Husqvarna FC 250 2018

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PIONEERING SINCE 1903

REPAIR MANUAL2018

FC250

Art. no. 3403058en

Husqrna

MOTORCYCLES

Main Page

Table of Contents4
Checking the Starter Motor6
Means of Representation 19
Symbols Used9
Formats Used9
Safety Advice10
Repair Manual10
Degrees of Risk and Symbols10
Work Rules10
Important Notes 311
Manufacturer and Implied Warranty11
Fuel, Auxiliary Substances11
Spare Parts, Accessories11
Figures11
Serial Numbers12
Vehicle Identification Number12
Type Label12
Engine Number12
Fork Article Number12
Shock Absorber Article Number13
Motorcycle14
Raising the Motorcycle with a Lift Stand14
Removing the Motorcycle from the Lift Stand14
Starting the Vehicle14
Starting the Motorcycle to Check the 8 Function15
Fork, Triple Clamp16
Air Suspension AER 4816
Checking the Basic Setting of the Fork16
Adjusting the Fork Air Pressure17
Adjusting the Compression Damping of the Fork18
Adjusting the Rebound Damping of the Fork18
Bleeding the Fork Legs19
Cleaning the Dust Boots of the Fork Legs19
Removing the Fork Legs20
Installing the Fork Legs21
Removing the Fork Protector21
Installing the Fork Protector22
Servicing the Fork22
Disassembling the Fork Legs23
Disassembling the Air Cartridge27
Disassembling the Shock Absorber Cartridge28
Checking the Fork Legs30
Assembling the Shock Absorber Cartridge31
Assembling the Air Cartridge33
Assembling the Fork Legs35
Lubricating the Steering Head Bearing41
Removing the Lower Triple Clamp42
Installing the Lower Triple Clamp43
Checking Steering Head Bearing Play45
Changing the Steering Head Bearing46
Adjusting Steering Head Bearing Play47
7 Handlebar,Controls48
Handlebar Position48
Adjusting the Handlebar Position48
Clutch Lever49
Checking the Rubber Grips49
Checking Throttle Cable Routing50
Checking Throttle Cable Play50
Adjusting Throttle Cable Play51
Setting the Characteristic Map of the Throttle Response52
Frame54
Checking the Frame54
Changing the Footrests54
Shock Absorber, Link Fork56
Adjusting the High-Speed Compression Damping of the Shock Absorber56
Adjusting the Low-Speed Compression Damping of the Shock Absorber56
Adjusting the Rebound Damping of the Shock Absorber57
Measuring the Rear Wheel Dimension Unloaded58
Checking the Static Sag of the Shock Absorber58
Checking the Riding Sag of the Shock Absorber59
Shock Absorber59
Adjusting the Riding Sag60
Removing the Shock Absorber61
Installing the Shock Absorber63
Checking the Shock Absorber Linkage64
Servicing the Shock Absorber66
Removing the Spring67
Disassembling the Damper68
Disassembling the Piston Rod69
Disassembling the Seal Ring Retainer70
Changing the Pilot Bushing71
Checking the Damper72
Removing the Heim Joint73
Installing the Heim Joint74
Assembling Seal Ring Retainer74
Assembling the Piston Rod75
Assembling the Damper77
Bleeding and Filling the Damper79
Filling Damper with Nitrogen82
Installing the Spring83
Checking the Link Fork84
Checking the Fork Bearing for Play84
Removing the Link Fork85
Installing the Link Fork86
Changing the Fork Bearing88
Changing the Heim Joint90
Checking the Heim Joint for Play92
Exhaust System93
Removing the Manifold93
Installing the Manifold94
Removing the Main Silencer95
Installing the Main Silencer95
Changing the Glass Fiber Yarn Filling of the Main Silencer96
Air Filter 1197
Removing the Air Filter Box Cover97
Installing the Air Filter Box Cover97
Removing the Air Filter97
Installing the Air Filter98
Cleaning the Air Filter and Air Filter Box98
Sealing the Air Filter Box99
12 Fuel Tank, Seat, Trim100
Opening Fuel Tank Filler Cap100
Closing the Fuel Tank Filler Cap100
Removing the Right Side Cover101
Installing the Right Side Cover101
Removing the Seat101
Mounting the Seat102
Removing the Fuel Tank103
Installing the Fuel Tank104
Checking the Fuel Pressure106
Changing the Fuel Pump107
Changing the Fuel Filter110
Changing the Fuel Screen113
Mask, Fender 13115
Removing Front Fender115
Installing Front Fender115
Removing the Start Number Plate116
Installing the Start Number Plate116
Wheels 14117
Checking Tire Pressure117
Checking the Tire Condition117
Checking the Wheel Bearing for Play118
Checking the Brake Discs118
Checking Spoke Tension119
Checking the Rim Run-Out119
Frontwheel120
Removing the Front Wheel120
Installing the Front Wheel121
Changing the Front Brake Disc122
Changing the Front Wheel Bearing122
Rear Wheel124
Removing the Rear Wheel124
Installing the Rear Wheel125
Changing the Rear Brake Disc126
Checking the Chain Tension127
Adjusting the Chain Tension128
Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide128
Checking for Chain Dirt Accumulation131
Cleaning the Chain131
Changing the Drivetrain Kit132
Changing the Rear Wheel Bearing134
15 Wiring Harness, Battery136
Changing the Main Fuse136
Of the 12 V Battery137
Connecting the Negative Cable of the 12 V Battery137
Removing the 12 V Battery138
Installing the 12 V Battery139
Charging the 12 V Battery139
Checking the Charging Voltage141
Checking the Open-Circuit Current141
Checking the Capacitor142
Checking the Starter Relay143
16 Brake System144
Checking the Front Brake Linings144
Changing the Front Brake Linings144
Checking the Free Travel of the Hand Brake Lever (Option: 17.3.26 Brembo)147
Hand Brake Lever148
Checking the Front Brake Fluid Level149
Adding Front Brake Fluid149
Changing the Front Brake Fluid151
Checking the Brake Linings of the Rear Brake154
Changing the Rear Brake Linings155
Brake Lever158
Foot Brake Lever158
Checking the Rear Brake Fluid Level160
Adding Rear Brake Fluid160
Changing the Rear Brake Fluid162
17 Engine166
Removing the Engine166
Installing the Engine173
Engine Disassembly181
Preparations181
Removing the Clutch Push Rod181
Draining the Engine Oil181
Removing the Oil Filter182
Gear Position Sensor, Removing182
Removing the Spark Plug183
Removing the Valve Cover183
Starter Motor, Removing184
Positioning the Engine at Ignition Top Dead Center184
Removing the Timing Chain Tensioner185
Removing the Camshafts185
Cylinder Head, Removing186
Removing the Piston186
Removing the Rotor187
Starter Drive, Removing187
Removing the Suction Pump188
17.3.17 Water Pump Impeller, Removing189
Removing the Clutch Cover189
Removing the Clutch Discs190
Removing the Clutch Basket190
Removing the Primary Gear Wheel191
Timing Chain, Removing191
Removing the Force Pump192
Removing the Locking Lever192
Shift Drum Locating Unit, Removing193
Removing the Shift Shaft193
17.3.27 Spacer, Removing193
Removing the Left Engine Case193
Shift Rails, Removing194
Removing the Shift Drum194
Removing the Shift Forks195
Removing the Transmission Shafts195
Removing the Crankshaft195
Working on Individual Parts196
Working on the Right Section of the Engine Case196
Working on the Left Section of the Engine Case198
Work on the Clutch Cover199
Checking the Oil Pressure201
Control Valve201
Checking the Lubrication System202
Removing the Crankshaft Bearing Inner Race202
Installing the Crankshaft Bearing Inner Race203
Connecting Rod, Conrod Bearing, and Crank Pin, Changing203
Checking the Crankshaft Run-Out at the Bearing Pin205
Measuring the Crankshaft End Play206
Removing the Drive Gear Wheel of the Balancer Shaft206
Installing the Drive Gear Wheel of the Balancer Shaft207
Cylinder - Nikasil ® Coating207
Checking/Measuring the Cylinder207
Checking/Measuring the Piston208
Measuring the Piston/Cylinder Mounting Clearance209
Checking the Piston Ring End Gap209
Camshafts, Checking210
Checking the Pivot Points of the Camshafts210
Valves, Removing211
Valves, Checking212
Valve Springs, Checking212
Checking the Valve Spring Seat213
Checking the Cam Levers213
Checking the Cylinder Head213
Installing the Valves214
Checking the Freewheel215
Freewheel, Removing215
Freewheel, Installing216
Checking the Electric Starter Drive217
Checking the Timing Assembly218
Preparing the Timing Chain Tensioner for Installation219
Checking the Clutch220
Checking the Shift Mechanism221
Preassembling the Shift Shaft222
Disassembling the Main Shaft223
Disassembling the Countershaft224
Checking the Transmission224
Assembling the Main Shaft226
Assembling the Countershaft227
Engine Assembly228
Installing the Crankshaft228
Installing the Transmission Shafts228
Shift Forks, Installing229
Installing the Shift Drum229
Shift Rails, Installing229
Left Engine Case, Installing230
Installing the Spacer230
Shift Shaft, Installing231
Shift Drum Locating Unit, Installing231
Locking Lever, Installing231
Installing the Force Pump231
Installing the Suction Pump232
Installing the Timing Chain233
Installing the Primary Gear Wheel234
Installing the Clutch Basket234
Installing the Clutch Discs235
Installing the Clutch Cover236
Water Pump Cover, Installing237
Starter Drive, Installing238
Installing the Rotor238
Installing the Piston238
Installing the Cylinder Head240
Installing the Camshafts241
Installing the Timing Chain Tensioner242
Checking the Valve Clearance242
Adjusting the Valve Clearance243
Installing the Starter Motor244
Installing the Valve Cover244
Spark Plug, Installing245
Gear Position Sensor, Installing245
Installing the Oil Filter246
Installing the Oil Screen246
Installing the Clutch Push Rod247
Removing the Engine from the Engine Assembly Stand247
18 Clutch248
Checking/Correcting the Fluid Level of the Hydraulic Clutch248
Changing the Hydraulic Clutch Fluid249
Checking the Clutch250
Water Pump, Cooling System 19257
Cooling System257
Checking the Antifreeze and Coolant Level257
Checking the Coolant Level258
Draining the Coolant259
Refilling with Coolant259
Lubrication System261
Oil Circuit261
Checking the Engine Oil Level261
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen262
Adding Engine Oil265
Checking the Oil Pressure266
Ignition System268
Ignition Coil - Checking the Secondary Winding268
Connector268
Alternator - Checking the Stator Winding268
Crankshaft Speed Sensor269
Speed Sensor269
Changing the Spark Plug270
22 Cylinder Head272
Checking the Valve Clearance272
Adjusting the Valve Clearance275
23 Electric Starter System276
Throttle Valve Body 24277
Adjusting the Idle Speed277
Performing the Initialization Run277
Technical Data 25279
Engine279
Tolerance, Engine Wear Limits280
Engine Tightening Torques281
Capacities283
Engine Oil283
Coolant283
Fuel283
Chassis283
Electrical System284
Tires284
Fork284
Shock Absorber285
Chassis Tightening Torques285
26 Cleaning/Protective Treatment288
Cleaning the Motorcycle288
27 Storage290
Putting into Operation after Storage291
28 Service Schedule292
Additional Information292
Required Work292
Recommended Work293
Wiring Diagram 29295
30 Substances300
Auxiliary Substances302
32 Special Tools304
Standards 33323
34 List of Abbreviations324
Index325

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Husqvarna FC 250 2018 Specifications

General

Brand	Husqvarna
Model	FC 250 2018
Category	Motorcycle
Language	English

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