a PIONEERING SINCE 1903 REPAIR MANUAL 2014 FE 250 AU FE 250 US | FE 250 EU st. no, 34030020 Husqvarna’INTRODUCTION 1 ead this repair manual carefully and thoroughly before beginning work, The vehicle will only be able to meet the demands placed on itf the specified service work is performed regularly and property This repair manual was written to correspond to the latest state of this model series. We reserve the right to make changes in the interest of technical advancement without updating this repair manual at the same time, We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here. Its assumed that the repair work will be performed by a fully trained mechanic. All specifications are non-binding. Husqvama Motorcycles GmbH specifically reserves the right to modify or delete technical speci- fications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to ‘adapt these to local conditions, as well as to stop production of a particular model without prior notice. Husqvarna accepts no ia- bility for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply (©2015 Husqvama Motorcycles GmbH, Mattighofen Austria Alrights reserved Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright osn1:2 000 TOV defined in the ISO 9001 international quality management standard, Issued by: TUV Management Service 340300260 08/2015,TABLE OF CONTENTS 1 MEANS OF REPRESENTATION.. 1 12 2 SAFETY ADVICE. 2a 22 23 24 3 IMPORTANT NOTES. 3a 32 33 34 4 SERIAL NUMBERS... 4a 42 43 4a 45 46 5 MOTORCYCLE... BA 52 53 5a 6 FORK, TRIPLE CLAMP... et 62 63 64 6s 66 67 68 69 6.10 ett 612 6.13 6.14 615 6.16 617 18 6.19 620 621 6.22 6.23 624 6.25 6.26 627 6.28 6.29 7 HANDLEBAR, CONTROLS.. 7A ‘Symbols used Formats used. Repair Manual. Safety ADVICE enn Degrees of risk and symbols... Work rules... Manufacturer and implied warranty Operating and auxliary substances Spare parts, accessories. Figures... Chassis number. ‘Type label (FE 250 EU/AU) Key number (FE 250 EU/AU)... Engine number. Fork part number... Shock absorber article number Raising the motoreyclo with ait stand. Removing the motorcycle from the lft stand... 17 Starting " Starting the motorcycle for a check. 12 ‘Adjusting the compression damping of the fork Ajsting the rebound damping ofthe fork... 13 Bleeding the fork legs.. 13 Cleaning the dust boots ofthe fork lg 14 Loosening the fork protector. 14 Positioning the fork protector 18 Removing the fork legs.. Installing the fork legs. Removing the fork protector. 16 Installing the fork protector.. Performing a fork service. Disassembling the fork legs. Removing the spring Disassembling the cartridge... Disassembling the piston rod. Disassembling the hydrostop unit Disassembling the seal ring retainer ‘Checking the fork legs. ‘Assembling the seal ring retainer. ‘Assembling the hydrostop unit. ‘Assembling the piston rod. ‘Assembling the cartridge. ‘Assembling the fork leg sen Lubricating the steering head bearing Removing the lower triple clamp... Installing the lower triple clamp... ‘Checking the steering head bearing play . Changing the steering head bearing. ‘Adjusting the play ofthe steering head bearing Handlebar position 10 " 2 7.2 Adjusting the handlebar position... 37 7.3 Adjusting the basic position of the clutch lever 7.4 Checking the routing ofthe throttle cable. 98 7.8 Checking the play in the throttle cable 38 7.6 Adjusting the play in the throttle cable... 39, FRAME 40 8.1 Removing the engine guard, 40 8.2 Installing the engine guard.. 40 83 Checking the frame. se ‘SHOCK ABSORBER, SWINGARM, a1 9.1 Adjusting the high-speed compression ‘damping of the shock absorber. a 9.2 Adjusting the low-speed compression ‘damping of the shock absorber. a 9.3 Adjusting the rebound damping of the shock absorber. 9.4 Measuring rear wheel sag unloaded. 9.5 Checking the static sag of the shock absorber. 9.6 Checking the riding sag ofthe shock absorber. 43 9.7 Adjusting the spring preload ofthe shock AbSOMDE nn meas 9.8 Adjusting the riding 5g... 9.9 Removing the shock absorber. 9.10 Installing the shook absorber... 9.11 Checking the shack absorber linkage 45 9.12 Servicing the shock absorber. a7 9.13 Removing the spring. 9.14 Disassembling the damper. 48, 9.15 Disassembling the piston rod... 49 9.16 Disassembling the seal ring retainer so 80 9.17 Changing the pilot bushing.. 51 9.18 Checking the damper 52 9.19 Removing the heim joint $2 9.20 Installing the heim joint 53 9.21 Assembling the seal ring retainer. 54 9.22 Assembling the piston rod. soe 86 9.23 Assembling the damper. 58 9.24 Bleading and filing the damper 58 9.25 Filing the damper with nitrogen... 60 9.26 Installing the sprin 9.27 Checking the swingarm 9.28 Removing the swingarm 9.29 Installing the swingarm.. : o 9.30 Changing the swingarm bearing 64 EXHAUST... 10.1 Removing the manifol.. 87 10.2 Installing the manifold 6 10.3 Removing the main silencer. 69 10.4 Installing the main silenceteneunn 70 10.5 Changing the glass fiber yarn filing of the main silencer... . AIR FILTER, 11.1. Removing the air fter box COVEr 72 14.2 Installing the ar iter Box COVE ncnnnnnnnn 72, 14.8 Removing the air filter enn 72 11.4 Installing the ar filter. 72 11.8 Cleaning the air fiter and air fiter box. a7TABLE OF CONTENTS 14.6 Sealing the air fter box 12 FUEL TANK, SEAT, TRIM... 12.1. Opening filler cap. 12.2 Closing filer cap 12.3 Removing the right side cover. 12.4 _ Installing the rignt side cover, 12.5 Removing the seat.. 12.6 Mounting the seat... 12.7 Removing the fuel tank. 12.8 Installing the fuel tank 12.9 Changing the fuel screen 12.10 Changing the fuel fiter. 12.11 Changing the fuel pump 42.12 Checking the fuel pressure. 13. MASK, FENDER 18.1. Removing the front fender 18.2 _ Installing the front fender 18.3 Removing the headlight mask with the headlight. Instaling the heacot mask withthe headlight. ns 14 WHEELS. 14.1. Checking the tire air pressure. 14.2 Checking the tire condition. 14.3. Checking the brake discs. 14.4 Checking spoke tension... 145 Front wheel... os 14.5.1 Removing the front wheel. 14.5.2 Instaling the front wheel 14.5.3 Removing the front brake disc.. 14.5.4 Instaling the front brake disc 14.5.5 Changing the front wheel bearing 89 146 Rear wheel... 14.6.1 Removing the rear wheel. 146.2 Instaling the rear wheal 14.6.3 Removing the rear brake disc 14.6.4 Installing the rear brake disc... 14.6.5 Checking the chain tension. 14.6.6 Adjusting the chain tension.. 14.6.7 Checking the chain, rear sprocket, engine sprocket and chain guide... Checking for chain dirt accumulation .. Cleaning the chain... Changing the drivetrain kit. Changing the rear wheel bearing 85 13.4 92 1468 1469 146.10 146.11 15. WIRING HARNESS, BATTERY, 100 15.1. Changing the main fuse. 100 16.2 Changing the fuses of individual power CONSUMEES svn . 100 183. Checking the starter relay 101 15.4 Removing the battery... sane 102 16.5 Installing the battery 102 15.6 Checking the charging voltage. 103 15.7 Checking the quiescent current. 103 16 BRAKE SYSTEM 104 16.1. Checking the front brake linings 104 16.2 Changing the front brake linings, 104 16.3 Checking free travel of hand brake lever... 108, 16.4 Adjusting the basic position of the hand brake lever (FE 250 US)... e105 7 18 16.5 Adjusting free travel of hand brake lever (FE 250 EAU)... : Checking the front brake fui level ‘Adding front brake fluid. Changing the front brake fi. ‘Checking the rear brake linings Changing the rear brake linings (Checking the free travel of foot brake lever. ‘Adjusting the basic position of the foot brake lever ‘Checking the rear brake fluid level 16.14 Adding rear brake fluid 16.15 Changing the rear brake fd. LIGHTING SYSTEM, INSTRUMENTS. 166 167 168 169 16.10 16.11 16.12 16.13 17.1 Setting the speedometer 17.2. Setting the kilometers or miles 17.3. Setting the clock... 17.4 Setting the wheel circumference 17.5. Setting the service display. 17.8 Checking the headlight setting 17.7 Adjusting the headlight range... ENGINE 18.1 Removing the engine. 18.2 _ Installing the engine.. 18.3 Engine disassembly. 18.3.1 Preparations... 183.2 Removing the clutch push rod. 18.3.3 Removing the spacer 18.3.4 Draining the engine oil 18.3.5 Removing the oil iter. 18.3.6 Removing the spark plug 18.3.7 Removing the valve cover 18.3.8 Removing the alternator cover... 18.3.9. Removing the torque limiter 183.10 Positioning the engine a nition top ead center: 18.8.1 Removing the timing chain tensioner. 18.3.12 Removing the camshaft 18.3.13 Removing the cylinder head. 183.14 Removing the piston 18.3.15 Removing the starter dive 18.3.16 Removing the suction pump 18.3.17 Removing the water pump wheel... 18.3.18 Removing the clutch cover. 18.3.19 Removing the clutch discs. 183.20 Removing the clutch basket. 183.21 Removing the shift shaft. 18.3.22 Removing the shift drum locating unit. 183.23 Removing the locking lever 183.24 Removing the force pump, 18.3.25 Removing the primary gear 183.26 Removing the timing chain... 183.27 Removing the spacer 18.3.28 Removing the left section of the engine case. 18.3.29 Removing the shit rails. 183.30 Removing the shift drum. 183.31 Removing the shift forks 18.3.32 Removing the transmission shafts. 18.3.33 Removing the crankshaft . 107 107 106 108 . 109 110 Tr 112 112 113 114 116 116 417 47 17 118 118 119 120 120 . 124 128 128 129 129 129 130 130 130 131 131 131 192 192 133 133 134 135 136 136 136 137 198 138 138 198 139 139 140 140 140 141 1a 141 1aTABLE OF CONTENTS 18.4 Work on individual parts... 18.4.1 Work on the right section of the engine CSC 4842 — Work onthe left section ofthe engine case. : 1843 Wotkon the clutch cover 18.4.4 Checking the oil pressure regulator valve 18.4.5 Checking the lubrication system. 18.4.6 Removing the crankshaft bearing inner race 18.47 Instalng the crankshaft bearing inner 18.4.8 Changing the connecting rod, cond bearing, and crank pin nn 18.4.9 Checking the crankshaft run-out at the bearing pin .. 184.10 Measuring the crankshaft end play 18.4.11 Removing the drive wheel of the balancer shat 18.4.12 Installing the drive wheel of the balancer shat 18.4.13 Cylinder - Nikasit® coating... 184.14 Checking/measuring the cylind: 18.4.1 Checking/measuring the piston 18.4.16 Measuring the piston/cylinder mounting clearance. 18.4.17 Checking the piston ring end gap.. 18.418 Checking the camshafts. 18.419 Work on the intake camshaft 18.4.20 Checking the pivot points of the camshatts 18.421 Removing the valves 18.422 Checking the valves.. 18.4.23 Checking the valve springs. 18.4.24 Checking the valve spring seat 18.4.25 Checking the cam levers... 184.26 Checking the cylinder head. 18.4.27 _Instaling the valves. 18.4.28 Checking the freewheel 18.4.29 Removing the freewheel 18.430 _Instaling the freewheel 18.4.31 Checking the electric starter drive. 18.4.32 Checking the timing assembly 18.4.33 Preparing the timing chain tensioner for installation 18.4.34 Checking the clutch .. 18.4.35 Checking the shift mechanism.. 184.36 Preassembling the shift shaft 18.4.37 Disassembling the main shaft 18.4.38 Disassembling the countershatt. 18.4.39 Checking the transmission. 18.4.40 Assembling the main shaft. 18.4.41 Assembling the countershaft 18.5 Engine assembly... 18.5.1 Installing the crankshaft. 18.5.2 _Instaling the transmission shatt 18.5.3 Instaling the shift forks 18.5.4 Installing the shift drum 18.5.5 Installing the shift rails. 18.5.6 _Instaling the left engine case.. 18.5.7 Installing the spacer 185 142 . 142 143 . 144 145 146 . 146 147 147 149 149 149 150 150 180 151 151 182 182 152 183 154 185 185 186 156 - 186 187 188 158 159 160 161 . 161 163 164 164 165 165 166 167 168 168 169 169 169 170 170 171 19 a 23 24 4 18.5.8 Installing the timing chain... 171 18.5.9. Instaling the primary gear, 171 18.5.10 _Instaling the force pump. 172 18.5.1 Installing the suction pump. 172 18.512 Instaling the locking lever... 173 185.13 _Instaling the shit crum locating nit vnc 173 185.14 _Instaling the shift shaft. 174 185.15 Instaling the clutch basket... 174 185.16 _Instaling the clutch dises. 175 18.5.17 Installing the clutch cover 176 185.18 _Instaling the water pump cover. 17 185.19 _Instaling the starter drive. 17 185.20 _ Installing the piston 178 185.21 Installing the cylinder head. 180 185.22 _Instaling the camshafts. seoenes 181 18.5.28 _Instaling the timing chain tensione.. 181 185.24 Checking the valve clearance wn 182 185.25 Adjusting the valve clearance. 183 185.26 _Instaling the torque limiter. 183 18.5.27 Installing the alternator cover. 183 185.28 _Instaling the valve cover. 184 185.29 _Instaling the spark plug 184 18.5.30 _ Installing the ol filter. 185 18.5.31 Installing the oll screen... 185 185.32 Installing the spacer 186 18.5.3 Installing the clutch push rod 186 18.5.34 Removing the engine from the engine assembly stand i) CLUTCH... 187 19.1. Checking/tectyng the fud level of the hydraulic clutch 187 19.2 Changing the hydraulic clutch fluid 187 WATER PUMP, COOLING SYSTEM 188 20.1 Cooling system.. 188 20.2 Checking the antiveeze and coolant level... 188 20.3 Checking the coolant level. 189 20.4 Draining the coolant. . 189 20.5 Refilling coolant 190 LUBRICATION SYSTEM 191 214 Oil circuit ' 191 212. Checking the engine cil level... 191 21.3 Changing the ongine ol and oil fier cleaning the oll screen... rns 21.4 Adding engine oil . 194 21.5 Checking the engine ol pressure . 194 IGNITION SYSTEM. 196 22.1 Ignition coll - checking the secondary winding, 196 22.2 Checking the spark plug connector. 196 22.3 Altemator - checking the stator winding... 196 22.4 Removing the stator and ignition pulse generator 197 22.5. Installing the stator and ignition puso generator. 197 ELECTRIC STARTER. 198 23.1 Checking the starter motor. 198 ‘THROTTLE VALVE BODY 199 24.1 Adjusting the idle speed 199 24.2 Executing the initialization run.. 199)TABLE OF CONTENTS 25. TECHNICAL DATA 200 25.1 Engine : 200 252 Engine tolerance, wear limits. 200 25.3 Engine tightening torques. 201 28.4 Capacities nn : 202 25.4.1 Engine oil 202 254.2 Coolant... 202 25.43 Fuel 202 255 ChaSSI8 vesnnnnsnnnn soe 208 25.6 Electrical system. 203, 28.7 Tires... ns 204 258 Fork. 204 25.9 Shock absorber 204 25.10 Chassis tightening torques. 205 26 CLEANING, CARE... 208 26.1 Cleaning the motorcycie... St 26.2 Checks and maintenance steps for winter operation, 207 27 STORAGE ee 208 2741 Storage 208 27.2 Preparing for use after storage. 208 28 SERVICE SCHEDULE... : 209 28.1 Service schedule. 209 28.2 Service work (as additional order) 210 29 WIRING DIAGRAM... 212 29.1 Page 1 of 8 (FE 250 EU) 212 29.2 Page 2 of 8 (FE 250 EU). 214 216 218 220 29.3 Page 3 of 8 (FE 250 EU). 29.4 Page 4 of 8 (FE 250 EU).. 29.5 Page S of 8 (FE 250 EU). 29.6 Page 6 of 8 (FE 250 EU). 29.7 Page 7 of 8 (FE 250 EU).. 20.8 Page 8 of 8 (FE 250 EU)... 29.9 Page 1 of 8 (FE 250 AU). 224 228 228 29.10 Page 2 of 8 (FE 250 AU)nnenes 230 29.11 Page 3 of & (FE 250 AU), 232 29.12 Page 4 of 8 (FE 250 AU). 234 29.13 Page 5 of 8 (FE 250 AU}. 29.14 Page 6 of 8 (FE 250 AU) 29.15. Page 7 of 8 (FE 250 AU)... 29.16 Page 8 of 8 (FE 250 AU}.. 29.17 Page 1 of 6 (FE 250 US) runs 29.18 Page 2 of 6 (FE 250 US). 246. 236 238 240 29.19 Page 3 of 6 (FE 250 US)-nnrnnn 248, 29.20 Page 4 of 6 (FE 250 US), 250 29.21 Page 5 of 6 (FE 250 US). 252 29.22 Page 6 of 6 (FE 250 US) 254 80 SUBSTANCES srr 256 31 AUXILIARY SUBSTANCES. 257 32 SPECIAL TOOLS. 259 33 STANDARDS... ns 270 INDEX. an1 MEANS OF REPRESENTATION 6 The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates a page reference (more information is provided on the specified page). x Indicates an unexpected reaction (e.g. of a work step or a function) + Indicates information with more details or tip. » Indicates the result ofa testing step. wi Denotes a voltage measurement. ry Denotes a current measurement. o Denotes a resistance measurement. ‘The typographical formats used in this document are explained below. Proprietary name Identifies a proprietary name. Name® Identifies a protected name. Brand™ Identifies a trademark, Underlined terms Refer to technical details of the vehicle or indicate technical terms, which are explained in the glossary.2 SAFETY ADVICE 7 2A RepairManual Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you repair and maintain your vehicle. This manual assumes that the necessary special Husqvarna tools and Husqvarna workplace and workshop equipment are avail able. ‘Anumber of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety instructions are highlighted in the text and are referred to at the relevant passages. Info The vehicle has various information and warning labels at prominent locations. Do not remove information/warring labels. I they are missing, you or others may not recognize dangers and may therefore be injured. Danger Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken, Warning Indicates a danger that is likely to lead to fatal or Serious injury f the appropriate measures are not taken. Caution Indicates a danger that may lead to minor injuries if the appropriate measures are not taken, Note Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken. Warning Indicates a danger that will lead to environmental damage if the appropriate measures are not taken. ‘Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in parentheses. E.g.: bearing puller (15112017000) During assembly, non-reusable parts (@.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced by new parts. In some instances, a thread locker (e.g. Lectite®) is required. The manufacturer instructions for use must be followed. After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts. ‘After you complete the repair or service work, check the operating safety of the vehicle.3 IMPORTANT NOTES 8 84 Manufacturer and implied warranty The work prescribed in the service schedule must be cartied out by an authorized Husqvarna Motorcycles workshop only and con- firmed both in the customer's Service & Warranty Booklet and in the Husqvarna Motorcycles Dealer.net; otherwise, all warranty claims will be void. Damage or secondary damage caused by tampering 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 booklet Warning Environmental hazard Improper handling of fuel is a danger to the environment. = Donot allow fuel to get into the ground water, the ground, or the sewage system. Use the operating and auxiliary substances (such as fuel and lubricants) as specified in the manual. Only use spare parts and accessories approved and/or recommended by Husqvama. Husqvarna accepts no lability for other prod- ucts and any resulting damage or loss. ‘The current Husky Power parts for your vehicle can be found on the Husqvama website. Intemational Husqvarna Motorcycles website: wwrw.husqvarna-motorcycles.com ‘The figures contained in the manual may depict special equipment. Inthe interest of clarity, some components may be shown disassembled or may not be shown at all. Its not always necessary to disassemble the component to perform the activity in question. Please follow the instructions in the text.4 SERIAL NUMBERS ° ‘The chassis number @ Is stamped onthe steering head on te right. 4010-10 ‘The type label @ is fixed to the front of the steering head. 401046-10 ‘The key number @ for the steering lock is stamped onto the key connector. 40224710) “The engine number @) is stamped on the left side ofthe engine under the engine sprocket. ‘The fork part number @ is stamped on the inner side of the fork stub.4 SERIAL NUMBERS 10 46 Shock absorberarticlenumber ‘The shock absorber article number @ is stamped on the top ofthe shock absorber above the adjusting ring towards the engine side. sora-05 MOTORCYCLE " Note Danger of damage The parked vehicle may roll away or fall over. = Always place the vehicle on a firm and even surface. = Raise the motorcycle at the frame underneath the engine. Lift stand (61829085000) (* p. 266) ‘Neither wheel is in contact with the ground. aoiaor| ~ Secure the motorcycle against falling over. Note Danger of damage The parked vehicle may roll away or fall over. = Always place the vehicle on a firm and even surface, = Remove the motorcycle from the lf stand. = Remove the lit stand, = To park the motorcycle, press side stand @ to the ground with your foot and lean the motorcycle on it. © Info Then you are riding, the side stand must be folded up and secured with the rubber band! 40104210 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. = When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an. enclosed space without an effective exhaust extraction system. Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine. —_Always warm up the engine at low engine speeds. ~ aise the motoreyele off othe stand and secure the stand with the rubber band @ = Shit ransmission to neutral (FE 250 AU) = Tur the emergency OFF switch tthe postion O. Cconaition “ambient temperature: < 20° (< 68 °F) = Pullthe ile speed austing serew all he way out = Prass the electric starter button, Info I Press the electric starter button for at most 5 seconds, Wait for a least 5 seconds before trying again. ‘Warning lamp Fl lights up briefly as a functional control when starting, 400733-015 MOTORCYCLE 2 54 Starting the motoreycleforacheck Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an ‘enclosed space without an effective exhaust extraction system, © Info I Press the starter for a maximum of § seconds. Wait for at least 5 seconds before trying again. — Shift transmission to neutral (FE 250 AU) "Tum the emergency OFF switch to the position ©. — Press the electric starter button Info To not open the throtte.6 FORK, TRIPLE CLAMP 1% Info TThe hycrautic compression damping determines the fork suspension behavior. ~ Turn the white agusting screw @ lhe way clockwise Info T Adjusting screw @ is located at the upper end of the left fork eg. “The compression damping is located in the left fork leg COMP (white adjusting screw). The rebound damping is located in the right fork leg REB (red adjusting screw) Turn counterclockwise by the number of clicks corresponding to the fork type. [cooss9-10] Guideline ‘Compression damping Comfort 15 clicks ‘Standard 18 clicks Sport TT licks Info TTum clockwise to increase damping: tum counterclockwise to reduce damping. Info TThe hydraulic rebound damping determines the fork suspension behavior. = Tu the red adjusting screw @ all the way clockwise. Info TAcjusting screw @ is located at the upper end of the right fork leg, “The rebound damping is located in the right fork leg REB (red adjusting screw). The compression damping is located in the left fork leg COMP (white adjusting screw). Turn counterclockwise by the number of clicks corresponding to the fork type. Guideline Rebound damping ‘Comfort 15 clicks Standard 18 clicks Sport Tt elicks Info ‘Turn clockwise to increase damping; turn counterclockwise to reduce damping. Preparatory work = Raise the motorcycle with a litt stand, (*" p. 11)6 FORK, TRIPLE CLAMP 4 40255610] 10006010 Main work = Release bleeder screws @. 7 Any excess pressure escapes from the interior of he fork. = Tighten th bleeder screws. 19 work = Remove the motorcycle from the lft stand. (*" p. 11) Preparatory work = Raise the motoroycle witha lift stand. (*” p. 11) — Loosen the fork protector. (* p. 14) Main work = Push dust boots @ of both fork legs downward Info T The dust boots remove dust and coarse ditt particles from the inside fork tubes. Overtime, dirt can penetrate behind the dust boots If this dit is not removed, the oil seals behind can stat to leak. ‘Warning Danger of accidents Reduced braking efficiency due to cil or grease on. the brake discs. — Always keep the brake discs free of oll and grease, and clean them with brake cleaner when necessary. = Clean and oll the dust boots and inner fork tubes of both fork legs. Universal oll spray (* p. 258) Press the dust boots back into their normal position. = Remove excess oll Finishing work = Position the fork protector. (* p. 15) Remove the motorcycle from the lft stand. (* p. 11) = Remove screws @) and remove the clamp. = Remove serews @ on th left forleg, Push te fork protector downwards = Remove the serews on the ight fork eg. Push the frk protector downwards6 FORK, TRIPLE CLAMP 18 = Position the fork protector on the left fork leg. Mount and tighten screws @. Guideline Remaining screws, chassis M6 10.Nm (7.4 Ibf A) = Position the brake line, wiring harness, and clamp. Mount and tighten sorews @. Position the fork protector on the right fork leg. Mount and tighten the screws. Guideline Remaining screws, chassis M6 10 Nm (7.4 IBF) Preparatory work = Switch off all power consumers and switch off the engine. — Remove the headlight mask with the headlight. (*" p. 85) — Raise the motorcycle with a lift stand. (7 p. 11) — Remove the front wheel. (* p. 88) Main work = Remove screws @ and takeoff he lamp. = Remove the cable tie(s). = Remove screws @ and takeoff the brake caliper. = Alou he brake caliper anc brake te to hang tension ‘eet te side, ~ Loosen screws @. Take out the let fork eg. ~ Loosen screws @. Take out the right fork tog. Main work = Position the fork legs. Y Bleeder screws @ are positioned toward the front. Info ‘The compression damping is located in lft fork lag COMP (white ‘agjusting screw). The rebound damping is located in right fork leg REB (red adjusting screw) Grooves are milled into the side of the upper end of the fork legs. The sec- ‘ond milled groove (trom the top) must be flush with the top edge of the Upper triple clamp. = Tighten screws @. Guideline Screw, top triple clamp MB 17 Nm (12.5 IbF = Tighten screws @. Guideline Screw, bottom triple clamp M8 15.Nm (11.1 IbF A)6 FORK, TRIPLE CLAMP 1 Position the brake caliper, and mount and tighten screws @. Guideline ‘Screw, front brake caliper | MB 25Nm Loctite® 243% (18.4 tot) = Mount the cable taf) Position the brake line, wiring harness, and clamp. Mount and tighten screws @. Finishing work = Install the front wheel. (* p. 88) = Install the headlight mask with the headlight. (*" p. 85) = Check the headlight setting. (* p. 118) Preparatory work ‘Switch off all power consumers and switch off the engine. - Remove the headlight mask with the headlight. ( p. 85) - Raise the motorcycle with a lit stand. (7 p. 11) ~ Remove the front wheel. (* p. 88) = Remove the fork legs. (* p. 15) Main work ~ Remove screws @ on the left fork leg. Remove the fork protector upwards. ~ Remove the screws on the right fork leg. Remove the fork protector upwards. Main work. = Position the fork protector on the left fork lag. Mount and tighten screws @. Guideline Flemaining screws, chassis M6 10 Nm (7.4 IbF = Position the fork protector on the right fork lag. Mount and tighten the screws. Guideline Remaining screws, chassis M6 10.Nm (7.4 Ibf ft) Finishing work Install the fork legs. (* p. 15) Install the front wheel. (* p. 88) Install the headlight mask with the headlight. (7p. 85) Check the headlight setting. (* p. 118)6 FORK, TRIPLE CLAMP 7 G11 Performing afork service OM 000 20102601 Condition ‘The fork legs have been removed. = Disassemble the fork legs. (* p. 17) = Remove the spring. (* p. 19) Disassemble the cartridge. (* p. 20) = Disassemble the piston rod. (*” p. 21) = Disassemble the hydrostop unit. (7 p. 22) = Disassemble the seal ring retainer. (*” p. 22) = Cheok the fork legs. (#* p. 28) Assemble the seal ring retainer. (7 p. 24) Assemble the hydrostop unit. (*" p. 24) Assemble the piston rod. (* p. 25) Assemble the cartridge. (7 p. 26) Assemble the fork lags. (* p. 27) Info ‘The steps are identical for both fork legs. 20169010 2017-10 Condition The fork logs are disassembled. Note down the current state of rebound damping @ REB (red adjuster of right fork eg) = Note down the current state of compression damping @ COMP (white adjuster of lft fork lg). Fully open the adjusters of the rebound and compression damping. = Clamp the fork leg in the area of the lower triple clamp. Clamping stand (114038) (*" p. 268) = Remove the screw. Remove aduster @. = olease scrw cap @ ‘Special socket (T14047) (7 p. 268) Info ‘The cartridge cannot be taken off yet.6 FORK, TRIPLE CLAMP 18 20170710 Unolamp the fork leg. Push the outer tube down. Drain the fork ol. Camp the for leg wth the axe lamp, Release hydrostop unt @ and remove it. Info Do not use an impact wrench. Place a pan underneath since oil will un out, Remove the cartridge from the fork leg. Press-out tool (114051) (* p. 269) Info Removing the O-ring seat from the cartridge usually requires the applica- ton of force, Remove dust boot @. Remove fork protection ring @. © Info “The fork protection ring does not necessarily need to be removed for repair work, Remove lock ing @. Info [The lock ring has a ground end against which a screwdriver can be posi- tioned! Warm the outer tube in rea @ of the lower siding bushing. Guideine 50 °C (122 °F) Pull the outer tube forcefully off of the inner tube. Info. 1H the tower stiding bushing @ must be pulled out of its bearing seat.6 FORK, TRIPLE CLAMP 19 Er = Remove the upper sliding bushing @. Info Do not use a tool; pull the ends apart slightly by hand, = Take of the lower sliding bushing ®. ~ Take off supporting @ ~ Take off sealing @ ~ Take off lock ring @. = Take off dust boot @. = Unclamp the fork og. Info the steps are identical for both fork legs. - al Pcorrze-ts a 201720-10 ~ Preparatory work = Disassemble the fork legs. ( p. 17) Main work = Pull the spring down. Mount the open end wrench on the hexagonal part. = Clamp the open end wrench in the vise, Release screw cap @ but do not remove it yet. ‘Special socket (T14047) (* p. 268) Pull the spring down. Remove the open end wrench. — Remove the screw cap. = Remove the spring with the preload spacers).6 FORK, TRIPLE CLAMP 20 Info the steps are identical for both fork legs. 20-10 201704-10 201795-10 Preparatory work = Disassemble the fork legs. (* p. 17) = Remove the spring. (* p. 19) Main work ~ Degrease piston rod @ and clamp it in the vise. ‘Clamping stand (1140495) (* p. 268) ~ Remove adjusting tbe @. Unscrew spring guide ~ Remove spring seat @. = Pull the piston rod out of the cartridge. Clamp the tube of the cartridge into a vise. ‘Clamping stand (1140495) (* p. 269) = Release seal ring retainer @ and remove with the washer. = Remove lock ring @. = Pullreservoir @ off of the tube. = Pulseove @ outo he reser. = Remove spring @.6 FORK, TRIPLE CLAMP a 201708-11 Remove seal rings @ and O-ing @. Remove pilot bushings @. Info I The steps are identical for both fork lags, except forthe hydrostop needle and valve. e-4 201726-10 '201720-10 201780-10 Preparatory work Disassemble the fork legs. (* p. 17) Remove the spring. (* p. 19) Disassemble the cartridge. ( p. 20) Main work Degrease the piston rod. ‘Clamp the piston rod with the special tool as far up as possible. ‘Glamping stand (1140498) (* p. 268) Release hydrostop needle @ and remove it from the piston rod The valve @ usually remains in the hydrostop needle. © Info - siver hycrostop needle on compression damping side. - red hydrostop needle on rebound damping side. Remove the rebound shim stack @ Remove piston @ Remove the compression shim stack @. Remove spring Remove adapter @ with spring @ and washer. Remove spring @.6 FORK, TRIPLE CLAMP 2 Q rt 2017010 = Remove valve needle @ from the piston rod, Info the adjusting tube can be used for ths. Info T the steps are Identical for both fork legs. 2017-10) Preparatory work = Disassemble the fork legs. (© p. 17) Main work = Mount the hydrostop unit on a fiting hexagon socket and clamp into a vice. = Remove sleeve @. = Remove shim stack @. = Remove adapter @ = Remove hub @ with washers @. Info I itis possible that only one washer or no washer is present. = Remove the O-ring from the hub. = Remove shim stack ®. = Remove washer @. = Remove Oving @. Info HTho stops are identical for both fork logs. Preparatory work = Disassemble the fork legs. (* p. 17) = Remove the spring. (# p. 19) Disassemble the cartridge. (** p. 20)6 FORK, TRIPLE CLAMP 2 Main work = "Remove pot bushing support @ = Remove O-ring @ and sea cng @. 201700-10 Condition ‘The fork legs have been disassembled. = Check the inner tube and axle clamp for damage. » there is damage: = Change the inner tube, ne 2002-10] - Measure the outside diameter at multiple locations of the inner tube. ‘Outside diameter of inner tube 47.975... 48.005 mm (1.88878. 4.88996 in) » Ifthe measured value is smaller than the specified value: = Change the inner tube. = Measure the run-out ofthe inner tube. Inner tube run-out *€0.20 mm (= 0.0079 in) » If the measured value is larger than the specified value: = Change the inner tube. — Measure the inside diameter at multiple locations of the outer tube. Inside diameter of outer tube = 49.20 mm (= 1.937 in) » Ifthe measured value is larger than the specified value: = Change the outer tube. Check the outer tube for damage. » there is damage: = Change the outer tube.6 FORK, TRIPLE CLAMP 24 = Check he surace of the sicing bushings > ithe bronze-colored layer @ under scng layer @ is visible or the surface is rough = Change the sicing bushings. = Cheok the spring length. Guideline Spring length with preload spaceris) _| 472 mm (18.58 in) » Ifthe measured value is larger than the specified value: = Reduce the thickness of the preload spacers. » Ifthe measured value is smaller than the specified value: = Increase the thickness of the preload spacers. Info TThe steps are identical for both fork legs. = Mount and grease sealing @. Lubricant 7158). p. 257) @| ~ Nortmdaese one @ Lubricant (T158) (* p. 257) | ~ Postion plot busting support @ 20100010 Info I The steps are identical for both fork legs. = Mount and grease O-ring @ Lubricant (T158) (*" p. 257) ~ Mount washer @. = Mount shim stack @ with the smaller washers facing downward. = Mount the new O-ring on hub @. — Mount the hub with washers @. Info I itis possible that only one or no washer is present. = Mount and tighten adapter Guideline Hydrostop unit adapter M6x0.5 7Nm 62 fA)