Husqvarna FE 350 AU 2016

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PIONEERING SINCE 1903

REPAIR MANUAL2016

FE 350

FE 350 S

Art. no. 3403027en

Husqrna

MOTORCYCLES

Main Page

Table of Contents4
Means of Representation9
Symbols Used9
Formats Used9
Safety Advice10
Repair Manual10
Degrees of Risk and Symbols10
Work Rules10
Important Notes11
Manufacturer and Implied Warranty11
Operating and Auxiliary Substances11
Spare Parts, Accessories11
Figures11
Serial Numbers12
Chassis Number12
Type Label (FE EU/AU, 7 FE 350 S US)12
Key Number (FE EU/AU, FE 350 S US)13
Engine Number13
Fork Part Number13
Shock Absorber Article Number14
Motorcycle15
Raising the Motorcycle with a Lift Stand15
Lift Stand15
Starting15
Starting the Motorcycle for a Check16
Fork, Triple Clamp17
Adjusting the Compression Damping 9 of the Fork17
Adjusting the Rebound Damping of 9.1 the Fork17
Bleeding the Fork Legs18
Cleaning the Dust Boots of the Fork Legs18
Removing the Fork Legs19
Installing the Fork Legs19
Removing the Fork Protector21
Installing the Fork Protector21
Performing a Fork Service21
Disassembling the Fork Legs22
Removing the Spring24
Disassembling the Cartridge25
Disassembling the Piston Rod26
Disassembling the Hydrostop Unit27
Disassembling the Seal Ring Retainer28
Checking the Fork Legs28
Assembling the Seal Ring Retainer30
Assembling the Hydrostop Unit30
Assembling the Piston Rod31
Assembling the Cartridge32
Assembling the Fork Legs34
Lubricating the Steering Head Bearing38
Removing the Lower Triple Clamp39
Installing the Lower Triple Clamp40
Checking the Play of the Steering Head Bearing42
Changing the Steering Head Bearing43
Adjusting the Steering Head Bearing Play44
7 Handlebar,Controls46
Handlebar Position46
Adjusting the Handlebar Position46
Adjusting the Basic Position of the Clutch Lever47
Checking the Routing of the Throttle Cable47
Checking the Play in the Throttle Cable48
Adjusting the Play in the Throttle Cable49
Frame50
Removing the Engine Guard50
Installing the Engine Guard50
Checking the Frame50
Shock Absorber, Swingarm51
Adjusting the High-Speed Compression Damping of the Shock Absorber51
Adjusting the Low-Speed Compression Damping of the Shock Absorber51
Adjusting the Rebound Damping of the Shock Absorber52
Measuring Rear Wheel Sag Unloaded53
Checking the Static Sag of the Shock Absorber53
Checking the Riding Sag of the Shock Absorber54
Shock Absorber54
Adjusting the Riding Sag55
Removing the Shock Absorber56
Installing the Shock Absorber57
Checking the Shock Absorber Linkage57
Servicing the Shock Absorber59
Removing the Spring60
Disassembling the Damper61
Disassembling the Piston Rod62
Disassembling the Seal Ring Retainer63
Changing the Pilot Bushing64
Checking the Damper65
Removing the Heim Joint66
Installing the Heim Joint67
Assembling Seal Ring Retainer67
Assembling the Piston Rod68
Assembling the Damper70
Bleeding and Filling the Damper72
Filling Damper with Nitrogen75
Installing the Spring76
Checking the Swingarm77
Checking the Swingarm Bearing for Play77
Removing the Swingarm79
Installing the Swingarm80
Changing the Swingarm Bearing81
Exhaust85
Removing the Manifold85
Installing the Manifold87
Removing the Main Silencer89
Installing the Main Silencer89
Changing the Glass Fiber Yarn Filling in the Main Silencer90
Spark Arrestor, Cleaning92
11 Air Filter94
Removing the Air Filter Box Cover94
Installing the Air Filter Box Cover94
Removing the Air Filter94
Installing the Air Filter95
Cleaning the Air Filter and Air Filter Box95
Sealing the Air Filter Box96
Fuel Tank, Seat, Trim97
Opening the Filler Cap97
Closing the Filler Cap98
Removing the Right Side Cover98
Installing the Right Side Cover98
Removing the Seat99
Mounting the Seat99
Removing the Fuel Tank100
Installing the Fuel Tank102
Changing the Fuel Screen103
Changing the Fuel Filter105
Changing the Fuel Pump107
Checking the Fuel Pressure109
Removing the Activated Charcoal Filter (FE 350 S US)110
Installing the Activated Charcoal Filter (FE 350 S US)111
13 Mask, Fender113
Removing Front Fender113
Installing Front Fender114
Removing the Headlight Mask with the Headlight115
Installing the Headlight Mask with the Headlight116
14 Wheels119
Checking the Tire Air Pressure119
Checking the Tire Condition119
Checking the Wheel Bearing for Play120
Checking the Brake Discs121
Checking Spoke Tension121
Checking the Rim Run-Out122
Front Wheel123
Removing the Front Wheel123
Installing the Front Wheel124
Changing the Front Brake Disc125
Changing Front Wheel Bearing125
Rear Wheel127
Removing the Rear Wheel127
Installing the Rear Wheel128
Changing the Rear Brake Disc130
Checking the Chain Tension131
Adjusting the Chain Tension131
Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide133
Checking for Chain Dirt Accumulation135
Cleaning the Chain135
Changing the Drivetrain Kit136
Changing the Rear Wheel Bearing138
15 Wiring Harness, Battery142
Changing the Fuses of Individual Power Consumers142
Changing the Main Fuse144
Checking the Starter Relay145
Removing the Battery145
Installing the Battery146
Recharging the Battery147
Checking the Charging Voltage148
Checking the Open-Circuit Current148
16 Brake System150
Checking the Front Brake Linings150
Changing the Front Brake Linings150
Checking the Free Travel of the Hand Brake Lever153
Adjusting the Basic Position of the Hand Brake Lever (FE 350 US)153
Adjusting Free Travel of Hand Brake Lever (FE EU/AU, FE 350 S US)154
Checking the Front Brake Fluid Level154
Adding Front Brake Fluid155
Changing the Front Brake Fluid156
Checking the Rear Brake Linings159
Changing the Rear Brake Linings160
Checking the Free Travel of Foot162
Brake Lever162
Adjusting the Basic Position of the Foot Brake Lever163
Checking the Rear Brake Fluid Level163
Adding Rear Brake Fluid164
Changing the Rear Brake Fluid165
Lighting System, Instruments168
Adjusting the Combination Instrument168
Adjusting the Kilometers or Miles169
Adjusting the Clock169
Setting the Wheel Circumference170
Adjusting the Service Display170
Checking the Headlight Setting171
Adjusting the Headlight Range171
18 Engine173
Removing the Engine173
Installing the Engine177
Engine Disassembly183
Preparations183
Removing the Clutch Push Rod183
Removing the Spacer183
Draining the Engine Oil183
Removing the Oil Filter184
Removing the Spark Plug184
Removing the Valve Cover185
Removing the Alternator Cover185
Removing the Torque Limiter186
Positioning the Engine at Ignition Top Dead Center186
Removing the Timing Chain Tensioner186
Removing the Camshaft187
Removing the Cylinder Head187
Removing the Piston188
Removing the Starter Drive188
Removing the Suction Pump190
Removing the Water Pump Wheel191
Removing the Clutch Cover191
Removing the Clutch Discs191
Removing the Clutch Basket192
Removing the Shift Shaft193
Removing the Shift Drum Locating Unit193
Removing the Locking Lever194
Removing the Force Pump194
Removing the Primary Gear195
Removing the Timing Chain195
Removing the Spacer195
Removing the Left Section of the Engine Case196
Removing the Shift Rails196
Removing the Shift Drum197
Removing the Shift Forks197
Removing the Transmission Shafts197
Removing the Crankshaft198
Working on Individual Parts198
Work on the Right Section of the Engine Case198
Working on the Left Section of the Engine Case200
Work on the Clutch Cover201
Checking the Oil Pressure Regulator Valve203
Checking the Lubrication System204
Removing the Crankshaft Bearing Inner Race204
Installing the Crankshaft Bearing Inner Race205
Changing the Connecting Rod, Conrod Bearing and Crank Pin205
Checking the Crankshaft Run-Out at the Bearing Pin207
Measuring the Crankshaft End Play207
Removing the Drive Wheel of the Balancer Shaft208
Installing the Drive Wheel of the Balancer Shaft208
Cylinder - Nikasil ® Coating208
18.4.14 Checking/Measuring the Cylinder208
Checking/Measuring the Piston209
Measuring the Piston/Cylinder Mounting Clearance210
Checking the Piston Ring End Gap210
Changing the Camshaft Bearing211
Checking the Camshafts211
Checking the Pivot Points of the Camshafts212
Removing the Valves213
Checking the Valves214
Checking the Valve Springs214
Checking the Valve Spring Seat214
Checking the Cam Levers215
Checking the Cylinder Head215
Installing the Valves216
Checking the Freewheel217
Removing the Freewheel217
Installing the Freewheel218
Checking the Electric Starter Drive219
Checking the Timing Assembly220
Preparing the Timing Chain Tensioner for Installation221
Checking the Clutch222
Checking the Shift Mechanism223
Preassembling the Shift Shaft224
Disassembling the Main Shaft225
Disassembling the Countershaft226
Checking the Transmission226
Assembling the Main Shaft228
Assembling the Countershaft229
Engine Assembly230
Installing the Crankshaft230
Installing the Transmission Shafts230
Installing the Shift Forks231
Installing the Shift Drum231
Installing the Shift Rails231
Installing the Left Engine Case232
Installing the Spacer233
Installing the Timing Chain233
Installing the Primary Gear234
Installing the Force Pump234
Installing the Suction Pump235
Installing the Locking Lever236
Installing the Shift Drum Locating Unit236
Installing the Shift Shaft236
Installing the Clutch Basket236
Installing the Clutch Discs237
Installing the Clutch Cover239
Installing the Water Pump Cover240
Installing the Starter Drive241
Installing the Piston242
Installing the Cylinder Head244
Installing the Camshafts245
Checking the Valve Timing246
Adjusting the Valve Timing246
Installing the Timing Chain Tensioner248
Checking the Valve Clearance249
Adjusting the Valve Clearance250
Installing the Torque Limiter250
Installing the Alternator Cover250
Installing the Valve Cover251
Installing the Spark Plug251
Installing the Oil Filter252
Installing the Oil Screen252
Installing the Spacer253
Installing the Clutch Push Rod253
Removing the Engine from the Engine Assembly Stand253
19 Clutch254
Checking/Correcting the Fluid Level of the Hydraulic Clutch254
Changing the Hydraulic Clutch Fluid255
20 Water Pump, Cooling System257
Cooling System257
Checking the Antifreeze and Coolant Level257
Checking the Coolant Level258
Draining the Coolant259
Refilling Coolant260
Lubrication System261
Oil Circuit261
Checking the Engine Oil Level261
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen262
Adding Engine Oil264
Checking the Engine Oil Pressure265
22 Ignition System267
Ignition Coil - Checking the Secondary Winding267
Checking the Spark Plug Connector267
Alternator - Checking the Stator Winding267
Removing the Stator and Ignition Pulse Generator268
Installing the Stator and Ignition 30.11 Pulse Generator269
23 Cylinder Head270
Checking the Valve Clearance270
Adjusting the Valve Clearance273
24 Electric Starter275
Checking the Starter Motor275
25 Throttle Valve Body276
Adjusting the Idle Speed276
Executing the Initialization Run276
26 Technical Data278
Engine278
Tolerance, Engine Wear Limits279
Engine Tightening Torques279
Capacities281
Engine Oil281
Coolant281
Fuel282
Chassis282
Electrical System283
Tires283
Fork283
Shock Absorber284
Chassis Tightening Torques284
27 Cleaning, Care287
Cleaning the Motorcycle287
Checks and Maintenance Steps for Winter Operation288
28 Storage289
Preparing for Use after Storage290
29 Service Schedule291
Service Work (as Additional Order)292
30 Wiring Diagram295
Eu)296
Eu)298
Eu)300
Eu)302
Eu)304
Eu)306
Eu)308
Fe Au)310
Fe Au)312
Fe Au)314
Fe Au)316
Fe Au)318
Fe Au)320
Fe Au)322
Fe Au)324
Fe 350 Us)326
Fe 350 Us)328
Fe 350 Us)330
Fe 350 Us)332
Fe 350 Us)334
Fe 350 Us)336
Fe 350 S Us)338
Fe 350 S Us)340
Fe 350 S Us)342
Fe 350 S Us)344
Fe 350 S Us)346
Fe 350 S Us)348
Fe 350 S Us)350
Fe 350 S Us)352
Substances354
32 Auxiliary Substances356
33 Special Tools358
Standards374
35 List of Abbreviations375
Index376

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Husqvarna FE 350 AU 2016 Specifications

General

Brand	Husqvarna
Model	FE 350 AU 2016
Category	Motorcycle
Language	English

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