Husqvarna FC 250 2015

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PIONEERING SINCE 1903

REPAIR MANUAL2015

FC250

Art. no. 3403012en

Husqrna

MOTORCYCLES

Main Page

Table of Contents4
Installing the Rotor and Ignition Pulse Generator6
Installing the Piston6
Means of Representation8
Symbols Used8
Formats Used8
Brake Lever8
Safety Advice9
Repair Manual9
Degrees of Risk and Symbols9
Work Rules9
Important Notes10
Manufacturer and Implied Warranty10
Operating and Auxiliary Substances10
Spare Parts, Accessories10
Figures10
Serial Numbers11
Chassis Number11
Type Label11
Engine Number11
Fork Part Number11
Shock Absorber Article Number11
Motorcycle12
Raising the Motorcycle with a Lift Stand12
Removing the Motorcycle from the Lift Stand12
Starting12
Starting the Motorcycle to Make Checks13
Fork, Triple Clamp14
Adjusting the Compression Damping of the 9.13 Fork14
Adjusting the Rebound Damping of the Fork14
Bleeding the Fork Legs14
Cleaning the Dust Boots of the Fork Legs15
Removing the Fork Legs15
Installing the Fork Legs16
Removing the Fork Protector16
Installing the Fork Protector17
Performing a Fork Service17
Disassembling the Fork Legs17
Removing the Spring19
Disassembling the Cartridge21
Disassembling the Piston Rod22
Disassembling the Hydrostop Unit23
Disassembling the Seal Ring Retainer24
Checking the Fork Legs24
Assembling the Seal Ring Retainer25
Assembling the Hydrostop Unit26
Assembling the Piston Rod27
Assembling the Cartridge28
Assembling the Fork Legs29
Greasing the Steering Head Bearing33
Removing the Lower Triple Clamp33
Installing the Lower Triple Clamp34
Checking the Steering Head Bearing Play35
Changing the Steering Head Bearing36
Adjusting the Play of the Steering Head Bearing37
Handlebar,Controls38
Handlebar Position38
Adjusting the Handlebar Position38
Adjusting the Basic Position of the Clutch Lever38
Checking the Throttle Cable Routing39
Checking the Play in the Throttle Cable40
Adjusting the Play in the Throttle Cable40
Frame41
Checking the Frame41
Shock Absorber, Swingarm42
Adjusting the High-Speed Compression Damping of the Shock Absorber42
Adjusting the Low-Speed Compression Damping of the Shock Absorber42
Adjusting the Rebound Damping of the Shock Absorber43
Measuring Rear Wheel Sag Unloaded43
Checking the Static Sag of the Shock Absorber43
Checking the Riding Sag of the Shock Absorber44
Adjusting the Spring Preload of the Shock Absorber44
Adjusting the Riding Sag45
Removing the Shock Absorber45
Installing the Shock Absorber46
Checking the Shock Absorber Linkage47
Servicing the Shock Absorber49
Removing the Spring50
Disassembling the Damper50
Disassembling the Piston Rod51
Disassembling the Seal Ring Retainer52
Changing the Pilot Bushing53
Checking the Damper54
Removing the Heim Joint54
Installing the Heim Joint55
Assembling the Seal Ring Retainer56
Assembling the Piston Rod57
Assembling the Damper58
Bleeding and Filling the Damper60
Filling the Damper with Nitrogen62
Installing the Spring63
Checking the Swingarm64
Removing the Swingarm64
Installing the Swingarm65
Changing the Swingarm Bearing66
Exhaust69
Removing the Manifold69
Installing the Manifold69
Removing the Main Silencer70
Installing the Main Silencer70
Changing the Glass Fiber Yarn Filling of the Main Silencer70
Air Filter72
Removing the Air Filter Box Lid72
Installing the Air Filter Box Lid72
Removing the Air Filter72
Installing the Air Filter72
Cleaning the Air Filter and Air Filter Box73
Sealing the Air Filter Box73
Fuel Tank, Seat, Trim74
Opening the Filler Cap74
Closing the Filler Cap74
Removing the Right Side Cover74
Installing the Right Side Cover75
Removing the Seat75
Mounting the Seat75
Removing the Fuel Tank75
Installing the Fuel Tank76
Checking the Fuel Pressure77
Changing the Fuel Pump79
Changing the Fuel Filter80
Changing the Fuel Screen83
Mask, Fender84
Removing the Front Fender84
Installing the Front Fender84
Removing the Start Number Plate84
Installing the Start Number Plate85
Wheels86
Checking the Tire Air Pressure86
Checking the Tire Condition86
Checking the Brake Discs86
Checking the Spoke Tension87
Front Wheel88
Removing the Front Wheel88
Installing the Front Wheel88
Removing the Brake Disc of the Front Brake89
Installing the Brake Disc of the Front Brake89
Changing the Front Wheel Bearing89
Rear Wheel91
Removing the Rear Wheel91
Installing the Rear Wheel92
Removing the Brake Disc of the Rear Brake93
Installing the Brake Disc of the Rear Brake93
Checking the Chain Tension93
Adjusting the Chain Tension94
Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide95
Checking for Chain Dirt Accumulation97
Cleaning the Chain97
Changing the Drivetrain Kit97
Changing the Rear Wheel Bearing99
Wiring Harness, Battery101
Changing the Main Fuse101
Removing the Battery101
Installing the Battery102
Recharging the Battery102
Checking the Charging Voltage103
Checking the Open-Circuit Current104
Checking the Capacitor104
Checking the Starter Relay104
Brake System106
Checking the Front Brake Linings106
Changing the Front Brake Linings106
Checking the Free Travel of the Hand Brake Lever107
Checking the Front Brake Fluid Level108
Adding Front Brake Fluid109
Changing the Front Brake Fluid110
Checking the Rear Brake Linings111
Changing the Rear Brake Linings111
Checking the Free Travel of Foot Brake Lever113
Adjusting the Basic Position of the Foot Brake Lever113
Checking the Rear Brake Fluid Level114
Adding Rear Brake Fluid114
Changing the Rear Brake Fluid115
Engine118
Removing the Engine118
Installing the Engine123
Engine Disassembly128
Preparations128
Removing the Clutch Push Rod129
Removing the Spacer129
Draining the Engine Oil129
Removing the Oil Filter130
Removing the Spark Plug130
Removing the Valve Cover130
Removing the Starter Motor131
Positioning the Engine at Ignition Top Dead Center132
Removing the Timing Chain Tensioner132
Removing the Camshaft132
Removing the Cylinder Head133
Removing the Piston133
Removing the Rotor134
Removing the Starter Drive134
Removing the Suction Pump135
Removing the Water Pump Wheel135
Removing the Clutch Cover136
Removing the Clutch Discs136
Removing the Clutch Basket136
Removing the Shift Shaft137
Removing the Shift Drum Locating Unit137
Removing the Locking Lever138
Removing the Force Pump138
Removing the Primary Gear139
Removing the Timing Chain139
Removing the Spacer139
Removing the Left Section of the Engine Case139
Removing the Shift Rails140
Removing the Shift Drum140
Removing the Shift Forks141
Removing the Transmission Shafts141
Removing the Crankshaft141
Working on Individual Parts142
Work on the Right Section of the Engine Case142
Work on the Left Section of the Engine Case143
Work on the Clutch Cover144
Checking the Oil Pressure Regulator Valve145
Checking the Lubrication System146
Removing the Crankshaft Bearing Inner Race146
Installing the Crankshaft Bearing Inner Race147
Changing the Connecting Rod, Conrod Bearing, and Crank Pin147
Checking the Crankshaft Run-Out at the Bearing Pin148
Measuring the Crankshaft End Play149
Removing the Drive Wheel of the Balancer Shaft149
Installing the Drive Wheel of the Balancer Shaft149
Cylinder - Nikasil Coating150
Checking/Measuring the Cylinder150
Checking/Measuring the Piston150
Measuring the Piston/Cylinder Mounting Clearance151
Checking the Piston Ring End Gap151
Checking the Camshafts152
Checking the Pivot Points of the Camshafts152
Removing the Valves153
Checking the Valves154
Checking the Valve Springs154
Checking the Valve Spring Seat154
Checking the Cam Levers155
Checking the Cylinder Head155
Installing the Valves155
Checking the Freewheel156
Removing the Freewheel157
Installing the Freewheel157
Checking the Electric Starter Drive158
Checking the Timing Assembly159
Preparing the Timing Chain Tensioner for Installation160
Checking the Clutch160
Checking the Shift Mechanism162
Preassembling the Shift Shaft163
Disassembling the Main Shaft163
Disassembling the Countershaft164
Checking the Transmission164
Assembling the Main Shaft165
Assembling the Countershaft166
Engine Assembly167
Installing the Crankshaft167
Installing the Transmission Shafts168
Installing the Shift Forks168
Installing the Shift Drum168
Installing the Shift Rails169
Installing the Left Engine Case169
Installing the Spacer170
Installing the Timing Chain170
Installing the Primary Gear170
Installing the Force Pump171
Installing the Suction Pump171
Installing the Locking Lever172
Installing the Shift Drum Locating Unit172
Installing the Shift Shaft173
Installing the Clutch Basket173
Installing the Clutch Discs174
Installing the Clutch Cover174
Installing the Water Pump Cover175
Installing the Cylinder Head178
Installing the Camshafts179
Installing the Timing Chain Tensioner179
Checking the Valve Clearance180
Adjusting the Valve Clearance180
Installing the Starter Motor181
Installing the Valve Cover182
Installing the Spark Plug183
Installing the Oil Filter183
Installing the Oil Screen183
Installing the Spacer184
Installing the Clutch Push Rod184
Removing the Engine from the Engine184
Assembly Stand184
Clutch185
Checking/Correcting the Fluid Level of the Hydraulic Clutch185
Changing the Hydraulic Clutch Fluid185
Water Pump, Cooling System187
Cooling System187
Checking the Antifreeze and Coolant Level187
Checking the Coolant Level188
Draining the Coolant188
Refilling with Coolant189
Lubrication System190
Oil Circuit190
Checking the Engine Oil Level190
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen191
Adding Engine Oil193
Checking the Engine Oil Pressure193
Ignition System195
Ignition Coil - Checking the Secondary195
Winding195
Checking the Spark Plug Connector195
Alternator - Checking the Stator Winding195
Removing the Stator and Ignition Pulse Generator196
Installing the Stator and Ignition Pulse Generator196
Electric Starter197
Checking the Starter Motor197
Throttle Valve Body198
Adjusting the Idle Speed198
Executing the Initialization Run198
Technical Data200
Engine200
Engine Tolerance, Wear Limits200
Engine Tightening Torques201
Capacities202
Engine Oil202
Coolant202
Fuel202
Chassis203
Electrical System203
Tires203
Fork204
Shock Absorber204
Chassis Tightening Torques205
Cleaning/Protective Treatment206
Cleaning the Motorcycle206
Storage207
Putting into Operation after Storage207
Service Schedule208
Service Work (as Additional Order)209
Fc 250 Eu)210
Wiring Diagram211
Fc 250 Eu)212
Fc 250 Eu)214
Fc 250 Us)216
Fc 250 Us)218
Fc 250 Us)220
Substances222
Auxiliary Substances223
Special Tools225
Standards237
Index238

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Husqvarna FC 250 2015 Specifications

General

Brand	Husqvarna
Model	FC 250 2015
Category	Motorcycle
Language	English

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