HUSABERG FE 450 (2005), FE 501 (2005), FS 450 (2005), FS 650 E/6 (2005), FC 450/4 (2005) Repair Manual

REPARATURANLEITUNG

REPAIR MANUAL

MANUEL DE REPARATION

“

04

Edition 2004

PREFACE

This manual contains detailed instructions on repairing the engine. It was prepared according
to the state of the art for this model series. We reserve the right to make modifications based
on technical progress without making the respective corrections in this repair manual.

This manual does not contain a description of general shop or working methods. It does not
include safety rules generally observed in workshops and is based on the assumption that the
work is performed by a mechanic who has completed his vocational training.

Please read the entire manual before starting to work.

WARNING: failing to observe these instructions can be dangerous to life and limb.

CAUTION: failing to observe these instructions may damage the motorcycle/engine components
or impair the motorcycle's traffic safety.

NOTE: provides useful information.

Only use ORIGINAL HUSABERG SPARE PARTS if parts need to be replaced.

The engine will only continue to operate safely if the prescribed service work is performed
regularly and professionally.

Subject to changes in construction and design.

C

by HUSABERG All rights reserved

INDEX

A

B

C

D

E

F

G

H

I

J

K

L

M

N

GENERAL INFORMATION

DISMOUNTING AND MOUNTING THE ENGINE

DISASSEMBLING THE ENGINE

SERVICING THE INDIVIDUAL PARTS

ASSEMBLING THE ENGINE

ELECTRIC SYSTEM

FUEL SYSTEM

TROUBLESHOOTING

TECHNICAL SPECIFICATIONS

PERIODIC MAINTENANCE SCHEDULE

WIRING DIAGRAMS

TABLE OF CONTENTS

GENERAL INFORMATION

Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1

Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1

Checking the oil level . . . . . . . . . . . . . . . . . . . . . . .A1

Changing the engine oil . . . . . . . . . . . . . . . . . . . . .A2

Cleaning the oil screen . . . . . . . . . . . . . . . . . . . . . .A2

Changing the oil filter . . . . . . . . . . . . . . . . . . . . . . .A3

Checking the oil level in the hydraulic clutch . . . . .A4

Bleeding the clutch . . . . . . . . . . . . . . . . . . . . . . . . .A4

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5

Preservation for winter operation . . . . . . . . . . . . . .A5

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6

DISMOUNTING AND MOUNTING THE ENGINE

Dismounting the engine . . . . . . . . . . . . . . . . . . . . .B1

Mounting the engine . . . . . . . . . . . . . . . . . . . . . . .B5

Bleeding the cooling system . . . . . . . . . . . . . . . . . .B9

Adjusting the decompression cable . . . . . . . . . . . .B9

Adjusting the throttle cable . . . . . . . . . . . . . . . . . .B9

DISASSEMBLING THE ENGINE

Blocking the engine . . . . . . . . . . . . . . . . . . . . . . . .C1

Removing the rotor . . . . . . . . . . . . . . . . . . . . . . . . .C2

Removing the pressure relief valve . . . . . . . . . . . . .C2

Removing the clutch . . . . . . . . . . . . . . . . . . . . . . . .C3

Removing inner clutch hub . . . . . . . . . . . . . . . . . . .C4

Removing primary pinion and the idler shaft gear

. .C4

Removing the oil pump . . . . . . . . . . . . . . . . . . . . .C5

Removing the chain tensioner . . . . . . . . . . . . . . . .C6

Separating the timing chain . . . . . . . . . . . . . . . . . .C6

Removing the cylinder head . . . . . . . . . . . . . . . . . .C7

Separating the housing . . . . . . . . . . . . . . . . . . . . .C7

Removing the crankshaft . . . . . . . . . . . . . . . . . . . .C8

Removing the transmission . . . . . . . . . . . . . . . . . . .C8

Removing the idler shaft . . . . . . . . . . . . . . . . . . . . .C9

SERVICING THE INDIVIDUAL PARTS

Important . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1

Left housing half . . . . . . . . . . . . . . . . . . . . . . . . . .D1

Right housing half . . . . . . . . . . . . . . . . . . . . . . . . . .D2

Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . .D3

Clutch cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D3

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D4

Press out the crank pin . . . . . . . . . . . . . . . . . . . . . .D5

Press in the crank pin . . . . . . . . . . . . . . . . . . . . . . .D6

Checking the crankshaft journal . . . . . . . . . . . . . . .D7

Outer dimension of the crankshaft webs . . . . . . . .D7

Balancing the axial clearance of the crankshaft . . .D8

Nikasil cylinder coating . . . . . . . . . . . . . . . . . . . . . .D9

Measuring the piston and cylinder liner,

determining the piston mounting clearance . . . . .D9

Checking the piston . . . . . . . . . . . . . . . . . . . . . . .D10

Checking the piston ring end gap . . . . . . . . . . . .D10

Checking the oil pump for wear . . . . . . . . . . . . . .D10

Cylinder head top section . . . . . . . . . . . . . . . . . .D11

Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . .D12

Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D14

Timing chain tensioner . . . . . . . . . . . . . . . . . . . . .D15

Timing train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D15

Checking the clutch for wear . . . . . . . . . . . . . . . .D16

Checking the kickstarter for wear . . . . . . . . . . . . .D17

Shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . .D18

Assembling the main shaft (four-speed) . . . . . . . .D19

Assembling the main shaft (six-speed) . . . . . . . . .D20

Assembling the countershaft (four/six-speed) . . .D21

Starter drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D22

Checking the freewheel. . . . . . . . . . . . . . . . . . . . .D22

Checking the freewheel hub . . . . . . . . . . . . . . . . .D22

ASSEMBLING THE ENGINE

Mounting the idler shaft . . . . . . . . . . . . . . . . . . . . .E1

Mounting the crankshaft . . . . . . . . . . . . . . . . . . . .E2

Mounting the cylinder head . . . . . . . . . . . . . . . . . .E4

Mounting the timing chain . . . . . . . . . . . . . . . . . . .E5

Mounting the timing chain tensioner . . . . . . . . . . .E7

Adjusting the valve clearance . . . . . . . . . . . . . . . . .E7

Mounting the oil pump . . . . . . . . . . . . . . . . . . . . . .E8

Mounting the shift mechanism . . . . . . . . . . . . . . . .E8

Mounting the kickstarter shaft . . . . . . . . . . . . . . . . .E9

Mounting the clutch . . . . . . . . . . . . . . . . . . . . . . . .E9

Mounting the clutch cover . . . . . . . . . . . . . . . . . .E11

Mounting the pressure relief valve . . . . . . . . . . . .E13

Mounting rotor and pick up . . . . . . . . . . . . . . . . .E13

ELECTRIC SYSTEM

Checking for loss of current . . . . . . . . . . . . . . . . . .F1

Dismounting/mounting the battery . . . . . . . . . . . . .F1

Charging the battery . . . . . . . . . . . . . . . . . . . . . . . .F1

Filling the battery . . . . . . . . . . . . . . . . . . . . . . . . . .F2

Checking the starter . . . . . . . . . . . . . . . . . . . . . . . .F2

Checking the starter relay . . . . . . . . . . . . . . . . . . . .F3

Checking the main fuse . . . . . . . . . . . . . . . . . . . . . .F3

Checking the voltage regulator . . . . . . . . . . . . . . . .F4

Kokusan 4K3B dynamic generator values . . . . . . . .F4

Troubleshooting in the ignition system . . . . . . . . . .F5

CDI unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F6

Checking the ignition coil . . . . . . . . . . . . . . . . . . . .F6

Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . .F7

Checking the stator and pulse generator . . . . . . . .F7

Replacing the stator in FC models (Kokusan 4K-3A) . .

F7

Replacing the stator in FE and FS models (Kokusan 4K-3B

) . .F7

Static ignition values Kokusan 4K-3A/B . . . . . . . . .F8

Static generator values Kokusan 4K3B . . . . . . . . .F10

FUEL SYSTEM

KEIHIN FCR-MX 39/41 . . . . . . . . . . . . . . . . . . . . . .G1

Disassembling the carburetor . . . . . . . . . . . . . . . . .G2

Choke slide and hot start knob . . . . . . . . . . . . . . .G5

Accelerator pump . . . . . . . . . . . . . . . . . . . . . . . . . .G5

Jet needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G5

Float needle valve . . . . . . . . . . . . . . . . . . . . . . . . .G5

Throttle slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G6

Assembling the carburetor . . . . . . . . . . . . . . . . . . .G6

Adjusting the throttle sensor position . . . . . . . . .G10

Checking the throttle sensor . . . . . . . . . . . . . . . .G11

Dismounting and mounting the throttle sensor . .G11

Adjusting the idle . . . . . . . . . . . . . . . . . . . . . . . . .G12

Checking/adjusting the float height . . . . . . . . . . .G13

TROUBLESHOOTING

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .H1

TECHNICAL SPECIFICATIONS

Engine 450, 501 . . . . . . . . . . . . . . . . . . . . . . . . . . . .I1

Carburetor 450, 501 . . . . . . . . . . . . . . . . . . . . . . . . .I1

Engine 550, 650 . . . . . . . . . . . . . . . . . . . . . . . . . . . .I2

Carburetor 550, 650 . . . . . . . . . . . . . . . . . . . . . . . . .I2

Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I3

Engine torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4

Chassis torques . . . . . . . . . . . . . . . . . . . . . . . . . . . .I5

Mounting clearances, engine wear limits . . . . . . . ..I6

PERIODIC MAINTENANCE SCHEDULE

FC 450, 550/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J1

FE 450 - 650e/6, FS 450, 650e/6 . . . . . . . . . . . . . . .J2

Additional work - driver . . . . . . . . . . . . . . . . . . . . . .J3

Additional work - workshop . . . . . . . . . . . . . . . . . ..J4

WIRING DIAGRAMS

FC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .K1

FE models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .K2

FE USA models . . . . . . . . . . . . . . . . . . . . . . . . . . . .K4

FS models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .K6

Cable colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .K8

ENGINE OIL

Only use fully synthetic brand-name engine oils (e.g.:
Motorex Power Synt. 4T) that meet or exceed the Jaso
T903 MA quality requirements (information on the can).

CAUTION: not enough engine oil or low-quality
oil will lead to premature engine wear.

CHECKING THE ENGINE OIL LEVEL

NOTE: the engine oil level can be checked
when the engine is cold or warm.

–Place the motorcycle on a level surface (not on the

side stand).
If the engine is cold, the engine oil should be visible at
the lower edge (A) of the inspection glass.
If the engine is warm, the engine oil should reach the
upper edge (B) of the inspection glass.
Add engine oil if necessary.

CAUTION: not enough engine oil or low-quality
oil will lead to premature engine wear.

– Check the engine for leakage.

GENERAL INFORMATION

A
1

A

B

0°C

32°F

10W/50

5W/40

JASO T903 MA

TEMPERATURE

OIL CIRCUIT

DESCRIPTION:

The oil pump (1) draws the engine oil from the oil sump through the oil screen (2) and pumps it past the pressure
relief valve (3) to the oil filter (4). It continues to the crankshaft (5), partly branching off through a hole to lubricate
and cool the piston (6) and the piston pin bearing. Once through the crankshaft, the engine oil is pumped to the
conrod bearing (7) and branches off again to the bearings in the balance weight (8).
The camshaft (9) is lubricated by the engine oil which is transported to the cylinder head by the timing chain (10).
On the downward movement of the piston, engine oil is pressed from the crankcase through the diaphragm
valve (not depicted) to the transmission and shift mechanism.

1

2

3

4

6

5

8

7

9

10

CHANGING THE ENGINE OIL

NOTE: Replace the oil screen and the oil filter
when you change the engine oil.

Change the engine oil when the engine is at
operating temperature.

WARNING: the engine oil will be very hot when
the engine is at operating temperature – be
careful not to burn yourself.

– Place the motorcycle on a level surface, remove the

plug (1) and allow the oil to drain into a suitable vessel.

– Thoroughly clean the plug (with the magnet).

– After the oil is completely drained, clean the sealing

area, mount the plug with a new seal ring and tighten

to 20 Nm.

CLEANING THE OIL SCREEN

NOTE: the oil screen (3) is located in the plug
with the hexagon drive (2) next to the oil drain
plug on the right side of the engine.

–Dismount the plug with the oil screen, thoroughly

clean the parts and blow clean with compressed air.

– Check the O-rings (4) for damage and replace if

necessary.

– Insert the oil screen in the plug, mount and tighten the

plug to 15 Nm.

GENERAL INFORMATION

A

2

1

2

3

4

4

GENERAL INFORMATION

A
3

CHANGING THE OIL FILTER

– Place a suitable vessel under the engine to allow the

oil to drain.

– Remove both bolts (1) and screw an M6 bolt in the

center hole (2) of the oil filter cover.

NOTE: only tighten the bolt by hand, otherwise
you will damage the oil filter cover.

– Pull the oil filter cover (3) out of the hole with the bolt

M6 and remove the bolt.

– Use pliers to pull the oil filter element (4) from the

housing.

– Clean the oil filter cover, the sealing areas on the

O-rings and the engine case. check the O-rings (5) in

the oil filter cover for damage and replace if necessary.

– Lay the motorcycle down and fill the oil filter housing

approx. half-full with engine oil. Insert the oil filter in

the housing.

–Grease the O-rings in the oil filter cover and mount the

cover. Mount the bolts and tighten to 6 Nm.

–Place the motorcycle in an upright position again.

– Unscrew the oil filler plug (6) and add 1 liter of fully

synthetic engine oil (e.g.: Motorex Power Synt. 4T).

–Start the engine and check all of the plugs and the oil

filter cover for leakage.

– Finally, check the engine oil level and correct if

necessary.

1

1

2

3

4

6

5

5

GENERAL INFORMATION

A

4

CHECKING THE OIL LEVEL IN THE
HYDRAULIC CLUTCH

Remove the cover to check the oil level in the master
cylinder of the clutch. Remove the screws (1) and lift off
the cover together with the rubber boot (2). The oil level
should be 4 mm below the upper edge when the master
cylinder is in a horizontal position. If necessary, add SAE
10 biodegradable hydraulic oil (e.g.: Motorex clutch fluid

75).

CAUTION: only fill SAE 10 biodegradable
hydraulic oil into the master cylinder. Do not
add brake fluid.

BLEEDING THE CLUTCH

To bleed, remove the cover on the master cylinder of the
clutch. Remove the screws (1) and lift off the cover
together with the rubber boot (2). Remove the vent
nipple from the slave cylinder of the clutch. Mount the
bleeder syringe (3) filled with SAE 10 biodegradable
hydraulic oil (e.g.: Motorex clutch fluid 75).

Continue to add oil until the oil runs out of the hole (A) in
the master cylinder without bubbles. Make sure the oil
does not overflow.

CAUTION: after bleeding the clutch, check the
oil level in the master cylinder. Only fill SAE 10
biodegradable hydraulic oil (e.g.: Motorex
clutch fluid 75) into the master cylinder. Do not
use brake fluid or mix with mineral hydraulic oil.

1

2

3

A

GENERAL INFORMATION

A
5

Clean the motorcycle regularly to retain the beauty of the plastic parts.
Use warm water with a commercial detergent and a sponge. Coarse dirt can be removed with a soft water jet.

CAUTION: never clean the motorcycle with a power washer or a high pressure jet. This will cause the
water to reach the electric components, socket connectors, cables, bearings, carburetor, etc. and
will cause these parts to malfunction or break.

– Only use commercial detergents to clean the engine. Use a brush to clean any heavily soiled areas.
– Before you start cleaning, close the exhaust pipe to prevent water from penetrating.
–After cleaning the motorcycle thoroughly with a soft water jet, dry with compressed air and a soft cloth. Drain

the float chamber in the carburetor. Take a short ride until the engine reaches the operating temperature,
applying the brakes while driving. The heat will cause the water to evaporate from the inaccessible engine and
brake areas.

–Slide back the protection covers on the handlebar instruments to allow water that has penetrated to

evaporate.

– After the motorcycle has cooled down, oil or grease all of the sliding and bearing points. Treat the chain with

chain spray. Oil the fuel tap.

–To prevent defects in the electric system, apply contact spray to the emergency stop switch, the short-circuit

button, the light switch and the socket connector.

If the motorcycle is used during the winter where roads will be spread with salt, precautions must be taken to
protect the motorcycle against the aggressive road salt.
– Clean the motorcycle thoroughly and allow to dry after each ride.
–Treat the engine, carburetor, swing arm and all other bare or galvanized parts (except the brake disks) with a

wax-based anti-corrosion agent.

WARNING: do not allow any anti-corrosion agent to get on the brake disks since this will significantly
reduce the braking effect.

CAUTION: clean the motorcycle with cold water and dry thoroughly after driving on salted roads.

If your motorcycle is to be immobilized for a longer period of time, proceed as follows:
–Clean the motorcycle thoroughly.
– Change the engine oil, the short and the long oil filter (old engine oil contains aggressive impurities).
– Check the quantity of antifreeze and coolant.
–Allow the engine to warm up, close the fuel tap and wait until the engine stalls. Open the drain plug on the

float chamber to allow any remaining fuel to drain.

– Remove the spark plug and fill approx. 5 cm

3

of engine oil into the cylinder through the spark plug hole.
Actuate the kickstarter 10 times to distribute the engine oil over the cylinder wall and mount the spark plug
again.

– Set the piston in the compression position to close the valves.
– Drain the fuel from the tank into a suitable vessel.
– Check the tire air pressure.
–Oil the bearing points on the control levers, footrests, chain, etc.
–Dismount and charge the battery.
– The storage site should be dry and not have any extreme fluctuations in the temperature.
– Cover the motorcycle with a permeable cover or blanket. Do not use impermeable material since it will not

allow any moisture to escape and cause corrosion.

CAUTION: Do not briefly run the engine of an immobilized motorcycle since the engine will not
become warm enough and any vapor produced during the combustion process will condense and
cause corrosion.

STARTING UP AFTER IMMOBILIZATION
– Connect the charged battery (check for correct polarity).
– Fill fresh fuel into the tank.
– Inspect the motorcycle as you would before each start-up (see Driving Instructions)
– Go on a short, cautious test ride

CLEANING

PRESERVATION FOR WINTER OPERATION

STORAGE

GENERAL INFORMATION

A

6

SPECIAL TOOLS - ENGINE

2

1

3

4

22

23

6

7

8

9

10

11

12

13

14

15

16

17

18

20

19

5

21

24

25

26

27

GENERAL INFORMATION

A
7

FIG PART NUMBER DESCRIPTION

1 560.12.001.000 Universal engine work stand
2 800.29.002.000 Engine holder for universal engine work stand
3 309098 Silicone three bond sealing compound
46 899 785 Loctite 243 blue 10 ml

800.29.059.000 Loctite 2701 green 10 ml
5 503.29.050.000 Bleeder syringe for hydraulic clutch
6 590.29.041.000 Feeler gauge for valve clearance
7 590.29.072.000 16 mm spark plug wrench
8 580.30.080.000 Locking bolt
9 590.29.019.000 Valve lifter

10 510.12.011.000 Circlip pliers inverted
11 600.29.015.000 Piston ring clamp
12 590.29.026.006 6 mm limit plug gauge for valve guide
13 580.12.009.000 Rotor extractor
14 800.29.030.000 Timing chain riveting tool
15 590.29.033.000 Extractor for timing gear and camshaft bearing
16 584.29.037.037 Mounting tool for bearing inner rings on crankshaft
17 151.12.017.000 Bearing extractor
18 151.12.018.000 12-16 mm insert for bearing extractor
19 800.29.004.000 Gear segment
20 800.29.003.000 Clutch holder
21 800.29.020.000 Housing separating tool
22 800.29.031.000 Protection cover for crankshaft
23 590.29.005.010 Mounting sleeve for the shaft seal ring on the water pump
24 800.29.005.000

Mounting sleeve for the left shaft seal ring on the the crankshaft

800.29.105.000

Mounting sleeve for the right shaft seal ring on the crankshaft

800.29.205.000

Mounting sleeve for the shaft seal ring on the kickstarter shaft
25 800.29.035.000 Pressing tool for conrod bearing (out)
26 800.29.036.000 Pressing tool for conrod bearing (in)
27 800.29.052.000 Safety TORX TX20 for the carburetor potentiometer

SPECIAL TOOLS - ENGINE

DISMOUNTING AND MOUNTING THE ENGINE

B
1

DISMOUNTING THE ENGINE

– Thoroughly clean the motorcycle and jack up on a

sturdy work stand.
– Remove the seat.
– Unscrew the air filter (1).
–Close both fuel taps and disconnect the fuel hoses
– Unscrew both lateral bolts (2) on the spoiler.

NOTE: Hold the retaining sleeve on the radiator
shield with pliers if it turns at the same time.

– Remove the tank with the spoilers.
–Disconnect the ground and positive cable.

– Loosen the hose clamp connecting the water pump

(3), remove the hose and drain the cooling liquid in a

suitable vessel.

– Loosen the hose clamps on the cylinder head (4) and

the radiator (5) and dismount both radiator hoses

together with the overflow hose (6).

–Dismount the engine vent hose (7).
– Remove the three nuts (8) from the radiator mounting

and pull the radiator out of the right side of the frame.

1

5

5

6

2

3

4

8

8

8

7

DISMOUNTING AND MOUNTING THE ENGINE

B

2

–Dismount the right frame protector (1).

– Unscrew the bearing bolt (2) on the foot brake lever

and tilt the foot brake lever aside.
– Remove the retaining clip from the push rod holder (3),

pull out the bolt and the foot brake lever

–Disconnect the generator and pickup connector (4)

and remove the cable clips from the clutch line.

– Open the chain joint (5), separate the chain and

remove.
– Unscrew the clutch slave cylinder (6) and let it hang to

the side.

–Dismount the positive starter cable (7) from the starter

engine.
– Unscrew the engine ground connection (8).
– Remove both bolts (9) and pull the starter engine (10)

out of the engine case.

1

2

3

5

8

7

9

4

6

10

DISMOUNTING AND MOUNTING THE ENGINE

B
3

– Remove the retaining bolt from the starter relay (1),

disconnect the connectors from the starter relay and

lift out the starter relay.
– Unscrew the nut on the chain roller bolt (2).
–Dismount the starter holding bridge (3) and lift the

battery out of the frame together with the battery

case.

–Use a suitable tool (hooked handle) to detach the front

(4) and rear (5) exhaust springs.

– Remove the exhaust nuts (6) from the cylinder head

and pull both exhaust pipes out of the intermediate

exhaust pipe (7) one at a time.
– Unscrew the bolt (8) and remove the intermediate

exhaust pipe.

–Loosen the clamps on the carburetor connection boots

and remove the rear carburetor connection boot (9).
– Pull the carburetor out of the front connection boot

and attach to the frame.

NOTE: leave the carburetor in the frame if it
does not need to be serviced.

Move the carburetor vent hoses towards the
rear.

–Disconnect the spark plug connector and separate the

decompression cable from the cylinder head.

1

2

3

4

5

6

6

8

9

7

DISMOUNTING AND MOUNTING THE ENGINE

B

4

– Remove the nut from the swing arm pivot (1) and

knock out the swing arm pivot with a suitable pipe.
– Pull the swing arm towards the back and let it rest

against the frame.

– Unscrew the engine mounting plantes (2) and remove

the bolts.

NOTE: hold the engine to prevent it from tilting
out of the frame.

–Lift the engine and lift out of the frame towards the

left.

1

2

DISMOUNTING AND MOUNTING THE ENGINE

B
5

MOUNTING THE ENGINE

–Lift the engine into the frame, position the engine

mounting plates (1), insert the bolts and screw on the

nuts but do not tighten yet.

– Position the swing arm and push in the swing arm

pivot (2) from the right until it touches the engine.
– Lift the engine until the swing arm pivot can be

pushed through the engine case, gently tapping with a

plastic hammer if necessary.
– Screw the nut on the swing arm pivot and tighten to

100 Nm.
–Tighten the nuts on the engine mounting plates to

25 Nm.

– Insert the carburetor in the front carburetor connection

boot and tighten the clamps.
–Mount the rear carburetor connection boot (3) and

tighten the clamps

2

1

3

DISMOUNTING AND MOUNTING THE ENGINE

B

6

– Mount the intermediate exhaust pipe (1) and tighten

the bolt (2).
–Use a suitable tool (hooked handle) to mount the rear

exhaust springs (3).

–Apply copper paste to the front exhaust pipe at the

connections to the cylinder head and mount.
– Screw on the exhaust nuts (4).
–Mount the front exhaust springs (5).

–Place the battery and battery case in the frame.
– Screw on the starter holding bridge (6).
–Mount the battery case and tighten the nut on the

chain roller bolt (7).
–Mount the starter relay and fix with the bolt (8), attach

the connector.

–Grease the O-ring on the starter engine and mount the

starter engine (9), tighten the bolts (10) to 10 Nm.
– Screw on the engine ground connection (11) and the

positive starter cable (12).

1

2

3

5

4

4

6

7

8

9

10

11

12

DISMOUNTING AND MOUNTING THE ENGINE

B
7

– Mount the clutch slave cylinder (1) and tighten the

bolts to 6 Nm.
– Position the chain and mount the chain joint (2).

– Connect the generator and pickup connector (3) and

fasten the wiring harness to the clutch line with cable

clips.

– Mount the bolt for the push rod holder (4) and secure

with the retaining clip.
– Position the foot brake lever, secure the bearing bolt

(5) with Loctite 243 and tighten the bearing bolt to

10 Nm.
– Screw on the frame protector (6) and secure with cable

clips.

–Slide the radiator into the frame from the right and

screw on with the 3 nuts (7).
– Mount the engine vent hose (8) and tighten the hose

clamps.

1

2

3

4

5

6

7

7

7

8

DISMOUNTING AND MOUNTING THE ENGINE

B

8

– Mount both radiator hoses and tighten the hose

clamps (1).
– Connect the overflow hose (2) and attach to the frame

with cable clips.

–Connect the battery cables.

– Mount the tank and tighten the two bolts (4) on the

side of the spoiler.
– Connect both fuel hoses and open the fuel taps.
– Mount the air filter (5) and screw tight.
–Mount the seat.

– Lift the motorcycle off the engine work stand.

–Bleed the cooling system.

– Check the engine oil level.

– Check the oil level and cooling liquid level again after

a short, cautious test ride.

1

1

1

2

3

4

DISMOUNTING AND MOUNTING THE ENGINE

B
9

BLEEDING THE COOLING SYSTEM

– Add cooling liquid until it reaches approx. 10 mm over

the radiator fins.
– Open the bleeder bolt (1) on the cylinder head until

cooling liquid escapes without bubbles, tighten the

bleeder bolt again to 6 Nm.
Check the cooling liquid level again after another short
ride and correct if necessary.

CHECKING THE ADJUSTMENT OF THE
HAND DECOMPRESSION CABLE

–Start the engine and slowly pull the hand

decompression lever at idling speed until you feel the

thumping of the rocker arm on the lever. The free

travel until you feel the thumping should be approx.

10 mm measured at the outer end of the lever. Correct

the free travel if necessary.
–To adjust, push back the protection cover (2), loosen

the counternut (3) and adjust the adjustment screw (4)

as required. Tighten the counternut and slide the

protection cover into place.

CAUTION: no free travel in the decompression
lever will lead to engine damage.

ADJUSTING THE THROTTLE CABLES

NOTE: The throttle grip should always have 3-5
mm free travel. In addition, the idling speed
should not change with the engine running if
the handlebar is turned all the way to the left
or right.

–To adjust the throttle cables, remove the seat and tank

with the spoilers. Push back the protection cover (5),

loosen the counternut (6) and adjust the adjusting

screw (7) as required. Turning the adjusting crew in a

counterclockwise direction will reduce the free travel,

turning it in a clockwise direction will increase the free

travel.
–Tighten the counternut and check the throttle grip for

smooth operation.
– Mount the tank and the seat.

5

6

1

10 mm

2

3

4

7

DISASSEMBLING THE ENGINE

C
1

– Thoroughly clean the outside of the engine and clamp

on a universal engine work stand.
– Drain the engine oil, remove the oil filter and the oil

screen (see Chapter A).

– Remove the kickstarter and the shift lever.

– Remove the circlip from the engine sprocket with

suitable pliers, pull the engine sprocket off the shaft.

–Remove the 4 bolts from the generator cover and

remove the generator cover.

– Pull both dowels from the housing and discard the

gasket.
– Unscrew the spark plug with the spark plug wrench

590.29.072.000.

LOCKING THE ENGINE

–Turn the crankshaft in a counterclockwise direction

until the pickup sensor (1) is aligned with the edge of

the shim (2) welded onto the rotor.
– Remove the plug and the copper gasket and screw in

the locking bolt (3) 580.30.080.000 by hand, turning

the crankshaft back and forth to allow the locking bolt

to engage in the recess in the crankshaft

2

3

1

DISASSEMBLING THE ENGINE

C

2

REMOVING THE ROTOR

– Remove the pickup sensor (1).
– Loosen the rotor nut (2) (17 mm – LH thread!) and

remove together with the corrugated washer.

– Screw the extractor 580.12.009.000 (3) to the rotor,

hold the extractor while you screw in the extractor bolt

until the rotor is released from the crankshaft. Remove

the rotor, unscrew the extractor from the rotor.

DISMOUNTING THE PRESSURE RELIEF
VALVE

– Unscrew the plug (4) on the pressure relief valve

together with the copper washer, pull the spring (5)

out of the hole and remove the ball (6) from the

engine case with a magnet or by tilting the engine.

– Remove the water pump cover (7), discard the gasket.

1

2

3

6

5

4

7

DISASSEMBLING THE ENGINE

C
3

– Remove the circlip (1) from the water pump shaft.
– Carefully pull out the water pump wheel (2) with pliers

and remove the pin (3) from the shaft.

– Remove all of the bolts in the clutch cover and remove

the clutch cover.

NOTE: the outer cover does not need to be
removed separately.

–Discard the gasket and the O-ring in the water duct,

pull the dowels out of the housing.

REMOVING THE CLUTCH

– Loosen the clutch bolts crosswise to prevent the clutch

disks from jamming. Remove the pressure cap (4)

together with the bolts, spring retainer and clutch

springs.

– Remove the pressure piece (5) and the push rod.
– Remove all of the clutch disks from the outer clutch

hub together.
– Remove the clutch sleeves from the inner clutch hub.
– Bend up the lock washer (6) for the clutch nut.

1

2

3

4

5

6

DISASSEMBLING THE ENGINE

C

4

REMOVING THE INNER CLUTCH HUB

– Unscrew the locking bolt.
– Insert the clutch holder (1) 800.29.003.000 in the outer

clutch hub with at least 6 clutch sleeves, lock the outer

clutch hub with the gear wheel segment (2)

(800.29.004.000) as shown in the photo and loosen the

nut (27 mm).

– Remove the clutch holder, the nut and lock washer and

the inner clutch hub (3).

– Remove the stepped disk (4) and both half disks (5).

REMOVING THE PRIMARY PINION AND
IDLER SHAFT GEAR

– Lock the primary pinion (6) with the special tool

800.29.004.000 (gear segment) as shown in the photo

and unscrew the nut (30 mm) on the primary pinion.

– Lock the idler shaft (7) with the special tool

800.29.004.000 (gear segment) as shown in the photo

and unscrew the nut (30 mm) on the idler shaft.

– Remove the outer clutch hub (8) with the two needle

bearings and the washer located below.

1

2

4

7

3

5

6

8

DISASSEMBLING THE ENGINE

C
5

– Pull the idler (1) and the freewheel (2) from the engine

case (only applies to starter models).

– Remove the circlip on the kickstarter idler gear (3) and

pull the kickstarter idler gear with the upper and lower

disk and the needle bearing off of the bearing bolt.

– Forcefully pull the kickstarter shaft (4) out of the

housing and dismount together with the gear wheel,

the bearing and the spring.

– Loosen the bolts on the shift locating drum (5) and on

the shift lock (6).
–Dismount the shift locating drum with the upper and

lower disk as well as the bolt.
– Relieve the shift lock spring and dismount the shift

locking lever together with the bolt, sleeve and spring.
–Dismount the shift shaft.
– Remove the primary pinion (7) and the gear on the

idler shaft (8), pry both woodruff keys out of the shaft

grooves.

REMOVING THE OIL PUMP

–Pry the circlip (9) on the oil pump gear (10) from the

shaft, removing the washer (11), oil pump gear and pin

(12).
– Loosen the three screws and remove the oil pump

cover (13).

–Dismount the oil pump shaft (14) together with the

inner rotor (15), pin and outer rotor (16).

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

DISASSEMBLING THE ENGINE

C

6

REMOVING THE CHAIN TENSIONER

– Remove the bolt (1) together with the seal ring and

chain tensioning spring.
– Unscrew the chain tensioner (2).

– Remove both valve covers, discarding the gaskets.
– Loosen the bolts on the cylinder head top section,

carefully tap on the side with a plastic hammer and

remove the cylinder head top section.

SEPARATING THE TIMING CHAIN

–Turn the camshaft until the chain joint (3) is on top and

can be easily opened.
– Remove the chain joint retainer, pull off the chain

shims and remove the chain joint.
– Pull the chain out of the chain tunnel.

NOTE: there are 2 types of chain joint retainers,
each has a different shape.

If the timing chain does not have a chain joint,
use timing chain separating tool

800.29.030.000 to open the chain.

– Apply the timing chain separating tool and turn the

spindle to open the timing chain.

NOTE: the timing chain can be separated at any
point. The pressed open chain link must be
replaced and can be replaced by a chain link
with a chain joint.

–Remove the camshaft and cap from the cylinder head.

1

2

3

DISASSEMBLING THE ENGINE

C
7

– Pull the rear sprocket (1) off of the idler shaft with the

extractor 590.29.033.000.

CAUTION: Hold the extractor and do not let it
touch the chain guide.

–Pry the woodruff key from the shaft.

REMOVING THE CYLINDER HEAD

– Remove the bolt on the left side (2).
– Loosen the 4 cylinder head bolts (3) crosswise and

remove together with the washers.
–Lift off the cylinder head with the sleeves and gasket,

discarding the gasket.

SEPARATING THE HOUSING HALVES

– Remove all of the housing bolts from the right housing

half.

– Screw the special tool 800.29.020.000 onto the right

housing half and separate the two housing halves by

turning in the spindle. Gently tap on the side of the

housing with a plastic hammer to prevent the housing

halves from being distorted.

NOTE: do not use a screwdriver or similar tool
to pry the housing halves apart since this will
damage the sealing areas.

– Remove the dowels.

1

2

3

3