HUSQVARNA FE 501 2022 (01) PDF DOCUMENT

The meaning of specific symbols is described below.

(All EU models)

This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies with the currently valid regulations and categories of the top international motorsports organizations.

Info:

This vehicle is only authorized for operation on public roads in the homologated (restricted) version. The derestricted version of this vehicle must only be operated in closed off areas away from public highway traffic. This vehicle is designed for use in offroad endurance competition, and not primarily for use in motocross.

(US)

This vehicle has been designed and built to withstand the normal stresses and strains of offroad leisure use.

Info:

This vehicle is not approved for use on public roads. This vehicle complies with the Californian and EPA emission requirements for offroad motorcycles. This vehicle is not designed for use in racing on closed circuits or for Motocross use.

The vehicle must only be used as intended. Dangers can arise for people, property and the environment through use not as intended. Any use of the vehicle beyond the intended and defined use constitutes misuse. Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the respective use.

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 (Environmental): Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.

Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:

1. The removal or rendering inoperative by any person other than for purposes of servicing, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or

2. the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below:

1. Removal or puncturing of the main silencers, baffles, manifolds or any other components which conduct emissions.

2. Removal or puncturing of parts of the intake system.

3. Lack of proper maintenance.

4. Replacing moving parts of the vehicle, or parts of the exhaust system or intake system, with parts other than those specified by the manufacturer.

(US)

An add-on or modified part must be compliant with applicable ARB evaporative emission control standards. A violation of this requirement is punishable by civil and/or criminal punishment.

Danger of accidents: A rider who is not fit to ride poses a danger to him or herself and others.

– Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.

– Do not operate the vehicle if you are physically or mentally impaired.

Danger of poisoning: Exhaust gases are toxic and inhaling them may result in unconsciousness and death.

– Always make sure there is sufficient ventilation when running the engine.

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

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 system before the vehicle parts have cooled down.

– Let the vehicle parts cool down before you perform any work on the vehicle.

Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. The vehicle should only be used by trained persons. An appropriate driver’s license is needed to drive the vehicle on public roads. Have malfunctions that impair safety immediately eliminated by an authorized workshop. Adhere to the information and warning labels on the vehicle.

Warning – Risk of injury: Missing or poor protective clothing presents an increased safety risk.

– Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with protectors on all rides.

– Always wear protective clothing that is in good condition and meets the legal regulations.

Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with remote key) or the engine must be at a standstill (models without ignition lock or remote key). 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.

Unless otherwise noted, normal conditions apply to all tasks and descriptions.

During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts, expansion screws, seals, sealing rings, O-rings, pins, and lock washers). In the case of certain screws, a screw adhesive is required. Observe the manufacturer’s instructions. If thread locker has already been applied to a new part, do not apply any additional thread locker. After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts. After completing a repair or service work, check the operating safety of the vehicle.

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 fuels and auxiliary substances in accordance with the Owner’s Manual and specification.

All EU models: The stop button is fitted on the left side of the handlebar.

US models: The stop button is fitted on the left side of the handlebar. Possible states:

– The stop button is in the basic position – In this position, the ignition circuit is closed and the engine can be started.

– Stop button pressed – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.

All EU models: The light switch is on the left side of the handlebar.

Possible states:

– Low beam on – Light switch is in the central position. In this position, the low beam and tail light are switched on.

– High beam on – Light switch is turned to the left. In this position, the high beam and the tail light are switched on.

US models: The light switch is located to the left of the combination instrument.

Possible states:

– Light off – Light switch is pressed in up to the stop. In this position, the light is switched off.

– Light on – Light switch is pulled out to the stop. In this position, the low beam and tail light are switched on.

The turn signal switch is on the left side of the handlebar.

The emergency OFF switch is on the right side of the handlebar.

All EU models: The start button is on the right side of the handlebar.

US models: The start button is on the right side of the handlebar.

Possible states:

– The start button is in the basic position.

– The start button is pressed – The starter motor is actuated in this position.

The combination switch is fitted on the left side of the handlebar. The engine characteristic can be changed using the MAP button. The traction control can also be activated via the combination switch.

Warning: If the combination switch is mounted, the vehicle’s road permit, if any, expires. Only operate the vehicle in closed-off areas remote from public road traffic if the combination switch is installed.

All EU models:

US models:

Opening the cap:

Danger – Fire hazard: Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled.

– Do not fuel 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.

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.

To open, press the release button, turn the fuel tank filler cap counter-clockwise, and lift it off.

Closing the cap:

Mount the fuel tank filler cap and turn it clockwise until the release button engages. Route the fuel tank breather hose without kinks.

The cold start button is fitted to the bottom of the throttle valve body. It extends the injection time if the engine is cold and the ambient temperature is low. To help the engine burn the increased fuel quantity, it must be supplied with additional oxygen by pushing the cold start button.

After briefly opening up the throttle and then releasing the throttle grip again, or turning the throttle grip towards the front, the cold start button returns to its original position. Always check that the button has returned to its basic position.

Possible states:

– The cold start button is activated – The cold start button is pushed in all the way.

– The cold start button is deactivated – The cold start button is in its basic position.

The idle speed is adjusted using the idle speed adjusting screw.

– Increase the idle speed by turning the idle speed adjusting screw clockwise.

– Decrease the idle speed by turning the idle speed adjusting screw counterclockwise.

The idle setting of the throttle valve body substantially influences the vehicle’s starting behavior, a stable idle speed, and the vehicle’s response when the throttle is opened. An engine with a correctly set idle speed is easier to start than an engine with the idle speed set incorrectly.

Locking the steering:

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

1. Park the vehicle.

2. Turn handlebar as far as possible to the right.

3. Lubricate the steering lock regularly with universal oil spray.

4. Insert the key for the steering lock into the steering lock, turn it to the left, push it in, and turn it to the right. Pull out the key for the steering lock.

Steering is no longer possible.

Unlocking the steering:

1. Insert the key for the steering lock into the steering lock, turn it to the left, pull it out, and turn it to the right. Pull out the key for the steering lock.

The handlebar can now be moved again.

Condition: The motorcycle is stationary.

1. Press and hold both buttons for 3 – 5 seconds. The Setup menu is displayed. The UNIT display flashes.

2. Press one of the buttons to select UNIT for the speed in kilometers KM/H or miles M/H.

3. Wait for 5 seconds. The combination instrument changes to the next menu item. The clock symbol flashes.

4. Press one of the buttons to select the 24 h or 12 h display for the clock.

5. Wait for 5 seconds. The combination instrument changes to the next menu item. The time symbol flashes.

– To reset the time, press the left button (value decreases).

– To advance the time, press the right button (value increases).

6. Wait for 5 seconds. The combination instrument changes to the next menu item. The service symbol flashes.

– To shorten the service interval, press the left button (value decreases).

– To extend the service interval, press the right button (value increases).

7. To switch off the service interval display, press and hold the left button until ‘off’ appears in the display.

Speed, time, and DST distance 1:

– Press one of the buttons until DST appears. KM/H or M/H shows the speed. The clock symbol shows the time. DST shows the distance since the last reset (e.g., between refueling stops). If the value of 39999.9 is exceeded, DST is automatically reset to 0.0.

– Press the left button briefly to go to the next display mode.

– Press the left button for 3-5 seconds to preset a value for DST.

– Press the right button for 3-5 seconds to reset DST to 0.0.

Speed, time, and DST2 distance 2:

– Press one of the buttons until DST2 appears. This functions similarly to DST. If the value of 39999.9 is exceeded, DST2 is automatically reset to 0.0.

– Press the left button briefly to go to the next display mode.

– Press the left button for 3-5 seconds to preset a value for DST2.

– Press the right button for 3-5 seconds to reset DST2 to 0.0.

AVG average speed, ART operating hours, and ODO total distance covered:

– Press one of the buttons until AVG, ART, and ODO appear.

– AVG shows the average speed since the last reset.

– ART shows the operating hours.

– ODO shows the total distance covered.

– Press the left button briefly to go to the next display mode.

– Press the left button for 3-5 seconds to show the remaining operating hours until the next service is due.

– Press the right button for 3-5 seconds to reset AVG to 0.0.

Safety Warnings:

– Do not operate the vehicle if you are not fit to ride due to alcohol, drugs, or medication, or if you are physically or mentally impaired.

– Wear appropriate and legal protective clothing (helmet, boots, gloves, etc.).

– Ensure tires have a similar tread pattern on front and rear wheels to avoid impaired handling.

– Adapt your riding speed to road conditions and your ability.

– Do not ride with a passenger; the vehicle is not designed for it.

– Take your foot off the foot brake lever if you do not want to brake to prevent overheating.

– Do not exceed the maximum permissible overall weight or axle loads.

– Do not leave the vehicle unattended with the engine running.

Pre-Ride Actions:

– Make sure the pre-sale inspection has been carried out.

– Read the entire Owner’s Manual carefully.

– Get to know the controls.

– Adjust the basic position of the clutch lever, hand brake lever, foot brake lever, and shift lever to your preference.

– Get used to the handling characteristics on a suitable surface before more challenging trips.

– Ride slowly and in a standing position to get a feel for the motorcycle.

– Do not make off-road trips that exceed your ability and experience.

– Hold the handlebar firmly and keep feet on the footrests.

– If carrying luggage, fix it firmly and close to the center of the vehicle, ensuring even weight distribution.

Guideline:

– Check the spoke tension after half an hour of operation.

– Run in the engine according to the manual’s instructions.

During the running-in phase, do not exceed the specified engine speed and engine performance. Avoid fully opening the throttle!

Guideline:

Lithium-ion batteries have more starting power at temperatures over 6 °C (43 °F). At lower temperatures, several attempts to start may be required.

1. Press the start button for 5 seconds.

2. Wait 15 seconds between attempts. At low temperatures, wait for 30 seconds. The pauses are necessary to allow heat to distribute through the battery.

3. The starting power increases as the battery warms up.

4. Always ensure the battery is charged enough for starting at low temperatures.

5. After 6 unsuccessful starting attempts, do not try again. Check the vehicle for other errors instead.

Use of the vehicle under difficult conditions (sand, wet, mud) can increase wear on components. It may be necessary to inspect or replace parts before the next scheduled service.

– Clean the air filter and air filter box. Check the air filter approx. every 30 minutes.

– Check the electrical connector for humidity and corrosion.

For riding on dry sand:

– Mount the air filter dust cover (79006920000).

– Mount the air filter sand cover (79006922000).

– Clean the chain, mount the steel sprocket, and grease the chain.

– Clean and straighten radiator fins.

– (450 EU) Change the clutch spring to hard (78932005000).

For riding on wet sand:

– Mount the air filter rain cover (79006921000).

– Clean the chain, mount the steel sprocket, and grease the chain.

– Clean and straighten radiator fins.

– (450 EU) Change the clutch spring to hard (78932005000).

For riding on wet and muddy circuits:

– Mount the air filter rain cover (79006921000).

– Mount the steel sprocket.

– Clean the motorcycle and straighten the bent radiator fins.

– (450 EU) Change the clutch spring to hard (78932005000).

For high temperatures or slow riding:

– Adjust the secondary drive to the road conditions.

– Clean the chain and radiator fins.

– Straighten bent radiator fins and check the coolant level.

For low temperatures or snow:

– Mount the air filter rain cover (79006921000).

Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition.

– Check the engine oil level.

– Check the electrical system.

– Check the front and rear brake fluid level.

– Check the front and rear brake linings.

– Check that the brake system is functioning properly.

– Check the coolant level.

– Check for chain dirt accumulation.

– Check the chain, rear sprocket, engine sprocket, and chain guide.

– Check the chain tension.

– Check the tire condition.

– Check the tire pressure.

– Check the spoke tension (incorrect tension will strongly impair riding safety).

– Clean the dust boots of the fork legs.

– Bleed the fork legs.

– Check the air filter.

– Check the settings of all controls and ensure they can be operated smoothly.

– Check all screws, nuts, and hose clips regularly for tightness.

– Check the fuel level.

Danger of poisoning: Exhaust gases are toxic. Always ensure sufficient ventilation. Use effective exhaust extraction when starting 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.

1. Take the motorcycle off the side stand and secure the side stand with the rubber strap.

2. Shift the transmission into neutral.

3. (All EU models) Turn the emergency OFF switch to the ‘on’ position.

4. If the ambient temperature is below 20 °C (68 °F), push the cold start button in all the way.

5. Press the start button.

Info: Press the start button for a maximum of 5 seconds. Wait 15 seconds before a further attempt (30 seconds at low temperatures). After 6 unsuccessful attempts, check the vehicle for errors. During the starting process, the malfunction indicator lamp lights up.

Warning: If the combination switch is mounted, the vehicle’s road permit, if any, expires. Only operate the vehicle in closed-off areas remote from public road traffic if the combination switch is installed.

The traction control reduces excessive slip on the rear wheel for more control and propulsion, particularly in wet conditions. It can be switched on or off during the ride. The last selected setting is activated on restart.

To switch traction control on or off, press the TC button.

Guideline: Engine speed must be ≤ 4,000 rpm to activate.

The TC LED lights up when the traction control is activated.

Starting off:

Ensure the side stand is folded up and secured. Pull the clutch lever, shift into first gear, release the clutch lever slowly, and at the same time open the throttle carefully.

Shifting and Riding:

Warning: Do not change down to a low gear at high engine speed, as the rear wheel could block and the engine could race.

– Shift into a higher gear when conditions allow. Release the throttle, pull the clutch lever, shift, release the clutch lever, and open the throttle.

– After reaching maximum speed, turn the throttle back to ¾ open to reduce fuel consumption.

– To shift down, apply the brakes and close the throttle. Pull the clutch lever, shift to a lower gear, release the clutch lever slowly, and then open the throttle or shift again.

– Switch off the engine if stationary for 2 minutes or more.

– Avoid frequent and lengthy slipping of the clutch to prevent overheating.

Braking:

Warning: Excessively forceful application of the brakes blocks the wheels. Adjust brake application to the riding situation.

Warning: A spongy pressure point reduces braking efficiency. Check the brake system and do not continue riding until the problem is eliminated.

– On sandy, wet, or slippery surfaces, use the rear brake.

– Always finish braking before entering a bend.

– Use the engine braking effect on long downhill stretches by changing down one or two gears without over-revving the engine.

Warning – Risk of misappropriation: Do not leave the vehicle unattended if the engine is running. Protect the vehicle against access by unauthorized persons.

Warning – Danger of burns: Vehicle components are very hot after operation. Let the vehicle parts cool down before performing any work.

Note – Material damage: Park on a firm and level surface to prevent the vehicle from rolling away or falling over. Ensure nobody sits on the vehicle when parked on a stand.

Note – Fire hazard: Do not park near flammable or explosive materials. Allow the vehicle to cool before covering it.

1. Apply the brakes on the motorcycle.

2. Shift the transmission into neutral.

3. Press and hold the stop button while the engine is idling until the engine stops.

4. Park the motorcycle on firm ground.

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

Note – Fire hazard: Hot vehicle components pose a fire hazard. Do not park near flammable materials and allow the vehicle to cool before covering.

1. Switch off the engine.

2. Use tension belts or other suitable devices to secure the motorcycle against falling over or rolling away.

Danger – Fire hazard: Fuel is highly flammable. Do not fuel near open flames or lit cigarettes. Switch off the engine. Avoid spilling fuel, especially on hot parts.

Warning – Danger of poisoning: Fuel is a health hazard. Avoid skin, eye, and clothing contact. Do not inhale vapors.

Note – Environmental hazard: Do not allow fuel to enter the groundwater, soil, or sewage system.

1. Switch off the engine.

2. Open the fuel tank filler cap.

3. Fill the fuel tank with fuel up to the specified measurement.

4. Close the fuel tank filler cap.

The symbols mean: ○ One-time interval; ● Periodic interval

The symbols mean: ○ One-time interval; ● Periodic interval

When adjusting the basic chassis setting, first adjust the shock absorber and then the fork. For optimal riding characteristics, the basic settings of the suspension components must match the rider’s weight.

As delivered, the motorcycle is adjusted for an average rider’s weight (with full protective clothing).

Guideline: Standard rider weight 75 … 85 kg (165 … 187 lb.)

If your weight is above or below this range, the basic setting of the suspension components must be adjusted. Small weight differences can be compensated by adjusting the spring preload, but for large differences, the springs must be replaced.

The compression damping of the shock absorber is divided into high-speed and low-speed ranges, which refer to the compression speed of the rear wheel, not the vehicle speed. High-speed affects landings after jumps, while low-speed affects riding over long ground swells. Modifications in one range affect the other.

Caution: The shock absorber is filled with highly compressed nitrogen. Follow the description provided carefully.

Adjusting the low-speed compression damping:

1. Turn the adjusting screw (1) clockwise with a screwdriver as far as the last perceptible click. Do not loosen fitting (2).

2. Turn counterclockwise by the number of clicks corresponding to the shock absorber type.

Turn clockwise to increase damping; counterclockwise to reduce damping.

Adjusting the high-speed compression damping:

1. Using an open end wrench, turn adjusting screw (1) clockwise all the way. Do not loosen fitting (2).

2. Turn counterclockwise by the number of turns corresponding to the shock absorber type.

Turn clockwise to increase damping; counterclockwise to reduce damping.

Caution: Parts of the shock absorber will move around if detached incorrectly. The shock is filled with highly compressed nitrogen. Follow the description provided.

1. Turn adjusting screw clockwise up to the last perceptible click.

2. Turn counterclockwise by the number of clicks corresponding to the shock absorber type.

Turn clockwise to increase damping; turn counterclockwise to reduce damping when the shock absorber rebounds.

Measuring the dimension of the rear wheel unloaded (Dimension A):

1. Raise the motorcycle with a lift stand.

2. Position a sag gage in the rear axle and measure the distance to the marking SAG on the rear fender. Note this value as dimension A.

3. Remove the motorcycle from the lift stand.

Checking the static sag:

1. Hold the motorcycle upright with an assistant.

2. Measure the distance again between the rear axle and the SAG marking. Note this value as dimension B.

3. The static sag is the difference between measurements A and B.

Guideline: Static sag should be 37 mm (1.46 in).

4. If the static sag is incorrect, adjust the spring preload of the shock absorber.

Checking the riding sag:

1. With an assistant holding the motorcycle, the rider (in full protective clothing) sits on the seat in a normal position and bounces up and down a few times.

2. The assistant measures the distance between the rear axle and the SAG marking. Note this value as dimension C.

3. The riding sag is the difference between measurements A and C.

Guideline: Riding sag should be 110 mm (4.33 in).

4. If the riding sag differs from the specified measurement, adjust the riding sag.

Caution: The shock absorber is filled with highly compressed nitrogen. Follow procedures carefully.

Preparatory work:

1. Raise the motorcycle with a lift stand.

2. Remove the shock absorber.

3. After removing, clean the shock absorber thoroughly.

Main work:

1. Loosen screw (1).

2. Turn adjusting ring (2) with a hook wrench until the spring is no longer under tension.

3. Tension the spring by turning adjusting ring (2) to the specified dimension A for spring preload.

Guideline: Spring preload should be 12 mm (0.47 in).

4. Tighten screw (1).

Guideline: Screw, shock absorber adjusting ring M5: 5 Nm (3.7 lbf ft).

Finishing work:

1. Install the shock absorber.

2. Remove the motorcycle from the lift stand.

If larger adjustments for rider weight are needed, you must choose and mount a suitable spring.

Preparatory work:

1. Raise the motorcycle with a lift stand.

2. Remove the shock absorber and clean it.

Main work:

Choose and mount a suitable spring based on rider weight. The spring rate is shown on the outside of the spring.

Finishing work:

1. Install the shock absorber.

2. Remove the motorcycle from the lift stand.

3. Check the static sag and riding sag of the shock absorber.

4. Adjust the rebound damping of the shock absorber.

The hydraulic damping determines the fork suspension behavior. The compression damping is in the left fork leg (COMP, white adjuster). The rebound damping is in the right fork leg (REB, red adjuster).

Adjusting the compression damping:

1. Turn the white adjuster clockwise as far as it will go.

2. Turn counterclockwise by the number of clicks for your desired setting.

Turn clockwise to increase damping; counterclockwise to reduce damping.

Adjusting the rebound damping:

1. Turn the red adjuster clockwise as far as it will go.

2. Turn counterclockwise by the number of clicks for your desired setting.

Turn clockwise to increase damping; counterclockwise to reduce damping.

Preparatory work:

– Raise the motorcycle with a lift stand.

Main work:

1. Turn T-grips (1) counterclockwise all the way. The marking +0 aligns with the right T-grip on both fork legs.

2. Turn the T-grips clockwise to your desired setting. Make adjustments by hand only and make the same adjustment on both fork legs.

The T-grips engage noticeably at the numerical values. Adjusting the spring preload has no influence on the rebound absorption setting, but you should set the rebound damping higher with a higher spring preload.

Finishing work:

– Remove the motorcycle from the lift stand.

Warning: A repaired handlebar poses a safety risk. If the handlebar is bent or straightened, the material becomes fatigued and may break. Change the handlebar if it is damaged or bent.

The upper triple clamp has two holes (15 mm apart) for the handlebar supports. The supports themselves have an offset of 3.5 mm, allowing for four different mounting positions.

1. Remove screws (1) and take off the handlebar clamps. Lay the handlebar to one side, covering components to protect them from damage. Do not bend cables and lines.

2. Remove screws (2) and take off the handlebar supports.

3. Place the handlebar supports in the required position. Mount and tighten screws (2).

Guideline: Screw, handlebar holder M10: 40 Nm (29.5 lbf ft) with Loctite® 243™.

4. Position the handlebar, ensuring cables and wiring are positioned correctly.

5. Position the handlebar clamps. Mount and tighten screws (1) evenly.

Guideline: Screw, handlebar clamp M8: 20 Nm (14.8 lbf ft). Ensure the gap width is even.

Raising the motorcycle:

1. Park the vehicle on a firm and level surface.

2. Raise the motorcycle at the frame underneath the engine using a lift stand (81329955100).

3. Ensure neither wheel is in contact with the ground.

4. Secure the motorcycle against falling over.

Removing the motorcycle from the lift stand:

1. Park the vehicle on a firm and level surface.

2. Remove the motorcycle from the lift stand.

3. Remove the lift stand.

4. To park the motorcycle, press the side stand to the ground with your foot and lean the motorcycle on it. Remember to fold up the side stand and secure it with the rubber strap when riding.

Preparatory work:

– Raise the motorcycle with a lift stand.

Main work:

1. Release the bleeder screws (1).

2. Any excess pressure escapes from the interior of the fork.

3. Tighten the bleeder screws.

Finishing work:

– Remove the motorcycle from the lift stand.

The dust boots remove dust and dirt from the inner fork tubes. Over time, dirt can accumulate behind them, causing the oil seals to leak if not removed.

Warning: Oil or grease on the brake discs reduces braking effect. Always keep discs free of oil and grease.

Preparatory work:

1. Raise the motorcycle with a lift stand.

2. Remove the fork protector.

Main work:

1. Push dust boots (1) of both fork legs downward.

2. Clean and oil the dust boots and inner fork tubes of both fork legs with universal oil spray.

3. Press the dust boots back into their installation position.

4. Remove excess oil.

Finishing work:

1. Install the fork protector.

2. Remove the motorcycle from the lift stand.

Removing the fork protector:

1. Remove screws (1) and take off the clamp.

2. Remove screws (2) on the left fork leg and take off the left fork protector.

3. Remove screws (3) on the right fork leg and take off the right fork protector.

Installing the fork protector:

1. Position the fork protector on the left fork leg. Mount and tighten screws (1).

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

2. Position the brake line, wiring harness, and clamp. Mount and tighten screws (2).

3. Position the fork protector on the right fork leg. Mount and tighten screws (3).

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

Removing the fork legs:

1. Remove the headlight mask with the headlight.

2. Raise the motorcycle with a lift stand.

3. Remove the front wheel.

4. Remove screws (1) and take off the clamp.

5. Remove the cable tie.

6. Remove screws (2) and take off the brake caliper. Allow the caliper and brake line to hang loosely to the side.

7. Loosen screws (3) and remove the left fork leg.

8. Loosen screws (4) and remove the right fork leg.

Installing the fork legs:

1. Position the fork legs. Bleeder screws (1) should be positioned toward the front. The second milled groove from the top of the fork legs must be flush with the upper edge of the upper triple clamp.

2. Tighten screws (2) of the top triple clamp.

Guideline: M8 screw: 17 Nm (12.5 lbf ft).

3. Tighten screws (3) of the bottom triple clamp.

Guideline: M8 screw: 15 Nm (11.1 lbf ft).

4. Position the brake caliper, and mount and tighten screws (4).

Guideline: M8 screw: 25 Nm (18.4 lbf ft) with Loctite® 243™.

5. Mount the cable ties.

6. Position the brake line, wiring harness, and clamp. Mount and tighten screws (5).

7. Install the front wheel, install the headlight mask, and check the headlight setting.

Warning: Incorrect steering head bearing play impairs handling and damages components. Correct it immediately.

Info: If the vehicle is operated for a lengthy period with play, the bearings and bearing seats can become damaged.

Preparatory work:

– Raise the motorcycle with a lift stand.

Main work:

1. Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel.

2. Play should not be detectable on the steering head bearing. If there is play, adjust the steering head bearing play.

3. Move the handlebar to and fro over the entire steering range. It must move easily with no detectable detent positions. If detent positions are detected, adjust the bearing play and check/replace the bearing if necessary.

4. Check the steering stop bolts for correct adjustment and locking.

Finishing work:

– Remove the motorcycle from the lift stand.

Preparatory work:

– Raise the motorcycle with a lift stand.

Main work:

1. Loosen screws (1) on the upper triple clamp.

2. Remove screw (2) from the top steering stem.

3. Loosen and retighten screw (3) on the top steering head.

Guideline: Screw, top steering head M20x1.5: 12 Nm (8.9 lbf ft).

4. Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses.

5. Tighten screws (1) on the upper triple clamp.

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

6. Mount and tighten screw (2) on the top steering stem.

Guideline: Screw, top steering stem M8: 17 Nm (12.5 lbf ft) with Loctite® 243™.

Finishing work:

1. Check the steering head bearing for play.

2. Remove the motorcycle from the lift stand.

Removing front fender:

1. Remove the headlight mask with the headlight.

2. Remove screws (1).

3. Remove screws (2). Take off the front fender.

Installing front fender:

1. Position the front fender. Mount and tighten screws (1).

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

2. Mount and tighten screws (2).

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

3. Install the headlight mask and check the headlight setting.

Removing the shock absorber:

1. Raise the motorcycle with a lift stand.

2. Remove cable ties and screws (1) with washers.

3. Detach the frame protector in area A and take it off.

4. Remove screw (2) and fitting (3). (Raising the link fork slightly may help).

5. Press angle lever (4) toward the rear and linkage lever (5) downward.

6. (All EU models) Disconnect the plug-in connector of the brake light switch.

7. Remove screws (6) and pull off the foot brake cylinder from the push rod.

8. Remove the connecting link of the chain and take off the chain.

9. Remove nut (7), pull out the swingarm pivot, and push the link fork back.

10. Hold the shock absorber and remove screw (8). Remove the shock absorber from the bottom.

Installing the shock absorber:

1. Carefully position the shock absorber from the bottom. Mount and tighten screw (1).

Guideline: Screw, top shock absorber M10: 60 Nm (44.3 lbf ft) with Loctite® 2701™.

2. Position the link fork and mount the swingarm pivot. Pay attention to flat area A. Mount and tighten nut (2).

Guideline: Nut, fork pivot M16x1.5: 100 Nm (73.8 lbf ft).

3. Mount the chain and connect it with the connecting link (closed side of lock must face direction of travel).

4. (All EU models) Join the plug-in connector of the brake light switch.

5. Position the foot brake cylinder, ensuring push rod (3) engages. Mount and tighten screws (4).

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

6. Position the angle lever and linkage lever. Mount and tighten fitting (5).

Guideline: Nut, linkage lever on angle lever M14x1.5: 60 Nm (44.3 lbf ft).

7. Mount and tighten screw (6).

Guideline: Screw, bottom shock absorber M10: 60 Nm (44.3 lbf ft) with Loctite® 2701™.

8. Attach frame protector in area C. Mount and tighten screws (7) with washers.

Guideline: Screw, frame protector M5: 3 Nm (2.2 lbf ft).

9. Mount new cable ties and remove the motorcycle from the lift stand.

Removing the seat:

1. Remove the air filter box cover.

2. Remove screw (1) with the bushing.

3. Pull the seat back and lift it off.

Mounting the seat:

1. Mount the front of the seat on the collar bushing of the fuel tank and the rear in the bracket.

2. Push the seat forward, ensuring it is latched correctly.

3. Mount and tighten screw (1) and the bushing.

Guideline: Screw, rear seat fixing M6: 10 Nm (7.4 lbf ft).

4. Install the air filter box cover.

Removing the cover:

– Pull off the air filter box cover sideways in areas A, B and C and take it off toward the rear.

Installing the cover:

1. Attach catch (1) of the air filter box in area A and push forward.

2. Engage the air filter box cover in areas B, C and D.

Note: Unfiltered intake air negatively affects engine service life. Only operate the vehicle with an air filter equipped.

Removing the air filter:

1. Remove the air filter box cover.

2. Detach retaining tab (1). Remove the air filter with its support.

3. Remove the air filter from the air filter support.

Cleaning the air filter and air filter box:

Note: Do not clean the air filter with fuel or petroleum as these substances attack the foam.

1. Wash the air filter thoroughly in a special cleaning liquid (e.g., air filter cleaner) and allow it to dry properly. Only press the air filter to dry it, never wring it out.

2. Oil the dry air filter with a high-grade foam air filter oil.

3. Clean the air filter box.

4. Check the intake flange for damage and looseness.

Installing the air filter:

1. Mount the clean air filter on the air filter support.

2. Grease the air filter in area A with long-life grease.

3. Insert the air filter and position retaining pin (1) in bushing B. The air filter must be correctly positioned.

4. Insert retaining tab (3). Retaining pin (2) is secured with retaining tab (3).

5. Install the air filter box cover.

Removing the cover:

1. Remove the air filter box cover and the seat.

2. Detach the side cover in area A, pull off sideways in area B, and take off toward the rear.

Installing the cover:

1. Attach the side cover with the holding lugs A from below and push upward.

2. Engage the side cover in areas B and C.

3. Mount the seat and install the air filter box cover.

Warning: The exhaust system gets very hot. Allow it to cool down before performing any work.

Removing the silencer:

1. Remove the air filter box cover, seat, and right side cover.

2. Detach spring (1) using a spring hook.

3. Remove screws (2) and take off the main silencer with the catalytic converter.

Installing the silencer:

1. Position the catalytic converter in the main silencer.

2. Position the main silencer. Mount screws (1), but do not tighten yet.

3. Attach spring (2) using a spring hook.

4. Tighten screws (1).

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

5. Install the right side cover, seat, and air filter box cover.

Warning: The exhaust system gets very hot. Allow it to cool down before any work.

Caution: Soot particles irritate the eyes and mucous membranes. Wear suitable breathing and eye protection.

Preparatory work:

1. Remove the air filter box cover, seat, right side cover, and main silencer.

Main work:

1. Remove all screws, and take off silencer cap (1) with O-ring (2).

2. Clean main silencer sleeve (3) and screen (4) of the spark arrestor with compressed air.

3. Position silencer cap (1) with O-ring (2).

4. Mount and tighten all of the screws.

Guideline: Screws on main silencer M5: 7 Nm (5.2 lbf ft).

Finishing work:

1. Install the main silencer, right side cover, seat, and air filter box cover.

Warning: The exhaust system gets very hot. Allow it to cool down before any work.

Preparatory work:

1. Remove the air filter box cover, seat, right side cover, and main silencer.

Main work (All EU models):

1. Remove all screws on the main silencer.

2. Take off silencer cap (1) with O-ring (2).

3. Remove glass fiber yarn filling (3) from main silencer (4).

4. Clean parts and check for damage.

5. Mount the new glass fiber yarn filling between the inner and outer tube.

6. Position the silencer cap with O-ring in the outer tube.

7. Mount and tighten all screws.

Guideline: Screws on main silencer M5: 7 Nm (5.2 lbf ft).

Main work (US):

1. Remove all screws on the main silencer.

2. Take off silencer cap (1) with the filter and O-ring (2).

3. Remove glass fiber yarn filling (3) from main silencer (4).

4. Follow steps 4-7 from the EU models instructions.

Finishing work:

1. Install the main silencer, right side cover, seat, and air filter box cover.

Danger – Fire Hazard & Poisoning: Fuel is highly flammable and toxic. Work in a well-ventilated area away from ignition sources. Avoid contact with skin, eyes, and clothing. Do not inhale vapors.

Removing the fuel tank:

1. Remove the air filter box cover, seat, and right side cover.

2. Unplug connector (1) of the fuel pump.

3. Clean quick release coupling (2) thoroughly with compressed air.

4. Disconnect the quick release coupling. Mount wash cap set (3) (81212016100).

5. Pull the fuel tank breather hose off the fuel tank lid.

6. Remove screws (4). (All EU models) Hang the horn and bracket to one side.

7. Remove screw (5) with the rubber bushing.

8. Pull both spoilers laterally off the radiator and lift off the fuel tank.

Installing the fuel tank:

1. Check the throttle cable routing.

2. Position the fuel tank and fit the two spoilers to the sides in front of the radiator bracket. Ensure no cables are trapped.

3. Attach the fuel tank breather hose.

4. Mount and tighten screw (1) with the rubber bushing.

Guideline: M6 screw: 10 Nm (7.4 lbf ft).

5. (All EU models) Position the horn with the horn bracket. Mount and tighten screws (2).

Guideline: M6 screw: 10 Nm (7.4 lbf ft).

6. Plug in connector (3) for the fuel pump.

7. Remove the wash cap set.

8. Clean the quick release coupling thoroughly. Lightly lubricate the O-ring with silicone spray.

9. Join quick release coupling (4). Route the cable and fuel line away from the exhaust system.

10. Install the right side cover, seat, and air filter box cover.

Warning: Incorrect chain tension damages components and can cause accidents. If too tight, components wear quickly. If too loose, the chain may fall off.

Checking chain tension:

1. Raise the motorcycle with a lift stand.

2. Pull the chain upward at the end of the chain sliding piece to measure tension (A).

Guideline: Chain tension should be 55 … 58 mm (2.17 … 2.28 in).

3. Repeat this measurement at different chain positions. If tension is incorrect, adjust it.

Adjusting chain tension:

1. Raise the motorcycle and check the current chain tension.

2. Loosen nut (1) and nuts (2).

3. Adjust the chain tension by turning adjusting screws (3) left and right to the guideline value.

4. Ensure markings on the left and right chain adjusters are in the same position relative to reference marks (A) for correct wheel alignment.

5. Tighten nuts (2).

6. Make sure chain adjusters (4) are fitted correctly on the adjusting screws.

7. Tighten nut (1).

Guideline: Nut, rear wheel spindle M20x1.5: 80 Nm (59 lbf ft).

8. Remove the motorcycle from the lift stand.

The blink codes are only displayed by the derestricted version of the vehicle.

Brake fluid DOT 4 / DOT 5.1:

– Use only brake fluid that complies with the DOT 4 or DOT 5.1 standard.

Coolant:

– Use high-grade, silicate-free coolant with corrosion inhibitor for aluminum motors. Antifreeze protection should be at least -25 °C (-13 °F). Recommended: MOTOREX® COOLANT M3.0.

Engine oil (SAE 10W/50):

– Use only fully synthetic engine oils that comply with JASO T903 MA2 and SAE 10W/50 standards. Recommended: MOTOREX® Cross Power 4T.

Fork oil (SAE 4):

– Use only oils that comply with SAE 4 standard. Part number: 48601166S1.

Shock absorber fluid (SAE 2.5):

– Use only oils that comply with SAE 2.5 standard. Part number: 50180751S1.

Super unleaded fuel (ROZ 95):

– Use super unleaded fuel (DIN EN 228 / ROZ 95). Fuel with an ethanol content of up to 10% (E10 fuel) is safe to use. Do not use fuel containing methanol or more than 10% ethanol.

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

– Off-road chain spray: MOTOREX® Chainlube Offroad

– Oil for foam air filter: MOTOREX® Racing Bio Liquid Power

– Preserving materials: MOTOREX® Moto Protect

– Silicone spray: MOTOREX® Silicone Spray

– Special cleaner for paint/metal/plastic: MOTOREX® Quick Cleaner

– Universal oil spray: MOTOREX® Joker 440 Synthetic