open end wrench. Tighten Preload Adjuster with
special tool ©
Guideline
Preload Adjuster on M12x1 25 Nm (18.4 Ibf ft)
the piston rod
Special socket (T14087) (S3 p. 351)
Push the outer tube upward.

Clamp the outer tube in the area of the lower triple clamp.
Clamping stand (T1403S) (BS p. 351)
Grease the O-ring of the screw cover.
Lubricant (T158) (U p. 336)
Mount and tighten screw cap ©.

Guideline
B04522-11
Screw cap on outer M51x1.5 40 Nm (29.5 Ibf ft)
tube
Ring wrench (T14017) ( p. 350)
Mount the adjuster.

Mount and tighten screw
Guideline
Screw, adjuster M4x0.5 2.5 Nm (1.84 Ibf ft)
Alternative 1
- Turn compression adjuster © and rebound adjuster
clockwise all the way.
- Turn counterclockwise by the number of clicks corre
sponding to the fork type.
36
Guideline
Rebound damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Compression damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
- Set the spring preload according to the fork type.
Guideline
Comfort +0
Standard +0
Sport +3
Alternative 2
Warning
Danger of accident Modifications to the sus
pension setting may seriously alter the handling
characteristic.
Extreme modifications to the suspension setting
may cause a serious deterioration in the handling
characteristic and overload components.
- Only make adjustments within the recom
mended range.
- Ride slowly to start with after making
adjustments to get the feel of the new
handling characteristic.
- Set the adjusters to the positions determined upon

removal.
- Remove the lower triple clamp. ( p. 38)

- Install the lower triple clamp. ( p. 39)
37
6.19 Removing the lower triple clamp

Preparatory work
- Remove the headlight mask with the headlight. (US p. 115)
- Remove the front wheel. ( p. 121)
- Remove the fork legs, (fii p. 18)
- Remove front fender. (BIS p. 114)
Main work
- Remove screw O-
- Remove screw ©
- Open cable holder © in front of the left radiator and detach
the clutch line.
- Open cable holder o in front of the right radiator and detach
the wiring harness.
- Remove the upper triple clamp with the handlebar and set
aside.
• Info
I Cover the components to protect them against dam
age.
Do not kink the cables and lines.
Remove O-ring © . Remove protective ring ©

Remove the lower triple clamp with the steering stem.
Remove the upper steering head bearing.
38
6.20 Installing the lower triple clamp

Main work
- Clean the bearing and sealing elements, check for damage,
and grease.
High viscosity grease (H p. 336)
- Insert the lower triple clamp with the steering stem. Mount
the upper steering head bearing.
- Check whether upper steering head seal o is correctly posi
tioned.
- Mount protective ring © and O-ring ©
B01632-10
Position the upper triple clamp with the handlebar.

Mount screw o but do not tighten yet.
Mount the clutch line with cable holder ©
Mount the wiring harness with cable holder 0
Position the fork legs.

^ Bleeder screws O are positioned toward the front.
• Info
I The rebound damping is located in the right fork leg
(red adjusting screw). The compression damping is
located in the left fork leg (white adjusting screw).
Grooves are milled into the side of the upper end of
the fork legs. The second milled groove (from the top)
402556-12
must be flush with the upper edge of the upper triple
clamp.
Tighten screws 0
Guideline
Screw, bottom triple M8 15 Nm (11.1 Ibfft)
clamp
39
Tighten screw ©.
Guideline
Screw, top steering M20x1.5 12 Nm (8.9 Ibfft)
head
Mount and tighten screw ©

Guideline
Screw, top M8 17 Nm (12.5 Ibfft)
steering stem Loctite®243™
Using a plastic hammer, tap lightly on the upper triple clamp

to avoid stresses.
Tighten screws ©
Guideline
Screw, top triple M8 17 Nm (12.5 Ibfft)
clamp
Position the brake caliper, and mount and tighten screws

Guideline
Screw, front M8 25 Nm (18.4 Ibfft)
brake caliper Loctite®243™
Mount the cable tie.

tighten screws ©
Finishing work
- Install front fender. (81 p. 114)
- Install the front wheel. (81 p. 122)
- Install the headlight mask with the headlight. ( p. 115)
- Check that the wiring harness, throttle cables, and brake and
clutch lines can move freely and are routed correctly.
- Check the play of the steering head bearing. ( p. 41)
- Check the headlight setting. (88 p. 165)
40
6.21 Checking the play of the steering head bearing
Warning
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and
damages components.
- Correct incorrect steering head bearing play immediately.
• Info
I If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the
bearing seats in the frame can become damaged over time.
Preparatory work
- Raise the motorcycle with a lift stand. (US p. 12)
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 play of the steering head bearing. ( p. 43)
- Move the handlebar to and fro over the entire steering range.
It must be possible to move the handlebar easily over the
entire steering range. There should be no detectable detent
positions.
» If detent positions are detected:
- Adjust the play of the steering head bearing. ( p. 43)
- Check the steering head bearing and change if neces
sary.
Finishing work
- Remove the motorcycle from the lift stand. (Ul p. 12)
6.22 Changing the steering head bearing

Preparatory work
- Remove the headlight mask with the headlight. (U p. 115)
- Remove the fork legs. ( p. 18)
- Remove front fender. (IS p. 114)
- Remove the lower triple clamp. ( p. 38)
41
Main work
- Remove lower bearing ring O with special tool
Tool bracket (58429089000) (fil p. 344)
Pressing tool (58429092000) ( p. 344)
- Press the new bearing ring up to the stop with special

tool ©.
Tool bracket (58429089000) (W p. 344)
Pressing tool (58429091000) ( 1 p. 344)
- Remove upper bearing ring © with special tool ©

Tool bracket (58429089000) (a p. 344)
Pressing tool (58429092000) ( p. 344)
- Press the new bearing ring up to the stop with special

tool
- Remove lower steering head bearing ©

- Remove the seal ring.
- Grease and mount the new seal ring.
- Press on the new bearing with a suitable tube as far as it will
go.
• Info
I Only press the bearing in via the inner ring.
Finishing work
- Install the lower triple clamp. (U p. 39)
- Install front fender. (S® p. 114)
42

- Install the headlight mask with the headlight, (ft p. 115)
- Check that the wiring harness, throttle cables, and brake and
clutch lines can move freely and are routed correctly.
- Check the play of the steering head bearing. (SO p. 41)
- Remove the motorcycle from the lift stand. (8S p. 12)
- Check the headlight setting. (H p. 165)
6.23 Adjusting the play of the steering head bearing

Preparatory work
- Raise the motorcycle with a lift stand. (SO p. 12)
Main work
- Loosen screws o Remove screw ©
- Loosen and retighten screw ©
Guideline
Screw, top steering M20x1.5 12 Nm (8.9 Ibf ft)
head
- Using a plastic hammer, tap lightly on the upper triple clamp
to avoid strains.
- Tighten screws ©
Guideline
Screw, top triple M8 17 Nm (12.5 Ibf ft)
clamp
- Mount and tighten screw ©

Guideline
Screw, top M8 17 Nm (12.5 Ibf ft)
steering stem Loctite®243™
Finishing work
- Check the play of the steering head bearing. (ftS p. 41)
- Remove the motorcycle from the lift stand. (SO p. 12)
43
7 HANDLEBAR, CONTROLS
7.1 Handlebar position

On the upper triple clamp, there are 2 holes at a distance of o
to each other.
Hole distance A 15 mm (0.59 in)
The holes on the handlebar support are placed at a distance
of © from the center.
Hole distance B 3.5 mm (0.138 in)
The handlebar can be mounted in four different positions. This
allows the handlebar to be mounted in the most comfortable
position for the rider.
7.2 Adjusting the handlebar position
Warning
Danger of accidents A repaired handlebar poses a safety risk.
If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a
result.
- Change the handlebar if the handlebar is damaged or bent.
Remove screws o . Take off the handlebar clamps. Remove

the handlebar and lay it to one side.
• Info
age.
Do not kink the cables and lines.
Remove screws 0 . Take off the handlebar supports.

Place the handlebar supports in the required position. Mount
and tighten screws 0
Guideline
Screw, handle- M10 40 Nm (29.5 Ibf ft)
bar support Loctite®243™
• Info
I Position the left and right handlebar supports evenly.
- Position the handlebar.
• Info
I Make sure the cables and wiring are positioned cor
rectly.
- Position the handlebar clamps. Mount screws O and tighten

evenly.
Guideline
Screw, handlebar M8 20 Nm (14.8 Ibf ft)
clamp
44
HANDLEBAR, CONTROLS 7
Info
Make sure the gap widths are even.
7.3 Adjusting the basic position of the clutch lever

Adjust the basic position of the clutch lever to your hand size
by turning adjusting screw o
• Info
I When the adjusting screw is turned counterclockwise,
the clutch lever moves away from the handlebar.
When the adjusting screw is turned clockwise, the
clutch lever moves closer to the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not
apply any force.
Do not make any adjustments while riding.
7.4 Checking throttle cable routing

Preparatory work
- Remove the air filter box cover. (U p. 96)
- Remove the seat. (U p. 100)
- Remove the right side cover. (fiS p. 100)
- Remove the fuel tank. (BS p. 102)
Main work
- Check throttle cable routing.
Both throttle cables must be routed, side by side, on the
back of the handlebars, above the fuel tank bracket on the
right of the frame to the throttle valve body. Both throttle
cables must be secured behind the fuel tank contact area
rubber band.
» If the throttle cable routing is not as specified:
- Correct throttle cable routing.
Finishing work
- Install the fuel tank. ( p. 103)
- Mount the seat. (HI p. 101)
- Install the air filter box cover. (W p. 96)
- Install the right side cover. ( p. 100)
45
7.5 Checking the play in the throttle cable

Check the throttle grip for smooth operation.
Turn the handlebar as far as possible to the right. Turn the
throttle grip back and forth slightly and determine the play in
throttle cable ©
Play in throttle cable 3 ... 5 mm (0.12 ... 0.2 in)
» If the throttle cable play does not meet the specified
value:
- Adjust the play in the throttle cable. ( p. 46)
Danger
Danger of poisoning Exhaust gases are toxic and
inhaling them may result in unconsciousness and
death.
- Always make sure there is sufficient ventilation
when running the engine.
- Use an effective exhaust extraction system when
starting or running the engine in an enclosed
space.
- Start the engine and let it run idle. Move the handlebar to and
fro over the entire steering range.
The idle speed must not change.
» If the idle speed changes:
- Adjust the play in the throttle cable. (W p. 46)
7.6 Adjusting the play in the throttle cable
• Info
I If the correct routing of the throttle cables has already been secured, the fuel tank does not need to be
removed.
Preparatory work
- Remove the air filter box cover. (88 p. 96)
- Remove the seat. (US p. 100)
- Remove the right side cover. (88 p. 100)
- Remove the fuel tank. (88 p. 102)
- Check throttle cable routing. ( p. 45)
Main work
- Move the handlebar to the straight-ahead position.
- Push back sleeve o
- Loosen nut ©
- Turn adjusting screw © in as far as possible.
- Loosen nut ©
- Turn adjusting screw © in as far as possible.
- Turn adjusting screw © so that there is play in the throttle
cable at the throttle grip.
46
HANDLEBAR, CONTROLS 7
Guideline
Play in throttle cable 3 ... 5 mm (0.12 ... 0.2 in)
- Unscrew the adjusting screw © until the smooth operation

or play in throttle cable is worsened.
- Turn the adjusting screw © approx, two turns further.
- Tighten nut ©
- Tighten nut ©.
- Slide on sleeve ©
- Check the throttle grip for smooth operation.
Finishing work
- Check the play in the throttle cable. ( p. 46)
7.7 Checking the rubber grip

Check the rubber grips on the handlebar for damage, wear,
and looseness.
• Info
I The rubber grips are vulcanized onto a sleeve on the
left and onto the handle tube of the throttle grip on the
right. The left sleeve is clamped onto the handlebar.
The rubber grip can only be replaced with the sleeve
or the throttle tube.
» If a rubber grip is damaged or worn:

- Change the rubber grip.
Check that screw o is firmly seated.

Guideline
Screw, fixed M4 5 Nm (3.7 Ibf ft)
grip Loctite®243™
The diamond © must be positioned visibly as shown in

the figure.
7.8 Setting the characteristic map of the throttle response
• Info
I On the throttle grip, the characteristic map of the throttle response is changed by changing the guide
plate.
A guide plate with a different characteristic map is supplied.
47
Main work
- Push back sleeve O-
- Remove screws 0 and half-shells ©
- Detach the throttle cables and take off the grip tube.
Remove guide plate o from handle tube ©

Position the required guide plate on the grip tube.
Guideline
The label OUTSIDE must be visible. Marking o must be
positioned at marking 0
Grey guide plate (79002014000)

Alternative 1
Black guide plate (79002014100)
• Info
I The gray guide plate opens the throttle valve more
slowly.
The black guide plate opens the throttle valve more
quickly.
The gray guide plate is mounted upon delivery.
Clean the outside of the handlebar and the inside of the grip
tube. Mount the grip tube on the handlebar.
Attach the throttle cables to the guide plate and route cor
rectly.
Position half-shells 0 , mount and tighten screws 0
Guideline
Screw, throttle grip M6 5 Nm (3.7 Ibf ft)
Slide on sleeve o and check the throttle grip for ease of

E01260-10
movement.
Finishing work
- Check the play in the throttle cable. (B8 p. 46)
48
FRAME 8
8.1 Removing the engine guard

Remove screws o and engine guard.
8.2 Installing the engine guard

Attach the engine guard on the frame at the rear and swing
up at the front.
Mount and tighten screws o
Guideline
Remaining screws, M6 10 Nm (7.4 Ibf ft)
chassis
8.3 Checking the frame

Check the frame for cracks and deformation.
» If the frame exhibits cracks or deformation due to a
mechanical impact:
- Change the frame.
• Info
I Always replace a frame that has been
damaged due to a mechanical impact. Repair
of the frame is not authorized by Husqvarna
Motorcycles.
8.4 Changing the footrests

Condition
The frame protectors have been removed on the left and right.
Left footrest
49
8 FRAME
- Remove split pin o and take off the washer.
- Press the spring with special tool ©

Footrest spring plier (79029083000) (IS p. 346)
S The special tool is applied to area O on the footrest.

- Remove pin©.
- Position the new footrest and pin.
• Info
I Only insert the pin to the extent that the spring can
still be mounted.
- Position spring as shown.

S Spring © engages in area ©
50
FRAME 8

Footrest spring plier (79029083000) (IS p. 346)
S The special tool is applied to area O on the footrest.

- Mount pin ©
- Mount the washer and split pin o

Right footrest
- Remove split pin o and take off the washer.
R00445-10

Footrest spring plier (79029083000) (fil p. 346)
S The special tool is applied to area © on the footrest.

- Remove pin ©.
- Position the new footrest and pin.
• Info
I Only insert the pin to the extent that the spring can
still be mounted.
51
8 FRAME
- Position spring as shown.

y Spring engages in area ©

Footrest spring plier (79029083000) (U p. 346)
^ The special tool is applied to area on the footrest.

- Mount pin 0
- Mount the washer and split pin
52
SHOCK ABSORBER, SWINGARM 9
9.1 Adjusting the high-speed compression damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incor
rectly.
The shock absorber is filled with highly compressed nitrogen.
- Please follow the description provided.
Info
The effect of the high-speed setting can be seen in fast compression of the shock absorber.
Using an open end wrench, turn adjusting screw o clock

wise all the way.
• Info
I Do not loosen fitting ©!
Turn counterclockwise by the number of turns corresponding

to the shock absorber type.
Guideline
Compression damping, high-speed
Comfort 2.5 turns
Standard 2 turns
Sport 1.5 turns
• Info
9.2 Adjusting the low-speed compression damping of the shock absorber
Caution
rectly.
Info
The effect of the low-speed setting can be seen in slow to normal compression of the shock absorber.
53
9 SHOCK ABSORBER, SWINGARM
Turn adjusting screw o clockwise with a screwdriver as far

as the last perceptible click.
• Info
I Do not loosen fitting

ing to the shock absorber type.
Guideline
Compression damping, low-speed
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
• Info
9.3 Adjusting the rebound damping of the shock absorber
Caution
rectly.
Turn adjusting screw o clockwise up to the last perceptible

click.
ing to the shock absorber type.
Guideline
Rebound damping
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Info
Turn clockwise to increase damping; turn counter
54
9.4 Measuring the rear wheel dimension unloaded

Preparatory work
- Raise the motorcycle with a lift stand. (SB p. 12)
Main work
- Position the sag gauge in the rear axle and measure the
distance to marking SAG on the rear fender.
Sag gauge (00029090500)
Pin for sag gauge (00029990010)
- Note down the value as dimension o
Finishing work
- Remove the motorcycle from the lift stand. (8JS p. 12)
- Measure dimension of rear wheel unloaded. (SB p. 55)

- Hold the motorcycle upright with the aid of an assistant.
- Again measure the distance between the rear axle and mark
ing SAG on the rear fender using the sag gauge.
- Note down the value as dimension ©
Info
The static sag is the difference between measure
ments © and ©
- Check the static sag.

Static sag 35 mm (1.38 in)
» If the static sag is less or more than the specified value:
- Adjust the spring preload of the shock absorber,
p. 56)
55
9.6 Checking the riding sag of the shock absorber

Measure dimension o of rear wheel unloaded. ( p. 55)
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.
S The rear wheel suspension levels out.
Another person again measures the distance between the
rear axle and marking SAG on the rear fender using the sag
gauge.
Note down the value as dimension 0
• Info
I The riding sag is the difference between measure
ments Q and 0
Check the riding sag.

Guideline
Riding sag 110 mm (4.33 in)
» If the riding sag differs from the specified measurement:
- Adjust the riding sag. (8J p. 57)
9.7 Adjusting the spring preload of the shock absorber
Caution
rectly.
• Info
I Before changing the spring preload, make a note of the present setting, e.g., by measuring the spring
length.
Preparatory work
- Remove the shock absorber. (B! p. 58)
- After removing the shock absorber, clean it thoroughly.
56
Main work
- Loosen screw ©
- Turn adjusting ring © until the spring is no longer under ten
sion.
Holding wrench (90129051000) (SI p. 347)
- Measure the overall spring length while the spring is not
under tension.
- Tighten the spring by turning adjusting ring © to measure
ment ©.
Guideline
Depending on the static sag and/or the riding sag, it

may be necessary to increase or decrease the spring
preload.
- Tighten screw ©
Guideline
Screw, shock M5 5 Nm (3.7 Ibf ft)
absorber adjusting
ring
Finishing work
- Install the shock absorber. ( p. 59)
- Check the free travel of the foot brake lever. (O p. 156)
- Remove the motorcycle from the lift stand. (H p. 12)
9.8 Adjusting the riding sag

Preparatory work
- Raise the motorcycle with a lift stand. (H p. 12)
- Remove the shock absorber. (IS p. 58)
- After removing the shock absorber, clean it thoroughly.
Main work
- Choose and mount a suitable spring.
Guideline
Spring rate
Weight of rider: 65 ... 45 N/mm (257 Ib/in)
75 kg (143 ... 165 lb.)
85 kg (165 ... 187 lb.)
95 kg (187 ... 209 lb.)
Info
The spring rate is shown on the outside of the spring.
Finishing work
- Install the shock absorber. (U p. 59)
- Check the free travel of the foot brake lever. ( p. 156)
57

- Check the static sag of the shock absorber. ( p. 55)
- Check the riding sag of the shock absorber. (P p. 56)
- Adjust the rebound damping of the shock absorber. (K8 p. 54)
9.9 Removing the shock absorber

Preparatory work
- Raise the motorcycle with a lift stand. (U p. 12)
Main work
- Remove the cable ties.
- Remove screws o
- Remove screws © with the washers.
- Remove the frame protectors on the left and right.
- Remove screw ©.
- Remove fitting ©
• Info
I Raise the wheel slightly to be able to remove the
screws more easily.
- Press angle lever © toward the rear.

- Press linkage lever © downward.
(All EU models)
- Remove the cable tie and rubber band.
- Separate plug-in connector of the brake light switch.
58
- Position the swingarm and mount the swingarm pivot.
• Info
1 Pay attention to flat area ©.
Mount and tighten nut

Guideline
Nut, swingarm pivot Ml 6x1.5 100 Nm (73.8 Ibfft)
- Mount the chain.

- Connect the chain with connecting link ©
Guideline
The closed side of the chain joint lock must face in the
direction of travel.
(All EU models)
- Join plug-in connector of the brake light switch.
- Fit the new rubber band and cable tie.
- Position the foot brake cylinder.

S Push rod o engages in the foot brake cylinder.
y The dust boot is correctly positioned.
- Mount and tighten screws ©
Guideline
chassis
- Position the angle lever and linkage lever.

- Mount and tighten fitting ©
Guideline
Nut, linkage lever on Ml 4x1.5 80 Nm (59 Ibfft)
angle lever
• Info
I Pay attention to flat area ©

Guideline
Screw, bottom M10 60 Nm (44.3 Ibfft)
shock absorber Loctite®2701 ™
60
• Info
I Raise the wheel slightly to be able to mount the screw
more easily.
Position the frame protectors on the left and right.

Mount and tighten screws ©
Guideline
Screw, frame pro- M5 3 Nm (2.2 Ibf ft)
tector
Mount and tighten screws © with the washers.

Guideline
tector
Mount the new cable ties.
Finishing work
- Check the free travel of the foot brake lever. ( p. 156)
- Remove the motorcycle from the lift stand. (© p. 12)
9.11 Checking the shock absorber linkage

Preparatory work
- Raise the motorcycle with a lift stand. (El p. 12)
Main work
- Remove screw ©
- Remove fitting ©
• Info
I Raise the swingarm slightly to be able to remove the
screws more easily.
- Remove fitting ©.
- Take off the angle lever.
61
- Check needle bearings o and © for damage and wear.

» If there is damage or wear:
- Change the needle bearings.
- Check spacers © and © for damage and wear.
- Change the spacers.
- Check the shaft seal rings for damage and wear.
- Change the shaft seal rings.
- Check dimension ©
54.91 ... 55.00 mm (2.1618 ... 2.1654 in)
» If dimension Q is below the specified value:

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

Mount fitting © but do not tighten yet.
Guideline
Nut, angle lever on Ml 4x1.5 80 Nm (59 Ibf ft)
swingarm
62
Mount screw o but do not tighten yet.

Guideline
Screw, bottom Ml 0 60 Nm (44.3 Ibf ft)
• Info
I Raise the swingarm slightly to be able to mount the
screw more easily.
Position the linkage lever.

Mount and tighten fitting
Guideline
Nut, linkage lever on Ml 4x1.5 80 Nm (59 Ibf ft)
angle lever
Tighten screw o
Guideline
Screw, bottom M10 60 Nm (44.3 Ibf ft)
Tighten fitting ©.
Guideline
swingarm
Finishing work
- Remove the motorcycle from the lift stand. (RS p. 12)
9.12 Servicing the shock absorber
Caution
rectly.
Condition
The shock absorber has been removed.
63
Remove the spring. ( p. 64)

Disassemble the damper. (EJ p. 65)
Disassemble the piston rod. ( p. 66)
Disassemble the seal ring retainer. (83 p. 67)
Check the damper. (81 p. 69)
Remove the heim joint. (83 p. 70)
Install the heim joint. (81 p. 71)
Assemble the seal ring retainer. (83 p. 71)
Assemble the piston rod. (81 p. 72)
Assemble the damper. (83 p. 74)
Install the spring. (81 p. 80)
B03060-01
9.13 Removing the spring

Condition
Clamp the shock absorber into the vise.

Guideline
Use soft jaws.
Measure and note the spring length while the spring is under
tension.
Loosen screw o
Turn the adjusting ring until the spring is completely without
tension.
Holding wrench (90129051000) (83 p. 347)
Remove lock ring ©

1 j J d
Remove spring retainer ©
1 i Remove washer ©■
®vW ©W^o
H
___ 1____ || B04385-10
64
Remove the spring.

Remove washer ©
9.14 Disassembling the damper

Preparatory work
- Remove the spring. (81 p. 64)
Main work
- Make a note of the present state of rebound o and com
pression damping ©
- Open the adjusters of the rebound and compression damp
ing completely.
- Slowly open screw ©

S The nitrogen pressure dissipates.
- Remove the screw with the O-ring.
- Remove locking cap ©.
- Press in seal ring retainer © using the special tool.
Pressing tool (T1216) (88 p. 349)
65
Remove lock ring ©
• Info
I Check inner surface; do not scratch. Remove any
burrs with sandpaper if necessary.
Remove the piston rod.
Remove adjusting ring © with the clamping ring.

Drain the oil.
Remove compression adjuster © . Remove the spring and

piston.
9.15 Disassembling the piston rod

Preparatory work
- Remove the spring. (IJS p. 64)
- Disassemble the damper. (El p. 65)
66
Main work
- Clamp the piston rod with the fork in a bench vise.
Guideline
Use soft jaws.
- Remove nut©.
- Remove washer ©
- Remove rebound shim stack ©
• Info
I Guide the rebound shim stack onto a screwdriver and
put them aside together.
- Remove piston ©.
- Remove compression shim stack ©.
• Info
I Guide the compression shim stack onto a screwdriver
and put them aside together.
- Remove rebound washer ©
- Remove seal ring retainer ©

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

Preparatory work
- Remove the spring. ( p. 64)
- Disassemble the damper. (Hi p. 65)
- Disassemble the piston rod. (IS p. 66)
67
Main work
- Remove O-ring ©
- Remove rebound rubber ©
- Remove centering disk © with spring o

- Remove seal ring ©.
B04412-10
- Remove washer © from seal ring ©

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

Preparatory work
- Remove the spring. (8S p. 64)
- Disassemble the damper. ( p. 65)
- Disassemble the piston rod. ( p. 66)
- Disassemble the seal ring retainer. ( p. 67)
Main work
- Press pilot bushing o out of seal ring retainer © with the
special tool.
Pressing tool (T1504) (U p. 351)
68
- Slide the new pilot bushing o onto the special tool.
Pressing tool (T1504) ( p. 351)
- Position the pilot bushing in the seal ring retainer using the
special tool.
- Support seal ring retainer © with sleeve o of the special

tool. Press the pilot bushing all the way in.
Mounting tool (T150S) (83 p. 352)
- Lubricate the special tool.
Shock absorber fluid (SAE 2.5) (50180751 SI) (63 p. 335)

Calibrating unit (T1205) (83 p. 348)
- Support seal ring retainer © with sleeve Q of the special

tool.
Mounting tool (T150S) (63 p. 352)
- Press the special tool through the new pilot bushing.
Calibrating unit (T1205) (63 p. 348)
S The pilot bushing is calibrated.

Finishing work
- Assemble the seal ring retainer. (61 p. 71)
A
9.18 Checking the damper

Condition
The damper has been disassembled.
- Measure the inside diameter on both ends and in the middle

of the damper cartridge.
Damper cartridge
Diameter < 50.08 mm (< 1.9716 in)

- Change the damper cartridge.
- Check the damper cartridge for damage and wear.
- Change the damper cartridge.
- Check the heim joint for damage and wear.
- Change the heim joint.
69
Measure the diameter of the piston rod.
Piston rod
Diameter > 17.95 mm (> 0.7067 in)

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

Check the piston rod for damage and wear.
Check the piston rings for damage and wear.

» If damage or a bronze-colored surface is visible:
- Change the piston.
B04410-10
9.19 Removing the heim joint

Condition
Clamp the shock absorber into the vise.

Guideline
Use soft jaws.
Remove both collar bushings o of the heim joint with a spe

cial tool.
Press the heim joint against a lock ring using the special tool.
Pressing tool (T1207S) (H p. 349)
Remove second lock ring ©
70
Place special tool o underneath and press out heim

joint using special tool ©
Pressing tool (T1207S) ( p. 349)
9.20 Installing the heim joint

- Position new heim joint O and the special tool in the bench
vise.
Guideline
Use soft jaws.
Pressing tool (T1206) (U p. 348)
- Press the heim joint all the way in.
Press the heim joint against the lock ring using the special
tool.
Pressing tool (T1207S) (U p. 349)
Mount second lock ring ©.
Position both collar bushings © and press in.
9.21 Assembling the seal ring retainer

Mount dust boot o with the special tool.
Grease the sealing lip of the dust boot.
Lubricant (T625) ( p. 336)
71
- Mount washer ®
- Position washer © on seal ring ©
- Grease seal ring o and mount with the washer facing down
ward.
Lubricant (T14034) ( p.336)
- Mount centering disk © with spring ©.
- Mount rebound rubber ©

- Grease the O-ring groove.
Lubricant (T158) (S3 p. 336)
- Mount O-ring ©
9.22 Assembling the piston rod

Preparatory work
- Assemble the seal ring retainer. (US p. 71)
Main work
- Clamp the piston rod with the fork in a bench vise.
Guideline
Use soft jaws.
- Mount rubber buffer O and locking cap ©.

- Position special tool on the piston rod.
Mounting sleeve (T1515) (iS p. 352)
- Grease the dust boot and slide the seal ring retainer © onto
the piston rod.
Lubricant (T625) (IS p. 336)
- Remove the special tool.
72
Mount rebound washer o with cut-out facing down.
Mount compression shim stack @ with the smaller washers

facing downward.
Sand down piston © on both sides on a surface plate using

1200 grit sandpaper.
Clean the piston.
Mount the piston.
Guideline
Mount rebound shim stack G with the smaller washers fac

ing upward.
Mount washer © with the groove facing downward.
73
Lubricate the thread of the piston rod.
Lubricant (T152) ( p.336)
Mount and tighten nut ©.

Guideline
Nut, piston rod M12x1 40 Nm (29.5 Ibf ft)
9.23 Assembling the damper

Preparatory work
- Assemble the seal ring retainer. (H p. 71)
- Assemble the piston rod. (U p. 72)
Main work
- Lubricate the O-rings of the compression adjuster.
Lubricant (T158) (U p. 336)
- Lubricate the thread.
Lubricant (T159) (US p. 336)
- Mount the piston with the spring.

- Mount and tighten compression adjuster o
Guideline
Compression damp- M31x1 35 Nm (25.8 Ibf ft)
ing adjuster
- Clamp the damper in a bench vise.

Guideline
Use soft jaws.
- Mount adjusting ring © with the clamping ring.
• Info
I The adjusting ring cannot be mounted after the piston
rod has been mounted.
B04406-10
- Fill the damper cartridge about half full.
Shock absorber fluid (SAE 2.5) (50180751 SI) (E® p. 335)
- Lubricate O-ring © of the seal ring retainer.
Lubricant (T158) (B3 p. 336)
- Mount the piston rod carefully.
74
- Mount seal ring retainer o and slide it under the ring groove.
- Mount lock ring ©
• Info
I Do not scratch the inside surface.
- Pull out the piston rod until the seal ring retainer is flush with
the lock ring.
- Mount locking cap © of the damper cartridge.

- Bleed and fill the damper. ( p. 76)
- Fill the damper with nitrogen. ( p. 79)
B04401-10
Alternative 1
- Turn adjusting screw © clockwise with a screwdriver as
far as the last perceptible click.
sponding to the shock absorber type.
Guideline
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
- Turn adjusting screw © all the way clockwise with a

socket wrench.
- Turn counterclockwise by the number of turns corre
Guideline
Comfort 2.5 turns
Standard 2 turns
Sport 1.5 turns
- Turn adjusting screw © clockwise up to the last percep

tible click.
Guideline
Rebound damping
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
75
Alternative 2
Warning
characteristic.

mended range.
- Position adjusting screws e © , and © in the location

determined during disassembly.
9.24 Bleeding and filling the damper
• Info
I Before working with the vacuum pump, carefully read the operating manual included with the vacuum
pump.
Open the adjusters of the rebound and compression damping completely.
Clamp the damper as shown.

Guideline
Use soft jaws.
• Info
I The filling port must be located at the highest position.
The piston rod moves in and out during filling; do not
immobilize it by holding it with your hand.
B04378-10
Remove the filling port screw with the O-ring.
Mount adapter o on the damper.
• Info
I Hand-tighten only without using a tool.
- Connect adapter O to connector © of the vacuum pump.
Vacuum pump (T1240S) (IS p. 349)
76
Adjust the control lever as shown.

S Control lever External tank © is set to Closed,
Damper © is set to Vacuum and Oil reservoir © is
set to Vacuum.
Activate On/Off switch ©.
S The suction process begins.
S Pressure gauge Q drops to the required value.
< 0 bar
S Vacuum gauge © drops to the required value.

4 mbar
Determine distance O between the floating piston and

reservoir hole with the special tool.
Depth micrometer (T107S) (E|! p. 347)
S The floating piston is located in the lowermost position.
When the vacuum gauge reaches the required value, turn

control lever Oil reservoir © to Equalize pressure.
Guideline
4 mbar
The pressure gauge increases to the required value.
0 bar
When the pressure gauge reaches the specified value, turn

control lever Damper © to Pressure.
Guideline
0 bar
S Oil is pumped into the damper.

S The pressure gauge increases to the required value.
3 bar

control lever Damper © to Vacuum.
Guideline
3 bar
The pressure gauge drops to the required value.
0 bar
77

control lever Oil reservoir © to Vacuum.
Guideline
0 bar
The vacuum gauge drops to the required value.
4 mbar
When the vacuum gauge reaches the required value, turn

control lever Oil reservoir © to Equalize Pressure.
Guideline
4 mbar
The pressure gauge drops to the required value.
0 bar

control lever Damper © to Pressure.
Closed Vacuum Guideline
0 bar
Open Vacuum Equalize y Oil is pumped into the damper.
pressure
y The pressure gauge increases to the required value.

3 bar

control lever Damper o
to Vacuum.
Guideline
3 bar
y The pressure gauge drops to the required value.

0 bar
When the pressure gauge reaches the required value, acti

vate the On/Off switch.
Guideline
0 bar
y The vacuum pump is switched off.
Slide O-ring © to the end of the special tool by the specified

value (distance © minus specified value).
Guideline
5 mm
Depth micrometer (T107S) (U p. 347)
Slide the floating piston into the reservoir to the shortened

position using the special tool.
78
• Info
I The floating piston must be positioned at exactly this
point when the rod is fully extended; otherwise,
damage will occur during compression of the shock
absorber.
Remove adapter o from connector 0 of the vacuum

pump.
• Info
I Hold the damper so that the filling port is at the high
est point.
Remove the adapter.

Mount and tighten screw ©.
Guideline
Screw, filling port Ml 0x1 14 Nm (10.3 Ibf ft)
9.25 Filling damper with nitrogen

Mount screw O with the O-ring and screw it in approx. 2 full
turns, but do not tighten it fully yet.
• Info
I The piston rod is fully extended.
Fix the special tool in the vise.
Filling tool (T170S1) p p. 352)

Filling adapter (T1296) p p. 349)
Connect the special tool to the pressure regulator of the filling

cylinder.
Filling gas - nitrogen
Adjust the pressure regulator.

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

^ The hexagonal part of tap handle © engages in the
hexagon socket of the filling port screw.
Open filler tap ©.
Fill the damper for at least 15 seconds.
Guideline
79
• Info
I Watch the pressure regulator dial.
Ensure that the damper is filled to the specified pres
sure.
- Screw the filling port shut with tap handle ©

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

- Ensure that adjusting ring o is mounted with the clamping
ring.
- Mount washer ©.
- Measure the total spring length while the spring is not under
tension.
- Position the spring.
Guideline
Spring rate
75 kg (143 ... 165 lb.)
85 kg (165 ... 187 lb.)
95 kg (187 ... 209 lb.)
- Mount washer ©
- Mount spring retainer ©.
- Mount lock ring ©
Alternative 1
- Tension the spring by turning the adjusting ring to the
prescribed value.
Guideline
Spring preload 14 mm (0.55 in)
Holding wrench (90129051000) ( p. 347)
80
Alternative 2
Warning
characteristic.

mended range.
- Tension the spring to the length measured during disas

sembly by turning the adjusting ring.
Holding wrench (90129051000) (P p. 347)
Tighten screw ©.
Guideline
Screw, shock M5 5 Nm (3.7 Ibf ft)
absorber adjusting
ring
9.27 Checking the swingarm

- Check the swingarm for damage, cracking, and deformation.
» If the swingarm shows signs of damage, cracking, or
deformation:
- Change the swingarm.
Info
Always change a damaged swingarm. Repair
of the swingarm is not authorized by Husq-
varna Motorcycles.
9.28 Checking the swingarm bearing for play

Preparatory work
- Place a load on the front of the vehicle.
S The rear wheel is not in contact with the ground.
81
Main work
- Move the swingarm up and down.
- Change the swingarm bearing. (81 p. 86)
- Move the swingarm from one side to the other.
- Change the swingarm bearing. (®! p. 86)
Finishing work
9.29 Removing the swingarm

Preparatory work
- Remove the rear wheel. ( p. 124)
Main work
- Remove screws O-
- Take off the frame protector on both sides.
- Take the brake line out of the guide.
82
Push the brake caliper forward, slip it out, and hang it to the
side.
• Info
age.
Remove connecting link © of the chain.
• Info
age.
Take off the chain.
Remove screw ©
Remove fitting ©
• Info
I Raise the swingarm slightly to be able to remove the
screws more easily.
R01069-10
Remove fitting ©
Take off the angle lever.
Remove nut ©
Remove the swingarm pivot.
Take off the swingarm.
83
9.30 Installing the swingarm

Main work
- Position the swingarm. Mount the swingarm pivot.
- Mount and tighten nut o
Guideline
Position the angle lever.

Mount fitting © but do not tighten yet.
Guideline
swingarm
Mount screw © but do not tighten yet.

Guideline
• Info
screw more easily.
Position the linkage lever.

Mount and tighten fitting ©
Guideline
Nut, linkage lever on Ml 4x1.5 80 Nm (59 Ibf ft)
angle lever
• Info
R01069-11 screw more easily.
- Tighten screw ©.
Guideline
- Tighten fitting ©
Guideline
Nut, angle lever on M14x1.5 80 Nm (59 Ibf ft)
swingarm
84
- Mount the chain.

- Connect the chain with connecting link ©
Guideline
- Position the brake caliper and pull it back.
- Position the brake line in the guide.
- Position the frame protectors on the left and right.

- Mount and tighten screws ©
Guideline
tector
- Mount the cable ties.
Finishing work
- Install the rear wheel. ( p. 125)
- Remove the motorcycle from the lift stand. (8S p. 12)
85
9.31 Changing the swingarm bearing

Preparatory work
- Raise the motorcycle with a lift stand. (SJ p. 12)
- Remove the swingarm. (8J) p. 82)
Left swingarm bearing

- Remove collar bushings o
- Remove bushing ©
- Remove shaft seal rings © using a suitable tool.

- Remove stop disks ©.
- Press out bearing 0 using a suitable tool.
- Using a suitable tool, press in new bearing 0
- Position the stop disks ©
- Press in shaft seal rings ©.
86
- Mount bushing ©.
- Grease the shaft seal rings.
Long-life grease ( p. 336)
- Position the collar bushings o with the shoulder facing

inward.
Right swingarm bearing

- Remove collar bushings ©.
- Remove bushing o
87
- Remove shaft seal rings © using a suitable tool.

- Press out bearing © using a suitable tool.
- Using a suitable tool, press in new bearing ©
- Press in shaft seal rings ©.
- Mount bushing o
- Grease the shaft seal rings.
- Position the collar bushings © with the shoulder facing

inward.
Finishing work
- Install the swingarm. (8JI p. 84)
- Install the rear wheel. (U p. 125)
9.32 Checking the heim joint for play

Preparatory work
- Raise the motorcycle with a lift stand, (il p. 12)
S The rear wheel is not in contact with the ground.
Main work
- Move the swingarm up and down.
- Change the heim joint. (ES p. 89)
88
Finishing work
- Remove the load from the front of the vehicle.
- Remove the motorcycle from the lift stand. (Si p. 12)
9.33 Changing the heim joint

Preparatory work
- Remove the shock absorber. (SP p. 58)
Main work
- Clamp the shock absorber into the vise.
Guideline
Use soft jaws.
- Remove both collar bushings o of the heim joint with a spe

cial tool.
- Press the heim joint against a lock ring using the special tool.
Pressing tool (T1207S) (i» p. 349)
- Remove second lock ring ©
- Place special tool Q underneath and press out heim

joint © using special tool ©
Pressing tool (T1207S) ( p. 349)
- Position the new heim joint © and the special tool.

Guideline
Use soft jaws.
- Press the heim joint all the way in.
89
- Press the heim joint against the lock ring using the special
tool.
Pressing tool (T1207S) (8J p. 349)
- Mount second lock ring ©
- Position both collar bushings o and press in.
Finishing work
- Install the shock absorber. (ES p. 59)
- Check the free travel of the foot brake lever. (IS p. 156)
90
EXHAUST 10
10.1 Removing the main silencer
Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
- Allow the exhaust system to cool down before performing any work on the vehicle.
Preparatory work
- Remove the right side cover. (IS p. 100)
Main work
- Remove screws o with the washers.
- Pull off the main silencer at the rubber sleeve e and the
spring ring from the manifold.
10.2 Installing the main silencer

Main work
- Mount the main silencer with the rubber sleeve o and
spring ring.
- Mount and tighten screws with the washers.
Guideline
chassis
Finishing work
- Install the right side cover. (EJ p. 100)
10.3 Removing the manifold

(All EU models)
- Remove the cable tie(s) and expose the cable.
91
10 EXHAUST
- Disconnect plug-in connector o of the lambda sensor.

- Expose the cable.
- Remove springs ©
- Loosen screw ©
- Remove screw ©
- Remove the exhaust manifold toward the front.
(All US models)
- Remove springs ©
- Loosen screw ©
- Remove screw ©
92
EXHAUST 10
Loosen screw ©
Remove screw ©
Remove the exhaust manifold toward the front.
10.4 Installing the manifold

(All EU models)
- Position the manifold and mount springs O-
Spring hook (5030501700004) (IS p. 347)

Guideline
chassis
- Tighten screw ©
Guideline
chassis
- Join plug-in connector © of the lambda sensor.
Route the cable without tension and secure it with a cable

tie.
93
10 EXHAUST
(All US models)
- Position the manifold and mount springs o
Spring hook (5030501700004) («9 p. 347)

Guideline
chassis
- Tighten screw ©
Guideline
chassis
- Mount and tighten screw ©■

Guideline
chassis
- Tighten screw ©
Guideline
chassis
10.5 Changing the glass fiber yarn filling in the main silencer
Warning
Danger of bums The exhaust system gets very hot when the vehicle is driven.
- Allow the exhaust system to cool down before performing any work on the vehicle.
• Info
I Over time, the fibers of the glass fiber yarn escape and the damper "burns" out.
Not only is the noise level higher, the performance characteristic changes.
Preparatory work
- Remove the right side cover. (S3 p. 100)
- Remove the main silencer. (tJ p. 91)
94
EXHAUST 10
Main work
- Remove screws o
- Pull out inner tube ©
- Remove the glass fiber yarn filling 0 from the inner tube.
- Clean the parts that need to be reinstalled and check for
damage.
- Fit the new glass fiber yarn filling 0 into the inner tube.
- Position outer tube o over the inner tube with the new glass
fiber yarn filling.
• Info
I Seal the connecting cap 0 to the outer tube with sili
cone.
- Mount and tighten screws O-

Guideline
Screws on the main M5 7 Nm (5.2 Ibf ft)
silencer
E01236-10
Finishing work
- Install the main silencer. ( p. 91)
- Install the right side cover. (SI p. 100)
95
11 AIR FILTER
11.1 Removing the air filter box cover

Pull off the air filter box cover sideways in areas o ©
and © , and remove toward the front.
11.2 Installing the air filter box cover

Position air filter box cover on collar bushings o and ©
and push toward the rear.
Engage the air filter box cover in areas © © and ©
11.3 Removing the air filter
Note
Engine damage Unfiltered intake air has a negative effect on the service life of the engine.
Dust and dirt will enter the engine without an air filter.
- Never start to use the vehicle without an air filter.
Note
Environmental hazard Hazardous substances cause environmental damage.
- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance
with the applicable regulations.
Preparatory work
- Remove the air filter box cover. (®S p. 96)
96
AIR FILTER 11
Main work
- Detach retaining tab O- Remove air filter with air filter sup
port.
- Remove air filter from air filter support.
11.4 Installing the air filter

Main work
- Mount the clean air filter on the air filter support.
- Grease the air filter in area ©.
- Insert air filter and position retaining pin o in bushing ©

y The air filter is correctly positioned.
- Insert retaining tab ©
y Retaining pin © is secured with retaining tab ©
• Info
I If the air filter is not mounted correctly, dust and dirt
may enter the engine and result in damage.
Finishing work
- Install the air filter box cover. (U p. 96)
11.5 Cleaning the air filter and air filter box
Note
Info
Do not clean the air filter with fuel or petroleum since these substances attack the foam.
Preparatory work
- Remove the air filter box cover. ((8 p. 96)
- Remove the air filter. (88 p. 96)
97
11 AIR FILTER
Main work
- Wash the air filter thoroughly in special cleaning liquid and
allow it to dry properly.
Air filter cleaner (El p. 336)
• Info
I Only press the air filter to dry it, never wring it out.
- Oil the dry air filter with a high quality filter oil.
Oil for foam air filter (i® p. 337)
- Clean the air filter box.

- Clean the intake flange and check it for damage and tight
ness.
Finishing work
- Install the air filter. P- 97)
- Install the air filter box cover. p. 96)
- Seal the air filter box in the marked area O

'S'
98
FUEL TANK, SEAT, TRIM 12
Danger
A Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
- Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
- Switch off the engine for refueling.
- Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
- If any fuel is spilled, wipe it off immediately.
- Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
- Avoid skin, eye and clothing contact with fuel.
- Immediately consult a doctor if you swallow fuel.
- Do not inhale fuel vapors.
- In case of skin contact, rinse the affected area with plenty of water.
- Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
- Change your clothing in case of fuel spills on them.
- Keep fuels correctly in a suitable canister, and out of the reach of children.
Note
Press release button 0>turn the filler cap counterclockwise,

and lift it free.
12.2 Closing the filler cap

Replace the filler cap and turn clockwise until release but
ton o locks in place.
• Info
I Route fuel tank breather hose e without kinks.
99
12 FUEL TANK, SEAT, TRIM
12.3 Removing the right side cover

Remove screw o
Pull off the side cover sideways in areas Q and © , and
remove toward the front.
12.4 Installing the right side cover

Position the side cover on collar bushings o and © , and
push toward the rear.
Engage the side cover in areas © and ©
Guideline
chassis
12.5 Removing the seat

Preparatory work
- Remove the air filter box cover. (W p. 96)
100
Main work
- Remove screw o
- Pull seat back and lift it off.
12.6 Mounting the seat

Main work
- Mount the front of the seat on the collar bushing of the fuel
tank, lower the seat at the rear, and push the seat forward.
- Make sure that the seat is locked in correctly.
- Mount and tighten screw o
Guideline
chassis
Finishing work
- Install the air filter box cover. ( p. 96)
101
12.7 Removing the fuel tank
Danger
Fire hazard Fuel is highly flammable.
Warning
Preparatory work
- Remove the seat. (E8 p. 100)
- Remove the right side cover. (IS p. 100)
Main work
- Unplug connector o of the fuel pump.
- Remove tube © from the fuel tank breather.
- Thoroughly clean the plug-in connection of the fuel line using

compressed air.
• Info
I Under no circumstances should dirt enter into the fuel
line. Dirt in the fuel line clogs the injection valve!
- Disconnect the plug-in connection of the fuel line.
• Info
I Remaining fuel may flow out of the fuel hose.
- Mount wash cap set ©.
Wash cap set (81212016100)
102
- Remove screws o with the collar bushings.

(All EU models)
- Hang the horn and horn bracket to one side.
- Remove screw © with the rubber bushing.
Danger
Warning
103
Main work
- Check throttle cable routing. ( p. 45)
- Position the fuel tank and fit the two spoilers to the sides in
front of the radiator bracket.
- Make sure that no cables or throttle cables are trapped or
damaged.
- Mount and tighten screw o with the rubber bushing.

Guideline
chassis
(All EU models)
- Position the horn with the horn bracket.
- Mount and tighten screws © with the collar bushings.

Guideline
chassis
Remove the wash cap set.

Thoroughly clean the plug-in connection of the fuel line using
compressed air.
• Info
Lubricate the O-ring and connect plug-in connection © for

the fuel line.
• Info
I Route the cable and fuel line at a safe distance from
the exhaust system.
104
- Attach fuel tank breather hose ©

- Plug in connector © for the fuel pump.
Finishing work
- Mount the seat. (8S p. 101)
- Install the air filter box cover. (H p. 96)
- Install the right side cover. (81 p. 100)
Danger
- Make sure that no fuel is spilled; particularly not on hot parts of the vehicle,
Warning
Condition
The fuel tank is completely full.
Ensure that the battery voltage does not drop below 12.5 V.
The diagnostics tool is disconnected.
Thoroughly clean the plug-in connection of the fuel line using

compressed air.
• Info
Press on the small metal plate and disconnect fuel hose con
nection o
105
Info
Remaining fuel may flow out of the fuel hose.
Mount special tool ©.
Pressure testing tool (61029094000) (II p. 345)
Mount special tool © with nozzle code 0,60.
Testing hose (61029093000) ( m p. 345)
Position the hose end in a fuel can.

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

Select "Actuator test" > "Fuel pump".
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 ... 3.65 bar (48.6 ...
active 52.9 psi)
» If the specification is not reached:

- Open the filler cap. (IS p. 99)
- Check the tank air vent system.
Check the fuel pressure with the filler cap open.
Fuel pressure
When the fuel pump is 3.35 ... 3.65 bar (48.6 ...
active 52.9 psi)

- Check that the fuel line is clear.
- Change the fuel filter. (SS p. 108)
400928-01 - Change the fuel pump. ( p. Ill)
Stop the "Actuator test" > "Fuel pump" by pressing the
"Quit" button.
Remove the special tools.
Join the fuel hose connection.
106
Danger
Warning
Note
- Clean plug-in connection o of the fuel line thoroughly with

compressed air.
• Info
- Disconnect the plug-in connection of the fuel line.
• Info
I Remaining fuel may flow out of the fuel hose.
- Pull fuel screen out of the connecting piece.

- Insert the new fuel screen all the way into the connecting
piece.
- Lubricate the O-ring and join the plug-in connection of the
fuel line.
107
Danger
death.
space.
- Start the engine and check the response.
12.11 Changing the fuel filter
Danger
Warning
Note
Preparatory work
- Drain the fuel from the fuel tank into a suitable container.
- Remove the air filter box cover. (IS p. 96)
- Remove the seat. (ES p. 100)
- Remove the right side cover. ( p. 100)
- Remove the fuel tank. (IS p. 102)
108
Main work
- Remove nut O with the gasket.
- Remove fuel connection © with the gasket.
- Remove screws ©
- Pull out the fuel pump.

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

- Pull back fuel pump housing ©
109
Change fuel screen ©

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

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

Mount nut o with gasket, but do not tighten yet.
O

Guideline
Screw, fuel pump EJOT PT® 2.3 Nm (1.7 Ibfft)
110
- Grease O-ring © slightly.
• Info
I Make sure that no grease gets into the fuel connec
tion.
Mount fuel connection © with the gasket but do not tighten

yet.
Tighten nut O-
Guideline
Nut, fuel pump fixa M12 15 Nm (11.1 Ibf ft)
tion
Tighten fuel connection

Guideline
Fuel connection on M8 10 Nm (7.4 Ibf ft)
fuel pump
R02956-10
Finishing work
- Mount the seat. (S8 p. 101)
- Install the right side cover. (II p. 100)
Danger
Warning
Ill
Note
Preparatory work
- Remove the air filter box cover. (BJ p. 96)
- Remove the seat. (H p. 100)
- Remove the right side cover. (U p. 100)
- Remove the fuel tank. (IS p. 102)
Main work
- Remove nut o with the gasket.
- Remove fuel connection © with the gasket.
- Remove screws ©.
- Pull out the fuel pump.
112
- Position the new fuel pump.

- Mount nut o with gasket, but do not tighten yet.

Guideline
Screw, fuel pump EJOT PT® 2.3 Nm (1.7 Ibfft)
- Grease O-ring © slightly,
• Info
I Make sure that no grease gets into the fuel connec
tion.
Mount fuel connection © with the gasket but do not tighten

yet.
Tighten nut o
Guideline
Nut, fuel pump fixa M12 15 Nm (11.1 Ibfft)
tion
Tighten fuel connection ©.

Guideline
Fuel connection on M8 10 Nm (7.4 Ibfft)
fuel pump
R02956-10
Finishing work
- Mount the seat. (Si p. 101)
- Install the right side cover. ( p. 100)
113
13 MASK, FENDER
13.1 Removing front fender

Preparatory work
- Remove the headlight mask with the headlight. (US p. 115)
Main work
- Remove screws o
- Remove screws . Take off the front fender.
13.2 Installing front fender

Main work
- Position front fender. Mount and tighten screws o and
Guideline
chassis
Finishing work
- Check the headlight setting. (EjS p. 165)
114
MASK, FENDER 13
13.3 Removing the headlight mask with the headlight

Detach brake line o and wiring harness ©
Release rubber bands ©. Slide the headlight mask up and

swing it forward.
(All EU models)
- Detach plug-in connectors o and take off the headlight
mask with the headlight.
(All US models)
- Detach plug-in connector © and take off the headlight
mask with the headlight.
13.4 Installing the headlight mask with the headlight

Main work
(All EU models)
- Connect plug-in connectors ©
115
13 MASK, FENDER
(All US models)
- Connect plug-in connector ©
Position the headlight mask and secure it with rubber

bands ©
S The holding lugs engage.
Position brake line © and wiring harness o in the brake

line guide.
Finishing work
- Check the headlight setting. (S3 p. 165)
116
WHEELS 14
14.1 Checking the tire air pressure
• Info
i Low tire air pressure leads to abnormal wear and overheating of the tire.
Correct tire air pressure ensures optimal riding comfort and maximum tire service life.
- Remove the dust cap.

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

front 1.0 bar (15 psi)
rear 1.0 bar (15 psi)
Tire air pressure, road (All EU models)

» If the tire pressure does not meet specifications:

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

- Change the tires.
117
14 WHEELS
Check the tire age.
• Info
I The tire date of manufacture is usually contained in
the tire label and is indicated by the last four digits
of the DOT number. The first two digits indicate the
week of manufacture and the last two digits the year
of manufacture.
Husqvarna Motorcycles recommends that the tires be
changed after 5 years at the latest, regardless of the
actual state of wear.
» If the tires are more than 5 years old:

- Change the tires.
14.3 Checking the wheel bearing for play

Preparatory work
- Place a load on the rear of the vehicle.
y The front wheel is not in contact with the ground.
Main work
- Move the front wheel from side to side.
• Info
I Hold the fork leg to check it.

- Change front wheel bearing. ( p. 123)

y The rear wheel is not in contact with the ground.
- Move the rear wheel from side to side.
• Info
I Hold the swingarm to check it.

- Change the rear wheel bearing. (© p. 133)
Finishing work
118
WHEELS 14
14.4 Checking the brake discs
Warning
Danger of accidents Worn-out brake discs reduce the braking effect.
- Make sure that worn-out brake discs are replaced immediately.
Check the front and rear brake disc thickness at multiple

points for the dimension ©
• Info
I Wear reduces the thickness of the brake disc around
the contact surface of the brake linings.
Brake discs - wear limit

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

- Change the front brake disc. (SS p. 122)
- Change the rear brake disc. (iS p. 126)
Check the front and rear brake discs for damage, cracking,
and deformation.
» If the brake disc exhibits damage, cracking, or deforma
tion:
- Change the front brake disc. (S8 p. 122)
- Change the rear brake disc. (SS p. 126)
14.5 Checking spoke tension
Warning
Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in
secondary damage.
The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes
is too low, then lateral and radial run-out will form in the wheel. Other spokes will become looser as a
result.
- Check spoke tension regularly, and in particular on a new vehicle.
Strike each spoke briefly using a screwdriver blade.
• Info
I The frequency of the sound depends on the spoke
length and spoke diameter.
If you hear different tone frequencies from different
spokes of equal length and diameter, this is an indica
tion of different spoke tensions.
You should hear a high note.
» If the spoke tension differs:

- Correct the spoke tension.
119
14 WHEELS
- Check the spoke torque.

Guideline
Spoke nipple, front M4.5 6 Nm (4.4 Ibfft)
wheel
Spoke nipple, rear M4.5 6 Nm (4.4 Ibf ft)
wheel
Torque wrench kit (58429094000) ( p. 344)
14.6 Checking the rim run-out
Warning
Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in
secondary damage.
The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes
is too low, then lateral and radial run-out will form in the wheel. Other spokes will become looser as a
result.
- Check spoke tension regularly, and in particular on a new vehicle.
• Info
I A loose spoke can unbalance the wheel and other spokes may loosen within a short period.
If the spokes are too tight, they can break due to local overload.
Check the spoke tension regularly, especially on a new motorcycle.
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)

- Center the rim.
Info
Center the rim by pulling the spoke nipple on
the other side of the rim run-out. If there is sig
nificant deformation, change the rim.
- Correct the spoke tension.
120
WHEELS 14
14.7.1 Removing the front wheel

Preparatory work
- Raise the motorcycle with a lift stand. (IS p. 12)
Main work
- Press the brake caliper onto the brake disc by hand in order
to push back the brake pistons.
• Info
I Make sure that you do not press the brake caliper
against the spokes when pushing back the brake pis
tons.
- Loosen screw o by several rotations.

- Loosen screws 0
- Press on screw o to push the wheel spindle out of the axle
clamp.
- Remove screw o
Warning
Danger of accidents Damaged brake discs reduce
the braking effect.
- Always lay the wheel down in such a way that the
brake disc is not damaged.
Hold the front wheel and remove the wheel spindle. Take the
front wheel out of the fork.
• Info
I Do not pull the hand brake lever when the front wheel
is removed.
Remove spacers
121
14 WHEELS
14.7.2 Installing the front wheel
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
- Always keep the brake discs free of oil and grease.
- Clean the brake discs with brake cleaner when necessary.
Check the wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn:
- Change front wheel bearing. (BJ p. 123)
Clean and grease shaft seal rings o and contact surface
of the spacers.
Insert the spacers.

H00935-10 Clean and grease the wheel spindle.
Jack up the front wheel into the fork, position it, and insert
the wheel spindle.
y The brake linings are correctly positioned.
Guideline
Screw, front wheel M20x1.5 35 Nm (25.8 Ibfft)
spindle
Operate the hand brake lever several times until the brake
linings are seated correctly against the brake disc.
Remove the motorcycle from the lift stand. ( p. 12)
Operate the front brake and compress the fork a few times
firmly.
y The fork legs straighten.
Tighten screws @.
Guideline
Screw, fork stub M8 15 Nm (11.1 Ibfft)
14.7.3 Changing the front brake disc
• Info
I If the brake discs are changed, the brake linings must also be changed.
Preparatory work
- Raise the motorcycle with a lift stand. (BS p. 12)
122
WHEELS 14
Main work
- Remove screws © Remove the brake disc.
- Clean the contact surface of the brake disc.
- Position the new brake disc with the label facing outward.
Guideline
Screw, front M6 14 Nm (10.3 Ibf ft)
brake disc Loctite®243™
Finishing work
14.7.4 Changing the front wheel bearing

Preparatory work
- Raise the motorcycle with a lift stand. (H p. 12)
Main work
- Remove shaft seal rings o and ©
Info
Spacing tube o can be pushed aside.
- Remove spacing tube ©

- Press in new bearing © all the way using a suitable tool.
• Info
I Only press the bearing in via the outer ring otherwise
the bearing will be damaged when it is pressed in.
123
14 WHEELS
Clean, grease, and mount spacing tube O-
Press in new bearing all the way using a suitable tool.
• Info
Grease new shaft seal rings © and O ar|d press in until

they are flush.
Finishing work
- Install the front wheel. (U p. 122)
Preparatory work
Main work
- Press the brake caliper onto the brake disc by hand in order
to push back the brake piston.
• Info
I Make sure when pushing back the brake piston that
you do not press the brake caliper against the spokes.
- Remove nut o
- Remove chain adjuster 0 Pull out wheel spindle © far
enough to allow the rear wheel to be pushed forward.
- Push the rear wheel forward as far as possible. Remove the
chain from the rear sprocket.
• Info
age.
Warning
Danger of accidents Damaged brake discs reduce
the braking effect.
- Always lay the wheel down in such a way that the
brake disc is not damaged.
124
WHEELS 14
- Hold the rear wheel and remove the wheel spindle. Take the
rear wheel out of the swingarm.
• Info
I Do not operate the foot brake lever when the rear
wheel is removed.
Remove spacers
14.8.2 Installing the rear wheel
Warning
Main work
- Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
- Change the rear wheel bearing. (0 p. 133)
- Clean and grease shaft seal rings o and contact surface Q
of the spacers.
Long-life grease (IS p. 336)
- Insert the spacers.
- Clean and grease the wheel spindle.
- Position the rear wheel and insert wheel spindle ©.

S The brake linings are correctly positioned.
- Mount the chain.
125
14 WHEELS
Position chain adjuster . Mount nut O , but do not tighten

it yet.
Make sure that chain adjusters © are fitted correctly on
adjusting screws ©.
Check the chain tension. (SI p. 128)
Tighten nut ©
Guideline
Nut, rear wheel spin- M20x1.5 80 Nm (59 Ibf ft)
die
• Info
I 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°.
Operate the foot brake lever repeatedly until the brake lin
ings are in contact with the brake disc and there is a pressure
point.
Finishing work
14.8.3 Changing the rear brake disc
• Info
I If the brake discs are changed, the brake linings must also be changed.
Preparatory work
- Raise the motorcycle with a lift stand. (SS p. 12)
- Remove the rear wheel. (SI p. 124)
Main work
- Remove screws o . Remove the brake disc.
- Clean the contact surface of the brake disc.
- Position the new brake disc with the label facing outward.
Guideline
Screw, rear M6 14 Nm (10.3 Ibf ft)
brake disc Loctite®243™
Finishing work
- Install the rear wheel. (BS p. 125)
126
WHEELS 14
14.8.4 Checking the chain for dirt

- Check the chain for heavy soiling.
» If the chain is very dirty:
- Clean the chain. (IS p. 127)
14.8.5 Cleaning the chain
Warning
Danger of accidents Oil or grease on the tires reduces the road grip.
- Remove the lubricant from the tires using a suitable cleaning agent.
Warning
Note
• Info
I The service life of the chain depends largely on its maintenance.
Preparatory work
- Raise the motorcycle with a lift stand. (US p. 12)
Main work
- Rinse off loose dirt with a soft jet of water.
- Remove old grease residue with chain cleaner.
Chain cleaner (US p. 336)
- After drying, apply chain spray.
Off-road chain spray (IS p. 337)
Finishing work
- Remove the motorcycle from the lift stand. (U p. 12)
127
14 WHEELS
14.8.6 Checking the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear
wheel bearings wear more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the
rear wheel locks or the engine will be damaged.
- Check the chain tension regularly.
- Set the chain tension in accordance with the specification.
Preparatory work
Main work
- Pull the chain at the end of the chain sliding component
upwards to measure chain tension ©
• Info
I The lower chain section o must be taut.
Because chain wear is not always even, repeat this
measurement at different chain positions.
Chain tension 55 ... 58 mm (2.17 ...

2.28 in)
» If the chain tension does not meet specifications:

- Adjust the chain tension. (IS p. 131)
Finishing work
14.8.7 Checking the chain, rear sprocket, engine sprocket, and chain guide
Preparatory work
Main work
- Shift the transmission to idle.
O OHO o O OHO O
- Check the chain, rear sprocket and engine sprocket for wear.
» If the rear sprocket and engine sprocket are worn:
- Change the drivetrain kit. (IS p. 131)
• Info
I The engine sprocket, rear sprocket and chain
should always be replaced together.
128
WHEELS 14
Pull at the top part of the chain with the specified weight ©.
Guideline
Weight, chain wear mea- 10 ... 15 kg (22 ... 33 lb.)
surement
Measure distance © of 18 chain rollers in the lower chain

section.
• Info
I Chain wear is not always even, so you should repeat
this measurement at different chain positions.
Maximum distance © 272 mm (10.71 in)

from 18 chain rollers at the
longest chain section
» If distance © is greater than the specified measurement:

- Change the drivetrain kit. ( p. 131)
16 17 18
400987-10
• Info
I When a new chain is mounted, the rear
sprocket and engine sprocket should also be
changed.
New chains wear out faster on old, worn
sprockets.
Check the chain sliding guard for wear.

» If the lower edge of the chain pins is in line with, or below,
the chain sliding guard:
- Change the chain sliding guard.
Check that the chain sliding guard is firmly seated.
» If the chain sliding guard is loose:
- Tighten the screws on the chain sliding guard.
Guideline
Screw, chain M6 14 Nm (10.3 Ibfft)
sliding guard Loctite®243™
129
14 WHEELS
Check the chain sliding piece for wear.

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

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

» If the chain guide is loose:
- Tighten the screws on the chain guide.
Guideline
Remaining M6 10 Nm (7.4 Ibfft)
screws, chassis
Remaining nuts, M6 10 Nm (7.4 Ibfft)
chassis
Finishing work
130
WHEELS 14
14.8.8 Adjusting the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear
wheel bearings wear more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the
rear wheel locks or the engine will be damaged.
- Check the chain tension regularly.
- Set the chain tension in accordance with the specification.
Preparatory work
- Check the chain tension. (M p. 128)
Main work
- Loosen nut O-
- Loosen nuts ©
- Adjust the chain tension by turning the left and right adjusting
screws ©.
Guideline
Chain tension 55 ... 58 mm (2.17 ...
2.28 in)
Turn adjusting screws © on the left and right so that the
markings on the left and right chain adjusters are in the
same position relative to reference marks © . The rear
wheel is then correctly aligned.
- Tighten nuts ©
- Make sure that chain adjusters o are fitted correctly on
adjusting screws ©
- Tighten nut O-
Guideline
Nut, rear wheel spin- M20x1.5 80 Nm (59 Ibfft)
die
• Info
I 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. (US p. 12)
14.8.9 Changing the drivetrain kit

Preparatory work
131
14 WHEELS
Main work
- Remove screw O with the washer.
- Remove screw ©
- Take off the engine sprocket cover.
Have an assistant operate the rear brake.

Remove screw © with the washer.
Remove the rear wheel. ( p. 124)
Remove connecting link © of the chain.
• Info
age.
Take off the chain.
Remove engine sprocket ©
Remove fittings © . Take off the rear sprocket.

Position the new rear sprocket. Mount and tighten the fit
tings.
Guideline
Nut, rear M8 35 Nm (25.8 Ibfft)
sprocket screw Loctite®2701 ™
132
WHEELS 14
Slide new engine sprocket © onto the countershaft.
Mount the new chain.

Connect the chain with connecting link ©
Guideline
Install the rear wheel. ( p. 125)

Mount and tighten screw © with the washer.
Guideline
Screw, drive Ml 0 60 Nm (44.3 Ibf ft)
chain engine Loctite®2701 ™
sprocket
Position engine sprocket cover.

Mount and tighten screw o with the washer.
Guideline
Screw, clutch slave M6 10 Nm (7.4 Ibf ft)
cylinder

Guideline
Screw, engine M8 20 Nm (14.8 Ibf ft)
sprocket cover
Finishing work
- Install the air filter box cover. (H p. 96)
- Remove the motorcycle from the lift stand. (8J p. 12)
14.8.10 Changing the rear wheel bearing

Preparatory work
133
14 WHEELS
Main work
- Remove shaft seal ring o
- Remove lock ring ©
- Remove shaft seal ring ©
- Using a suitable tool, press bearing © out from the inside to

the outside.
- Remove spacing tube ©.
- Using a suitable tool, press bearing © out from the inside to

the outside.
- Check spacer washer © for damage and wear.
» If the spacer washer is damaged or worn:
- Replace the spacer washer.
- Position spacer washer ©

- Press new bearing © all the way in from the outside to the
inside.
• Info
134
WHEELS 14
Clean, grease, and mount spacing tube ©.
Press new bearing © aH the way in from the outside to the

inside.
• Info
Grease new shaft seal ring © and press it in until it is flush.
Mount lock ring ©

S The lock ring engages audibly.
Grease new shaft seal ring O and press it in until it is flush.
Finishing work
- Install the rear wheel. (P P-125)
- Remove the motorcycle from the lift stand. ( P-12)
135
15 WIRING HARNESS, BATTERY
15.1 Ignition curve plug-in connector

Plug-in connector o of the ignition timing map adjustment is
located on the frame under the fuel tank.
• Info
I The ignition timing map connector has no function in the
homologated (restricted) condition of the motorcycle.
Possible states
• Soft - The plug-in connector of the ignition timing map
adjustment is disconnected to achieve better rideability.
• Performance - The plug-in connector of the ignition timing
map adjustment is joined to achieve higher performance.
15.2 Changing the main fuse
Warning
Fire hazard Incorrect fuses overload the electrical system.
- Only use fuses with the required ampere value.
- Do not bypass or repair fuses.
• Info
I The main fuse protects all power consumers of the vehicle.
Preparatory work
(All EU models)
- Press and hold the kill switch §3 while the engine is idling
until the engine stops.
(All US models)
- Press and hold the kill switch 53 while the engine is idling
- Remove the air filter box cover. (IS p. 96)
- Remove the seat. (®J p. 100)
Main work
- Pull the EFI control unit o upward off the rubber plugs and
hang to the side.
136
WIRING HARNESS, BATTERY 15
- Pull starter relay © from the holder.
- Take off protection caps ©

- Remove faulty main fuse ©■
• Info
I A faulty fuse has a burned-out fuse wire ©
A spare fuse © is located in the starter relay.
- Install a new main fuse.
- Check that the electrical system is functioning properly.
Tip
Insert a spare fuse so that it is available if needed.
- Attach the protection caps ©

- Mount the starter relay © onto the holder and route the
cable.
- Mount the EFI control unit ©on the rubber lugs.
Finishing work
- Mount the seat, (ii p. 101)
- Install the air filter box cover. (BJ p. 96)
137
15.3 Changing the fuses of individual power consumers
Info
The fuse box containing the fuses of individual power consumers is located under the seat.
Preparatory work
(All EU models)
(All US models)
- Remove the air filter box cover. (H p. 96)
- Remove the seat. (IS p. 100)
Main work
- Pull the EFI control unit O upward off the rubber plugs and
hang to the side.
- Open fuse box cover ©

- Remove the faulty fuse.
Guideline
(All EU models)
Fuse 1 -10 A - EFI control unit, lambda sensor, oil
pump, combination instrument, fuel injection, diagnos
tics connector
Fuse 2 -10 A - horn, brake light, radiator fan (optional),
turn signal (optional)
Fuse 3 - 10 A - high beam, low beam, position light, tail
light, license plate lamp
Fuse 4 - 5 A - fuel pump
(All US models)
Fuse 1 - 10 A - EFI control unit, oil pump, combination
instrument, fuel injection, diagnostics connector
Fuse 2 -10 A - radiator fan (optional)
Fuse 3 -10 A - low beam, position light, tail light
Fuse 4 - 5 A - fuel pump
Fuses res -10 A - spare fuse
138
Warning
Fire hazard Incorrect fuses overload the electrical
system.
- Only use fuses with the required ampere value.
- Do not bypass or repair fuses.
- Insert a spare fuse with the correct rating only.
Fuse (75011088010) (IS p. 294)

Fuse (75011088005) (U p. 294)
Tip
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 ©.
- Mount the EFI control unit o on the rubber lugs.
Finishing work
- Mount the seat. (S® p. 101)
- Install the air filter box cover. (W p. 96)
15.4 Disconnecting the negative cable of the battery

Preparatory work
(All EU models)
- Press and hold the kill switch while the engine is idling
(All US models)
- Press and hold the kill switch & while the engine is idling
- Remove the air filter box cover. (8S p. 96)
- Remove the seat. (US p. 100)
139
Main work
- Pull back negative terminal cover.
- Disconnect negative cable o of the battery.
15.5 Connecting the negative cable of the battery

Main work
- Connect negative cable Q of the battery.
Guideline
Screw, battery termi- M5 2.5 Nm (1.84 Ibf ft)
nal
• Info
I Contact disks must be mounted under the screws and
the cable lug with the claws toward the battery termi
nal.
- Slide negative terminal cover over the negative terminal.

Finishing work
- Mount the seat. (M p. 101)
15.6 Removing the battery
Warning
Risk of injury Batteries contain harmful substances.
- Keep batteries out of the reach of children.
- Keep sparks and open flames away from the batteries.
- Only charge batteries in well-ventilated rooms.
- Maintain a minimum clearance from inflammable materials when charging batteries.
Minimum clearance 1 m (3 ft)
- Do not charge deeply discharged batteries if charge is already below the minimum voltage.
Minimum voltage before the start of the charge 9V
- Dispose of batteries with less than the minimum voltage correctly.
Preparatory work
(All EU models)
(All US models)
- Remove the seat. (85 p. 100)
140
Main work
- Pull back the negative terminal cover O and disconnect
negative cable © from the battery.
- Pull back the positive terminal cover © and disconnect pos
itive cable o from the battery.
- Remove screw ©
- Pull holding bracket © forward and remove battery toward
the top.
15.7 Installing the battery

Main work
- Insert the battery into the battery compartment with the ter
minals facing forward and secure with holding bracket o
Battery (HJTZ5S-FP-C) (IS p. 294)

Guideline
chassis
Connect positive cable © to the battery.

Guideline
Screw, battery termi M5 2.5 Nm (1.84 Ibf ft)
nal
• Info
I Contact disks © must be mounted under the
screw © and the cable lug © with the claws toward
the battery terminal.
- Slide positive terminal cover © over the positive terminal.

- Connect negative cable © to the battery.
Guideline
Screw, battery termi- M5 2.5 Nm (1.84 Ibf ft)
nal
• Info
I Contact disks O must be mounted under the
screw © and the cable lug © with the claws toward
the battery terminal.
- Slide negative terminal cover © over the negative terminal.
141
Finishing work
- Mount the seat, (ii p. 101)
- Install the air filter box cover. (I p. 96)
15.8 Recharging the battery
Warning
Risk of injury Batteries contain harmful substances.
- Keep batteries out of the reach of children.
- Keep sparks and open flames away from the batteries.
- Only charge batteries in well-ventilated rooms.
- Maintain a minimum clearance from inflammable materials when charging batteries.
Minimum clearance 1 m (3 ft)
- Do not charge deeply discharged batteries if charge is already below the minimum voltage.
Minimum voltage before the start of the charge 9V
- Dispose of batteries with less than the minimum voltage correctly.
Note
Environmental hazard Batteries contain environmentally-hazardous materials.
- Do not dispose of batteries as household waste.
- Dispose of batteries at a collection point for used batteries.
Note
• Info
I Even when there is no load on the battery, it discharges steadily.
The charging level and the method of charging are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the service life of the battery.
If the charging current, charging voltage, or charging time are exceeded, the battery will be destroyed.
If the battery is depleted by repeated starting, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sul-
fated, destroying the battery.
The battery is maintenance-free.
Preparatory work
(All EU models)
(All US models)
- Remove the air filter box cover. p. 96)
- Remove the seat. ( p. 100)
- Disconnect the negative cable of the battery. (M p. 139)
142
Main work
- Connect the battery charger to the battery. Adjust the battery
charger.
EU battery charger XCharge-professional (00029095050)

(ill p. 338)
Alternative 1
US battery charger XCharge-professional
(00029095051) (IS p. 339)
311910-10
Alternative 2
UK battery charger XCharge-professional
(00029095052) (M p. 339)
Alternative 3
CH battery charger XCharge-professional
(00029095053) (IS p. 339)
• Info
I Follow the instructions of the charger and the manual.
- Disconnect the battery charger after charging the battery.

Guideline
The charging current, charging voltage, and charging time
must not be exceeded.
Charge the battery regularly 3 months
when the motorcycle is not
in use
Finishing work
- Connect the negative cable of the battery. (W p. 140)
- Mount the seat. (8S p. 101)
15.9 Checking the charging voltage

Condition
The battery must be fully functional and completely charged.
Carry out the start procedure. ( p. 12)
Measure the voltage between the specified points.
Measuring point plus (+) - Measuring point
Ground (-)
Charging voltage
5,000 rpm 13.5 ... 15.0 V
» If the displayed value is greater than the specified value:
- Change the voltage regulator.
143
15.10 Checking the open-circuit current

Preparatory work
(All EU models)
(All US models)
- Remove the seat. (IS p. 100)
Main work
- Disconnect the negative cable of the battery.
- Measure the current between battery ground (-) and the neg
ative cable.
• Info
I The value of the open-circuit current only applies to
vehicles in their original state without additional power
consumers.
Maximum open-circuit cur- <1.0 mA

rent

- Disconnect the voltage regulator from the wiring har
ness and perform the measurement again.
15.11 Checking the starter relay

Preparatory work
(All EU models)
(All US models)
- Remove the air filter box cover, (ii p. 96)
- Remove the seat. (B8 p. 100)
Main work
- Pull the EFI control unit o upward off the rubber plugs and
hang to the side.
144
- Disconnect the negative cable of the battery.

- Pull the starter relay off of the bracket.
- Pull off connector ©
- Disconnect cables © and © on the starter relay.
- Connect the starter relay to a 12 V power supply as per the

figure.
- Measure the resistance between the specified points.
Resistance of open circuit 0Q
» If the value displayed does not meet specifications:

- Change the starter relay.
Finishing work
- Mount the seat. (BS p. 101)
- Install the air filter box cover. (®S p. 96)
15.12 Diagnostics connector

Diagnostics connector o is located under the seat.
145
16 BRAKE SYSTEM
16.1 Checking the front brake linings
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
- Ensure that worn-out brake linings are replaced immediately.
Check the brake linings for minimum thickness
Minimum thickness Q > 1 mm (> 0.04 in)
» If the minimum thickness is less than specified:

- Change the front brake linings, (fii p. 146)
Check the brake linings for damage and cracking.
» If damage or wear is encountered:
- Change the front brake linings. (SS p. 146)
16.2 Changing the front brake linings
Warning
Danger of accidents Incorrect maintenance will cause the brake system to fail.
- Ensure that service work and repairs are performed professionally.
Warning
Skin irritation Brake fluid causes skin irritation.
- Keep brake fluid out of the reach of children.
- Wear suitable protective clothing and safety glasses.
- Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
- Consult a doctor immediately if brake fluid has been swallowed.
- Rinse the affected area with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
- If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
- Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule.
Warning
146
BRAKE SYSTEM 16
Warning
Danger of accidents 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.
If brake linings are used that differ from the original equipment, compliance with the original homolo
gation is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery
and the warranty shall be void.
- Only use brake linings approved and recommended by Husqvarna motorcycles.
Note
• Info
I Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not
designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
Move the brake fluid reservoir mounted on the handlebar to a

horizontal position.
Remove screws o
Take off cover © with membrane ©
Manually press the brake caliper toward the brake disc to

push back the brake pistons. Ensure that brake fluid does
not flow out of the brake fluid reservoir, if necessary extract
excess.
• Info
I Make sure that you do not press the brake caliper
against the spokes when pushing back the brake pis
tons.
Remove cotter pin ©

Push leaf spring © upwards and remove pin ©
Remove the brake linings.
Clean the brake caliper and brake caliper support.
147
16 BRAKE SYSTEM
Check that leaf spring © in the brake caliper and sliding

plate Q in the brake caliper support are seated correctly.
Insert the new brake linings.

Mount pin ©
S Leaf spring © engages in the groove on the pin.
• Info
I Always change the brake linings in pairs.
Mount cotter pins ©.

Operate the hand brake lever repeatedly until the brake lin
point.
Add brake fluid up to level ©

Guideline
Level © (brake fluid level 5 mm (0.2 in)
below reservoir rim)
Brake fluid DOT 4 / DOT 5.1 p p. 334)
Position cover © with membrane ©

Mount and tighten screws O-
• Info
I Clean up overflowed or spilled brake fluid immediately
with water.
16.3 Checking the free travel of the hand brake lever
Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit.
- Set the free travel on the hand brake lever in accordance with the specification.
148
BRAKE SYSTEM 16
(All EU models)
- Push the hand brake lever to the handlebar and check
free travel ©
Free travel of hand brake > 3 mm (> 0.12 in)
lever
» If the free travel does not match the specification:

- Adjust the free travel of the hand brake lever.
(All US models)
- Push the hand brake lever forward and check free
travel ©.
Free travel of hand brake > 3 mm (> 0.12 in)

lever
» If the free travel does not match the specification:
- Adjust the basic position of the hand brake lever.
(8JS p. 149)
16.4 Adjusting the basic position of the hand brake lever

Adjust the basic position of the hand brake lever to your hand
size by turning adjusting screw o
• Info
I Turn the adjusting screw clockwise to decrease the
distance between the hand brake lever and the han
dlebar.
Turn the adjusting screw counterclockwise to increase
the distance between the hand brake lever and the
handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not
apply any force.
Do not make any adjustments while riding.
16.5 Checking the front brake fluid level
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is
leaking or the brake linings are worn down.
- Check the brake system and do not continue riding until the problem is eliminated.
Warning
schedule.
149
16 BRAKE SYSTEM
- Move the brake fluid reservoir mounted on the handlebar to a

- Check the brake fluid level in the viewer o
» If the brake fluid level has dropped below marking ©
- Add front brake fluid. (H p. 150)
16.6 Adding front brake fluid
Warning
Warning
with the eyes.
Warning
schedule.
Note
• Info
Preparatory work
- Check the front brake linings. (US p. 146)
150
BRAKE SYSTEM 16
Main work
- Move the brake fluid reservoir mounted on the handlebar to a
- Remove screws o
- Take off cover © with membrane 0
- Add brake fluid to level ©.
Guideline
Level © (brake fluid level 5 mm (0.2 in)
below reservoir rim)
- Position cover with membrane. Mount and tighten screws.
• Info
with water.
16.7 Changing the front brake fluid
Warning
with the eyes.
Note
• Info
151
16 BRAKE SYSTEM
Move the brake fluid reservoir mounted on the handlebar to a

Cover painted parts.
Remove screws o
Take off cover © with the membrane.
Extract the old brake fluid out of the brake fluid reservoir
using a syringe and fill with fresh brake fluid.
Syringe (50329050000) (US p. 340)

Mount bleeder cover ©.
Bleeder cover (00029013019) (SS p. 338)

Connect the bleeding device.
Open shut-off valve ©
• Info
I Follow the instructions in the Owner's Manual of the
bleeding device.
Ensure that the filling pressure is set on pressure gauge ©.

Correct the filling pressure on pressure regulator © if neces
sary.
Guideline
Filling pressure 2 ... 2.5 bar (29 ... 36 psi)
Pull off protection cap © of the brake caliper bleeder screw.

Connect the bleeder bottle hose.
Open bleeder screw © by approx, one half turn.
• Info
I Drain until fresh brake fluid emerges in the bleeder
bottle hose without bubbles.
Tighten the bleeder screw.

Close shut-off valve ©
Open the bleeder screw again until brake fluid stops emerg
ing.
• Info
I Overfilling of the brake fluid reservoir is prevented.
- Tighten the bleeder screw. Remove the bleeder bottle hose.

Attach the protection cap.
- Disconnect the bleeding device. Remove the bleeder cover.
152
BRAKE SYSTEM 16
Add brake fluid up to level ©

Guideline
Dimension © 5 mm (0.2 in)
Brake fluid DOT 4 /DOT 5.1 (i® p. 334)
Position the cover with the membrane. Mount and tighten the
screws.
• Info
with water.
- Check the hand brake lever for a firm pressure point.
16.8 Checking the brake linings of the rear brake
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
- Ensure that worn-out brake linings are replaced immediately.
Check the brake linings for minimum thickness ©
Minimum thickness o > 1 mm (> 0.04 in)
» If the minimum thickness is less than specified:

- Change the rear brake linings. ( p. 153)
Check the brake linings for damage and cracking.
» If damage or wear is encountered:
- Change the rear brake linings. ( p. 153)
16.9 Changing the rear brake linings
Warning
Danger of accidents Incorrect maintenance will cause the brake system to fail.
- Ensure that service work and repairs are performed professionally.
Warning
with the eyes.
153
16 BRAKE SYSTEM
Warning
schedule.
Warning
A Warning
Danger of accidents 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.
If brake linings are used that differ from the original equipment, compliance with the original homolo
gation is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery
and the warranty shall be void.
- Only use brake linings approved and recommended by Husqvarna motorcycles.
Note
• Info
Stand the vehicle upright.

Remove the cable ties on the frame protector.
Remove screw cap o with membrane © and the shim.
Manually press the brake caliper to the brake disc to push

back the brake piston. Ensure that brake fluid does not flow
out of the brake fluid reservoir, extracting it by suction if it
does.
• Info
I Make sure when pushing back the brake piston that
you do not press the brake caliper against the spokes.
Remove cotter pin ©

Push leaf spring © downwards and remove pin ©.
154
BRAKE SYSTEM 16
Remove the brake linings.

Clean the brake caliper and brake caliper support.
Check that leaf spring o in the brake caliper and sliding

plate © in the brake caliper support are seated correctly.
Insert the new brake linings.

Mount pin ©
S Leaf spring © engages in the groove on the pin.
• Info
I Always change the brake linings in pairs.
Make sure that decoupling plate © is mounted on
the piston side brake lining.
Mount cotter pins ©

Operate the foot brake lever repeatedly until the brake lin
point.
Add brake fluid to level ©.
Mount and tighten screw cap o with membrane © and the

shim.
• Info
with water.
Mount new cable ties on the frame protector.
155
16 BRAKE SYSTEM
16.10 Checking the free travel of the foot brake lever
Warning
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear
brake.
- Set the free travel on the foot brake lever in accordance with the specification.
Disconnect spring o
Move the foot brake lever backwards and forwards between
the end stop and the foot brake cylinder piston bracket and
check free travel ©
Guideline
Free travel of foot brake 3 ... 5 mm (0.12 ... 0.2 in)
lever
» If the free travel does not meet specifications:

- Adjust the basic position of the foot brake lever.
[m p. 156)
Reconnect spring o
16.11 Adjusting the basic position of the foot brake lever
Warning
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear
brake.
- Set the free travel on the foot brake lever in accordance with the specification.
Disconnect spring o
Loosen nut o and turn it back with push rod © until you
have maximum free travel.
To adjust the basic position of the foot brake lever individu
ally, loosen nut © , and turn screw © accordingly.
• Info
I The range of adjustment is limited.
Turn push rod © accordingly until you have free travel ©.if
necessary, adjust the basic position of the foot brake lever.
Guideline
Free travel of foot brake 3 ... 5 mm (0.12 ... 0.2 in)
lever
Hold screw © and tighten nut ©

Guideline
Nut, foot brake lever M8 20 Nm (14.8 Ibfft)
stop
Hold push rod © and tighten nut ©
156
BRAKE SYSTEM 16
Guideline
Remaining nuts, M6 10 Nm (7.4 Ibf ft)
chassis
- Reconnect spring o
16.12 Checking the rear brake fluid level
Warning
Warning
schedule.

Check the brake fluid level in viewer o
» If the brake fluid level has dropped below marking ©:
- Add rear brake fluid. (BJ p. 157)
16.13 Adding rear brake fluid
Warning
Warning
with the eyes.
157
16 BRAKE SYSTEM
Warning
schedule.
Note
• Info
Preparatory work
- Check the brake linings of the rear brake. (SS p. 153)
Main work
- Stand the vehicle upright.
- Remove the cable ties on the frame protector.
- Remove screw cap o with membrane 0 and the shim.
- Add brake fluid up to the marking ©
Brake fluid DOT 4 / DOT 5.1 (SB p. 334)
- Mount and tighten screw cap with the membrane and the
shim.
• Info
with water.
- Mount new cable ties on the frame protector.
16.14 Changing the rear brake fluid
Warning
with the eyes.
158
BRAKE SYSTEM 16
Note
• Info
Remove the cable tie.
Cover painted parts.

Remove screw cap O with membrane © and the shim.
Extract the old brake fluid out of the brake fluid reservoir
using a syringe and fill with fresh brake fluid.
Syringe (50329050000) (P p. 340)

Brake fluid DOT 4 / DOT 5.1 (H p. 334)
Mount bleeder cover ©
Bleeder cover (00029013020) (SB p. 338)
Connect the bleeding device.
Open shut-off valve ©
• Info
I Follow the instructions in the Owner's Manual of the
bleeding device.
Ensure that the filling pressure is set on pressure gauge ©•

Correct the filling pressure on pressure regulator © if neces
sary.
Guideline
Filling pressure 2 ... 2.5 bar (29 ... 36 psi)
159
16 BRAKE SYSTEM
Pull off protection cap 0 of the bleeder screw. Connect the

bleeder bottle hose.
Open bleeder screw © by approx, one half turn.
• Info
I Drain until fresh brake fluid emerges in the bleeder
bottle hose without bubbles.
Tighten the bleeder screw.

Close shut-off valve ©
Open the bleeder screw again until brake fluid stops emerg
ing.
• Info
I Overfilling of the brake fluid reservoir is prevented.
Tighten the bleeder screw. Remove the bleeder bottle hose.

Attach the protection cap.
Disconnect the bleeding device. Remove the bleeder cover.
Correct the brake fluid to marking 0
Brake fluid DOT 4 / DOT 5.1 ( p. 334)
Mount and tighten screw cap with the membrane and the
shim.
• Info
with water.
Check the foot brake lever for a firm pressure point.

160
LIGHTING SYSTEM, INSTRUMENTS 17
17.1 Adjusting the combination instrument

Condition
The motorcycle is stationary.
Press both buttons for 3-5 seconds.
y The Setup menu is displayed. The UNIT display flashes.
Press one of the buttons to select UNIT for the speed in kilo
meters KM/H or miles M/H.
Wait for 5 seconds.

y The combination instrument changes to the next menu
item. The © symbol flashes.
Press one of the buttons to select the 24h or 12h display of
the clock.
- Wait for 5 seconds.

item. The 0 symbol flashes.
Resetting the time
- Press the left button.
y The value decreases.
Advancing the time
- Press the right button.
y The value increases.

item. The ** symbol flashes.
- Set the service.
Shortening the service interval
Extending the service interval
161
17 LIGHTING SYSTEM, INSTRUMENTS
Switching off the service interval display

- Press and hold the left button.
S off appears on the display.
17.2 Setting the kilometers or miles
• Info
I If the unit is changed, the value ODO is retained and converted accordingly.
Condition
^ The Setup menu is displayed. The UNIT display flashes.
Press one of the buttons to select UNIT for the speed in kilo
meters KM/H or miles M/H.
17.3 Setting the clock

Condition
S The Setup menu is displayed. The UNIT display flashes.
Wait for the menu of the clock 0 to flash.
Press one of the buttons to select the 24h or 12h display of
the clock.

S The combination instrument changes to the next menu
item. The 0 symbol flashes.
Resetting the time
The value decreases.
Advancing the time
S The value increases.
162
17.4 Adjusting the wheel circumference

Condition
Preparatory work
- Disconnect speedometer connector CZ.
Main work
- Press both buttons for 3-5 seconds.
- Wait for the menu TIRE to flash.

Reducing the wheel circumference
Enlarging the wheel circumference
Finishing work
- Plug in the speedometer connector CZ.
17.5 Setting the service display

Condition
- Press both buttons for 3-5 seconds.
- Wait for the menu of the service display to flash.
- Set the service.
Shortening the service interval
Extending the service interval
163
Switching off the service interval display

- Press and hold the left button.
S off appears on the display.
17.6 Changing the headlight bulb
Note
Damage to reflector Grease on the reflector reduces the brightness.
Grease on the bulb will evaporate due to the heat and be deposited on the reflector.
- Clean and degrease the bulbs before mounting.
- Do not touch the bulbs with your bare hands.
Preparatory work
- Remove the headlight mask with the headlight. (IS p. 115)
Main work
- Turn protection cap o
together with the underlying bulb
socket counterclockwise all the way and remove it.
- Pull bulb socket © of the position light out of the reflector.
- Pull out headlight bulb ©.

- Insert the new headlight bulb.
Headlight (HS1/socket BX43t) (IS p. 294)
- Insert the protection cap with the bulb socket into the reflec
tor and turn it clockwise all the way.
S O-ring © is correctly positioned.
- Insert the bulb socket of the position light into the reflector.
Finishing work
- Check the headlight setting. (8S p. 165)
164
17.7 Changing the turn signal bulb (All EU models)
Note
Damage to reflector Grease on the reflector reduces the brightness.
Grease on the bulb will evaporate due to the heat and be deposited on the reflector.
- Clean and degrease the bulbs before mounting.
- Do not touch the bulbs with your bare hands.
Main work
- Remove the screw on the rear of the turn signal housing.
- Carefully remove turn signal glass O-
- Lightly squeeze orange cap 0 in the area of the holding lugs
and take it off.
- Press the turn signal bulb lightly into the socket, turn it coun
terclockwise by about 30°, and take it out of the socket.
• Info
I Do not touch the reflector with your fingers and keep it
free from grease.
- Press the new turn signal bulb carefully into the socket and
turn it clockwise until it stops.
Turn signal (RIOW/socket BA15s) (8S p. 294)
- Mount the orange cap.

- Position the turn signal glass.
- Insert the screw and first turn counterclockwise until it
engages in the thread with a small jerk. Tighten the screw
lightly.
Finishing work
- Check that the turn signal system is functioning properly.
17.8 Checking the headlight setting

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.
Make another mark a distance 0 under the first mark.
Guideline
Distance 0 5 cm (2 in)
Position the vehicle vertically a distance Q away from the

wall.
Guideline
Distance Q 5 m (16 ft)
The rider now sits down on the motorcycle.

Switch on the low beam.
Check the headlight setting.
165
The boundary between light and dark must be exactly on

the lower mark for a motorcycle with driver.
» If the light-dark border does not meet specifications:

- Adjust the headlight range. ( P- 166)
17.9 Adjusting the headlight range

Preparatory work
- Check the headlight setting. (£8 p. 165)
Main work
- Loosen screw O-
- Adjust the headlight range by pivoting the headlight.
Guideline
The boundary between light and dark must be exactly on
the lower marking for a motorcycle with rider (instructions
on how to apply the marking: Checking the headlight set
ting).
• Info
I If you have a payload, you may have to correct the
headlight range.
- Tighten screw
17.10 Changing the combination instrument

Preparatory work
- Remove the headlight mask with the headlight. (U p. 115)
Main work
- Pull the combination instrument upward out of the holder.
- Using a coin, turn protection cap © all the way counter

clockwise and remove it.
- Remove combination instrument ©
- Insert the new battery with the label facing outward.
Combination instrument battery (CR 2032) (£8 p. 294)
- Check the O-ring of the protection cap for correct seating.
166
- Position protection cap © and turn all the way clockwise

using a coin.
- Press any button on the combination instrument.
S The combination instrument is activated.
- Position the combination instrument in the holder.
- Mount and tighten the screws with washers.
Finishing work
- Check the headlight setting. (IS p. 165)
- Adjust the combination instrument. (US p. 161)
17.11 Activation
Activating combination instrument
The combination instrument is activated when one of the buttons
is pressed or an impulse comes from the wheel speed sensor.
167
18 ENGINE
18.1 Cleaning the pressure sensor hose

Push back hose clamps o
Pull off pressure sensor hose ©.
Clean hose ©thoroughly and blow out with compressed air.
Mount pressure sensor hose ©.

Position hose clamps o
18.2 Removing the engine

Preparatory work
- Remove the engine guard. (H p. 49)
- Raise the motorcycle with a lift stand. (®8 p. 12)
- Remove the right side cover. ( p. 100)
(All EU models)
(All US models)
- Press and hold the kill switch K5 while the engine is idling
- Remove the seat. (®! p. 100)
- Disconnect the negative cable of the battery. (U p. 139)
- Drain the coolant. (H p. 265)
- Remove the manifold. (US p. 91)
168
ENGINE 18
Main work
- Take off the main silencer.

- Take off the frame protector.

- Remove the cable tie.
- Take off the frame protector.
- Loosen screw ©
- Remove screw 0
- Repeat these steps on the opposite side.
- Loosen hose clip 0

- Slightly raise the subframe.
- Remove hose clip ©
169
18 ENGINE
Raise the subframe slightly and secure.
Disconnect oil pump connector o
Remove hose clip @-

Pull the throttle valve body out of the intake flange toward the
rear and hang it to one side.
• Info
age.
Pay attention to the oil pump hose.

Remove screw ©.
Take off the engine sprocket cover.
Remove screws ©
Take off the slave cylinder of the clutch and hang it to one
side.
• Info
I Do not kink the clutch line.
Do not activate the clutch lever while the slave cylin
der of the clutch is removed.
170
ENGINE 18

Remove screw with the washer.
Remove connecting link of the chain.
• Info
age.
Take off the chain.
Remove engine sprocket ©.
Disconnect spark plug connector ©
Push back protection cap ©

Disconnect engine coolant temperature sensor connector.
171
18 ENGINE
Push back protection caps

Disconnect connector.
Pull off air release hose ©.
Disconnect plug-in connector €>.

Disconnect plug-in connector
Expose the cable.
Push back hose clamp

Pull off pressure sensor hose.
172
ENGINE 18
Loosen hose clip ©.

Pull off the radiator hose.
Loosen hose clip

Pull off the radiator hose.
Push back protection cap ® and remove the nut.

Hang the positive cable to the side.
Remove spring
173
18 ENGINE
Remove fitting
Slip the foot brake lever out toward the rear.
Remove screws © and ^).

Take off the engine braces.
Remove nut
Remove the swingarm pivot.
Carefully pull the swingarm back, and secure the swingarm.
Remove screws ^).
Lift out the engine sideways to the right.
• Info
I Pay attention to the oil pump.
The help of an assistant is useful in this step.
Make sure that the engine is sufficiently secured
against falling over.
Protect the frame and attachments against damage.
174
ENGINE 18
18.3 Installing the engine

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

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

Mount the swingarm pivot.
Mount nut ®, but do not tighten it yet.
Guideline
Position the engine braces.

Mount and tighten screws © and Q-
Guideline
Screw, engine M8 25 Nm (18.4 Ibfft)
brace Loctite®2701 ™
Tighten screws o and nut ©

Guideline
Engine bracket M10 60 Nm (44.3 Ibfft)
screw
Slip in the foot brake lever and position it.

Mount and tighten fitting ©
Guideline
Nut, foot brake lever 15 Nm (11.1 Ibfft)
S Push rod Q engages in the foot brake cylinder.

S The dust boot is correctly positioned.
175
18 ENGINE
Mount spring ©
Position the positive cable on the starter motor.

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

Position and tighten hose clip ©
Mount the radiator hose.

Position and tighten hose clip ©.
176
ENGINE 18
Position pressure sensor hose.

Position hose clamp ©
Join plug-in connectors and ©
Route the cable without tension and secure it with a cable tie.
Mount vent hose ©.
Plug in the connectors.

Position protection caps ©
177
18 ENGINE
Plug in the connector of the engine coolant temperature sen

sor.
Position protection cap ©.
Plug in spark plug connector ©
Slide engine sprocket © onto the countershaft.
Mount the chain.

Connect the chain with connecting link ©
Guideline

Guideline
Screw, drive M10 60 Nm (44.3 Ibfft)
chain engine Loctite®2701 ™
sprocket
178
ENGINE 18
Position the clutch slave cylinder with the gasket.

Mount and tighten screws
Guideline
cylinder
Position engine sprocket cover.

Mount and tighten screw with the washer.
Guideline
cylinder

Guideline
Screw, engine M8 20 Nm (14.8 Ibf ft)
sprocket cover
Position hose clip © but do not tighten yet.

Position the throttle valve body in the intake flange.
Plug in oil pump connector
Remove the locking piece and position the subframe.
• Info
I Watch out for the intake flange.
Position hose clip © but do not tighten yet.
179
18 ENGINE

Guideline
Screw, sub- M8 30 Nm (22.1 Ibfft)
frame Loctite®2701 ™
Remove screw ©
Guideline
Screw, sub- M8 30 Nm (22.1 Ibfft)
frame Loctite®2701 ™
Repeat these steps on the opposite side.

Tighten hose clips © and ©.
Position the frame protector.
Guideline
Screw, frame pro- M5 3 Nm (2.2 Ibfft)
tector
Position the frame protector.

Guideline
Screw, frame pro M5 3 Nm (2.2 Ibf ft)
tector
Mount the cable ties.

Install the manifold. ( p. 93)
Mount the main silencer with rubber sleeve ^).

Guideline
chassis
Connect the negative cable of the battery. (S3 p. 140)

Install the fuel tank. (S3 p. 103)
Install the air filter box cover. ( p. 96)
Install the right side cover. (W p. 100)
Mount the seat. (S3 p. 101)
180
ENGINE 18
- Remove filler plug @ with the O-ring, and fill up with gear oil.
Gear oil 0.80 1 Engine oil (15W/50)

(0.85 qt.) (1! p. 334)
- Mount and tighten filler plug @ with the O-ring.
Finishing work
- Remove the motorcycle from the lift stand. (fiS p. 12)
- Install the engine guard. ( p. 49)
- Refill with coolant. (SI p. 266)
- Go for a short test ride.
- Check the engine for leak tightness.
- Check the gear oil level. ( p. 273)
- Check the coolant level. (IS p. 265)
18.4 Engine disassembly
18.4.1 Clamping engine into the engine work stand

- Mount special tool o on engine assembly stand ©
Engine work stand (80329001000) (U p. 346)

Holder and fitting for work stand (55429002000) (SI p. 341)
- Mount the engine on special tool O-
18.4.2 Removing the shift lever

Remove screw o with the washers. Take off the shift lever.
181
18 ENGINE
18.4.3 Removing the clutch push rod

Remove clutch push rod
18.4.4 Draining the gear oil

Remove gear oil drain plug O with the magnet and seal ring.
Let the gear oil drain fully.
18.4.5 Removing the spacer

- Remove spacer o
- Take off O-ring ©
182
ENGINE 18
18.4.6 Removing the alternator cover

Remove screws o . Take off the alternator cover.
Remove the dowels and alternator cover gasket 0
18.4.7 Removing the kick starter

Remove screw o with the washer.
Take off the kick starter.
183
18 ENGINE
18.4.8 Removing injection valves

Remove screws O with insulating washers ©
Take off injection valves on both sides.
18.4.9 Removing the cylinder head

- Remove spark plug o
D04533-10
Loosen screws © in a crisscross pattern and remove them.

Remove the cylinder head.
D04534-10
(All TE 250i)
- Remove O-rings ® and ©
184
ENGINE 18
(All TE 300i)
- Remove O-rings © and ©
18.4.10 Removing the cylinder

(All TE 250i)
- Remove screws o and 0
- Take off both covers.
- Remove retainer © of ball socket ©

- Pull off the ball socket.
- Remove the gaskets on both sides.
- Remove nuts ©.
• Info
I Raise the cylinder slightly to be able to remove the
front nuts.
- Carefully slide the cylinder up and take it off.
185
18 ENGINE
- Take off gasket ©
(All TE 300i)
- Remove screws o and ©
- Take off both covers.
- Remove retainer © of ball socket o

- Pull off the ball socket.
- Remove the gaskets on both sides.
- Remove nuts ©
Info
Raise the cylinder slightly to be able to remove the
front nuts.
186
ENGINE 18
- Take off gasket ©
18.4.11 Removing the piston

(All TE 250i)
- Uncover the crankcase.
- Remove piston ring lock o
- Remove the piston pin.
- Take off the piston.
(All TE 300i)
- Uncover the crankcase.
- Remove piston ring lock O-
- Remove the piston pin.
- Take off the piston.
- Remove upper conrod bearing
18.4.12 Removing the water pump cover

Remove screws o
Take off the water pump cover.
Remove the form ring.
187
18 ENGINE
Remove dowels
18.4.13 Removing the clutch cover

Remove screws o
Take off the cap.
Remove adjusting spring with the auxiliary spring and

spring insert.
Remove screws ©.
- Take off the clutch cover at the top and slip out the linkage.
188
ENGINE 18
Remove dowels O and clutch cover gasket ©.
Remove screws ©
Take off the bearing support with the linkage and angle lever.
18.4.14 Removing the clutch discs

Remove screws o
Take off spring retainer ©
Take off spring washer ©.
Take off pretension ring ©
D04450-10
189
18 ENGINE
- Take off pressure cap ©.
- Remove clutch disc pack © completely.

- Remove clutch throw-out ©
18.4.15 Removing the clutch basket

Hold the primary gear using special tool o
Gear segment (56012004000) (H p. 342)
Remove nut G with the washer.

• Info
I Left-handed thread!
Bend up the lock washer.

Hold the inner clutch hub with the special tool. Loosen
nut ©.
Holding wrench (51129003000) (iS p. 340)
Remove the nut with the lock washer.
Take off inner clutch hub o and washer ©
• Info
I The washer usually sticks to the inner clutch hub.
Take off clutch basket ©.
190
ENGINE 18
Take off needle bearing e and collar bushing ©
18.4.16 Removing the balancer shaft

Position the special tool.
Hold the balancer shaft in place using the special tool o
Gear segment (56012004000) (£S p. 342)
Remove primary gear
Remove balancer shaft drive wheel Q-
Remove woodruff key ©
191
18 ENGINE
- Remove balancer shaft ©
18.4.17 Removing the kick starter shaft

Detach kick starter spring o
Remove kick starter shaft ©.
Info
Turn the kick starter shaft slightly to the left.
18.4.18 Removing the intermediate kick starter gear

Remove lock ring o with washer ©
Take off intermediate kick starter gear.
18.4.19 Removing the shift shaft

Push sliding plate o away from shift drum locating unit 0
Remove shift shaft © with washer.
192
ENGINE 18
18.4.20 Removing the shift drum locating unit

Remove screw O-
Push locking lever © away from shift drum locating unit ©
and take off the shift drum locating unit.
Relieve tension from the locking lever.
18.4.21 Removing the locking lever

Remove screw o with the washer.
Take off locking lever © with the sleeve and spring.
18.4.22 Removing the rotor

Hold the rotor with special tool o
Holding wrench (55429012000) (SI p. 342)
Remove nut © with the washer.
Mount special tool © , apply counterpressure, and pull off

the rotor by screwing in the screw.
Puller (58012009000) (P p. 343)
193
18 ENGINE
- Remove screws ©
- Take off the crankshaft position sensor.
- Take off Bendix
18.4.23 Removing the starter motor

Remove screw o
Take off cover 0
Remove screws ©.
Pull the starter motor out of the engine case as far as possi
ble.
• Info
I It is not possible to completely remove the starter
motor.
Remove screw ©
Remove spacer © using the special tool.
Footrest spring plier (58429083000) (tft p. 343)
194
ENGINE 18
Remove the starter motor.
Remove O-ring
18.4.24 Removing the reed valve housing

- Remove screws o
- Take off intake flange and gasket.
Remove reed valve housing ©

Take off the gasket.
18.4.25 Removing the left engine case section

Remove screws o
Tilt the left section of the engine case upward and remove the
fitting of the engine fixing arm.
Loosen the left section of the engine case by striking it lightly
with a plastic hammer and remove it.
• Info
I Do not pry it apart with screwdrivers, since the sealing
areas are easily damaged.
195
18 ENGINE
- Remove engine case gasket ©
18.4.26 Removing the shift rails

Remove shift rails
18.4.27 Removing the shift drum

Tilt shift forks O to the side.
Remove shift drum ©.
18.4.28 Removing the shift forks

Remove shift forks o
Info
Do not misplace the shift rollers.
196
ENGINE 18
18.4.29 Removing the transmission shafts

Remove lock ring ©
Pull both transmission shafts 0 out of the bearing seats

together.
• Info
I The stop disks of the transmission shafts usually stick
to the bearings.
18.4.30 Removing the crankshaft

Remove crankshaft o
Remove O-ring ©
Remove distance sleeve
197
18 ENGINE
18.5 Working on individual parts
18.5.1 Working on the right section of the engine case

Remove all dowels.
Remove shaft seal ring o of the crankshaft.
Remove lock ring ©
Remove screws © . Remove the bearing retainers.
Clean the engine case section thoroughly.
Warm the engine case section in an oven.
Guideline
180 °C (356 °F)
Knock the engine case section against a level wooden board.

This will cause the bearings to drop out of the bearing seats.
• Info
I Any bearings that remain in the engine case section
must be removed using a suitable tool.
Blow out lubrication bore Q with compressed air and check

that it is clear.
Insert the new cold bearings in the bearing seats of the
heated section of the engine case; if necessary, use a
suitable press drift to push them all the way in and make
them flush.
• Info
I When pressing the bearings in, ensure that the engine
case section is level to prevent damage.
Only press the bearings in via the outer ring; other
wise, the bearings will be damaged when they are
pressed in.
- After the engine case section has cooled, check that the
bearings are firmly seated.
• Info
I If the bearings are not firmly seated after cooling, it
is likely that they will rotate in the engine case when
warm. In this case, the engine case must be renewed.
- Press in shaft seal ring o for the crankshaft so it is flush,

with the open side facing inward.
- Mount lock ring ©.
- Mount and tighten screws © with the bearing retainers.
Guideline
Screw, bearing M5 7 Nm (5.2 Ibf ft)
retainer Loctite®243™
198
ENGINE 18
- Mount the dowels.
18.5.2 Working on the left section of the engine case

Remove all dowels.
Press shaft seal ring O of the crankshaft from the outside to
the inside using special tool 0
Pressing tool (75029044010) (<S p. 346)
Remove shaft seal ring © from the shift shaft and o from
the countershaft.
Remove shaft seal ring 0 from the balancer shaft.
Remove lock ring 0

Clean the engine case section thoroughly.
Warm the engine case section in an oven.
Guideline
180 °C (356 °F)
Knock the engine case section against a level wooden board.

This will cause the bearings to drop out of the bearing seats.
• Info
I Any bearings that remain in the engine case section
must be removed using a suitable tool.
Blow out lubrication bore 0 with compressed air and check

that it is clear.
199
18 ENGINE
Insert the new cold bearings in the bearing seats of the

heated section of the engine case; if necessary, use a
suitable press drift to push them all the way in and make
them flush.
• Info
I When pressing in, ensure that the section of the
engine case lies flat in order prevent damage.
Only press the bearings in via the outer ring; other
wise, the bearings will be damaged when they are
pressed in.
After the engine case section has cooled, check that the
bearings are firmly seated.
• Info
I If the bearings are not firmly seated after cooling, it
is likely that they will rotate in the engine case when
warm. In this case, the engine case must be renewed.
Position shaft seal ring O for the crankshaft on special

tool ©.
Pressing tool (50429005000) (U p. 340)
Press the shaft seal ring of the crankshaft from the outside to
the inside with the open side facing inward.
Mount lock ring ©.
Press in shaft seal ring © of the shift shaft so it is flush, with

the open side facing inward.
Press in shaft seal ring © of the countershaft so it is flush
with the open side facing in.
Press in shaft seal ring © for the balancer shaft so it is flush,
with the open side facing inward.
©
18.5.3 Removing the crankshaft bearing inner race

Fixate the crankshaft in the vice with special tool o
Separator plate (54829009000) ( p. 341)
Info
Use soft jaws.
Warm up special tool ©

Guideline
Push the warmed up special tool © onto the crankshaft

bearing inner race, press firmly together, and pull jointly from
the crankshaft.
200
ENGINE 18
18.5.4 Installing the crankshaft bearing inner race

- Fixate the crankshaft in the vice with special tool O-
Separator plate (54829009000) ( p. 341)
Info
Use soft jaws.
- Fleat the crankshaft bearing inner race in special tool © and

mount together.
Guideline
- Ensure that the new crankshaft bearing inner race is flush.
18.5.5 Changing the connecting rod, conrod bearing, and crank pin
Main work
- Position crankshaft o in the press using special tool ©
Separator plate (54829009000) (U p. 341)
- Press the crank pin out of the upper crankweb with a suitable
tool.
• Info
I Hold the lower crankweb.
- Remove the connecting rod and bearing.
Press the crank pin out of the lower crankweb.
Lubricate the new crank pin © and push in up to the stop.
201
18 ENGINE
Mount new bearing o with washers © and connecting

rod ©.
Info
Thoroughly oil the bearing.
Position special tool 0 on the press.

Crankshaft pressing tool (75029047000) (8J p. 346)
Crankshaft pressing tool insert (54829108000) (BS p. 341)
Insert the crankweb with the connecting rod and bearing.

Position the second crankweb.
Position special tool © with the heel pointing down.
Crankshaft pressing tool insert (54829108000) (i! p. 341)
Press in the upper crankweb as far as possible.
• Info
I The press mandrel must be positioned over the crank
pin.
Take the crankshaft out of the special tool and check that the
connecting rod can move freely.
Measure axial play Q between the connecting rod and the

crankwebs using the special tool.
Feeler gauge (59029041100) ( m. p. 345)
Connecting rod - axial play 0.60 ... 0.70 mm (0.0236 ...

of lower conrod bearing 0.0276 in)
» If the measured value is less than the specification:

- Correct it so the dimension is equal to the specified
value.
Finishing work
- Check the crankshaft run-out at the bearing pin. (S! p. 203)
202
ENGINE 18
18.5.6 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:
- Align the crankshaft.
18.5.7 Checking/measuring the cylinder

Check the cylinder bearing surface for damage.
» If the cylinder bearing surface is damaged:
- Change the cylinder and piston.
Measure the cylinder diameter at several locations on
the Q and o axes using a micrometer to identify oval
wear.
Guideline
Cylinder - drill hole diameter (All TE 250i)
Size 1 66.400 ... 66.412 mm
(2.61417 ... 2.61464 in)
Size II 66.412 ... 66.425 mm
(2.61464 ... 2.61515 in)
Cylinder - drill hole diameter (All TE 300i)
Size 1 72.000 ... 72.012 mm
(2.83464 ... 2.83511 in)
Size II 72.012 ... 72.025 mm
(2.83511 ... 2.83562 in)
• Info
I The cylinder size o is labeled on the right side of the
cylinder.
Using a straightedge and the special tool, check the sealing

surface of the cylinder head for distortion.
Feeler gauge (59029041100) ( m p. 345)
Cylinder/cylinder head - dis < 0.10 mm (< 0.0039 in)

tortion of sealing surface
» If the measured value does not meet specifications:

- Change the cylinder.
203
18 ENGINE
18.5.8 Cleaning the pressure sensor cylinder connection

Clean cylinder connection ©thoroughly ancj blow 0ut with
compressed air.
18.5.9 Removing the exhaust control

Remove screw O with the bushing and spring.
D04504-10
Remove screws ©.
Take off the retaining bracket.
Remove control shaft ©
204
ENGINE 18
Remove screw ©
Remove screw © with washer.
Take off the stop plate.
Take off gear segment 0
D04508-10
Remove screws ©
Take off the retaining bracket.
D04509-10
Remove control shaft ©
Remove screws ©
Take off the exhaust flange.
205
18 ENGINE
Remove O-rings ©
Take off the control flap.
18.5.10 Checking the exhaust control

Condition
The exhaust control and centrifugal timer are removed.
_________________________________________________________________________________________________________________ D04523-10
- Check control shafts o for damage and wear.

- Change the control shaft.
- Check gear segments © for damage and wear.
- Change the gear segments.
- Check bearing sleeves © for damage and wear.
- Change the bearing sleeves.
- Check control flap © for damage and wear.
- Change the control flap.
- Check spring © for damage and wear.
- Change the spring.
206
ENGINE 18
_________________________________________________________________________________________________________________ R04649-10
- Check pins © of the control lever for damage and wear.

- Change the control lever.
- Check ball head O on the linkage for damage and wear.
- Change the linkage.
- Check centrifugal timer © for damage and wear.
- Change the centrifugal timer.
- Check axial bearing © for damage and wear.
- Change the axial bearing.
18.5.11 Installing the exhaust control

Mount and grease O-rings O-
207
18 ENGINE
Mount the control shafts.

S The control shaft with marking Lis installed on the left.
Mount the retaining brackets.

Guideline
Screw, retain- M5 7 Nm (5.2 Ibfft)
ing bracket of Loctite®2701 ™
exhaust control
Mount and grease O-rings ©.
Mount and grease bearing sleeves ©
D04514-10
Set the control flap to the open position.

Mount O-rings ©
208
ENGINE 18
Degrease the sealing surface and coat thinly with sealant.
Loctite® 5910
Position the exhaust flange.
Mount and tighten screws ©.
Guideline
Screw, exhaust M6 8 Nm (5.9 Ibf ft)
flange
Info
Do not forget the spring hangers.
Position gear segment o
D04504-11
Position the spring with the short leg toward the outside.
Mount screw © with the bushing and spring but do not
tighten yet.
Guideline
Screw, control M6 10 Nm (7.4 Ibf ft)
flap, exhaust Loctite®243™
control
Attach the spring to the cylinder pin.

Tighten the screw.
Guideline
control
Position gear segment ©.
209
18 ENGINE
Position the stop plate.

Mount screw © with the washer but do not tighten yet.
• Info
I The screws are tightened when the Z dimension is
adjusted.
18.5.12 Cylinder - Nikasil® coating

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

- Check the piston bearing surface for damage.
» If the piston bearing surface is damaged:
- Replace the piston and, if necessary, the cylinder.
- Check that the piston rings move easily in the piston ring
grooves.
» If the piston ring is stiff:
- Clean the piston ring groove.
An old piston ring can be used to clean the

piston ring groove.
- Check the piston rings for damage.

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

» If the piston pin shows severe discoloration/signs of wear:
- Change the piston pin.
- Place the upper conrod bearing and piston pin in the con
necting rod and check the seating for play.
» If the piston pin seating has excessive play:
- Change the connecting rod, conrod bearing, and
crank pin.
210
ENGINE 18
Measure the piston at the piston skirt, at right angles to the

piston pin, at a distance ©.
Guideline
Distance © 50 mm (1.97 in)
Piston - diameter (All TE 250i)
Size 1 66.340 ... 66.350 mm
(2.61181 ... 2.6122 in)
Size II 66.351 ... 66.360 mm
(2.61224 ... 2.61259 in)
Piston - diameter (All TE 300i)
Size 1 71.940 ... 71.950 mm
(2.83228 ... 2.83267 in)
Size II 71.951 ... 71.960 mm
(2.83271 ... 2.83307 in)
Info
Piston dimensions o are marked on the piston head.
18.5.14 Checking the piston ring end gap

Remove the piston ring from the piston.
©
Place the piston ring in the cylinder and align with the piston.
Guideline
Below the upper edge of the 20 mm (0.79 in)
cylinder
Measure end gap Q with a feeler gauge.

Guideline
D04519-10
Piston ring - end gap
Ring 1 < 0.40 mm (< 0.0157 in)
Ring 2 < 0.40 mm (< 0.0157 in)
» If the end gap is greater than the specified value:

- Check/measure the cylinder. (US p. 203)
» If cylinder wear lies within the specified tolerance:
- Change the piston ring.
- Mount the piston ring with the marking facing toward the pis
ton head.
211
18 ENGINE
18.5.15 Measuring the piston/cylinder mounting clearance

- Check/measure the cylinder. ( p. 203)
- Check/measure the piston. (81 p. 210)
- The smallest piston/cylinder mounting clearance equals the
smallest cylinder bore diameter minus the largest piston
diameter. The largest piston/cylinder mounting clearance
equals the largest cylinder bore diameter minus the smallest
piston diameter.
Guideline
Piston/cylinder - mounting clearance (All TE 250i)
New condition 0.050 ... 0.074 mm (0.00197
... 0.00291 in)
Wear limit 0.10 mm (0.0039 in)
Piston/cylinder - mounting clearance (All TE 300i)
New condition 0.050 ... 0.085 mm (0.00197
... 0.00335 in)
18.5.16 Disassemble the reed valve housing
212
ENGINE 18
18.5.17 Checking the reed valve housing, reed valve and intake flange
Condition
Reed valve housing has been removed.
- Check intake flange o for damage and wear.

- Change the intake flange.
- Check reed valve © for damage and wear.
- Change the reed valve.
- Check the reed valve housing for damage and wear.
- Change the reed valve housing.
©
213
18 ENGINE
18.5.18 Assemble the reed valve housing

Position the inner reed valve O on both reed valve holders.
S The recesses are located on the right side.
Position holding strip 0

S The pins engage in the drilled holes.
Position the reed valve holders.
Mount screws © and screw in all the way.
• Info
1 Mount the screws at right angles to prevent damage.
Loosen screws © and tighten again.

Guideline
Screw, inner mem EJOTDELTAP r1 Nm (0.7 Ibfft)
brane sheets ® 35x25
S Distance © is equal on both sides.
214
ENGINE 18
Position the outer reed valve o on both sides.

y The recesses are located on the right side.
G01328-10
Position the clamping plates on both sides.

y After installation, the TOP marking must be visible as
shown.
Mount screws © on both sides and screw in all the way.
Loosen screws © and tighten again.
Guideline
Screw, outer mem EJOTDELTA P 1 Nm (0.7 Ibf ft)
brane sheets ® 30x6
G01326-11
Position gasket ©.
Position the reed valve housing in the support plate.

y The outer recess is located on the right in the direction of
travel when installed.
Guideline
Screw, membrane EJOTDELTA P ■1 Nm (0.7 Ibf ft)
support plate ®30x12
18.5.19 Working on the clutch cover
• Info
I Remove the outer clutch cover to avoid damage.
215
18 ENGINE
Remove nut o
Take off the water pump impeller.
Remove form washer ©
Remove centrifugal timer ©
Remove shaft seal ring ©
Press out bearing © toward the inside.
216
ENGINE 18
Remove shaft seal ring ©

Press in the new shaft seal ring all the way to the stop.
Press bearing © all the way in to the stop from the inside.
Press shaft seal ring © so it is flush.

Ensure that the bearing can turn freely and does not touch
the shaft seal ring.
Mount centrifugal timer ©
Position form washer ©
217
18 ENGINE
Mount the water pump impeller.

Mount and tighten nut o
Guideline
Cap nut, water M6 6 Nm (4.4 Ibf ft)
pump impeller Loctite®243™
18.5.20 Checking the clutch
- Check clutch push rod o for damage and wear.

- Change the clutch push rod.
- Place clutch push rod © on a flat surface and check for run-out.
» If there is run-out:
- Check spring retainer © for damage and wear.
- Change the spring retainer.
- Check pretension ring o for damage and wear.
- Change the pretension ring.
- Check spring washer © for damage and wear.
- Change the spring washer.
- Check the contact surface of pressure cap © for damage and wear.
- Change the pressure cap.
- Check clutch center © for damage and wear.
218
ENGINE 18

- Change the clutch center.
- Check damping rubber pieces © for damage and wear.
- Change the damping rubber pieces.
- Check inner clutch hub © for damage and wear.
- Change the inner clutch hub.
- Check the thrust surfaces of the clutch facing discs in clutch basket © for damage and wear.
- Change the clutch facing discs and the clutch basket.
- Check needle bearing © and collar sleeve © for damage and wear.
- Change the needle bearing and collar sleeve.
- Check intermediate discs © for damage and wear.
» If the intermediate discs are not flat or have punctiform outbreaks:
- Change all intermediate discs.
- Check clutch facing discs © for discoloration and scoring.
» If there is discoloration or scoring:
- Change all clutch facing discs.
- Check the thickness of clutch facing discs ©
Clutch facing disc - thickness > 1.9 mm (> 0.075 in)
» If the clutch facing disc does not meet specifications:

- Change all clutch facing discs.
18.5.21 Preassembling shift shaft

Secure the short end of the shift shaft in the bench vise.
Guideline
Use soft jaws.
Mount sliding plate O with the guide pin facing downward

and put the guide pin on the shift quadrant.
Mount pressure spring ©.
Slide on spring guide © , push return spring © , with the
offset end facing upward, over the spring guide and lift the
offset end over abutment bolt ©
Mount stop disk ©
219
18 ENGINE
18.5.22 Checking the shift mechanism
_________________________________________________________________________________________________________________ B04450-10
- Check shift forks o on plate Q for damage and wear (visual check).
- Change the shift fork.
- Check shift grooves © of shift drum © for wear.
» If the shift groove is worn:
- Change the shift drum.
- Check the seat of the shift drum in bearings ©
» If the shift drum is not seated correctly:
- Change the shift drum and/or the bearing.
- Check bearing © for stiffness and wear.
» If the bearings do not move freely or are worn:
- Change the bearings.
- Check the shift rollers for damage and wear.
- Change the shift rollers.
- Check shift rails © for run-out on a flat surface.
- Change the shift rail.
- Check the shift rails for scoring, wear and smooth operation in the shift forks.
» If there is scoring or corrosion, or if the shift fork is stiff:
- Change the shift rail.
- Check sliding plate © in contact areas © for wear.
» If the sliding plate is worn:
- Change the sliding plate.
- Check return surface © on the sliding plate for wear.
» If deep notches are present:
- Check guide pin © for looseness and wear.
220
ENGINE 18
» If the guide pin is loose and/or worn:

Preassemble the shift shaft. (SJ p. 219)

Check clearance G between the sliding plate and the shift
quadrant.
Shift shaft - sliding 0.40 ... 0.80 mm (0.0157 ...

plate/shift quadrant play 0.0315 in)
» If the measured value does not meet specifications:

18.5.23 Disassembling the main shaft
- Secure the main shaft with the toothed end facing downward in the vise.
Guideline
Use soft jaws.
- Remove stop disk o and second-gear fixed gear 0

- Remove fifth-gear idler gear 0 and needle bearing ©
- Remove stop disk ©.
- Remove lock ring @
- Remove third/fourth-gear sliding gear Q.
- Remove stop disk ©
- Remove sixth-gear idler gear 0
- Remove needle bearing ©
221
18 ENGINE
18.5.24 Disassembling the countershaft
B04446-10
- Secure the countershaft in the bench vise with the toothed end facing downward.
Guideline
Use soft jaws.
- Remove stop disk o and first-gear idler gear ©

- Remove needle bearing © and stop disk ©
- Remove sixth-gear sliding gear ©
- Remove third-gear idler gear © and needle bearing ©
- Remove fourth-gear idler gear
- Remove needle bearing ©
- Remove stop disk © and lock ring ©
- Remove fifth-gear sliding gear ©
- Remove second-gear idler gear © and needle bearing ©
©
18.5.25 Checking the transmission

Condition
The transmission has been disassembled.
ENGINE 18
001 00 0
O O©0© °©° © ©©
0
©©O © O o © © © © ©
© o ©o ©
© 0 (
)
B04444-10
- Check needle bearings o for damage and wear.

- Change the needle bearings.
- Check the pivot points of main shaft © and countershaft ® for damage and wear.
- Change the main shaft and/or countershaft.
- Check the tooth profiles of main shaft and countershaft @ for damage and wear.
- Change the main shaft and/or countershaft.
- Check the pivot points of idler gears o for damage and wear.
- Change the gear wheel pair.
- Check the shift dogs of idler gears o and sliding gears 0 for damage and wear.
- Check the tooth faces of idler gears o , sliding gears 0 , and fixed gear 0 for damage and wear.
- Check the tooth profiles of sliding gears © for damage and wear.
- Check sliding gears 0 for smooth operation in the profile of main shaft 0
» If the sliding gear does not move freely:
- Change the sliding gear or the main shaft.
- Check sliding gears 0 for smooth operation in the profile of countershaft 0
» If the sliding gear does not move freely:
- Change the sliding gear or the countershaft.
- Check stop disks G for damage and wear.
>> If there is damage or wear:
- Change the stop disks.
223
18 ENGINE
- Use new lock rings © with every repair.
18.5.26 Assembling the main shaft
• Info
I Use new lock rings with every repair.
Preparatory work
- Check the transmission. (83 p. 222)
- Carefully lubricate all parts before assembling.
Main work
- Secure the main shaft in the vise with the gear teeth facing downward.
Guideline
Use soft jaws.
- Mount needle bearing o

- Mount sixth-gear idler gear ©.
- Mount stop disk © and lock ring ©
- Mount third/fourth-gear sliding gear ©.
- Mount lock ring © and stop disk ©
- Mount needle bearing ©
- Mount fifth-gear idler gear ©.
- Mount second-gear fixed gear © and stop disk ©
- Finally, check all the gear wheels for smooth operation.
18.5.27 Assembling the countershaft
• Info
I Use new lock rings with every repair.
224
ENGINE 18
Preparatory work
- Check the transmission. (SI p. 222)
- Carefully lubricate all parts before assembling.
B04446-11
Main work
- Secure the countershaft in the bench vise with the toothed end facing downward.
Guideline
Use soft jaws.
- Mount needle bearing o and second-gear idler gear © onto the countershaft with the protruding collar
facing downward.
- Mount stop disk © and lock ring ©
- Mount fifth-gear sliding gear © with the shift groove facing up.
- Mount lock ring © and stop disk ©
- Mount needle bearing © and fourth-gear idler gear ©
- Mount needle bearing ©
- Mount third-gear idler gear {f).
- Mount stop disk © and lock ring ©.
- Mount sixth-gear sliding gear © with the shift groove facing downward.
- Mount stop disk ©
- Mount needle bearing © and first-gear idler gear ©
- Mount stop disk ©
- Finally, check all the gear wheels for smooth operation.
18 ENGINE
18.5.28 Checking the kick starter
_________________________________________________________________________________________________________________ 311436-10
- Check the gear teeth and bearing of kick starter gear o for damage and wear.
- Change the kick starter gear.
- Check the gear teeth and bearing of intermediate kick starter gear © for damage and wear.
- Change the intermediate kick starter gear.
- Check the gear teeth and contact surface of kick starter ratchet wheel © for damage and wear.
- Change the kick starter ratchet wheel.
- Check the gear teeth and bearing of kick starter shaft o for damage and wear.
- Change the kick starter shaft.
18.5.29 Preassembling the kick starter shaft

Mount bearing o
226
ENGINE 18
Mount kick starter gear © with washer ©
Mount lock ring ©

O
312203-10
Mount kick starter spring ©.

S The end of the kick starter spring engages in the hole.
312204-10
Mount kick starter ratchet wheel ©
© S Align markings © and ©
©
312205-10
Mount spring
18.5.30 Checking the electric starter drive

Condition
Bendix has been removed.
227
18 ENGINE
- Check the gear teeth of rotor o for damage and wear.

- Change the rotor.
- Check the gear teeth and bearing of the Bendix © for smooth operation, damage, and wear.
» If damaged or worn, or if the Bendix does not move easily:
- Change the Bendix.
- Check the gear mesh of starter motor © for damage and wear.
- Change the starter motor.
- Connect the negative cable of a 12-volt power supply to the housing of the starter motor. Connect the posi
tive cable of the power supply briefly with the connector of the starter motor.
» If the starter motor does not turn when the circuit is closed:
228
ENGINE 18
Position the right section of the engine case in the engine

work stand.
Engine work stand (80329001000) (83 p. 346)

Holder and fitting for work stand (55429002000) (83 p. 341)
Warm up the crankshaft bearing.

Guideline
100 °C (212 °F)
Slide crankshaft © all the way into the bearing seat of the
right section of the engine case.
18.6.2 Installing the transmission shafts

Oil all bearings.
Assemble the two transmission shafts o and slide them into

the bearing seats together.
Mount lock ring
18.6.3 Installing the shift forks

Arrange shift forks o © , and © as shown.
B04441-10
229
18 ENGINE
Position shift forks o@ , and © in the sliding gears.
18.6.4 Installing the shift drum

Push shift drum o into the bearing seat.
Position shift forks © in the shift grooves.
Info
Do not misplace the shift rollers.
18.6.5 Installing the shift rails

Mount shift rails
18.6.6 Installing the left engine case section

Coat the sealing area thinly with grease.
Mount engine case gasket O-
Check that dowels 0 are seated correctly.
230
ENGINE 18
Mount the left section of the engine case.
• Info
I Do not use the screws to pull the two sections of the
engine case together.
Mount screws © and, once all screws of the left section of

the engine case have been mounted, tighten.
Guideline
Screw, engine case M6x45 10 Nm (7.4 Ibf ft)
Mount screws Q and, once all screws of the left section of

the engine case have been mounted, tighten.
Guideline
Screw, engine case M6x60 10 Nm (7.4 Ibf ft)
Fix the engine in the engine work stand.

Remove the excess lengths of the engine case gasket in the
area of the cylinder support and the reed valve housing.
Grease the shaft seal ring and mount distance sleeve
18.6.7 Installing the reed valve housing

Position the gasket.
Position reed valve housing o in the engine case opening.
Position the intake flange with the gasket.

Guideline
Screw, intake M6 6 Nm (4.4 Ibf ft)
flange/reed valve
housing
231
18 ENGINE
18.6.8 Installing the starter motor

Grease and mount O-ring ©
Grease O-ring 0
Position the starter motor in the engine case.
Mount screws © but do not tighten yet.

Guideline
Screw, starter motor 10 Nm (7.4 Ibfft)
Mount spacer O flush in the engine case.

Guideline
Screw, starter M6 10 Nm (7.4 Ibfft)
motor bearing Loctite®243™
bush
Tighten screws ©
Guideline
Screw, starter motor 10 Nm (7.4 Ibfft)
232
ENGINE 18
Position cover ©
Mount and tighten screw o
Guideline
Screw, starter motor M6 8 Nm (5.9 Ibf ft)
protection cap
18.6.9 Installing the rotor

Grease and mount Bendix o
Lubricant (T625) (81 p. 336)
Position the crankshaft position sensor.

Guideline
Screw, M5 6 Nm (4.4 Ibf ft)
crankshaft Loctite®243™
position sensor
Ensure that the woodruff key is seated properly.

Grease the cone.
Mount the rotor and hold it with special tool ©
Holding wrench (54629012200) (!! p. 340)
Mount washer and nut O Tighten the nut.

Guideline
Nut, rotor M12x1 60 Nm (44.3 Ibf ft)
18.6.10 Installing the locking lever

Position locking lever o with the sleeve and spring ©
Guideline
Screw, locking M5 6 Nm (4.4 Ibf ft)
lever Loctite®243™
233
18 ENGINE
18.6.11 Installing the shift drum locating unit

Press locking lever O to the left and position the shift drum
locating unit.
• Info
I The flat surfaces Q of the shift drum locating unit are
not symmetric.
Relieve tension from the locking lever.
Mount and tighten screw 0

Guideline
Screw, shift M6 10 Nm (7.4 Ibfft)
drum locating Loctite®243™
18.6.12 Installing the shift shaft

Slide shift shaft o with the washer into the bearing seat.
Push sliding plate © away from shift drum locating unit ©
Insert the shift shaft all the way.
Let the sliding plate engage in the shift drum locating unit.
Shift through the transmission.
18.6.13 Installing the intermediate kick starter gear

Mount intermediate kick starter gear.
Mount lock ring O with washer ©
18.6.14 Installing the kick starter shaft

Preparatory work
- Preassemble the kick starter shaft. (® p. 226)
234
ENGINE 18
Main work
- Mount preassembled kick starter shaft ©
- Tension and attach kick starter spring ©
• Info
I Ensure that the distance from the kick starter spring to
the kick starter shaft is the same all around.
18.6.15 Installing the balancer shaft

Mount balancer shaft o
Mount woodruff key ©.
Mount balancer shaft drive wheel ©
235
18 ENGINE
Mount primary gear ©■

S Align markings Q and ©
Hold the primary gear using special tool ©
Gear segment (56012004000) (IS p. 342)

Guideline
Screw, balancer M8 30 Nm (22.1 Ibfft)
shaft Loctite®243™
Info
Use a new screw for every repair.
18.6.16 Installing the clutch basket

Mount collar bushing ©
Oil and mount needle bearing ©
Slide clutch basket © onto the gearbox main shaft.
Slide on washer © and inner clutch hub ©
236
ENGINE 18
Position the new lock washer and mount nut ©. Tighten the
nut, holding the inner clutch hub with a special tool.
Guideline
Nut, inner Ml 8x1.5 100 Nm (73.8 Ibf ft)
clutch hub Loctite® 648™
Holding wrench (51129003000) ( p. 340)
Secure the nut with the lock washer.
Hold the primary gear using special tool o
Gear segment (56012004000) (S3 p. 342)
Mount and tighten nut © with the washer.

Guideline
Nut, primary Ml 8LHx1.5 150 Nm (110.6 Ibf ft)
gear Loctite® 648™
Crank the engine to ensure that it can move easily.
18.6.17 Installing the clutch discs

- Thoroughly oil the clutch facing discs.
- Mount intermediate clutch disc o with marking S.
Guideline
Thickness of intermediate 1.0 mm (0.039 in)
clutch disc ©
Alternately place the clutch facing and 7 intermediate discs

into the clutch basket.
Guideline
clutch discs
Place intermediate clutch disc © into the clutch basket.

Guideline
clutch disc ©
Mount clutch throw-out o
237
18 ENGINE
- Position pressure cap ®.
Mount pretension ring with marking Top facing up.
Position spring washer ©
Position spring retainer © with marking I.
Mount screws © and tighten in a crisscross pattern.

Guideline
Screw, clutch spring M5 6 Nm (4.4 Ibf ft)
retainer
238
ENGINE 18
Using a straightedge and the special tool, check the spring

washer for distortion.
Feeler gauge (59029041100) ( p. 345)
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.
Feeler gauge (59029041100) (81 p. 345)

0.0039 in)

with marking III.
Feeler gauge (59029041100) (8S p. 345)

0.0039 in)

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

Position the bearing support with the angle lever and linkage.
Guideline
Screw, exhaust M5 6 Nm (4.4 Ibf ft)
control bearing Loctite®243™
support
Mount dowels ©.
Mount clutch cover gasket ©
D04444-11
239
18 ENGINE
Position the clutch cover and thread in the linkage.
Mount screws o but do not tighten yet.

Guideline
Screw, intermediate M6x25 10 Nm (7.4 Ibfft)
clutch cover

Guideline
clutch cover
Mount screws © but do not tighten yet.

Guideline
clutch cover
Mount screw O anc* tighten all screws in a crisscross pat

tern.
Guideline
clutch cover
Mount adjusting spring © with the auxiliary spring and

spring insert.
S The recess O in the spring insert engages in angle
lever ©.
240
ENGINE 18
Position the cap.

Guideline
Screw, exhaust con 5 Nm (3.7 Ibf ft)
trol cap
18.6.19 Installing the water pump cover

Mount dowels o
Mount the molded ring.

Position the water pump cover.
Mount and tighten screws 0
Guideline
Screw, water pump M6 10 Nm (7.4 Ibf ft)
cover
Mount and tighten screw © with the seal ring.

Guideline
Screw, water pump M6 10 Nm (7.4 Ibf ft)
cover
18.6.20 Installing the piston

(All TE 250i)
- Oil the upper conrod bearing and position it in the con
necting rod.
- Position the piston.
S Piston marking o must face the exhaust side.
241
18 ENGINE
- Cover the engine case opening with a cloth.

- Slide piston pin into the connecting rod by hand.
(All TE 300i)
- Oil the upper conrod bearing and position it in the con
necting rod.
- Position the piston.
y Piston marking o must face the exhaust side.
- Cover the engine case opening with a cloth.

- Slide piston pin © into the connecting rod by hand.
Position the piston ring locks in the 6 o'clock or 12 o'clock

position.
Ensure that the piston ring lock is in the correct position on
both sides.
Remove the cloth.
18.6.21 Installing the cylinder

(All TE 250i)
- Place the new cylinder base gasket o into position.
• Info
I If neither the piston, cylinder, crankshaft, or engine
case need to be changed, the same gasket thick
ness can be used as before.
- Oil the cylinder and piston.
242
ENGINE 18
- Position the piston ring.

S The anti-rotation lock engages in piston ring end ©
Slide the cylinder over the piston.

Push the cylinder down carefully.
Mount nuts © on both sides and tighten in a crisscross

pattern.
Guideline
Nut, cylinder base M10 35 Nm (25.8 Ibf ft)
(All TE 300i)
- Place new cylinder base gasket o in position.
• Info
I If neither the piston, cylinder, crankshaft, or engine
case need to be changed, the same gasket thick
ness can be used as before.
- Oil the cylinder and piston.
243
18 ENGINE
Position the piston ring.

y The anti-rotation lock engages in piston ring end ©
Slide the cylinder over the piston.

Push the cylinder down carefully.
Mount nuts © on both sides and tighten in a crisscross

pattern.
Guideline
Nut, cylinder base Ml 0 35 Nm (25.8 Ibf ft)
18.6.22 Checking the X-distance
• Info
I The X-distance is the distance defined for the piston protrusion, when the cylinder is clamped down and
the piston is at top dead center.
The X-distance must be checked very carefully. If the X-distance is too large, the compression
decreases and the engine loses power. If the X-distance is too small, the engine knocks and overheats.
244
ENGINE 18
(All TE 250i)
- Apply special tool o to the cylinder.
Setting gauge (54829001100) (8JS p. 341)
Position the piston at top dead center.

Check the X-distance using the special tool.
Feeler gauge (59029041100) ( p. 345)
X distance (upper edge of 0 ... 0.10 mm (0 ...

piston to upper edge of 0.0039 in)
cylinder)

- Adjust the X-distance. (81 p. 245)
(All TE 300i)
- Apply special tool o to the cylinder.
- Position the piston at top dead center.
- Check the X-distance using the special tool.
Feeler gauge (59029041100) ( p. 345)
X distance (upper edge of 0 ... 0.10 mm (0 ...

piston to upper edge of 0.0039 in)
cylinder)

- Adjust the X-distance. (IS p. 245)
18.6.23 Adjusting the X-distance
• Info
I The X-distance is adjusted by inserting cylinder base gaskets of various thicknesses.
Preparatory work
- Check the X-distance. (81 p. 244)
245
18 ENGINE
Main work
(All TE 250i)
- Remove nuts o
- Replace cylinder base gasket with a cylinder base

gasket of the required X-distance.
• Info
I Multiple cylinder base gaskets can be combined.
(All TE 300i)
- Remove nuts o
246
ENGINE 18
Replace cylinder base gasket © with a cylinder base

gasket of the required X-distance.
• Info
I Multiple cylinder base gaskets can be combined.
Finishing work
- Install the cylinder. (Si p. 242)
18.6.24 Adjusting the Z-distance
• Info
I The Z-distance is the distance from the lower edge of the control flap to the upper edge of the cylinder,
measured in the middle of the exhaust port.
Remove screws o and ©

Remove screws o and © but do not tighten yet.
Guideline
control
Adjust the Z dimension using the depth gauge.

Guideline
Z distance (height of control 49.0 mm (1.929 in)
flap) (All TE 250i)
flap) (All TE 300i)
Move control flap © up and position the depth gauge.
Position stop plate o so it is in contact with retaining

bracket ©
Tighten screws o and ©
Guideline
control
Check the Z dimension.
247
18 ENGINE
Guideline
flap) (All TE 250i)
flap) (All TE 300i)
Mount gasket ©
Push the control flap down all the way to the stop.
Mount ball socket O-
• Info
I The linkage may only be pulled upward slightly.
The control flap must not be swung upward.
Check the movement of the linkage.

Guideline
< 1 mm (< 0.04 in)
» If the linkage is pulled up further:

- Loosen lock nut ©
- Turn the ball socket until the linkage reaches the right
length.
- Tighten the lock nut.
Mount retainer ©
Position the gasket.

Position both covers.
Mount and tighten screws © and ©
Guideline
Screw, exhaust M5 4 Nm (3 Ibf ft)
control cover Loctite® 222™
248
ENGINE 18
18.6.25 Installing the cylinder head

(All TE 250i)
- Mount O-rings o and ©
• Info
I Ensure that the pins are seated correctly.
(All TE 300i)
- Mount O-rings o and 0
Put the cylinder head in place.

Mount screws with the washers and tighten them in a
crisscross pattern.
Guideline
Screw, cylinder head M8 27 Nm (19.9 Ibf ft)
• Info
1 Use new washers.
Mount and tighten spark plug O-

Guideline
Spark plug Ml 4x1.25 25 Nm (18.4 Ibf ft)
249
18 ENGINE
18.6.26 Installing injection valves

Position injection valves on both sides.
Mount and tighten screws o with insulating washers 0
Guideline
Screw, injection M5 3.5 Nm (2.58 Ibf ft)
valve holder Loctite®243™
18.6.27 Installing the kick starter

Position the kick starter.
Mount and tighten screw o with the washer.
Guideline
Screw, kick M8 25 Nm (18.4 Ibf ft)
starter Loctite®2701 ™
18.6.28 Installing the alternator cover

Mount dowels Oand put alternator cover gasket 0 in
place.
250
ENGINE 18
Position the alternator cover.

Guideline
Screw, alternator M6x20 8 Nm (5.9 Ibf ft)
cover

Guideline
Screw, alternator M6x25 8 Nm (5.9 Ibf ft)
cover
18.6.29 Installing the spacer

Before mounting, grease spacer o in area © and
O-ring ©.
Position the O-ring in the cut-out of the spacer.
Grease the shaft seal ring.
Push spacer o with the O-ring onto the countershaft with a

twisting motion.
S The cut-out with the O-ring must face inward.
^ The shaft seal ring rests against the spacer along its
entire circumference.
18.6.30 Installing the gear oil drain plug

Mount and tighten gear oil drain plug o with the magnet
and the new seal ring.
Guideline
Gear oil drain plug Ml 2x1.5 20 Nm (14.8 Ibf ft)
with magnet
251
18 ENGINE
18.6.31 Installing the clutch push rod

Mount clutch push rod
18.6.32 Installing the shift lever

Position the shift lever. Mount and tighten screw o with the
washers.
Guideline
Screw, shift M6 14 Nm (10.3 Ibfft)
lever Loctite®243™
18.6.33 Removing the engine from the engine work stand

- Remove the fitting from the special tool.
Holder and fitting for work stand (55429002000) (EJ p. 341)
Remove the engine from the engine work stand.

4
252
CLUTCH 19
19.1 Checking/correcting the fluid level of the hydraulic clutch
Warning
with the eyes.
Note
• Info
I The fluid level rises with increasing wear of the clutch facing discs.
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not
Move the clutch fluid reservoir mounted on the handlebar to a

Remove screws o
Check the fluid level.
Fluid level below container 4 mm (0.16 in)

rim
» If the level of the fluid does not meet specifications:

- Correct the fluid level of the hydraulic clutch.
Position cover with membrane. Mount and tighten screws.
• Info
with water.
253
19 CLUTCH
19.2 Changing the hydraulic clutch fluid
Warning
with the eyes.
Note
• Info
I Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not
Move the clutch fluid reservoir mounted on the handlebar to a

Remove screws o
Fill bleeding syringe © with the appropriate hydraulic fluid.
Syringe (50329050000) (ffl p. 340)

Brake fluid DOT 4 / DOT 5.1 (P p. 334)
On the slave cylinder, remove the protection cap and bleeder

screw © and mount bleeding syringe ©
254
CLUTCH 19
Now press the fluid into the system until it emerges from the
hole of the master cylinder without bubbles.
Now and then, extract fluid from the master cylinder reservoir
to prevent overflow.
Remove the bleeding syringe. Mount and tighten screws
bleeder screw. Mount the protection cap.
Correct the fluid level of the hydraulic clutch.
Guideline
Fluid level below container 4 mm (0.16 in)
rim
Position cover with membrane. Mount and tighten screws.
• Info
with water.
Danger
Warning
Main work
- Lay the vehicle on its side on the work stand.
Info
Cover the components to protect them against dam
age.
Remaining fuel may flow out of the fuel tank.
19 CLUTCH
Detach spring ©
Remove screws ©
Take off the clutch cover with the gasket.
Loosen screws © in a crisscross pattern and remove them.

Take off spring retainer ©
Take off spring washer ©
Take off pretension ring ©
256
CLUTCH 19
Take off pressure cap O-
Take off clutch throw-out © with clutch push rod ©
Remove sleeves ©
Remove clutch discs © completely.
Bend up the lock washer.

Hold the inner clutch hub with the special tool. Loosen
nut
Holding wrench (51129003000) p p. 340)
Remove the nut with the lock washer.
257
19 CLUTCH
Take off inner clutch hub © and washer ©
• Info
I The washer usually sticks to the inner clutch hub.
Take off clutch basket 0
Take off needle bearing © and collar bushing ©
• Info
I The needle bearing and collar sleeve may be in the
clutch basket.
- Check clutch push rod © for damage and wear.

- Place the clutch push rod © on a flat surface and check for run-out.
- Check spring retainer © for damage and wear.
- Change the spring retainer.
- Check pretension ring © for damage and wear.
- Change the pretension ring.
- Check spring washer © for damage and wear.
258
CLUTCH 19

- Change the spring washer.
- Check the contact surface of pressure cap o for damage and wear.
- Change the pressure cap.
- Check clutch center © for damage and wear.
- Change the clutch center.
- Check damping rubber pieces © for damage and wear.
- Change the damping rubber pieces.
- Check inner clutch hub © for damage and wear.
- Change the inner clutch hub.
- Check the thrust surfaces of the clutch facing discs in clutch basket © for damage and wear.
- Change the clutch facing discs and the clutch basket.
- Check needle bearing © and collar bushing © for damage and wear.
- Change the needle bearings and collar bushing.
- Check intermediate clutch discs © for damage and wear.
» If the intermediate clutch discs are not level and are pitted:
- Change all intermediate clutch discs.
- Check clutch facing discs © for discoloration and scoring.
» If there is discoloration or scoring:
- Change all the clutch facing discs.
- Check the thickness of clutch facing discs ©
Clutch facing disc - thickness > 1.9 mm (> 0.075 in)
» If the clutch facing disc does not meet the specifications:

- Change all the clutch facing discs.
Mount collar bushing © and needle bearing
259
19 CLUTCH
Mount clutch basket ©

S Turn the clutch basket until the gear teeth of the interme
diate kick starter gear mesh.
Mount washer © and inner clutch hub ©.
Position the new lock washer and mount nut © . Tighten the
nut, holding the inner clutch hub with a special tool.
Guideline
Nut, inner Ml 8x1.5 100 Nm (73.8 Ibfft)
clutch hub Loctite® 648™
Holding wrench (51129003000) ( p. 340)
Secure the nut with the lock washer.
Mount sleeves ©.
Oil the clutch facing discs thoroughly.

Mount intermediate clutch disc o with marking S.
Guideline
clutch disc ©
Alternately place the clutch facing and 7 intermediate discs

into the clutch basket.
Guideline
clutch discs
Place intermediate clutch disc © into the clutch basket.

Guideline
clutch disc ©
260
CLUTCH 19
Mount clutch throw-out © with clutch push rod ©
Position pressure cap O-
Mount pretension ring © with marking Top facing up.
Position spring washer ©
Position spring retainer © with marking I.

Mount screws © and tighten in a crisscross pattern.
Guideline
Screw, clutch spring M5 6 Nm (4.4 Ibf ft)
retainer
261
19 CLUTCH

Feeler gauge (59029041100) (H p. 345)

0.0039 in)

with marking II.
Feeler gauge (59029041100) (IS p. 345)

0.0039 in)

with marking III.
Feeler gauge (59029041100) ( p. 345)

0.0039 in)

- Change the clutch facing discs.
Position the clutch cover with the gasket.

Guideline
Screw, intermediate M6 10 Nm (7.4 Ibfft)
clutch cover
Attach spring o
262
CLUTCH 19
Place vehicle in upright position and lean on the side stand.
Finishing work
- Check the gear oil level. ( p. 273)
263
20 WATER PUMP, COOLING SYSTEM
20.1 Cooling system

Water pump O 'n the engine ensures forced circulation of the
coolant.
The pressure resulting from the warming of the cooling system is
regulated by a valve in radiator cap © . This ensures that operat
ing the vehicle at the specified coolant temperature will not result
in a risk of malfunctions.
120 °C (248 °F)
Cooling is effected by the air stream.

The lower the speed, the less the cooling effect. Dirty cooling fins
also reduce the cooling effect.
20.2 Checking the antifreeze and coolant level
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
- Do not open the radiator, the radiator hoses or other cooling system components if the engine or
the cooling system are at operating temperature.
- Allow the cooling system and the engine to cool down before you open the radiator, the radiator
hoses or other components of the cooling system.
- In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is toxic and a health hazard.
- Keep coolant out of the reach of children.
- Do not allow coolant to come into contact with the skin, the eyes and clothing.
- Consult a doctor immediately if coolant is swallowed.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
- Change clothing if coolant spills onto your clothing.
Condition
The engine is cold.
- Stand the motorcycle upright on a horizontal surface.

- Remove the radiator cap.
- Check the antifreeze in the coolant.
-25 ... -45 °C (-13 ... -49 °F)
» If the antifreeze in the coolant does not match the speci

fied value:
- Correct the antifreeze in the coolant.
- Check the coolant level in the radiator.
Coolant level O above the 10 mm (0.39 in)

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

- Correct the coolant level.
Coolant ( p. 334)
- Mount the radiator cap.
264
WATER PUMP, COOLING SYSTEM 20
20.3 Checking the coolant level
Warning
Warning
Condition
The engine is cold.

- Remove the radiator cap.
- Check the coolant level in the radiator.
Coolant level © above the 10 mm (0.39 in)

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

- Correct the coolant level.
Coolant ( p. 334)
- Mount the radiator cap.
20.4 Draining the coolant
Warning
265
Warning
Condition
The engine is cold.
Position the motorcycle upright.

Place a suitable container under the water pump cover.
Remove screw o . Take off radiator cap ©

Completely drain the coolant.
Mount and tighten screw o with a new seal ring.
Guideline
Screw, water pump M6 10 Nm (7.4 Ibfft)
cover
20.5 Refilling with coolant
Warning
Main work
- Make sure that screw o is tightened.
- Position the motorcycle upright.
266
WATER PUMP, COOLING SYSTEM 20
- Pour coolant in up to measurement o above the radiator

fins.
Guideline
radiator fins
Coolant (K8 p. 334)
- Push protection cap © upward over the thermostat.
- Unplug connector ©
- Remove thermostat © with O-ring and wait until the coolant
escapes without bubbles.
- Mount thermostat © with the O-ring and tighten.
Guideline
Screw, cylinder head Ml 0x1.25 12 Nm (8.9 Ibf ft)
temperature sensor
Plug in connector ©
Position the protection cap ©.
- Pour coolant in up to measurement © above the radiator

fins.
Guideline
radiator fins
Coolant (8S p. 334)
- Mount radiator cap ©
Danger
death.
space.
- Allow the engine to warm up and cool down again.
267
Finishing work
- Check the coolant level. (SI p. 265)
268
EXHAUST CONTROL 21
21.1 Checking/adjusting the exhaust control
Danger
death.
space.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
- Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake sys
tem before the vehicle parts have cooled down.
- Let the vehicle parts cool down before you perform any work on the vehicle.
Condition
The diagnostics tool is connected and running.
Preparatory work
- Raise the motorcycle with a lift stand. (iS p. 12)
Main work
- Remove screws ©
- Take off the cover with gasket.
- Position special tool © and mount and tighten screw ©

Guideline
Screw, exhaust con- M5 4 Nm (3 Ibf ft)
trol cover
S Stop is flush with the gear segment.
269
21 EXHAUST CONTROL
Execute "Engine electronics" > "Actuator test" > "Exhaust

control".
Start the motorcycle to check the function. ( p. 13)
Info
Let the engine warm up.
Bring the throttle grip into the full load position.

Check the position of the gear segment with the special tool.
» If the gear segment is below the recess (position O):

- Loosen the adjusting screw with special tool O until
it is flush with the locking cap. Screw in the adjusting
screw until the gear segment is flush with the recess
(position Q)
Socket wrench (55529021000) (BS p. 342)
• Info
I The final adjustment of the adjusting screw
must always be clockwise.
» If the gear segment is above the recess (position Q):

- Screw in the adjusting screw until the gear segment is
flush with the recess (position ©)
Socket wrench (55529021000) (US p. 342)
• Info
I The final adjustment of the adjusting screw
must always be clockwise.
» If the gear segment is flush with the recess (position O)

- The exhaust control is set correctly. No adjustment is
necessary.
(All EU models)
(All US models)
- Stop the "Exhaust control" actuator test by pressing
the "Quit" button.
Remove screw and take off special tool ©
270
EXHAUST CONTROL 21
Position the cover with the gasket.

Guideline
Screw, exhaust M5 4 Nm (3 Ibf ft)
control cover Loctite® 222™
Finishing work
- Remove the motorcycle from the lift stand. (fiS p. 12)
271
22 LUBRICATION SYSTEM
22.1 Changing the gear oil
Warning
Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden.
- Wear suitable protective clothing and safety gloves.
Note
• Info
I Drain the gear oil while the engine is at operating temperature.
Preparatory work
- Remove the engine guard. (iS p. 49)
- Park the motorcycle on a level surface.
- Place a suitable container under the engine.
Main work
- Remove gear oil drain plug O with magnet.
- Let the gear oil drain fully.
- Thoroughly clean the gear oil drain plug with magnet.
- Clean the sealing surface on the engine.
- Mount and tighten gear oil drain plug o with the magnet
and a new seal ring.
Guideline
Gear oil drain plug Ml 2x1.5 20 Nm (14.8 Ibfft)
with magnet
Remove filler plug © with the O-ring, and fill up with gear oil.
Gear oil 0.80 1 Engine oil (15W/50)

(0.85 qt.) (81 p. 334)
- Mount and tighten the filler plug together with the O-ring.
Danger
death.
space.
- Start the engine and check for tightness.
Finishing work
- Check the gear oil level. (81 p. 273)
- Install the engine guard. (U p. 49)
272
LUBRICATION SYSTEM 22
22.2 Checking the gear oil level
• Info
I The gear oil level must be checked when the engine is cold.
Preparatory work
Main work
- Detach the foot brake lever spring.
- Remove screw for checking gear oil level O-
- Check the gear oil level.
A small quantity of gear oil must run out of the drilled hole.
» If no gear oil runs out:

- Add gear oil. (IS p. 273)
- Mount and tighten the gear oil monitoring screw.
Guideline
Screw, gear oil level M6 10 Nm (7.4 Ibf ft)
check
- Attach the foot brake lever spring.
22.3 Adding gear oil
• Info
I Too little gear oil or poor-quality gear oil results in premature wear to the transmission.
Gear oil must only be topped up when the engine is cold.
Preparatory work
- Park the motorcycle on a level surface.
Main work
- Remove screw for checking gear oil level o
- Remove filler plug with the O-ring.

- Add gear oil until it emerges from the drill hole of the gear oil
monitoring screw.
Engine oil (15W/50) (B! p. 334)
Mount and tighten the gear oil monitoring screw.

Guideline
Screw, gear oil level M6 10 Nm (7.4 Ibf ft)
check
- Mount and tighten filler plug 0 with the O-ring.
273
Danger
death.
space.
- Start the engine and check for tightness.
22.4 Checking 2-stroke oil level
Warning
Engine failure The engine will not be lubricated unless there is 2-stroke oil in the oil tank.
If the oil level warning light lights up, the 2-stroke oil is sufficient for the remaining tank of fuel.
- As soon as the oil level warning light lights up, ride for no longer than until the remaining fuel in the
tank is depleted.
- At the next opportunity add 2-stroke oil before you refuel.
- Time the oil pump if the 2-stroke oil hose has been removed or the 2-stroke oil tank has been fully
depleted in error.
Preparatory work
Main work
- Check the 2-stroke oil level in the oil tank.
• Info
I For one tank of fuel, the 2-stroke oil tank must be filled
up to at least the MINmarking ©
The 2-stroke oil tank must be completely if possible.
» If the 2-stroke oil level is too low:

- Add 2-stroke oil. (8S p. 275)
22.5 Opening 2-stroke oil tank cap

Fold loop OuPward-
Turn the 2-stroke oil tank cap counterclockwise and pull it
up.
274
22.6 Closing 2-stroke oil tank cap

Put the 2-stroke oil tank cap on and turn it clockwise.
Fold loop ©down.
y The 2-stroke oil tank cap engages.
22.7 Adding 2-stroke oil
Warning
tank is depleted.
depleted in error.
Open 2-stroke oil tank cap. ( p. 274)
Fill the 2-stroke oil tank up to the lower edge o of the filler
neck.
2-stroke oil tank 0.7 1 (0.7 qt.) Engine oil, 2-stroke

content approx. (m p. 334)
Close 2-stroke oil tank cap. (m p. 275)
22.8 Priming oil pump
Warning
tank is depleted.
depleted in error.
Condition
The engine is off.
Preparatory work
- Remove the air filter box cover. (H p. 96)
275

- Check 2-stroke oil level. ( p. 274)
Main work
- Remove protection cap o of the diagnostics connector.
V00985-10
- Put throttle grip © into full throttle position and secure.
- Plug in wake-up connector © for priming the oil pump to the

diagnostics connector ©
S The combination instrument lighting is activated.
• Info
I The connector is included as part of the motorcycle's
separate enclosure.
- Wait for at least five seconds.

- Release the fixing means from the throttle grip.
S The oil pump is timed.
• Info
I The oil pump is actuated at various speeds.
The procedure is clearly audible.
- Wait until you can no longer hear the oil pump working.
- Disconnect the wake-up connector from the diagnostics con
nector.
- Check whether air bubbles are visible in the hose ©

» If air bubbles are visible:
- Repeat the entire procedure until air bubbles are no
longer visible.
- Mount protection cap on the diagnostics connector.
276
Finishing work
- Mount the seat. (IS p. 101)
- Install the air filter box cover. (El p. 96)
22.9 Changing the oil pump

Condition
Oil tank is empty.
Main work
- Unplug connector o
- Push back hose clamp ©.

- Pull off the tube from the throttle valve body.
Info
Residual oil may escape from the tube.
- Push back hose clamp ©
- Remove screw ©
- Pull off the hose from the oil tank.
Info
Residual oil may escape from the oil tank.
- Remove the oil pump with hoses.

- Position new oil pump with hoses.
- Mount hose on the oil tank.
Guideline
Screw, oil pump M6 7 Nm (5.2 Ibf ft)
277
- Position hose clamp ©
- Mount hose on the throttle valve body.

- Position hose clamp ©.
- Plug in connector o
Finishing work
- Check 2-stroke oil level. ( p. 274)
- Prime the oil pump. (81 p. 275)
- Mount the seat. (U p. 101)
278
IGNITION SYSTEM 23
23.1 Checking the ignition system
Warning
Risk of injury The ignition system is under high voltage.
- To avoid the danger of an electric shock, do not touch metal parts and the ends of the connection
cable during and immediately after measuring.

(All EU models)
- Unplug the spark plug connector and remove it from the igni
tion wire.
- Remove the spark plug.
- Hold the free end of the ignition wire at a distance o from
ground.
Guideline
Distance Q 5 mm (0.2 in)
- Press the kick starter robustly through its full range.
Info
Do not open the throttle.
- Check the ignition spark.

» If no ignition spark is visible:
- Check the emergency OFF switch.
- Check the wiring harness to the emergency OFF
switch.
- Check the kill switch.
- Check the ground connection of the EFI control unit
and ignition coil.
- Check the cable from the EFI control unit to the igni
tion coil.
• Info
I The EFI control unit cannot be tested using
simple methods but only using an ignition test
bench.
- Ignition coil - check the primary winding, (il p. 280)

- Check the crankshaft position sensor. (IS p. 282)
- Check the stator winding of the alternator. (KB p. 281)
Fit spark the plug connector on the ignition wire again. Mount
the spark plug in the spark plug connector. Hold the spark
plug to ground.
Press the kick starter robustly through its full range.
• Info
I Do not open the throttle.
Check the ignition spark.
279
23 IGNITION SYSTEM
» If no ignition spark is visible:

- Check the spark plug connector. (IS p. 281)
- Change the spark plug. ( p. 283)
23.2 Ignition coil - checking the primary winding
Warning
Risk of injury The ignition system is under high voltage.
- To avoid the danger of an electric shock, do not touch metal parts and the ends of the connection
cable during and immediately after measuring.
Condition
Ignition coil cylinder 1 is disconnected.
Ignition coil cylinder 1 - check the primary winding
resistance.
Measure the resistance between the specified
points.
Ignition coil pin 1 (-) - Ignition coil pin 2 (+)
Ignition coil
Primary winding resis- 0.337 ... 0.412 Q
tance at: 20 °C (68 °F)
» If the displayed value does not correspond to the

nominal value:
- Change the ignition coil.
Condition
Ignition coil cylinder 1 is connected.
- Connect the special tool to the multimeter.
Peak voltage adapter (58429042000) (61 p. 343)
• Info
I When using the peak voltage adapter, adjust the
measuring range of the multimeter to DCV.
- Start the motorcycle to check the function. ( p. 13)

Ignition coil cylinder 1 - check the primary winding voltage.
Measure the voltage between the specified points.
Ignition coil pin 1 (-) - Ignition coil pin 2 (+)
• Info
I Connect the black measuring lead to pin 2 and the
red measuring lead to pin 1 of the ignition coil.
Ignition coil
Voltage, primary wind 200 ... 250 V
ing
» If the displayed value does not correspond to the

nominal value:
- Change the ignition coil.
280
IGNITION SYSTEM 23
23.3 Checking the spark plug connector

Condition
Spark plug connector cylinder 1 has been removed.
Measure the resistance between the specified points.

Measuring point 1 - Measuring point 2
Spark plug connector

Resistance at: 20 °C 4.3 ... 5.7 kQ
(68 °F)

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

Condition
The stator is disconnected.
Preparatory work
- Remove the air filter box cover. (US p. 96)
Main work
Stator winding measurement I - check the resistance.
Stator, connector EZ pin 1 - Stator, connector EZ pin
Alternator
Stator winding resis 0.368 ... 0.552 Q
tance at: 20 °C (68 °F)
» If the indicated value does not correspond to the setpoint

value:
- Change the stator.
Stator winding measurement II - check the resistance.
Stator, connector EZ pin 1 - Stator, connector EZ pin
3
Alternator
Stator winding resis 0.368 ... 0.552 Q
tance at: 20 °C (68 °F)
» If the indicated value does not correspond to the setpoint

value:
281
23 IGNITION SYSTEM
Stator winding - checking the short circuit to ground (terminal 31).

Stator, connector EZ pin 1 - Measuring point Ground (-)
» If the indicated value does not correspond to the setpoint value:

Finishing work
- Mount the seat. (81 p. 101)
- Install the air filter box cover. ( I p. 96)
23.5 Checking the crankshaft position sensor

Condition
Crankshaft speed sensor is disconnected.

Crankshaft position sensor, connector AT pin 1 -
Crankshaft position sensor, connector AT pin 2
Crankshaft speed sensor

Resistance at: 20 °C 80 ... 120 Q
(68 °F)

- Change the crankshaft position sensor.

Crankshaft position sensor, connector AT pin 1 - Measuring point Ground (-)
Resistance 00 Cl

- Change the crankshaft position sensor.
- Connect the special tool to the multimeter.
282
IGNITION SYSTEM 23
Peak voltage adapter (58429042000) (El p. 343)
• Info
I When using the peak voltage adapter, adjust the measuring range of the multimeter to DCV.
- Start the motorcycle to check the function. ( p. 13)
Check the crankshaft position sensor voltage.

Measure the voltage between the specified points,
Crankshaft position sensor, connector AT pin 1 -
Crankshaft position sensor, connector AT pin 2
Crankshaft speed sensor

Voltage at starting 2 ... 4 V
engine speed

- Change the crankshaft position sensor,
23.6 Changing the spark plug

Disconnect spark plug connector o
Remove spark plug © using a suitable tool.

Mount and tighten the new spark plug using a suitable tool.
Guideline
Plug in spark plug connector
283
23 IGNITION SYSTEM
23.7 Changing the spark plug and spark plug connector

Disconnect spark plug connector o
Remove spark plug © using a suitable tool.

Mount and tighten the new spark plug using a suitable tool.
Guideline
Spark plug M14x1.25 25 Nm (18.4 Ibfft)
Remove spark plug connector o

Mount new spark plug connector o
Plug in spark plug connector
23.8 Removing the stator

Condition
The alternator cover has been removed.
284
IGNITION SYSTEM 23
Remove screws ©
Remove retaining bracket ©
Remove cable sleeve © from the alternator cover.
Remove the stator from the alternator cover.
23.9 Installing the stator

Position the stator in the alternator cover.
Position cable sleeve o in the alternator cover.
Guideline
Screw, stator M5 6 Nm (4.4 Ibf ft)
Loctite®243™
Mount retaining bracket ©
285
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 with the connector of the starter
motor.
» If the starter motor does not turn when the circuit is
closed:
286
THROTTLE VALVE BODY 25
25.1 Adjusting the idle speed
Warning
Danger of accidents The engine may go out spontaneously if the idle speed is set too low.
- Set the idle speed to the specified value.
Run the engine until warm.

S The cold start button is deactivated - A further 14 turn
returns the cold start button back to the basic position.
(IS p. 288)
Danger
death.
space.
- Adjust the idle speed by turning idle speed adjusting

screw o
Guideline
Idle speed 1,400 ... 1,500 rpm
Tachometer (45129075000) (1i p. 339)
• Info
I Turn clockwise to decrease the idle speed.
Turn counterclockwise to increase the idle speed.
Make the setting in small steps.
An incorrect idle speed can have a negative impact on
overall engine running.
25.2 Programming ambient pressure
Danger
death.
space.
287
25 THROTTLE VALVE BODY
• Info
I If the vehicle is ridden with the engine running at various heights above sea level, the ambient pressure
is programmed on an ongoing basis.
If the vehicle is transported over great differences in height, the ambient pressure must be
reprogrammed.
Start the vehicle at the new height above sea level and switch
off the engine again.
Wait for at least five seconds.
Start the vehicle again and check the response of the vehicle.
» If the response has not improved:
- Repeat procedure.
25.3 Cold start button

The cold start button o
is fitted on the side of the throttle valve
body.
The injection system extends the injection time if the engine is
cold and the outside temperature is low. To help the engine burn
the increased amount of fuel, it must be supplied with additional
oxygen by pulling the cold start button.
• Info
I If the engine is warm, the cold start button must be deac
tivated.
Possible states
• The cold start button is activated - The cold start button is
pulled out all the way and turned by a % turn.
• The cold start button is deactivated - A further !A turn
returns the cold start button back to the basic position.
288
TECHNICAL DATA 26
Design 1-cylinder 2-stroke engine, water-cooled, with reed

intake, exhaust control and transfer duct injection
Displacement 249 cm3 (15.19 cu in)
Stroke 72 mm (2.83 in)
Hole 66.4 mm (2.614 in)
Exhaust valve, beginning of adjustment 5,500 rpm
Crankshaft bearing 1 grooved ball bearing/1 roller bearing
Conrod bearing Needle bearing
Piston pin bearing Needle bearing
Piston Cast aluminum
Piston rings 2 half keystone rings
X distance (upper edge of piston to upper edge of 0 ... 0.10 mm (0 ... 0.0039 in)
cylinder)
Z distance (height of control flap) 49.0 mm (1.929 in)
Primary transmission 26:73
Clutch Multidisc clutch in oil bath/hydraulically activated
Transmission 6-gear, claw shifted
Transmission ratio
First gear 14:32
Second gear 16:26
Third gear 20:25
Fourth gear 22:23
Fifth gear 25:22
Sixth gear 26:20
Ignition system Contactless controlled, fully electronic ignition with
digital ignition adjustment, type Continental
Spark plug NGKZGR7G1
Spark plug electrode gap 1.3 mm (0.051 in)
Starting aid Kick starter and electric starter
26.1.2 All TE 300i

Design 1-cylinder 2-stroke engine, water-cooled, with reed
intake, exhaust control and transfer duct injection
Displacement 293.2 cm3 (17.892 cu in)
Stroke 72 mm (2.83 in)
Hole 72 mm (2.83 in)
Exhaust valve, beginning of adjustment 5,500 rpm
Crankshaft bearing 1 grooved ball bearing/1 roller bearing
Conrod bearing Needle bearing
Piston pin bearing Needle bearing
Piston Cast aluminum
Piston rings 2 rectangular rings
289
26 TECHNICAL DATA
X distance (upper edge of piston to upper edge of 0 ... 0.10 mm (0 ... 0.0039 in)
cylinder)
Z distance (height of control flap) 49.5 mm (1.949 in)
Primary transmission 26:73
Clutch Multidisc clutch in oil bath/hydraulically activated
Transmission 6-gear, claw shifted
Transmission ratio
First gear 14:32
Second gear 16:26
Third gear 20:25
Fourth gear 22:23
Fifth gear 25:22
Sixth gear 26:20
Ignition system Contactless controlled, fully electronic ignition with
digital ignition adjustment, type Continental
Spark plug NGKZGR 7 G1
Spark plug electrode gap 1.3 mm (0.051 in)
Starting aid Kick starter and electric starter
26.2 Tolerance, engine wear limits
26.2.1 All TE 250i

Piston - diameter
Sizel 66.340 ... 66.350 mm (2.61181 ... 2.6122 in)
Size II 66.351 ... 66.360 mm (2.61224 ... 2.61259 in)
Piston/cylinder - mounting clearance
New condition 0.050 ... 0.074 mm (0.00197 ... 0.00291 in)
Ring 1 < 0.40 mm (< 0.0157 in)
Ring 2 < 0.40 mm (< 0.0157 in)
Connecting rod - axial play of lower conrod bearing 0.60 ... 0.70 mm (0.0236 ... 0.0276 in)
Crankshaft - run-out at bearing pin < 0.03 mm (< 0.0012 in)
Clutch facing disc - thickness >1.9 mm (> 0.075 in)
Thrust surface, clutch facing discs in clutch basket < 0.5 mm (< 0.02 in)
Shift shaft - sliding plate/shift quadrant play 0.40 ... 0.80 mm (0.0157 ... 0.0315 in)
Cylinder - drill hole diameter
Size 1 66.400 ... 66.412 mm (2.61417 ... 2.61464 in)
Size II 66.412 ... 66.425 mm (2.61464 ... 2.61515 in)
Cylinder/cylinder head - distortion of sealing surface < 0.10 mm (< 0.0039 in)
26.2.2 All TE 300i

Piston - diameter
Size 1 71.940 ... 71.950 mm (2.83228 ... 2.83267 in)
Size II 71.951 ... 71.960 mm (2.83271 ... 2.83307 in)
290
TECHNICAL DATA 26
Piston/cylinder - mounting clearance

New condition 0.050 ... 0.085 mm (0.00197 ... 0.00335 in)
Ring 1 < 0.40 mm (< 0.0157 in)
Ring 2 < 0.40 mm (< 0.0157 in)
Connecting rod - axial play of lower conrod bearing 0.60 ... 0.70 mm (0.0236 ... 0.0276 in)
Crankshaft - run-out at bearing pin < 0.03 mm (< 0.0012 in)
Clutch facing disc - thickness >1.9 mm (> 0.075 in)
Thrust surface, clutch facing discs in clutch basket < 0.5 mm (< 0.02 in)
Shift shaft - sliding plate/shift quadrant play 0.40 ... 0.80 mm (0.0157 ... 0.0315 in)
Cylinder - drill hole diameter
Size 1 72.000 ... 72.012 mm (2.83464 ... 2.83511 in)
Size II 72.012 ... 72.025 mm (2.83511 ... 2.83562 in)
Cylinder/cylinder head - distortion of sealing surface < 0.10 mm (< 0.0039 in)
26.3 Engine tightening torques
Screw, inner membrane sheets EJOTDELTA PT® 35x25 1 Nm (0.7 Ibf ft)
Screw, membrane support plate EJOTDELTA PT® 30x12 1 Nm (0.7 Ibf ft)
Screw, outer membrane sheets EJOTDELTA PT® 30x6 1 Nm (0.7 Ibf ft)
Screw, angle lever, exhaust con M5 6 Nm (4.4 Ibf ft)
trol Loctite®243™
Screw, bearing retainer M5 7 Nm (5.2 Ibf ft)
Loctite®243™
Screw, clutch spring retainer M5 6 Nm (4.4 Ibf ft)
Screw, crankshaft position sensor M5 6 Nm (4.4 Ibf ft)
Loctite®243™
Screw, exhaust control bearing M5 6 Nm (4.4 Ibf ft)
support Loctite®243™
Screw, exhaust control cap M5 5 Nm (3.7 Ibf ft)
Screw, exhaust control cover M5 4 Nm (3 Ibf ft)
Loctite® 222™
Screw, injection valve holder M5 3.5 Nm (2.58 Ibf ft)
Loctite®243™
Screw, locking lever M5 6 Nm (4.4 Ibf ft)
Loctite®243™
Screw, retaining bracket of M5 7 Nm (5.2 Ibf ft)
exhaust control Loctite®2701 ™
Screw, stator M5 6 Nm (4.4 Ibf ft)
Loctite®243™
Cap nut, water pump impeller M6 6 Nm (4.4 Ibf ft)
Loctite®243™
Screw, alternator cover M6 8 Nm (5.9 Ibf ft)
Screw, clutch slave cylinder M6 10 Nm (7.4 Ibf ft)
Screw, control flap, exhaust con M6 10 Nm (7.4 Ibf ft)
trol Loctite®243™
Screw, engine case M6 10 Nm (7.4 Ibf ft)
291
26 TECHNICAL DATA
Screw, exhaust flange M6 8 Nm (5.9 Ibf ft)

Screw, gear oil level check M6 10 Nm (7.4 Ibf ft)
Screw, intake flange/reed valve M6 6 Nm (4.4 Ibf ft)
housing
Screw, intermediate clutch cover M6 10 Nm (7.4 Ibf ft)
Screw, intermediate kick starter M6 10 Nm (7.4 Ibf ft)
gear Loctite®243™
Screw, kick starter stop plate M6 10 Nm (7.4 Ibf ft)
Loctite®243™
Screw, outer clutch cover M6 8 Nm (5.9 Ibf ft)
Screw, shift drum locating M6 10 Nm (7.4 Ibf ft)
Loctite®243™
Screw, shift lever M6 14 Nm (10.3 Ibf ft)
Loctite®243™
Screw, starter motor M6 10 Nm (7.4 Ibf ft)
Screw, starter motor bearing bush M6 10 Nm (7.4 Ibf ft)
Loctite®243™
Screw, starter motor protection M6 8 Nm (5.9 Ibf ft)
cap
Screw, vacuum connections M6 8 Nm (5.9 Ibf ft)
Loctite®2701 ™
Screw, water pump cover M6 10 Nm (7.4 Ibf ft)
Screw, balancer shaft M8 30 Nm (22.1 Ibf ft)
Loctite®243™
Screw, cylinder head M8 27 Nm (19.9 Ibf ft)
Screw, kick starter M8 25 Nm (18.4 Ibf ft)
Loctite®2701 ™
Nut, cylinder base M10 35 Nm (25.8 Ibf ft)
Screw, drive chain engine M10 60 Nm (44.3 Ibf ft)
sprocket Loctite®2701 ™
Stud, cylinder base M10 25 Nm (18.4 Ibf ft)
Loctite®243™
Screw, cylinder head temperature Ml 0x1.25 12 Nm (8.9 Ibf ft)
sensor
Nut, rotor Ml 2x1 60 Nm (44.3 Ibf ft)
Gear oil drain plug with magnet Ml 2x1.5 20 Nm (14.8 Ibf ft)
Nut, inner clutch hub Ml 8x1.5 100 Nm (73.8 Ibf ft)
Loctite® 648™
Nut, primary gear M18LHx1.5 150 Nm (110.6 Ibf ft)
Loctite® 648™
292
TECHNICAL DATA 26
26.4.1 Gear oil

Gear oil 0.80 I (0.85 qt.) Engine oil (15W/50) ( p.334)
26.4.2 Engine oil

2-stroke oil tank content approx. 0.7 I (0.7 qt.) Engine oil, 2-stroke ( p. 334)
26.4.3 Coolant
Coolant 1.2 I (1.3 qt.) Coolant ( p. 334)
Total fuel tank capacity, approx. 9 I (2.4 US gal) Super unleaded (ROZ 95/RON
95/PON 91) p p. 335)
Fuel reserve, approx. 1.5 I (1.6 qt.)
26.5 Chassis
Frame Central tube frame made of chrome molybdenum

steel tubing
Fork WP SuspensionXplor 48 PA
Suspension travel
front 300 mm (11.81 in)
rear 330 mm (12.99 in)
Fork offset 22 mm (0.87 in)
Shock absorber WP Suspension 5018 DCC Link
Brake system Disc brakes, brake calipers on floating bearings
Brake discs - diameter
front 260 mm (10.24 in)
rear 220 mm (8.66 in)
Brake discs - wear limit
front 2.5 mm (0.098 in)
rear 3.5 mm (0.138 in)
Tire air pressure, road (All EU models)
Tire air pressure, off-road
Secondary ratio (All EU models) 14:50 (13:50)
Secondary ratio (All US models) 13:50
Chain 5/8 x1/4"
Rear sprockets available 48, 50, 52
Steering head angle 63.5°
Wheelbase 1,495 ± 10 mm (58.86 ± 0.39 in)
293
26 TECHNICAL DATA
Seat height unloaded 960 mm (37.8 in)

Ground clearance unloaded 370 mm (14.57 in)
Weight without fuel approx. (TE 250i EU) 107.6 kg (237.2 lb.)
Weight without fuel approx. (TE 250i US) 105.2 kg (231.9 lb.)
Weight without fuel approx. (TE 300i EU) 107.8 kg (237.7 lb.)
Weight without fuel approx. (TE 300i US) 105.4 kg (232.4 lb.)
Maximum permissible front axle load 145 kg (320 lb.)
Maximum permissible rear axle load 190 kg (419 lb.)
Maximum permissible overall weight 335 kg (739 lb.)
26.6 Electrical system
Battery HJTZ5S-FP-C Lithium-ion battery

Battery voltage: 12 V
Nominal capacity: 2.0 Ah
Maintenance-free
Combination instrument battery CR 2032 Battery voltage: 3 V
Fuse 75011088005 5A
Fuse 75011088010 10 A
Fuse 58011109120 20 A
Headlight HS1/socket BX43t 12 V
35/35 W
Position light W5W/socket W2.1x9.5d 12 V
5W
Indicator lamps W2.3W / socket W2x4.6d 12 V
2.3 W
Turn signal (All EU models) RIOW/socket BA15s 12 V
10W
Brake/tail light LED
License plate lamp (All EU mod LED
els)
26.7 Tires
Validity Front tire Rear tire

(All EU models) 90/90 - 21 M/C 54M M+S TT 140/80 - 18 M/C 70M M+S TT
Metzeler MCE 6 DAYS EXTREME Metzeler MCE 6 DAYS EXTREME
(All US models) 90/90 - 21 54M TT 110/100- 18 64MTT
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
294
TECHNICAL DATA 26
26.8 Fork
Fork article number 14.15.8S.63

Fork WP SuspensionXplor 48 PA
Compression damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Rebound damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Comfort +0
Standard +0
Sport +3
Spring length with preload spacer(s) 474 mm (18.66 in)
Spring rate
Weight of rider: 65 ... 75 kg (143 ... 165 lb.) 4.0 N/mm (22.8 Ib/in)
Weight of rider: 75 ... 85 kg (165 ... 187 lb.) 4.2 N/mm (24 Ib/in)
Weight of rider: 85 ... 95 kg (187 ... 209 lb.) 4.4 N/mm (25.1 Ib/in)
Fork length 928 mm (36.54 in)
Fork oil per fork leg 642 ± 10 ml (21.71 ± 0.34 fl. oz.) Fork oil (SAE 4) (48601166S1)
p p. 335)
26.9 Shock absorber
Shock absorber article number 18.15.7S.69

Shock absorber WP Suspension 5018 DCC Link
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Comfort 2.5 turns
Standard 2 turns
Sport 1.5 turns
Rebound damping
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Spring preload 14 mm (0.55 in)
Spring rate
Weight of rider: 65 ... 75 kg (143 ... 165 lb.) 45 N/mm (257 Ib/in)
295
26 TECHNICAL DATA
Spring length 260 mm (10.24 in)

Static sag 35 mm (1.38 in)
Riding sag 110 mm (4.33 in)
Fitted length 477 mm (18.78 in)
Shock absorber fluid (US p. 335) SAE 2.5
26.10 Chassis tightening torques
Remaining screws, chassis EJOT PT® K60x25-Z 2 Nm (1.5 Ibf ft)

Screw, fuel pump EJOT PT® 2.3 Nm (1.7 Ibf ft)
Screw, intake air temperature sen EJOTDELTA PT® 45x12-Z 0.7 Nm (0.52 Ibf ft)
sor
Screw, oil fill level sensor G 3/4 11 7 Nm (5.2 Ibf ft)
Screw, seat fixing EJOT EJOFORM PT® K60x23/18 2.5 Nm (1.84 Ibf ft)
Screw, fixed grip M4 5 Nm (3.7 Ibf ft)
Loctite®243™
Spoke nipple, front wheel M4.5 6 Nm (4.4 Ibf ft)
Spoke nipple, rear wheel M4.5 6 Nm (4.4 Ibf ft)
Remaining nuts, chassis M5 5 Nm (3.7 Ibf ft)
Remaining screws, chassis M5 5 Nm (3.7 Ibf ft)
Screw, battery terminal M5 2.5 Nm (1.84 Ibf ft)
Screw, shock absorber adjusting M5 5 Nm (3.7 Ibf ft)
ring
Nut, starter motor M6 4 Nm (3 Ibf ft)
Remaining nuts, chassis M6 10 Nm (7.4 Ibf ft)
Screw, absorbing element on M6 6 Nm (4.4 Ibf ft)
frame
Screw, absorbing element on M6 6 Nm (4.4 Ibf ft)
manifold
Screw, ball joint of push rod on M6 10 Nm (7.4 Ibf ft)
foot brake cylinder Loctite®243™
Screw, chain sliding guard M6 14 Nm (10.3 Ibf ft)
Loctite®243™
Screw, front brake disc M6 14 Nm (10.3 Ibf ft)
Loctite®243™
Screw, oil pump M6 7 Nm (5.2 Ibf ft)
Screw, oil pump holder on oil tank M6 6 Nm (4.4 Ibf ft)
Screw, rear brake disc M6 14 Nm (10.3 Ibf ft)
Loctite®243™
Screw, throttle grip M6 5 Nm (3.7 Ibf ft)
Fuel connection on fuel pump M8 10 Nm (7.4 Ibf ft)
Nut, foot brake lever M8 15 Nm (11.1 Ibf ft)
Nut, foot brake lever stop M8 20 Nm (14.8 Ibf ft)
Nut, pull switch (All US models) M8 0.4 Nm (0.3 Ibf ft)
Nut, rear sprocket screw M8 35 Nm (25.8 Ibf ft)
Loctite®2701 ™
296
TECHNICAL DATA 26
Nut, rim lock M8 12 Nm (8.9 Ibfft)

Remaining nuts, chassis M8 25 Nm (18.4 Ibfft)
Remaining screws, chassis M8 25 Nm (18.4 Ibfft)
Screw, bottom triple clamp M8 15 Nm (11.1 Ibfft)
Screw, chain sliding piece M8 15 Nm (11.1 Ibfft)
Screw, engine brace M8 25 Nm (18.4 Ibfft)
Loctite®2701 ™
Screw, fork stub M8 15 Nm (11.1 Ibfft)
Screw, front brake caliper M8 25 Nm (18.4 Ibfft)
Loctite®243™
Screw, handlebar clamp M8 20 Nm (14.8 Ibfft)
Screw, side stand attachment M8 35 Nm (25.8 Ibfft)
Loctite®2701 ™
Screw, subframe M8 30 Nm (22.1 Ibf ft)
Loctite®2701 ™
Screw, top steering stem M8 17 Nm (12.5 Ibfft)
Loctite®243™
Screw, top triple clamp M8 17 Nm (12.5 Ibfft)
Engine bracket screw M10 60 Nm (44.3 Ibf ft)
Remaining nuts, chassis M10 45 Nm (33.2 Ibfft)
Screw, bottom shock absorber M10 60 Nm (44.3 Ibf ft)
Loctite®2701 ™
Screw, handlebar support M10 40 Nm (29.5 Ibfft)
Loctite®243™
Screw, top shock absorber M10 60 Nm (44.3 Ibf ft)
Loctite®2701 ™
Nut, fuel pump fixation M12 15 Nm (11.1 Ibfft)
Nut, angle lever on swingarm Ml 4x1.5 80 Nm (59 Ibf ft)
Nut, linkage lever on angle lever Ml 4x1.5 80 Nm (59 Ibfft)
Nut, rear wheel spindle M20x1.5 80 Nm (59 Ibf ft)
Screw, front wheel spindle M20x1.5 35 Nm (25.8 Ibfft)
Screw, top steering head M20x1.5 12 Nm (8.9 Ibfft)
Screw-in nozzles, cooling system M20x1.5 12 Nm (8.9 Ibfft)
Loctite®243™
297
27 CLEANING, CARE
27.1 Cleaning the motorcycle
Note
Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly.
The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc.
Pressure which is too high causes malfunctions and destroys components.
- Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.
- Maintain a minimum distance between the nozzle of the pressure cleaner and the component.
Minimum clearance 60 cm (23.6 in)
Note
• Info
I To maintain the value and appearance of the motorcycle over a long period, clean it regularly.
Avoid direct sunshine when cleaning the motorcycle.
Close off the exhaust system to keep water from entering.

Remove coarse dirt particles with a gentle water jet.
Spray heavily soiled parts with a normal commercial motorcy
cle cleaner and then brush off with a soft brush.
Motorcycle cleaner (IS p. 337)
• Info
I Use warm water containing normal motorcycle cleaner
and a soft sponge.
Never apply motorcycle cleaner to a dry vehicle;
always rinse the vehicle with water first.
After rinsing the motorcycle with a gentle spray of water,

allow it to dry thoroughly.
Remove the closure of the exhaust system.
Warning
Danger of accidents Moisture and dirt impair the
brake system.
- Brake carefully several times to dry out and
remove dirt from the brake linings and the brake
discs.
- After cleaning, ride the vehicle a short distance until the

engine warms up.
• Info
I The heat produced causes water at inaccessible loca
tions in the engine and on the brake system to evapo
rate.
298
CLEANING, CARE 27
- After the motorcycle has cooled down, lubricate all moving

parts and pivot points.
- Clean the chain. ( p. 127)
- Treat bare metal (except for brake discs and the exhaust sys
tem) with a corrosion inhibitor.
Preserving materials for paints, metal and rubber

(IS p. 337)
- Treat all plastic parts and powder-coated parts with a mild
cleaning and care product.
Special cleaner for glossy and matte paint finishes, metal

and plastic surfaces (EJS p. 337)
(All EU models)
- Oil the steering lock.
Universal oil spray (IS p. 337)
27.2 Checks and maintenance steps for winter operation
• Info
I If you use the motorcycle in winter, salt can be expected on the roads. You should therefore take pre
cautions against aggressive road salt.
If the vehicle has been used on salted roads, use cold water for cleaning after riding. Warm water
enhances the corrosive effects of salt.
Clean the motorcycle. ( p. 298)

Clean the brakes.
• Info
I After EVERY trip on salted roads, thoroughly wash
the cool and installed brake calipers and brake linings
with cold water and dry carefully.
After riding on salted roads, thoroughly wash the vehi
cle with cold water and dry it well.
Treat the engine, the swingarm, and all other bare or galva
nized parts (except brake discs) with a wax-based corrosion
inhibitor.
• Info
I Corrosion inhibitor is not permitted to come in contact
with the brake discs as this would greatly reduce the
braking force.
- Clean the chain. (US p. 127)
299
28 STORAGE
28.1 Storage
Warning
• Info
I If you plan to garage the motorcycle for a longer period, perform the following steps or have them per
formed.
Before storing the motorcycle, check all parts for function and wear. If service, repairs, or replacements
are necessary, you should do this during the storage period (less workshop overload). In this way, you
can avoid long workshop waiting times at the start of the new season.
Clean the motorcycle. ( p. 298)

Change the gear oil. (IS p. 272)
Check the antifreeze and coolant level. (IS p. 264)
When refueling for the last time before taking the motorcycle
out of service, add fuel additive.
Refuel.
Check the tire air pressure, (S® p. 117)
Remove the battery. (® p. 140)
Recharge the battery.
Guideline
Storage temperature of bat 0 ... 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
I Husqvarna Motorcycles recommends raising the
motorcycle.

- Cover the vehicle with a tarp or similar cover that is perme
able to air.
300
STORAGE 28
• Info
I Do not use non-porous materials since they prevent
humidity from escaping, thus causing corrosion.
Avoid running the engine for a short time only.
Because the engine will not warm up sufficiently,
the water vapor produced during combustion will
condense, causing engine parts and the exhaust
system to rust.
28.2 Preparing for use after storage

Remove the motorcycle from the lift stand. ( p. 12)
Install the battery. ( p. 141)
Perform checks and maintenance measures when preparing
for use.
Make a test ride.
301
29 SERVICE SCHEDULE
29.1 Additional information

Any further work that results from the compulsory work or from the recommended work must be ordered sepa
rately and invoiced separately.
Different service intervals may apply in your country, depending on the local operating conditions.
Individual service intervals and scopes may change in the course of technical developments. The most up-
to-date service schedule can always be found on Husqvarna Motorcycles Dealer.net. Your authorized Husq-
varna Motorcycles dealer will be glad to advise you.
29.2 Required work
Every 10 operating hours when used for motorsports

Every 40 operating hours
Once after 5 operating hours
Once after 1 operating hour
Read out the fault memory using the Husqvarna Motorcycles diagnostics tool. O o • • •
Check that the electrical system is functioning properly. O • • •
Check and charge the battery. • • •
Check the front brake linings. (ES p. 146) • • •
Check the brake linings of the rear brake. (El p. 153) • • •
Check the brake discs. (HI p. 119) • • •
Check the brake lines for damage and leakage. • • •
Check the rear brake fluid level. (E8 p. 157) • • •
Check the free travel of the foot brake lever. (ES p. 156) • • •
Check the frame. (El p. 49) • • •
Check the swingarm. (ES p. 81) • • •
Check the swingarm bearing for play. (El p. 81) • •
Check the heim joint for play. (El p. 88) • •
Check the shock absorber linkage. (ES p. 61) • •
Check the tire condition. (El p. 117) O • • •
Check the tire air pressure. (8JS p. 117) O • • •
Check the wheel bearing for play. (U p. 118) • • •
Check the wheel hubs. • • •
Check the rim run-out. (ES p. 120) O • •
Check the spoke tension. (ES p. 119) O • • •
Check the chain, rear sprocket, engine sprocket, and chain guide. (ES p. 128) • • •
Check the chain tension. (ES p. 128) O • • •
Grease all moving parts (e.g. side stand, hand lever, chain, etc.) and check for smooth • • •
operation.
Check/correct the fluid level of the hydraulic clutch. ( p. 253) • • •
Check the front brake fluid level, (ill p. 149) • • •
Check the free travel of the hand brake lever. ( p. 148) • • •
Check the play of the steering head bearing. (ES p. 41) O • • •
Change the spark plug and spark plug connector. (IS p. 284) •
Check the reed valve housing, reed valve, and intake flange. ( p. 213) • •
Change the gear oil. (ES p. 272) o •
302
SERVICE SCHEDULE 29

Once after 1 operating hour
Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, O • • •
leaks, and incorrect routing.

Check the antifreeze and coolant level. (P p. 264) O • • •
Check the cables for damage and for routing without kinks. • • •
Check that the throttle cables are undamaged, routed without sharp bends, and set O • • •
correctly.
Clean the air filter and air filter box. (88 p. 97) • • •
Change glass fiber yarn filling in the main silencer. (81 p. 94) • •
Service the fork. (IS p. 20) •
Service the shock absorber. (8JS p. 63) •
Check the screws and nuts for tightness. O • • •
Change the fuel screen. (88 p. 107) O • • •
Check the fuel pressure. (IB p. 105) • • •
Check the headlight setting. (81 p. 165) o • • •
Check idle. • • •
Final check: Check the vehicle for operating safety and take a test ride. o o • • •
Read out the fault memory after the test ride using the Husqvarna Motorcycles diag o o • • •
nostics tool.
Make the service entry in the Husqvarna Motorcycles Dealer.net and in the Service o o • • •
and Warranty Booklet.
o One-time interval
• Periodic interval
29.3 Recommended work

Annually
Change the front brake fluid. ( p. 151)
Change the rear brake fluid. (81 p. 158)
Change the hydraulic clutch fluid. (81 p. 254)
Grease the steering head bearing. (88 p. 37)
Clean the pressure sensor hose. ( p. 168)
Service the fork. (8! p. 20) o
Service the shock absorber. (0 p. 63) o
Check the electric starter drive. (El p. 227)

Change the fuel filter. (El p. 108)
Change the piston and check the cylinder.
303
29 SERVICE SCHEDULE

Annually
Change the oil pump. (8S p. 277) •
Perform minor engine service. (Check the exhaust control for functioning and • • • •
smooth operation. Check the clutch.)
Perform major engine service including removing and installing engine. • •
(Change the connecting rod, conrod bearing, and crank pin. Clean the
pressure sensor cylinder connection. Check the transmission and shift
mechanism. Change all engine bearings.)
o One-time interval
• Periodic interval
304
SERVICE SCHEDULE 29
305
30 WIRING DIAGRAM
30.1 Page 1 of 8 (All EU models)

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WIRING DIAGRAM 30
Components:
A11 EFI control unit
G10 Battery
K10 Starter relay with main fuse
Ml 0 Electric starter system
S21 E-tip switch
307
30 WIRING DIAGRAM
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308
WIRING DIAGRAM 30
Components:
F2 Fuse
F3 Fuse
G20 Alternator
K12 Light relay
K30 Power relay
T20 Voltage regulator
X285 Radiator fan connector
X295 Diagnostics connector
309
30 WIRING DIAGRAM
310
WIRING DIAGRAM 30
Components:
El 3 Low beam, high beam
PI 3 Speedometer
PI 5 Horn
P35 Parking light
S22 Light switch, horn button, kill switch
311
30 WIRING DIAGRAM
312
WIRING DIAGRAM 30
Components:
B76 Front brake light switch
B77 Rear brake light switch
K20 Turn signal relay
P21 Turn signal indicator lamp
P41 Turn signal, front left
P42 Turn signal, front right
P45 Turn signal, rear left
P46 Turn signal, rear right
S25 Turn signal switch
313
30 WIRING DIAGRAM
314
WIRING DIAGRAM 30
Components:
E60 License plate lamp
P36 Brake/tail light
315
30 WIRING DIAGRAM
316
WIRING DIAGRAM 30
Components:
B32 Fuel level sensor
B35 Oil level sensor
B51 Lambda sensor
FI Fuse
PI 3 Speedometer
P27 Oil level warning lamp
R51 Ignition coil
317
30 WIRING DIAGRAM
318
WIRING DIAGRAM 30
Components:
B70 Front wheel speed sensor
F4 Fuse
M13 Fuel pump
M35 Oil pump
M51 Injection valve 0
PI 3 Speedometer
R30 CAN-bus terminating resistor 1
319
30 WIRING DIAGRAM
320
WIRING DIAGRAM 30
Components:
B12 Intake air temperature sensor
B21 Engine coolant temperature sensor
B26 Rollover sensor
B37 Crankshaft speed sensor
B43 Throttle valve position sensor
B47 Crankcase pressure sensor
S55 Map-Select switch (optional)
Cable colors:
bl Black
br Brown
bu Blue
gn Green
gr Gray
Ibu Light blue
or Orange
pk Pink
pu Violet
rd Red
wh White
ye Yellow
321
30 WIRING DIAGRAM
30.9 Page 1 of 6 (All US models)

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322
WIRING DIAGRAM 30
Components:
G10 Battery
K10 Starter relay with main fuse
Ml 0 Electric starter system
S21 E-tip switch
S20 Kill switch
323
30 WIRING DIAGRAM
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324
WIRING DIAGRAM 30
Components:
F2 Fuse
F3 Fuse
G20 Alternator
K12 Light relay
K30 Power relay
T20 Voltage regulator
X285 Radiator fan connector
325
30 WIRING DIAGRAM

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326
WIRING DIAGRAM 30
Components:
El 3 Low beam, high beam
P35 Parking light
P36 Brake/tail light
S30 Light switch
327
30 WIRING DIAGRAM
328
WIRING DIAGRAM 30
Components:
B32 Fuel level sensor
B35 Oil level sensor
FI Fuse
PI 3 Speedometer
P27 Oil level warning lamp
R51 Ignition coil
329
30 WIRING DIAGRAM
330
WIRING DIAGRAM 30
Components:
B70 Front wheel speed sensor
F4 Fuse
M13 Fuel pump
M35 Oil pump
PI 3 Speedometer
R30 CAN-bus terminating resistor 1
331
30 WIRING DIAGRAM
332
WIRING DIAGRAM 30
Components:
B12 Intake air temperature sensor
B21 Engine coolant temperature sensor
B26 Rollover sensor
B37 Crankshaft speed sensor
B43 Throttle valve position sensor
B47 Crankcase pressure sensor
S55 Map-Select switch (optional)
Cable colors:
bl Black
br Brown
bu Blue
gn Green
gr Gray
Ibu Light blue
or Orange
pk Pink
pu Violet
rd Red
wh White
ye Yellow
333
31 SUBSTANCES
Brake fluid DOT 4 / DOT 5.1

Standard/classification
- DOT
Guideline
- Use only brake fluid that complies with the specified standard (see specifications on the container) and that
exhibits the corresponding properties.
Recommended supplier
Castrol
- REACT PERFORMANCE DOT 4
Motorex®
- Brake Fluid DOT 5.1
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.
- Do not use pure water as only coolant is able to meet the requirements needed in terms of corrosion pro
tection and lubrication properties.
- Only use coolant that complies with the requirements stated (see specifications on the container) and that
has the relevant properties.
Antifreeze protection to at least -25 °C (-13 °F)
The mixture ratio must be adjusted to the necessary antifreeze protection. Use distilled water if the coolant
needs to be diluted.
The use of premixed coolant is recommended.
Observe the coolant manufacturer specifications for antifreeze protection, dilution and miscibility (compatibility)
with other coolants.
Motorex®
- COOLANT M3.0
Engine oil (15W/50)

- JASO T903 MA2 p p. 353)
- SAE p p. 353) (15W/50)
Guideline
- Use only engine oils that comply with the specified standards (see specifications on the container) and that
possess the corresponding properties.
Motorex®
- Top Speed 4T
Engine oil, 2-stroke

- JASO FD p p. 353)
Guideline
- Only use high grade 2-stroke engine oil of a reputable brand.
Fully synthetic
334
SUBSTANCES 31
Motorex®
- Cross Power 2T
Fork oil (SAE 4) (48601166S1)

- SAE (81 p. 353) (SAE 4)
Guideline
- Use only oils that comply with the specified standards (see specifications on the container) and that exhibit
the corresponding properties.
Shock absorber fluid (SAE 2.5) (50180751 SI)

- SAE (m p. 353) (SAE 2.5)
Guideline
- Use only oils that comply with the specified standards (see specifications on the container) and that exhibit
the corresponding properties.
Super unleaded (ROZ 95/RON 95/PON 91)

- DIN EN 228 (ROZ 95/RON 95/PON 91)
Guideline
- Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.
- Fuel with an ethanol content of up to 10 % (El 0 fuel) is safe to use.
• Info
I Do not use fuel containing methanol (e. g. Ml 5, M85, Ml 00) or more than 10 % ethanol (e. g. El 5,
E25, E85, El 00).
335
32 AUXILIARY SUBSTANCES
Air filter cleaner

Motorex®
- Racing Bio Dirt Remover
Chain cleaner
Motorex®
- Chain Clean
High viscosity grease

SKF®
- LGHB 2
Long-life grease
Motorex®
- Bike Grease 2000
Lubricant (T158)
Lubcon®
- Turmogrease® PP 300
Lubricant (T14034)
WP Performance Systems
- WP Racing Grease IPR 2
Lubricant (T625)
Molykote®
- 33 Medium
Lubricant (T152)
Bel-Ray®
- Molylube® Anti-Seize
Lubricant (T159)
Bel-Ray®
- MC-11®
336
AUXILIARY SUBSTANCES 32
Motorcycle cleaner
Motorex®
- Moto Clean
Multi-purpose grease (00062010051)

Kliiber Lubrication®
- CENTOPLEX 2 EP
Off-road chain spray

Motorex®
- Chainlube Offroad
Oil for foam air filter

Motorex®
- Racing Bio Liquid Power
Preserving materials for paints, metal and rubber

Motorex®
- Moto Protect
Special cleaner for glossy and matte paint finishes, metal and plastic surfaces
Motorex®
- Quick Cleaner
Universal oil spray

Motorex®
- Joker 440 Synthetic
337
33 SPECIAL TOOLS
Bleeder cover
Art. no.: 00029013019
A.
00029013019
H02440-01
Bleeder cover
Art. no.: 00029013020
A
00029013020
H02441-01
Bleeding device
Art. no.: 00029013100
EU battery charger XCharge-professional

Art. no.: 00029095050
Feature
EU safety plug
Nominal voltage 230 V
Mains fuse 16 A
Power cable length 5 m (16 ft)
approx.
Charger cable 5 m (16 ft)
length approx.
338
SPECIAL TOOLS 33
US battery charger XCharge-professional

Art. no.: 00029095051
Feature
US plug
Mains fuse 32 A
approx.
length approx.
UK battery charger XCharge-professional

Art. no.: 00029095052
Feature
UK safety plug
Mains fuse 16 A
approx.
length approx.
CH battery charger XCharge-professional

Art. no.: 00029095053
Feature
CH plug
Mains fuse 16 A
approx.
length approx.
Tachometer
Art. no.: 45129075000
339
33 SPECIAL TOOLS
Syringe
Art. no.: 50329050000
Pressing tool
Art. no.: 50429005000
A
50429005000
H00568-01
Holding wrench
Art. no.: 51129003000
Holding wrench
Art. no.: 54629012200
340
SPECIAL TOOLS 33
Setting gauge
Art. no.: 54829001100
Separator plate
Art. no.: 54829009000
Crankshaft pressing tool insert

Art. no.: 54829108000
54829108000
H00994-01
Holder and fitting for work stand

Art. no.: 55429002000
341
33 SPECIAL TOOLS
Holding wrench
Art. no.: 55429012000
A
55429012000
HO1176-01
Socket wrench
Art. no.: 55529021000
A
/1\ Feature
Square 5 mm (0.2 in)
55529021000
H02866-01
Adjusting gauge
Art. no.: 55529022000
A
a
55529022000
H02867-01
Gear segment
Art. no.: 56012004000
A
•4!
56012004000
H00588-01
342
SPECIAL TOOLS 33
Puller
Art. no.: 58012009000
58012009000
H00592-01
Puller
Art. no.: 58429037043
AA
IA Feature
Inside diameter 43.9 mm (1.728 in)
58429037043
H00598-01
Peak voltage adapter

Art. no.: 58429042000
58429042000
H00599-01
Footrest spring plier

Art. no.: 58429083000
58429083000
H00601-01
343
33 SPECIAL TOOLS
Tool bracket
Art. no.: 58429089000
Pressing tool
Art. no.: 58429091000
A
58429091000
H00604-01
Pressing tool
Art. no.: 58429092000
58429092000
H00605-01
Torque wrench kit

Art. no.: 58429094000
Feature
Torque 3 ... 15 Nm (2.2 ... 11.1 Ibfft)
Open ended bit 3.9 mm (0.154 in)
Bit diameter 5.9 mm (0.232 in)
344
SPECIAL TOOLS 33
Feeler gauge
Art. no.: 59029041100
A
ZJA Feature
5 piece 0.10 ... 0.25 mm (0.0039 ... 0.0098 in)
59029041100
H00616-01
Hose clamp plier

Art. no.: 60029057000
A
60029057000
H00650-01
Testing hose
Art. no.: 61029093000
A
61029093000
H00659-01
Pressure testing tool

Art. no.: 61029094000
4x
61029094000
H00660-01
345
33 SPECIAL TOOLS
Pressing tool
Art. no.: 75029044010
75029044010
H00712-01
Crankshaft pressing tool

Art. no.: 75029047000
Footrest spring plier

Art. no.: 79029083000
79029083000
H00804-01
Engine work stand

Art. no.: 80329001000
346
SPECIAL TOOLS 33
Lift stand
Art. no.: 81329955100
Feature
Height 315 ... 425 mm (12.4 ... 16.73 in)
Load < 150 kg (< 331 lb.)
H00985-01
Holding wrench
Art. no.: 90129051000
Spring hook
Art. no.: 5030501700004
Depth micrometer
Art. no.: T107S
347
33 SPECIAL TOOLS
Art. no.: T120

Feature
Diameter 8 mm (0.31 in)
Art. no.: T1204

Feature
Diameter 25.5 ... 30.5 mm (1.004 ... 1.201 in)
Art. no.: T1205

Feature
Art. no.: T1206

Feature
Diameter 15 ... 30 mm (0.59 ... 1.18 in)
348
SPECIAL TOOLS 33
Art. no.: T1207S
Art. no.: T1216

Feature
Diameter 38 ... 49 mm (1.5 ... 1.93 in)
Art. no.: T1240S
Art. no.: T1296
349
33 SPECIAL TOOLS
Protecting sleeve
Art. no.: T1401
Feature
Clamping stand
Art. no.: T14016S
Feature
Ring wrench
Art. no.: T14017
Feature
Hexagonal part 50 mm (1.97 in)
Support tool
Art. no.: T14026S1
Feature
M12
350
SPECIAL TOOLS 33
Clamping stand
Art. no.: T1403S
Feature
Mounting tool
Art. no.: T14040S
Feature
Special socket
Art. no.: T14087
Feature
Drive 1/2 in
External diameter 44 mm (1.73 in)
Internal diameter 29.5 mm (1.161 in)
Pressing tool
Art. no.: T1504
Feature
T1504
H00899-01
351
33 SPECIAL TOOLS
Mounting tool
Art. no.: T150S
Mounting sleeve
Art. no.: T1515
Feature
Filling tool
Art. no.: T170S1
2x A
T170S1
H00855-01
352
STANDARDS 34
JASO T903 MA2

Different technical development directions required a separate specification for motorcycles - the
JASO T903 MA2 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.
In most motorcycle engines, the transmission and clutch are lubricated with the same oil.
The JASO T903 MA2 standard meets these special requirements.
SAE
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying
oils according to their viscosity. The viscosity describes only one property of oil and says nothing about quality.
JASO FD
JASO FD is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands
of racing. Thanks to first rate synthetic esters and specially designed additives, superb combustion is achieved
even under extreme operating conditions.
353
35 INDEX OF SPECIAL TERMS
TPI Injection into transfer ducts (Trans Electronic fuel injection in which two injection valves
fer Port Injection) in the transfer ducts of the cylinders are used
PA Preload adjuster Device on the spring elements which enables adjust
ment of the spring preload
354
LIST OF ABBREVIATIONS 36
Art. no. Article number

ca. circa
cf. compare
e.g. for example
etc. et cetera
i.a. inter alia
no. number
poss. possibly
355
INDEX
Brake linings
2 front brake, changing ..................................... 146
2-stroke oil level front brake, checking ..................................... 146
checking.......................................... ...............274 of rear brake, changing................................... 153
rear brake, checking........................................ 153
2-stroke oil tank cap
closing ............................................ ...............275 C
opening .......................................... ...............274 Capacity
A Coolant .............................................................. 293
Accessories ...................................... ....................9 fuel ......................................................................293
Gear oil............................................. 181,272,293
Air filter
cleaning .......................................... ................. 97 Cartridge
installing.......................................... ................. 97 of fork legs, disassembling ................................ 23
removing ....................................... ................. 96 of the fork legs, assembling................................ 29
Air filter box Chain

cleaning .......................................... ................. 97 checking........................................................... 128
sealing ............................................ ................. 98 cleaning ........................................................... 127
Air filter box cover Chain guide

installing.......................................... ................. 96 checking........................................................... 128
removing ....................................... ................. 96 Chain tension
Alternator adjusting........................................................... 131
stator winding, checking............... ...............281 checking........................................................... 128
Ambient pressure Characteristic map of the throttle response

programming................................... ...............287 adjusting.................................................................47
Antifreeze Charging voltage

checking.......................................... ...............264 checking........................................................... 143
Auxiliary substances ......................... ....................9 Chassis number ....................................................... 10

Cleaning, care............................................... 298-299
B
Clutch
Battery
fluid level, checking/correcting .................... 253
installing........................................................... 141
fluid, changing.....................................................254
negative cable, connecting ........................... 140
Clutch lever
negative cable, disconnecting ...................... 139
basic position, adjusting ..................................... 45
recharging ...................................................... 142
removing ......................................................... 140 Cold start button.....................................................288
Brake disc Combination instrument

front brake, changing ..................................... 122 adjusting........................................................... 161
of rear brake, changing................................... 126 battery, changing............................................ 166
service display, setting ................................... 163
Brake discs
setting the clock ............................................ 162
checking........................................................... 119
setting the kilometers or miles...................... 162
Brake fluid
Compression damping
front brake, adding.......................................... 150
fork, adjusting ....................................................... 15
front brake, changing ..................................... 151
of rear brake, adding ..................................... 157 Coolant
of rear brake, changing................................... 158 draining .............................................................. 265
refilling .................................................................266
Brake fluid level
front brake, checking ..................................... 149 Coolant level
rear brake, checking....................................... 157 checking.................................................... 264-265
Cooling system ....................................................... 264
356
INDEX
Crankshaft position sensor reed valve, checking........................................ 213

checking........................................................... 282 stator, removing ............................................ 284
Cylinder - Nikasil® coating................................ 210 Engine assembly
alternator cover, installing.............................. 250
balancer shaft, installing ................................ 235
Diagnostics connector ..................................... 145
clutch basket, installing ................................ 236
Drivetrain kit clutch cover, installing ................................... 239
changing ......................................................... 131 clutch discs, installing ................................... 237
clutch push rod, installing .................................252
crankshaft, installing........................................ 228
Engine
cylinder head, installing ................................ 249
assembling ......................................................... 228
cylinder, installing ............................................. 242
disassembling ................................................. 181
engine, removing from the engine work stand 252
installing........................................................... 175
gear oil drain plug, installing ......................... 251
removing ......................................................... 168
intermediate kick starter gear, installing . . . 234
technical data - engine......................................289
kick starter shaft, installing ........................... 234
working on individual parts ........................... 198
kick starter shaft, preassembling .....................226
Engine - work on the individual parts
kick starter, installing ..................................... 250
connecting rod, conrod bearing, and crank
left engine case section, installing .................. 230
pin, changing .................................................... 201
locking lever, installing ................................... 233
crankshaft bearing inner race, installing . . . 201
piston, installing............................................... 241
crankshaft bearing inner race, removing . . . 200
reed valve housing, installing......................... 231
crankshaft run-out at the bearing pin, checking 203
rotor, installing................................................. 233
cylinder, checking/measuring ......................... 203
shift drum locating unit, installing.....................234
engine case section, right .............................. 198
shift drum, installing........................................ 230
exhaust control, checking .................................206
shift forks, installing ........................................ 229
exhaust control, removing.................................204
shift lever, installing ........................................ 252
kick starter, checking ........................................ 226
shift rails, installing.......................................... 230
main shaft, disassembling.................................221
shift shaft, installing ...........................................234
piston ring end gap, checking ......................... 211
spacer, installing ............................................ 251
piston, checking ............................................ 210
starter motor, installing................................... 232
piston, measuring ............................................. 210
transmission shafts, installing ...................... 229
piston/cylinder, measuring the mounting
water pump cover, installing ......................... 241
clearance ............................................................212
X-distance, adjusting ..................................... 245
reed valve housing, assembling....................... 214
X-distance, checking ..................................... 244
reed valve housing, disassembling.................. 212
Z-distance, setting.......................................... 247
shift mechanism, checking .............................. 220
shift shaft, preassembling .................................219 Engine disassembly
stator, installing ............................................... 285 alternator cover, removing ........................... 183
transmission, checking......................................222 balancer shaft, removing................................ 191
clutch basket, removing ................................ 190
Engine - working on the individual parts
clutch cover, removing ................................... 188
clutch cover ....................................................... 215
clutch discs, removing ................................... 189
clutch, checking ............................................. 218
clutch push rod, removing.............................. 182
countershaft, assembling .................................224
crankshaft, removing ..................................... 197
countershaft, disassembling ............................222
cylinder head, removing ................................ 184
cylinder - Nikasil® coating .............................. 210
cylinder, removing .......................................... 185
electric starter drive, checking......................... 227
engine, clamping into the engine work stand 181
engine case section, left ................................ 199
gear oil, draining ............................................ 182
exhaust control, installing .............................. 207
injection valves, installing .............................. 250
intake flange, checking......................................213
Injection valves, removing.............................. 184
main shaft, assembling......................................224
intermediate kick starter gear, removing ... 192
reed valve housing, checking ......................... 213
357
INDEX
kick starter shaft, removing........................... 192 of the tap compression, assembling the .... 28
kick starter, removing..................................... 183 removing .............................................................. 18
left engine case section, removing ............... 195 spring preload, adjusting ................................... 16
locking lever, removing................................... 193 Fork protector
piston, removing ............................................ 187 installing.................................................................18
reed valve housing, removing ...................... 195 removing .............................................................. 18
rotor, removing ............................................... 193
Frame
shift drum locating unit, removing ............... 193
checking.................................................................49
shift drum, removing ..................................... 196
shift forks, removing........................................ 196 Front fender
installing........................................................... 114
shift lever, removing........................................ 181
removing ......................................................... 114
shift rails, removing ........................................ 196
shift shaft, removing........................................ 192 Front wheel
spacer, removing............................................ 182 installing........................................................... 122
starter motor, removing ................................ 194 removing ......................................................... 121
transmission shafts, removing ...................... 197 Fuel filter
water pump cover, removing......................... 187 changing ......................................................... 108
Engine guard Fuel pressure
installing.................................................................49 checking........................................................... 105
removing .............................................................. 49
Fuel pump
Engine number ......................................................... 10 changing ......................................................... Ill
Engine sprocket Fuel screen
checking........................................................... 128 changing ......................................................... 107
Exhaust control Fuel tank
checking/adjusting............................................. 269 installing........................................................... 103
F removing ......................................................... 102
Figures .......................................................................... 9 Fuse

individual power consumers, changing .... 138
Filler cap
main fuse, changing........................................ 136
closing ................................................................... 99
opening .................................................................99 G
Foot brake lever Gear oil
free travel, checking........................................ 156 adding .............................................................. 273
Foot brake pedal changing ............................................................ 272
basic position, adjusting ................................ 156 Gear oil level
Footrests checking.............................................................. 273
changing .............................................................. 49 H
Fork Hand brake lever
article number....................................................... 10 basic position, adjusting .................................. 149
Fork legs free travel, checking......................................... 148
assembling ............................................................32
Handlebar position............................................... 44
bleeding .................................................................16 adjusting.................................................................44
cartridge, assembling.......................................... 29
Headlight
cartridge, disassembling..................................... 23
range, adjusting................................................. 166
checking.................................................................27
disassembling .......................................................20 Headlight adjustment
dust boots, cleaning............................................. 17 checking............................................................. 165
fork, servicing .......................................................20 Headlight bulb
installing.................................................................19 changing .......................................................... 164
of tap compression, disassembling ..................26
358
INDEX
Headlight mask with headlight P

installing........................................................... 115
Play in throttle cable
removing ......................................................... 115
adjusting..............................................................46
Heim joint
Preparing for use
checking.................................................................88
after storage .................................................... 301
High-speed compression damping
R
shock absorber, adjusting................................
adjusting...................................
5353
Rear sprocket
1
checking........................................................... 128
Idle speed
Rear wheel
adjusting................................................. .... 287
installing........................................................... 125
Ignition coil removing ......................................................... 124
primary winding, checking ................. ____ 280
Rebound damping
Ignition system fork, adjusting ....................................................... 15
checking................................................. ____ 279 shock absorber, adjusting................................... 54
Ignition timing map Refueling
plug-in connector ................................ ____ 136 2-stroke oil ...................................................... 275
Implied warranty....................................... ............ 9 Riding sag
L adjusting.................................................................57
Lower triple clamp Right side cover

installing................................................. ..........39 installing........................................................... 100
removing ............................................... ..........38 removing ......................................................... 100
Low-speed compression damping Rim run-out

shock absorber, adjusting.................... ..........53 checking........................................................... 120
M Rubber grip
checking.................................................................47
Main fuse
changing ............................................... ____ 136 S
Main silencer Seat

glass fiber yarn filling, changing.......... ..........94 mounting ........................... . . 101
installing................................................. ..........91 removing ........................... . . 100
removing ............................................... ..........91 Service schedule................... 302-305
Manifold Servicing the fork ................. ____20
installing................................................. ..........93 Servicing the shock absorber ____63
removing ............................................... ..........91 Shock absorber
Motorcycle article number.................... ____11
cleaning ................................................. ____ 298 damper, assembling.......... ____74
lift stand, raising with ........................... ..........12 damper, bleeding and filling ____76
removing from lift stand ...................... ..........12 damper, checking ............ ____69
damper, disassembling . . . ____65
O
damper, filling with nitrogen ____79
Oil pump heim joint, changing.......... ____89
changing ............................................................277 heim joint, installing .......... ____71
priming.................................................................275 heim joint, removing.......... ____70
Open-circuit current installing.............................. ____59
checking........................................................... 144 pilot bushing, changing . . . ____68
piston rod, assembling . . . ____72
Operating substances ............................................... 9
piston rod, disassembling . ____66
removing ........................... ____58
riding sag, checking.......... ____56
359
INDEX
seal ring retainer, assembling . . 71 electrical system ................................................294

seal ring retainer, disassembling . . . . 67 engine - tolerance, wear limits......................... 290
shock absorber, servicing............... . . 63 engine tightening torques .................................291
spring preload, adjusting ............... . . 56 fork ......................................................................295
spring, installing................................ . . 80 shock absorber .................................................. 295
spring, removing ............................. . . 64 tires ......................................................................294
static sag, checking ......................... . . 55 Throttle cable play
Shock absorber linkage checking.................................................................46
checking............................................ . . 61 Throttle cable routing
Spare parts.......................................... . . . 9 checking.................................................................45
Spark plug Tire air pressure
changing .......................................... . 283 checking........................................................... 117
Spark plug and spark plug connector Tire condition
changing .......................................... . 284 checking........................................................... 117
Spark plug connector Turn signal bulb
checking............................................ . 281 changing ......................................................... 165
Speedometer Type label................................................................... 10
wheel circumference, adjusting . . . . 163 W
Spoke tension Warranty........................................................................9
checking............................................ . 119
Wheel bearing
Starter motor checking........................................................... 118
checking............................................ . 286 of the front wheel, changing ......................... 123
Starter relay of the rear wheel, changing ........................... 133
checking............................................ . 144 Winter operation
Starting................................................. 12-13 checks and maintenance steps ....................... 299
Steering head bearing Wiring diagram............................................. 306-333
changing .......................................... . . 41 Page 1 of 6 ......................................................... 322
greasing ............................................ . . 37 Page 1 of 8 ...................................................... 306
Steering head bearing play Page 2 of 6 ......................................................... 324
adjusting............................................ . . 43 Page 2 of 8 ...................................................... 308
checking............................................ . . 41 Page 3 of 6 ......................................................... 326
Page 3 of 8 ......................................................... 310
Storage................................................. . 300
Page 4 of 6 ......................................................... 328
Swingarm Page 4 of 8 ......................................................... 312
checking............................................ . . 81 Page 5 of 6 ...................................................... 330
installing............................................ . . 84
Page 5 of 8 ...................................................... 314
removing .......................................... . . 82
Page 6 of 6 ......................................................... 332
Swingarm bearing Page 6 of 8 ...................................................... 316
changing .............................................................. 86 Page 7 of 8 ......................................................... 318
checking.................................................................81 Page 8 of 8 ...................................................... 320
T Work rules ...................................................................8
Tap compression
of fork legs, assembling ..................................... 28
of fork legs, disassembling .................................26
Technical data
capacities......................................................... 293
chassis.................................................................293
chassis tightening torques .............................. 296
360
PIONEERING SINCE 1903
3403080en
05/2018
Husqvarna Husqvarna Motorcycles GmbH

StallhofnerstraBe 3 5230 Mattighofen
www.husqvarna-motorcycles.com
Austria Photo: Mitterbauer,
MOTORCYCLES Husqvarna Motorcycles GmbH

2019 Husqvarna TE 250i - TE300i Service Repair Manual PDF

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PIONEERING SINCE 1903

REPAIR MANUAL 2019

© 2018 Husqvarna Motorcycles GmbH, Mattighofen Austria

ISO 9001(12 100 6061)

Husqvarna Motorcycles GmbH

This document is valid for the following models:

1 MEANS OF REPRESENTATION....................... 7 6.15 Assembling the tap compression.......28

15.7 Installing the battery..........................141 18.4 Engine disassembly......................... 181

23 IGNITION SYSTEM.........................................279 29 SERVICE SCHEDULE................................... 302

23.1 Checking the ignition system...........279 29.1 Additional information........................302

27 CLEANING, CARE........................................ 298

27.1 Cleaning the motorcycle....................298

The meaning of specific symbols is described below.

Indicates an unexpected reaction (e.g. of a work step or a function).

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

Indicates information with more details or tips,

Indicates the result of a testing step

Indicates a voltage measurement,

Indicates a current measurement,

Indicates a resistance measurement.

Indicates the end of an activity including potential rework,

1.2 Formats used

Name® Indicates a protected name.

Brand™ Indicates a brand available on the open market.

2.1 Repair manual

2.2 Safety advice

2.3 Degrees of risk and symbols

2.4 Work rules

3.1 Manufacturer and implied warranty

3.2 Operating and auxiliary substances

3.3 Spare parts, accessories

4.1 Chassis number

4.2 Type label (All EU models)

4.3 Engine number

4.4 Fork article number

4.5 Shock absorber article number

5.1 Raising the motorcycle with a lift stand

Raise the motorcycle at the frame underneath the engine.

5.2 Removing the motorcycle from the lift stand

Remove the motorcycle from the lift stand.

5.3 Starting the vehicle

Press the electric starter button or push the kick starter

5.4 Starting the motorcycle to check the function

- Shift gear to neutral.

6.1 Adjusting the compression damping of the fork

Turn white adjusting screw o clockwise as far as it will go.

Turn counterclockwise by the number of clicks correspond­

6.2 Adjusting the rebound damping of the fork

Turn red adjusting screw o clockwise as far as it will go.

Turn counterclockwise by the number of clicks correspond­

6.3 Adjusting the spring preload of the fork

- Turn the adjusting wings clockwise.

6.4 Bleeding the fork legs

6.5 Cleaning the dust boots of the fork legs

6.6 Removing the fork protector

6.7 Installing the fork protector

6.8 Removing the fork legs

Loosen screws 0 Remove the left fork leg.

6.9 Installing the fork legs

Turn counterclockwise by the number of clicks correspond

Turn counterclockwise by the number of clicks correspond

Warm up the outer tube in area © of the lower sliding bush

Mount and tighten nut © with the collar facing down

Warm up the outer tube in area © of the lower sliding bush